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SERVICE MANUAL - K&T Parts House Lawn Mower Parts & Chain

1. 4 ldler gear 1 Clearance between idler gear and shaft measure the bore in the idler gear for the shaft and the diameter of the shaft to find the clearance If the clearance exceeds the limit replace the gear or shaft whichever is badly worn 3 Tappets Unit mm in 1 Cam contact face Item Standard Limit Check the cam contact face of each tappet for Clearance between 0 03 to 0 0 0 20 abnormal wear Replace the tappet if the face idler gear and shaft 0 0012 to 0 0028 0 0079 is defective Good Bad Bad 85 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 ldler shaft replacement a Removal Install a new idler shaft to the cylinder block Heat the ring gear evenly with an so that its dimension from the face of the block acetylene torch Tap the ring gear all the is 26 5 0 5 mm 1 043 0 020 in way around with a bar and a hammer as shown in the illustration to remove it from the flywheel 26 5 0 5 mm 1 043 0 020 in b Installation Heat a new ring gear up to a temperature of 150 C 302 F with a piston heater and install it to the flywheel with its unchamfered side foremost 5 Flywheel and ring gear 1 Flatness difference between lower and higher measurements of flywheel Put the flywheel on the surface plate Set a dial indicator at one side of the friction clutch contact face and move it over to the opposite side of the face as shown in t
2. Nut at poppet 13 02 15 91 lbfeft TO RESERVOIR WHEN NEUTRAL AND LOWER POSITION UNLOADER VALVE t valve BODY SPRING TO RESERVOIR WHEN NEUTRAL AND LOWER POSITION ea TO RESERVOIR fi TA AN PORT SPRING CYLINDER PORT CHECK VALVE 10 4 HYDRAULIC LIFT REASSEMBLING Reassemble hydraulic lift with reverse procedure of disassembling 1 LIFT SHAFT AND CYLINDER REASSEMBLING Reassemble the lift shaft and cylinder with reverse procedure of disassembling Use following values for reassembling as adjustment and service standard 1 Cylinder reassembling 1 Apply oil at o ring for the assembling 2 Apply liquid packing threebond 1208D to mating surface of the cylinder and housing 3 Apply molybdenum MoS2 to piston PISTON ROD LIFT CASE SAFETY VALVE PISTON CYLINDER APPLY MOLYBDENUM 2 Lift shaft reassembling 1 Aline the bolt hole for lock bolt on the power arm and lift shaft Tightening torque of lock bolt 8 68 12 3lbfeft 2 Aline the punch mark on the lift shaft and lift arm K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 Install the bushing 9 to piston rod 10 5 Drive in bushing at lift shaft to 0 374 0 394 Bushing should be placed with its slit in deep as shown in the following drawing coming as shown in the following drawing 6 Apply molybdenum MoS2 to spline of lift 4 Install the bushings 3 to
3. 9 Piston separation from connecting rod 1 Use Piston Pin Setting Tool 31A9100100 special tool to separate the piston from the connecting rod Do not attempt to remove the piston pin by tapping Replace a piston pin which needs a greater force for removal K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 Insert the push rod of the tool into the bore in the piston for the piston pin and using an arbor press remove the piston pin 3 Use this Piston Pin Setting Tool to install the connecting rod to the piston Push rod tool Connecting rod Arrow mark Piston uy ie Np ai 43 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 4 REASSEMBLING 1 CYLINDER HEAD REASSEMBLING 7 Valve Lock Valve retainer Valve spring Rocker cover 0 Valve 2 Reassemble the cylinder head with reverse 1 procedure of disassembling Use the following 2 Rocker shaft assembly 3 Valve push rod values as adjustment and service standard 4 Cylinder head bolt 5 6 Cylinder head Cylinder head gasket Valve stem seal 8 9 1 1 12 Valve cap 1 Cylinder head bottom face cleaning Scrape the gasket from the bottom face of the cylinder head 2 Valve stem seal installation Using Box 12 install the valve stem seal in position in the valve guide After installation make sure
4. a Grind all the journals of one crankshaft to the same undersize b Finish the journal fillets to a radius of 2 mm 0 08 in o Measure the diameter of the journal as shown in the illustration to find the clearance between the journal and main bearing 90 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 5 Crankshaft gear installation a lnstall the key in position on the crank shaft b Install the gear in position with its keyway in alignment with the key as shown in the illustration 2 mm 0 08 in 2 mm 0 08 in 3 Runout Support the crankshaft on its front and rear journals in V blocks or in a lathe and check runout at the center journal with a dial indica tor as shown in the illustration Depending on the amount of runout repair the crankshaft by grinding or by straightening with a press If runout exceeds the limit replace the crank shaft 4 Cylinder block 1 Bore Measure the bore at the top middle and bot tom points on axes A and B with a cylinder bore gauge as shown in the illustration If any one of the cylinders exceeds the limit hone out all the bores for oversize pistons Unit mm in Item Standard Limit Crankshaft runout 0 025 0 00098 0 05 0 0020 4 Crankshaft gear removal Use a gear puller to remove the gear from the crankshaft NOTE Do not remove the gear unless the gear or crankshaft is defective
5. 0 0098 1 8799 000197 0 50 47 50 0050 5 0 0197 187012 0125 0 75 47 259 035 0 0295 1 8602 9 00138 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com Measuring diagram a Grind all the crankpins of one crankshaft to the same undersize b Finish the crankpin fillets to a radius of 2 5 mm 0 098 in Unit mm in Item Nominal size Standard Limit Diameter 52 51 985to of journal 2 05 52 000 standard 2 04665to 2 04724 clearance 0 030 to 20 aranes between journal and main bakween 0 077 pearing o journal and 0 00118to 0 100 a Install the main bearing upper and main bearing 0 00303 0 00394 lower halves and cap to the cylinder block and tighten the cap bolts to the specified torque Measure the bore in the bearing for the journal as shown in the illustration c lf the clearance exceeds the limit install a new bearing and check the clearance again d lf the clearance still exceeds the limit grind the journal to 0 25 mm 0 0098in 0 50 l l 5 25 0 25 kgfem mm 0 0197 in or 0 75 mm 0 0295 in Tightening torque 38 1 8 Ibfeft undersize and use undersizemain bearing 51 5 2 5 Nem Journal undersize Unit mm in Item Undersize Finish 0 25 51 75 0 015 0 0098 2 0374 0 00059 0 50 51 50 0 015 3 0 0197 2 0276 0 00059 0 75 51 25 0 015 0 0295 2 0177 0 00059
6. or in nozzle orifice Disassembly sequence and inspection points 1 Retaining nut 4 Pin 2 Nozzle tip assembly 5 Spring 3 Piece 6 Washer 7 Body 105 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 5 FAN BELT 1 Measure the deflection of the belt Apply 10 kgf 22 Ibf 98 N force midway between the alternator pulley and the crankshaft pulley 2 Adjust the belt if the deflection is not correct Loosen the adjusting bolt and move the alternator to obtain the required belt deflection Unit mm in Item Standard Deflection 10 to 12 0 4 to 0 5 Adjusting plate bolt ie Ga DMD EY Apply 10 kgf 22 lbf 98 N force midway between crankshaft pulley and alternator pulley 106 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 7 SPECIAL TOOLS Tool No Tool Name 31A91 00100 Piston Pin Setting Tool Piston pin removal and installation 406808 T332340 Camshaft Bushing Installer Camshaft front bushing removal and installation 404704 T332270 Compression Gauge Adaptor Compression pressure measurement 404931 MD998054 Oil Pressure Switch Socket Oil pressure switch removal Wrench 26 and installation 404840 NOTE In addition these special tools commercially available tools such as bearing puller valve seat cutting tool valve guide installing tool valve spring compressing tool
7. Lo Place snap ring that square side face to force 7 Install the spring pin that its slit faces to direction of force as shown below Slit FE Shaft Slit movement Shaft parE movement 8 Replace the cotter pin for the reassembling and bend it 9 Tighten the bolts and nuts etc to obtain the specified tightening torque by torque wrench 10 For the battery installation connect the positive cable first and then connect the negative cable K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 7 GENERAL INFORMATION CLEANING Clean all metal parts except bearings in mineral spirits or by steam cleaning Do not use caustic soda for steam cleaning After cleaning dry and put oil on all parts Clean oil passages with compressed air Clean bearings in kerosene dry the bearings completely and put oil on the bearings INSPECTION Check all parts when the parts are disassembled Replace all parts that have wear or damage Small scoring or grooves can be removed with a hone or crocus cloth Complete visual inspection for indications of wear pitting and the replacement of parts necessary will prevent early failures BEARINGS Check bearings for easy action If bearings have a loose fit or rough action replace the bearings Wash bearings with a good solvent or kerosene and permit to air dry DO NOT DRY BEARINGS WITH COMPRESSED AIR NEEDLE BEARINGS Before you press needl
8. for connecting rod big end 0 0039 to 0 0138 0 0197 4 Connecting rod cap removal 1 Lay the cylinder block on its side 2 Put identification on each connecting rod and cap combination as to its location in the engine 3 Remove the caps 5 Piston removal 1 Turn the crankshaft until the piston is at top center 2 Push the piston and connecting rod away from the crankshaft with the handle of a hammer or the like until the piston rings are above the cylinder Remove the piston and connecting rod Do Steps 1 and 2 for the removal of the other pistons K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 6 End play measurement for crankshaft Set a dial indicator so that it will touch the end of the crankshaft and measure the end play If the end play exceeds the limit replace the flanged bearing in No 3 journal Unit mm in Item Standard Limit End play for 0 050 to 0 175 0 500 crankshaft 0 00197 to 0 00689 0 01969 end play 7 Main bearing cap removal 1 Lay the cylinder block with its bottom oil pan side up 2 Remove the bolts that hold the main bearing caps in position Remove the caps 3 Remove the front and rear bearing caps with a sliding hammer 8 Crankshaft removal Remove the crankshaft CAUTION Do not cause damage to the bearings NOTE Put identification on each main bearing as to its location in the engine
9. 91 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com Unit mm in Piston and piston ring Bore Size Size code Standard Limit Standard STD 73 oo 3 07 re 0 25 0 0098 25 oversize 78 25 203 Standard 3 0807 9 40 2 0 50 0 0197 50 oversize 78 50 903 0 08 3 0905 8 0012 Taper and out of round 0 01 0 0004 maximum 2 Warpage of top face Using a heavy accurate straight edge and a feeler gauge check the top face for warpage in two positions lengthwise two crosswise and two widthwise as shown in the illustration If warpage exceeds the limit reface the top face with a surface grinder The maximum permissible amount of stock to be removed from the cylinder head and block by grinding is 0 2 mm 0 008 in intotal Checking cylinder block top face for warpage Unit mm in Item Standard Limit block top face Warpage of cylinder 0 05 0 0020 0 10 maximum 0 0039 92 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 COOLING SYSTEM 3 Thermoswitch standard Hang the thermoswitch in the pan of oil with its temperature sensing end below the surface of oil and measure the resistance while heating the oil as shown in the illustration If the resis tance is incorrect replace the thermoswitch 1 Water pump Check the impeller and shaft for rotation
10. Test method Criteria Low idle speed Use a tachometer Standard farm engine 980 rpm Exhaust smoke 1 Check by quickly increasing engine speed under no load Not too much black or gray smoke condition 2 Check by staring load Orifice discharge pattern Remove injection nozzle and reinstall it with orifice toward outside of engine Look at discharge pattern by cranking the engine with starter Good discharge pattern Check delivery valve for wear or damage Check plunger for wear rusting or scoring Check tappet for wear ce 65 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 9 ELECTRICAL SYSTEM REASSEMBLING 1 starter Follow the reverse of disassembly and use the procedure that follows 1 Lubrication Lubrication the following starter components with grease after the starter has been assembled a Armature shaft gear and reduction gear b Bearing c Washer and stopper ring of pinion shaft d Pinion e Sliding surfaces of lever ANCAUTION Do not put grease on the starter mounting face brushes commutator and other electrical parts 2 Stopper ring installation Put the stopper ring on the pinion shaft Using a puller pull the pinion stopper to fit the ring in the groove Apply grease to contact surfaces of overrunning clutch and lever 3 Pinion shaft end play adjustment The m
11. 17 and remove cover 9 housing 1 backup elements 12 seal elements 13 busing 2 drive gear 3 bushing 14 bushing 5 driven gear 4 bushing 6 o rings 10 7 and keys 18 PUMP II 1 HOUSING 2 BUSHING 3 DRIVE GEAR 4 DRIVEN GEAR 5 BUSHING 6 BUSHING 7 0 RING 8 FRENGE 9 COVER 10 O RING 11 KNOCK PIN 12 BACK UP ELEMENT 13 SEAL ELEMENT 14 BUSHING 15 OIL SEAL C RING BOLT KEY 3 4 5 6 7 1 1 18 2 Remove snap ring 16 and oil seal 15 from flange 8 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 Pump II disassembling 2 Control valve disassembling 1 Remove plug at unload valve and remove 8 Do 00 3 spring and unload valve 2 Remove plug at poppet and remove plate and spring at spool 3 Remove nuts at poppet and spool Remove spool poppet and spring 4 Remove plug at check valve and remove check valve and spring TO RESERVOIR WHEN NEUTRAL AND LOWER a 12 03 2 an 4 6 0 UNLOADER VALVE VALVE BODY SPRING SPOOL VALVE 1 Remove fixing bolts 12 and remove cover TO RESERVOIR 2 gasket 7 gear A 3 gear B 4 WHEN NEUTRAL es Ge Me ne snap ring 10 and oil seal 9 from body 1 AND LOWER RN A POSITION a mA q sh PUMP TO RESERVOIR JEN R om POSITION P Mm 1 Control valve removal ZA e O Eo Disconnect the linkage at
12. If they do not rotate freely or have noise replace the water pump assembly Resistance at 120 C 30m Q 248 F Temperature at which 111 3 5 C switch is turned ON 232 6 3 F Oil in the pan is hot Any contact can cause severe burns 2 Thermostat standard Hang the thermostat in the pan of water as shown in the illustration The thermostat must be below the surface of the water and its must be away from the sides of the pan Heat the water uniformly in the pan and measure a temperature at which the valve starts opening and a temperature at which the valve lift distance is 8 mm 0 3 in Replace the thermostat if defective Temperature at which 85 1 5 C valve starts opening 180 2 7 F 4 Thermounit standard Temperature at which 95 C Hang the thermounit in the pan of antifreeze valve lift is 8 mm 0 3 in 203 F with its temperature sensing end below the surface of antifreeze and measure the resist ance while heating the antifreeze as shown in the illustration If the resistance is incorrect Water in the pan is hot Any contact can replace the thermounit cause severe burns 50 C 122 F 80 10 Q Standard 80 C 176 F 29 5 2 5 Q 120 C 248 F 10 10 3 Q Antifreeze in the pan is hot Any contact can cause severe burns 93 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 6
13. Item Limit inside micrometer caliper to find the clearance Bend dial indicator reading 0 3 0 012 between the stem and guide If the clearance of valve push rod maximum exceeds the limit replace the guide or valve whichever is badly worn Inside micrometer caliper 5 Valves valve guides and valve seats 1 Diameter of valve stem Measure the diameter of the valve stem as shown in the illustration If the stem is worn Unit mm in beyond the limit or if it is abnormally worn Item Nominal Standard Limit replace the valve s ze 0 02 to Unit mm in Clearance Inlet 0 05 0 10 Item Nominal Standard Limit between valve 0 008to 0 0039 SIze Inlet 6 6 6 56510 ie ad 0 0020 valve 0 260 6 580 and valve 0 05to Diameter 0 25846to 6 500 guide Exhaust 0 085 0 15 of valve 0 25905 0 25591 valve 0 0020to 0 0059 stem Exhaust 6 6 6 530to 0 00335 ee ee Height to 9 5t010 5 O oo top of valve 10 0 39 0 374to guide 0 413 Measuring N O T E diagram Before measuring the valve guides clear the guides of lacquer and carbon J 3 Valve guide replacement a Remove the guide from the cylinder head by pushing it with a tool and an arbor press from the bottom side of the head 80 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com b Install a new guide into the cylinder head by pushing it w
14. oil filter wrench etc are necessary 107 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 5 CLUTCH apes oe 5 1 DISASSEMBLING 1 DISASSEMBLING CLUTCH ASSY 1 Remove the fixing bolts of clutch cover and remove the clutch assy from engine flywheel When loosen the fixing bolts loosen them diagonally cw N r A Release bearing hub 2 Remove cotter pin clevis pin and release lever 3 Pull out the clutch lever with removing the release lever Release lever e Clutch assy Release hub Clutch lever 2 Take out cover assy and disk assy A 3 Hold A older Release bearing Main shaft i 5 2 REASSEMBLING 1 REASSEMBLING CLUTCH LEVER 1 Reassemble the clutch lever release lever release hub with reverse procedure of Clutch cover disassembling Use the following values as adjustment and service standard for the installation For the installation of release bearing depress the inner hub Clutch disk Coupling 2 Make sure the direction of release lever and 2 DISASSEMBLING CLUTCH LEVER release hub for the reassembling 1 Remove the release hub with release bearing by moving the clutch lever 4 J 3 Apply the lithium grease inside of release hub before assembling 108 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 REASSEMBLING CLUTCH ASSY 5 3 ADJUSTMENT 1 Reassemble the clutch assy with reverse 1 CLUTCH PEDAL
15. test a Install the injection nozzle on the tester Slowly operate the tester handle to bleed remove air from the tester b Operate the tester handle at a speed of one stroke per second to make a slow increase in pressure until the valve in the injection nozzle starts to open Read the maximum gauge pressure at the instant fluid flows from the tip c If the injection pressure is incorrect disassemble the nozzle and change the thickness of the washer Injection pressure 140 kgf cm valve opening pressure 1991 psi Standard 13729 kPa X TS Fo NOT EN An increase or decrease of washer thickness by 0 1 mm 0 004 in will vary injection pressure by 10 kgf cm 142 psi 981kPa 10 kinds of washer are available in thicknesses from 1 25 mm 0 0493 in to 1 70 mm 0 0669 in in increments of 0 05 mm 0 0020 in P AWARNING When the injection nozzles are tested be sure to wear eye protection Fuel comes from the orifices in the nozzle tip with high pressure The fuel can pierce go through the skin and cause serious injury to the operator Keep the tip of the nozzle pointed away from the operator and into the fuel collector p 2 Orifice restriction test a Look at the orifice discharge pattern shape of discharge when fluid begins to flow through the injection nozzle The discharge must be straight Any change is an indication of a bad nozzle b Operate the tester h
16. 079in by liner 2 Install the sleeve to hub that the bigger chamfer side of sleeve face to spline step side of hub Front ai Spline side 3 Install the spring with shifting the setting position of spring between both sides of hub Spring Front side Buck side K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 COVER D REINSTALLATION 2 Shuttle linkage Reinstall the cover D sub assy with Adjust the wire length See page 16 reverse procedure of removal Use following values as adjustment and 4 COVER D SUB ASSY PES RoE UE Te service standard for reassembling Reassemble the cover D sub assy with reverse procedure of dis assembling 1 Shuttle Shaft 1 Adjust the endplay at A and B to 0 002 0 079in by shim Detail x rea AS E i Taa e malen FIL eles geese oad aserise Gor Ses ru bs ww j A 120 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 6 6 TRANSMISSION CASE REASSEMBLING 2 COVER E SUB ASSY REASSEMBLING Redssomble the transmission casewith Reassemble the rear differential case with reverse procedure of disassembling reverse procedure of disassembling Use following values as adjustment and service 1 REAR DIFFERENTIAL CASE REASSEMBLING i standard for reassembling Reassemble the rear differential case with 1 Drive shaft reverse procedure of disassembling Use i following
17. 6 9 QTS Fuel Tank lL_ L L35 liters 9 2 Gallons NOTE Use the capacities listed above only as a guide Always use the dipstick or level plug to make sure the units are filled to the correct level Fuel Specifications A P I Gravity Min 34 Flash Point Min 60 C 140 F Cloud Point Wax Appearance Point Max 21 C 5 8F Pour Point Max ___ _ __ 14 8 F Distillation Temperature 90 Point 282 to 338fIC 539 to 64 0fIF Viscosity at 38fIC Centistokes A 2 0 t0 4 3 Saybolt second Universal _ ___ 32 to 40 Cetane Number Min 43 45 to 55 for winter or high altitude Water and Sediment by Volume Max ___ 0 05 of 1 Sulfer by weight Max H _ __ 0 50 of 1 Copper Strip Corrosion Max ___ No 2 Ash by weight Max __ _ _ 0 01 of 1 Fuel Filter Cup Service Interval __ Every 10 Hours Fuel Filter Element Change Replace yearly or as needed Fuel injectors Valve Leakage Rate No Leakage Permissible Slight Moistening of the Nozzle Tips is allowed 7 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 POWER TRANSMISSION DIAGRAM 2700RPM
18. A 14 and remove lever A 14 and lever B 13 2 Remove snap ring at link H 7 and link 6 and remove link H 7 pin and collars 3 156 1 CONTROL VALVE 2 GUIDE 3 ROLLER 4 SPRING POWER ARM 6 LINK 7 LINK H 8 PLATE 9 POSITION SHAFT 10 DRAFT SHAFT 11 SHAFT 3 Remove spring 4 4 Remove snap ring at position shaft 9 and draft shaft 10 and disconnect from link B 17 5 Remove snap rings at link J 18 and remove link J 18 6 Remove snap rings at link E 20 and remove link E 20 7 Remove spring pin at arm 12 and remove arm 12 shaft 11 and link 19 8 Remove pin from power arm K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 POSITION CONTROL LEVER REMOVAL 1 Remove piston control lever 2 Remove rod A 3 Remove plate F UP DOWN POSITION CONTROL LEVER SO eer LOCK NUT SHIM 1 SCREW 4 PRATER P LIFT CASE 4 FLOW CONTROL VALVE DISASSEMBLING E SNY 1 Loosen lock nuts 3 and remove screw 4 oe Ef OF SHIM 2 XG plate 5 washer and spring 6 p ef Q A SPRI 2 Remove sleeve 8 ball 9 and spring 10 a BALL 9 K g SLEEVE 8 3 Remove fixing bolts of plate 7 and remove SPRING 6 i NUT 3 plate 7 shims 1 and 2 3 PLATE 5 157 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 10 3 MAIN HYDRAULICS REASSEMBLING Reassemble the main hydraulics with reverse procedu
19. FINAL CASE 1 Remove fixing bolts of knuckle arm and DISASSEMBLING remove knuckle arm from gear case 2 Remove fixing bolts of cover and remove Knuckle arm L H cover from gear case 3 Remove snap ring 1 and remove bearing 2 gear 38T liner and axle shaft from cover 4 Remove snap ring 3 and bearing 4 from cover Axle shaft 4 KING PIN CASE DISASSEMBLING 1 KING PIN CASE 2 KING PIN SHAFT 3 LINER 6 9 DIFFERENTIAL SHAFT 0 GEAR 13T 1 ARM HOLDER 2 COVER 3 BEARING 4 BEARING 8 CENTER CASE L H 1 1 1 1 1 133 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 1 Remove fixing bolts of king pin case assy and remove king pin case assy 2 Remove fixing bolts of arm holder 11 and remove arm holder 11 from king pin case 1 3 Remove fixing bolts of cover 12 and remove cover 12 from king pin case 1 4 Remove king pin shaft 2 liners 3 bearings 13 14 gear 18T and gear 13T from king pin case 1 3 CENTER CASE DIFF CASE DISASSEMBLING 1 CENTER CASE R H 2 CENTER CASE L H 3 DIFFERENTIAL CASE 4 RING GEAR 5 SIDE GEAR 6 PINION 7 DIFFERENTIAL SHAFT 8 GEAR 14T 9 PINION SHAFT 0 LINER 1 S 10 JO LINER 12 O RING 13 DRAIN PLUG 14 JOINT 15 BEARING DIFFERENTIAL CASE 1 1 12 Bearin 2 a 1 Remove gear 14T 8 bearing 15 and diff shaft 7 4 Disassemble
20. R H and brake link R H Remove the spring pin and remove the brake pedal L H 2 R H and brake shaft 1 from bracket Remove snap ring from link shaft 5 Remove fixing bolts of link shaft and remove link shaft 5 Brake arm SH T al 7 aie Ly Brake a H 2 6 1 BRAKE SHAFT 4 JOINT 2 ROD 5 LINK SHAFT 3 BRAKE PEDAL R H 6 BRAKE LINK L H 7 ROD K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 6 Disconnect the brake rod between brake link 7 4 DIFFERENTIAL CASE ASSY R H and R H brake lever REASSEMBLING Reassemble the differential case assy with 7 Remove snap ring and remove brake link R H reverse procedure of disassembling from link shaft 1 DIFFERENTIAL CASE ASSY REASSEMBLING Reassemble the differential case assy with reverse procedure of disassembling Use following values for reassembling of differential case assy as adjustment and service standard 8 Remove fixing bolts of link shaft and remove link shaft 9 Remove fixing bolt of parking brake lever 6 and remove parking brake collar and spring from bracket Prakejassy Ru 1 Adjust the backlash between diff pinion gear ee and diff side gear to 0 004 0 012 in by adjusting liner 9 2 Apply bond threebond 137 to the fixing bolts of ring gear Tightening torque of ring gear fixing bolts 30 38 36 1 7lbfeft 3 Install the spring pin in the manner that
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22. be checked for ahead e Clogged air cleaner e Poor quality fuel 2 Inspection procedure Is injection timing correct not too advanced ae Make adjustment to the timing Yes Oo Is solenoid switch normal P Check the switch G Yes Is injection pressure injection nozzle valve No Make adjustment to the pressure opening pressure correct not too low gt J Pan amp Yes Is compression pressure correct NO Check valves piston rings and cylinder head gasket 4 Yes i Fuel injection pump is faulty 28 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com Problem 2 Overheating 1 Items to be checked for ahead Overheating might also be caused by abnormal operating conditions If the engine is over heating but its cooling system is not cont ributing to this trouble it is necessary to check the difference between the ambient temper ature when the engine is in normal operation with the thermostat fully open If the ambient temperature is higher than the normal coolant temperature by more than 140 F 108 C investigate other items than those related to the engine cooling system e Insufficient coolant and exterior coolant leaks e Loose fan belt e Radiator core openings plugged with dirt 2 Inspection procedure Are cooling system components water pump water hoses No radiator thermostat and cylinder he
23. bracket K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 Alternator 1 through bolts 2 pulley 3 rotor 4 rear bearing 5 bearing retainer 6 front bearing 7 front bracket Re 8 stator core 9 brush holder 10 rectifier 11 rear bracket Disassembly procedure 3 Stator core and rectifier removal 1 Stator core separation from front bracket a Unsolder the leads from the rectifier and a Pry the stator core off the front bracket remove the stator core from the rectifier with a screwdriver as shown in the illustration CAUTION 4 Unsolder the leads as quickly as possible to CAUTION prevent damage to the diodes in the rectifier Be careful not to insert the screwdriver too deep Damage to the stator core can be the result b Remove the screws that hold the rectifier in position and remove the rectifier 2 Pulley removal a Hold the rotor assembly in a vise by using thick cloth as shown in the illus tration Remove the nut that holds the pulley in position and remove the pulley and spacer b Remove the rotor assembly from the front bracket Unsolder Rectifier 64 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 Injection pump Check the injection pump for items listed in the chart below and replace it if defective Do not attempt to make repairs by disassembling Test item
24. cap 27 DRIVER 2 Turn spool 17 and sleeve 16 until pin 20 comes to horizontal Push spool 17 2 Remove rota set 24 and o ring 21 ang SIEVE 16 and ae seal grand bushing 3 from housing SEAL GRAND BUSHIONG ROTA SET 3 Remove release bearing 7 and thrust 3 Remove drive 23 and spacer plate 22 needle 8 from spool 17 and sleeve 16 4 Remove o ring from housing THRUST NEEDLE RELEASE BEARING SPACER PLATE 22 DRIVE 23 O RING 143 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 Pull out spool 17 and sleeve 16 from housing Pull them out to opposite side of flange 5 Remove pin 20 from spool 17 and sleeve 16 assy PIN 6 Push spool in the sleeve slightly as shown and remove centering springs 19 6 pieces from spool Remove spool 17 from sleeve 16 by pulling to opposite direction of centering spring 19 removal CENTERING SPRING 19 Do not disassemble or adjust the adjust plug for relief pressure setting at dealer 9 3 HYDRAULIC CYLINDER DISASSEMBLING 1 HYDRAULIC CYLINDER ASSY REMOVAL 1 Remove hydraulic hoses 2 hoses from hydraulic cylinder 2 Drain coolant from radiator and remove radiator drain hose s Ias S m a Te RD we K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 Disconnect battery negative code and positive 6 Remove c
25. clearance is out of limit replace them limit 0 197 in NOTE Replace outer ring inner ring and corn by set 2 Synchronizer sleeve Hub a Make sure synchronizer sleeve and hab can be slided smoothly b Make sure there is no damages on both end of sleeve NOTE a Replace the synchronizer sleeve and hab by set 3 Synchronizer spring a Make sure there is no deformation or breakage Installation direction of sleeve Slit 124 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 6 Checking the hydraulic clutch 1 Clutch disk Measure the clutch disk thickness and check the wear of disk In case of the depth of groove of disk is out of service limit replace the disk Depth of groove Standard value 0 0028 0 0079 in Service limit 0 0012 in 2 Steel plate Check the flatness of steel plate In case that the flatness of steel plate is out of 1 Case 9 Brake disk service limit replace the steel plate 2 Piston 10 Seal ring set Flatness 3 Seal ring 11 Gear set 40T Standard value Less than 0 0059 in 4 Disk assy 12 Seal ring Service limit 0 0118 in 5 Ring set 13 Ring 6 Spring 14 Back plate 3 Elston ane Seal ning 7 Washer 15 Belleville spring Check the wear of piston and seal ring 8 Return plate 16 Ring 125 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 7 REA
26. in position with its oil holes in alignment with those of the oil gallery Notch in bushing Ends of bushing 3 Lobe lift Measure the lobe height and base circle as shown in the illustration Subtract the base circle from the lobe height to find the lobe life If the lobe lift exceeds the limit replace the camshaft 2 Bushing replacement Use Camshaft Bushing Installer ST332340 special tool for camshaft bushing replacement a Removal Remove the oil pan Using a remover end of the Installer push out the bushing into the cylinder block Crush and take out the bushing from the block 84 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com Unit mm in 2 Clearance between tappet and cylinder Item Standard Limit block Lobe height 35 72 34 72 Measure the diameter of the tappet and the of camshaft 1 4063 1 3669 bore in the cylinder block for the tappet to find the clearance If the clearance exceeds the 2 Fuel injection pump camshaft limit replace the tappet Measure the lobe height and base circle as Unit mm in shown in the illustration Subtract the base Item Standard circle from the height to find the lobe life Clearance between 0 15 0 0059 If the lobe lift exceeds the limit replace the tappet and cylinder block camshaft Unit mm in Item Standard Limit Lobe height of fuel injection 44 1 73 43 1 69 pump camshaft
27. it to the specified torque 2 Thermostat installation 1 Put the thermostat in the thermostat case 2 Put a new gasket in position on the thermostat case Install the thermostat assembly in position on the cylinder head To be coated with thread sealant Three Bond 1104 Tightening torque 2 3 0 4 kgf m 16 6 3 Ibf ft 22 6 4 N m 3 Cooling fan installation 1 Install the spacers in position in the fan as shown 2 Install the pulley in position on the water pump Install the fan and spacer combi nation in position on the pulley 70 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com Adjusting plate bolt Apply 22lbs 10kgf 98 N force midway maa between crankshaft pulley and alternator pulley 11 ELECTRICAL SYSTEM REINSTALLATION 1 Glow plug installation Install the glow plug in position in the precombustion chamber and tighten in to the specified torque 1 75 0 25 kgfem Tightening torque 12 7 1 8 lbfeft 17 2 2 5 Nem 2 Alternator installation 1 Put the alternator in position Install the adjusting plate bolt in position to hold the alternator in position 2 Put the belt in position on the pulley Move the alternator away from the engine to make an adjustment to the belt 3 Tighten the bolts 4 Make sure the deflection tension of the belt is correct Unit in mm Deflection under 22 lbs 0 4 to 0 5 10 kgf 98 N f
28. lead and stator core as shown in the illustration Any continuity shows there is a grounded circuit in the stator core Replace the stator core elas an f ENE AFAA VEEN b Test for continuity between the slip ring and shaft or core as shown in the illustration Any continuity shows there is a grounded circuit in the field coil Replace the field coil 98 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 Brushes a Make replacement of brushes that have been worn down to or beyond the wear limit line oR Wear limit line b To remove the brushes from the brush holder for replacement unsolder the leads from the brushes This will permit removal of the brushes and springs Unsolder Brush holder c To install the new brushes put them in position in the brush holder and solder the leads to the brushes 3 Glow plug Test for continuity between the terminal and body as shown in the illustration Item Standard Resistance 0 55 Q K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 6 ADJUSTMENT 1 VALVE CLEARANCE NOTE Make an adjustment to the valve clearance when the engine is cold 1 Slightly loosen the cylinder head bolts and retighten them to the specified torque in number sequence 9 0 5 kgfem Tightening torque 65 4 Ibfeft 88 5 Nem 2 Find top dead center comp
29. shaft Snap ring 3 O Snap ring 2 Counter shaft ge 09 Liner Gear 31T Snap ring 1 Gear 27T Gear 30T 3 Remove drive shaft Liner K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 Disassemble PTO hydraulic clutch assy 1 Case 9 2 Piston 10 3 Seal ring 11 4 Disk assy 12 Seal ring 5 Ring set 13 Ring 6 Spring 14 Back plate 7 Washer 15 Belleville spring 8 Return plate 16 Ring 3 4WD SHAFT DISASSEMBLING AWD shaft Ae O sy G Q X Bushing Sleeve X Cover C 112 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 6 2 CENTER CASE DISASSEMBLING 2 COVER C SUB ASSY DISASSEMBLING 1 Disassemble drive shaft 1 Remove drive shaft and remove pipe shaft 2 Remove bearing 1 gear 18T collar 2 gear 23T gear 29T collar and gear 35T 1 COVER C SUB ASSY REMOVAL 1 Remove the fixing bolts of main shift lever holder and remove the holder Cover C yy OW Drive shaft gt Collar 2 lt 4 Liner RS BY Bearing 1 Gear 18T t Gear 23T Gear 29T Gear 35T 2 Disassemble select shaft 1 Remove select shaft with gears 2 Remove bearing14 and remove synchronize gears and hubs 3 Remove bearing 16 and remove gear 24 collar 23 gear 21 and collar 22 3 Remove fixing bolts of cover C and remove cover C assy Adaputa Shaft rail ow Shift fork NG 1 Select shaft 13 Spr
30. 1 3 4 2 180 After the valve clearance on the valves for all cylinders has been adjusted turn the crankshaft two or three times and make sure the valve clearance is correct K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 FUEL INJECTION TIMING 1 Preparation 1 Close the fuel filter valve 2 Disconnect the No 1 fuel injection pipe from the cylinder head and injection pump 3 Remove No 1 delivery valve holder from the injection pump Remove the delivery valve and spring from the holder Restore the delivery valve holder only to the injection pump 4 Connect the fuel injection pipe to the injection pump 5 Hold the speed control lever in the low speed position 2 Slowly turn the crankshaft clockwise looking at the free end of the injection pipe The instant fuel stops coming out is the fuel injection timing NOTE Turn the crankshaft in reverse direction just a little and do Step 2 again to verify the injection timing 2 Inspection 2 2Fuel flow method 1 Open the fuel filter Turn the starter switch key to ON position NOTE Fuel will come from the injection pipe with high pressure when the starter switch key is turned to ON position if the engine is equipped with an electric fuel pump Direct fuel flow into the container 3 The fuel injection timing is correct if IT mark on the crankshaft pulley is aligned with the mark on th
31. 16 15 Main bearing upper 16 Cylinder block Reassemble the cylinder block crankshaft 2 Install the flanged bearing in the No 3 pistons and oil pan with reverse procedure journal of disassemble Use following values for 3 Lightly lubricate the inside surfaces of the reassembling as adjustment and service bearings with engine oil standard 1 Main bearing installation 1 Install the upper halves of the main bearings in the cylinder block and the lower halves in the main bearing caps so their tabs fit into the notches in the cylinder block and the main bearing caps 52 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 Crankshaft installation 1 Clean the crankshaft with cleaning solvent and blow dry with compressed air 2 Fasten a hoist to the crankshaft and hold it in horizontal position Carefully put the crankshaft in position in the cylinder block 3 Lightly lubricate the crankshaft journals with engine oil 3 Main bearing cap installation 1 Coat the mating surfaces of the rear bearing cap and cylinder block with Three Bond 1212 2 Install the main bearing caps in position Make sure the number arrow head on the main bearing cap is toward the front of the engine 3 Tighten the main bearing cap bolts finger tight only Install the front and bearing caps in position so their end faces are even with the end faces of the cylinder block 4 Tight
32. 166 167 168 170 www mymowerparts com I GENERAL 3 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 1 SAFETY This a symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED The message that follows the symbol contains important information about safety Carefully read the message Make sure you fully understand the causes of possible injury or death ree To prevent injury always follow the Warning Caution and Danger notes in this section and throughout the WARNING When working in the area of the manual fan belt with the engine running avoid loose clothing if possible and use extreme caution Bo4 WARNING Read the operators manual to liari ith trol belie KONSI MWIN ile BONSE Corie WARNING When doing checks and testing aiai on the equipment hydraulics follow the procedures as they are written DO NOT WARNING Operate the machine and change the procedure equipment controls from the seat position ly A d xri injury M ONET MENOA Could TERUNA serous WARNING When putting the hydraulic Ae cylinders on this machine through the necessary cycles to check operation or to WARNING This is a one man machine no sie n fee a circuit Make sure all people riders allowed are out ol the way aia AWD Vdd WARNING Before starting the engine study the Operators Manual safely messages Read all safety signs on the machine Clear the area of other persons Learn and practice s
33. 2 Filter installation 1 Wipe the installation surface of filter base and apply the oil to the packing of filter for the installation 2 Turn 2 3 3 4 further at the point of filter packing touch to installation surface of filter base by hand MARK aaa 0 59 0 66 IN SN O MSs OIL FILTER a BALL SPRING l a gt K amp T Saw Shop 606 678 9623 or 606 561 4983 3 Tightening torques of hydraulic line www mymowerparts com 1 STANDARD BOLT TORQUES Bolt Grade Indicated on Bolt Head 2 STANDARD TORQUE DATA FOR REPLACEMENT NUTS AND BOLTS Bott Size 4T 6T 7T 8T 1 5 to 2 Ib ft 3 to 4 Ib ft 4 to 4 5 lb ft 4 5 to 5 b ft 5mm 2 to 3 Nm 4 to 5 Nm 5 to 6 Nm 6 to 7 Nm 4 to 5 Ib ft 6 to 7 5 Ib ft 7 5 to 9 Ib ft 9 to 10 5 Ib ft 6mm 5 to 7 Nm 8 to 10 Nm 10 to 12 Nm 12 to 14 Nm 9 to 12 5 Ib ft 15 to 18 5 Ib ft 18 5 to 21 5 Ib ft 21 5 to 25 lb ft 8mm 12 to 17 Nm 20 to 25 Nm 25 to 29 Nm 29 to 34 Nm 15 to 21 5 lb ft 29 to 36 Ib ft 36 to 43 5 Ib ft 43 5 to 50 Ib ft 10 mm 20 to 29 Nm 39 to 49 Nm 49 to 59 Nm 59 to 69 Nm 32 5 to 40 Ib ft 50 to 58 Ib ft 61 to 68 5 lb fl 69 to 79 Ib ft 12 mm 44 to 54 Nm 69 to 78 Nm 83 to 93 Nm 93 to 107 Nm 47 to 58 lb ft 72 5 to 87 b ft 87 to 97 5 lb ft 97 5 to 108 5 lb ft 14mm 64 to 78 Nm 98 to 118 Nm 118 to 182 Nm 132 to 147 Nm 65 to 80 Ib ft 94 to 108 5 Ib ft 112 to 127 Ib ft 130 to 144 5 Ib ft 16
34. 23 or 606 561 4983 www mymowerparts com b The valve margin must be not less than the limit If the margin seems to be less hes a 3 to 1 8 mm than the limit when the valve is refaced 0 051 to 0 071 in replace the valve os KK Y K W 45 60 N 7 Valve lapping Be sure to lap the valves in the seas after refacing or replacing the valves or valve seats a Put a small amount of lapping compound on the valve face 6 Valve seat refacing a Before refacing the valve seat check the a N O T D clearance between the valve and guide a Do not put lapping compound on the and replace the guide if necessary valve stem b Cut the valve seat with a valve seat b Use a lapping compound of 120 to 150 cutter commercially available or grind mesh for initial lapping and a compound it with a valve seat grinder and finish of finer than 200 mesh for finish lapping the width of valve seat and the angle of c Mixing the compound with a small seat face to the correct values amount of engine oil will help put the g Pompous on the valve face uniformly F b Using a lapping tool hold the valve against the seat and rotate it only a part of a turn then raise the valve off its seal rotating it to a new position Press the valve against the seal for another part of a turn Repeat this operation until the compound wears and loses its cutting property Unit mm in Item Standard Limit Angle of 45 se
35. 3 1 HOUSINGS REMOVAL 2 Remove the main shift lever linkages 3 Lift the center case and remove it from 1 CLUTCH HOUSING REMOVAL transmission case 1 Remove the fixing bolts between clutch housing and center case 2 Lift the clutch housing and remove it from center case Center case Clutch housing Center case 2 CENTER CASE REMOVAL 1 Remove the fixing bolts between center case and transmission case 21 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 HYDRAULIC LIFT CASE REMOVAL 1 Remove the seat and seat bracket 2 Remove the lever grip from position control lever and remove the lever guide by removing the fixing bolts 3 Remove the top link bracket Top link bracket 8 REAR AXLE CASE REMOVAL 1 Remove the ROPS 1 Remove hinge pin and position pin Remove ROPS upper flame 2 Remove fixing bolts of ROPS lower flame and remove ROPS lower flame 4 Remove the fixing bolts of hydraulic lift case and lift up the hydraulic lift case to remove 22 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 Remove mounting bolts of ROPS lower bracket and remove the bracket 2 Disconnect the brake rod at brake lever on the rear axle case bs Rops lower beached i i i r Lj I 3 Lift the rear axle case and remove the mounting bolts 4 Remove the rear axle assy 3 2 HOUSING REINSTALLATION Reinstall the housin
36. 6 6 6 6 5 LUBRICATION SYSTEM 1 0il pump Visually check the pump for rough rotation or other defects Replace the pump assembly if defective 2 0il pressure switch 1 Test for continuity between the terminal and body with an ohmmeter as shown in the illustration No continuity is the cause for replacing theswitch 2 lnsert a small diameter bar into the oil hole in the switch and lightly push it in to test for no continuity as shown in the illustra tion Any continuity is the cause for replacing the switch 3 Apply a pressure air of 0 5kgf cm 7psi 49kpa to the switch through the oil hole to test for no continuity Any continuity is the cause for replacing the switch Also check for air leaks Any air leak is an indication of a ruptured diaphragm In such a case replace the switch 3 Pressure relief valve 1 Check the valve seat for contact Check the spring for damage 2 Measure the oil pressure at which the relief valve opens the oil pressure with the engine running at the rated rpm If the pressure is not correct remove the cap nut increase or decrease the amount of shims The engine oil pressure tap is located on the right side of the engine Relief valve 3 5 0 5kgf cm Opening pressure 50 7psi 343 49kPa Cap nut moo Lin ii mii ci LIA See Si Nill Shims 94 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 6 ELECTRICAL S
37. ADJUSTMENT procedure of disassembling Use following 1 Depress the clutch pedal by hand and values as adjustment and service standard measure the amount of pedal free play at for the assembling pedal Pedal free play 0 79 1 18in 2 Set the clutch disk surface which spline boss sticking out longer face to clutch housing n Clutch pedal az Clutch housing 2 In case that the free play is out of standard value adjust the rod length by turning the 3 Apply the lithium grease to the spline of clutch adjust nut disk 4 Before installing the clutch assy to engine clean flywheel end Aline the center of clutch Blake wed disk ID and flywheel bearing ID 5 Tightening torque of clutch assy fixing bolts Baek 18 21 7 lbfeft Clutch pedal Clutch lever j Spring i Saporte N we o gt b Adjust nut Apply the grease at pivot point of the pedal 109 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 STOPPER ADJUSTMENT 1 Adjust the stopper length and lock the stopper by lock nut Stopper length 0 79in 2 Depress the clutch pedal to the stopper and make sure the clutch is disengaged 5 4 CHECK AND MAINTENANCE 1 CLUTCH DISK 1 Measure the depth from clutch lining surface to rivet Rivet Depth from linig surface of livet 0 051 0 075 0 1378 in 110 2 In case that the measurement is out of the following lim
38. E DISASSEMBLING 6 3 TRANSMISSION CASE DISASSEMBLING 6 4 CLUTCH HOUSING REASSEMBLING 6 5 CENTER CASE REASSEMBLING 6 6 TRANSMISSION CASE REASSEMBLING 6 7 CHECK AND MAINTENANCE 7 REAR AXLE 7 1 DIFFERENTIAL CASE ASSY DISASSEMBLING 7 2 REAR AXLE DISASSEMBLING 7 3 BRAKE CONTROL DISASSEMBLING 7 4 DIFFERENTIAL CASE ASSY REASSEMBLING 7 5 REAR AXLE REASSEMBLING 7 6 BRAKE CONTROL REASSEMBLING 7 7 CHECK AND MAINTENANCE 8 FRONT AXLE 8 1 FRONT AXLE DISASSEMBLING 8 2 FRONT AXLE REASSEMBLING 8 3 FRONT AXLE CHECK AND MAINTENANCE 9 STEERING 9 1 OPERATOR CONTROL AREA DISASSEMBLING 9 2 STEERING UNIT DISASSEMBLING 9 3 HYDRAULIC CYLINDER DISASSEMBLING 9 4 OPERATOR CONTROL AREA REASSEMBLING 9 5 STEERING UNIT REASSEMBLING 9 6 HYDRAULIC CYLINDER REASSEMBLING 9 7 CHECK AND MAINTENANCE 10 HYDRAULICS 10 1 MAIN HYDRAULICS DISASSEMBLING 10 2 HYDRAULIC LIFT DISASSEMBLING 10 3 MAIN HYDRAULICS REASSEMBLING 10 4 HYDRAULIC LIFT REASSEMBLING 10 5 HYDRAULIC LINE CHECKING 10 6 HYDRAULIC CHECK AND MAINTENANCE 11 ELECTRICAL 11 1 ELECTRICAL DIAGRAM 11 2 SPECIFICATION 2 K amp T Saw Shop 606 678 9623 or 606 561 4983 108 108 108 109 111 111 113 115 117 118 121 123 126 126 126 127 128 129 130 131 132 132 135 139 141 141 142 144 146 147 150 152 153 153 155 158 159 164
39. MAINTENANCE 1 BACKLASH 1 Check the backlash of diff case assy and end play In case that the measurement value is out of standard readjust it 2 Check the backlash of bevel gears In case that the backlash is out of standard readjust it Item Standard value in Backlash between bevel 0 008 0 0157 gear14T and 18T Backlash between bevel 0 008 0 0157 gear 13T and 38T 2 CLEARANCE AT BUSHING 1 Check the clearance between front bracket rear bracket and bushing In case that the clearance is out of service limit replace the bushing ltem Standard value in Service limit in Clearance between 0 0012 0 0026 0 0008 holder and front bracket Clearance between case 0 0012 0 0032 0 0008 and rear bracket bushing 2 Check the clearance at bushing of final gear case L H R H In case that the clearance is out of service limit replace the bushing Item Standard value in Service limit in Clearance between king 0 00118 0 0079 pin case and bushing 0 00315 Item Standard value in Backlash of side gear and pinion 0 004 0 012 End play of diff assy 0 0 004 Backlash between pinion 0 0098 shaft and ring gear 0 0138 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 CLEARANCE BETWEEN KNUCKLE ARM HOLDER AND BUSHING 1 Check the clearance between knuckle arm holder and bushing In case that the c
40. MENT NUTS AND BOLTS Torque Specifications 10 SIZE GRADE 8 8 GRADE 10 9 5mm 4 Ib ft 5 5 Nm 5 5 Ib ft 7 5 Nm 6mm 7 Ib ft QNm 9 Ib ft 12 5 Nm 8mm 17 Ib ft 22 5 Nm 23 Ib ft 31 5 Nm 10mm 32 5 Ib ft 44 Nm 46 lb ft 62 Nm 12mm 57 Ib ft 77 5 Nm 81 Ib ft 110 Nm 14mm 88 5 Ib ftt 20 Nm 125 5 Ib ft 170 Nm 16mm 140 Ib ft 190 Nm 196 Ib ft 265 Nm 18mm 192 Ib ft 260 Nm 269 5 Ib ft 865 Nm 9 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 6 PRECAUTIONS FOR DISASSEMBLY Place the tractor on level and hard ground put the range shift lever in the L position apply the park brakes and stop the engine Put blocks in front of and behind the front wheels 1 Disassembly 1 Always use tools that are in good condition and be sure you understand how to use them before performing any job Use a work bench if necessary Also use bins to keep removed parts in order of removal 2 When disassemble the electrical parts place the stater key on OFF position and disconnect the negative side of battery cable In case of removing the battery disconnect the negative cable first and disconnect positive cable 3 Parts must be restored to their respective components from which they were removed at disassembly This means that all parts must be set aside separately in groups each marked for its component so that the same combination or set can be reproduced at assembly 4 Carefu
41. Move the joint to front side and remove the 4WD shaft Tape Red 3 BATTERY CODE DISCONNECTION 1 Disconnect Battery Code Negative and joint loosen fixing bolts of bracket 4WD shaft cover A 13 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 FRONT amp REAR HOLDER REMOVAL 1 Remove mounting bolts of front holder 5 FRONT AXLE ASSY REMOVAL 1 Lift up the chassis by jack and remove the front axle assy from chassis 1 2 FRONT AXLE ASSY REINSTALLATION Install the front axle assy with reversed procedure of removal Use following adjustment and service standards for the reinstallation 1 When reinstall the front axle assy to chassis tighten the mounting bolts of the rear holder first Tightening Torque 86 8 97 6lbf ft 12 13 5 kgf m 2 Measure the clearance between front holder and chassis Put the shims of which thickness is half of the measured clearance Tighten the mounting bolts of Front Holder Tightening Torque 61 5 68 7lbf ft 8 5 9 5 kgf m 3 When reinstall the hoses to the cylinder install the hose with red tape to lower side of the port 4 After install the hoses turn the steering wheel to left and make sure the front axle is steered to left 5 When reinstall the 4WD shaft apply the grease to the spline 6 Make sure the snap ring is in the groove 7 After reinstall the front axle assy check the toe in and readju
42. NTROL SPRING SLEEVE CONTROL MARK SPOOL GROOVE FOR SPRING 2 Make sure that the spool 17 can be turned smoothly 3 In case that the sleeve and spool have aliment mark aline the mark 4 Put together 3 springs and other 3 springs back to back and install them to spool and sleeve Use special tool for their installation as shown below CENTERING SPRING 19 CENTERING SPRING oo eo Qofo 90 ang S K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 9 6 HYDRAULIC CYLINDER ASSY 1 Packing case tightening torque 72 33lbfeft REASSEMBLING Apply the threebond 1901 to thread Reassemble the hydraulic cylinder assy with reverse procedure of disassembling N O T E 1 HYDRAULIC CYLINDER ASSY In case of removing the nose take the REASSEMBLING following procedure for air removal Reassemble hydraulic cylinder assy with reverse procedure of disassembling Use following values for reassembling as adjustment and service standard 1 Set the engine speed to 1500 2000 rpm 2 Turn the steering wheel upto maximum steering angle and relief the relief valve for approximate 3 seconds 3 Turn the steering to left and right by turns and repeat it 3 to 4 times Front axle 150 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 Direction of installation of dust seal and U packing is as shown in the following drawing 3 After tighten the
43. PTO 8 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 5 TIGHTENING TORQUES STANDARD BOLT TORQUES Bolt Grade Indicated on Bolt Head Bolt Size 4T 6T 7T 8T 1 5 to 2 lb ft 3 to 4 b ft 4 to 4 5 lb ft 4 5 to 5 lb ft 5mm 2 to 3 Nm 4 to 5 Nm 5 to 6 Nm 6 to 7 Nm 4to 5 Ib ft 6to 7 5 Ibft 7 5 to 9 Ib ft 9 to 10 5 Ib ft 6mm 5 to 7 Nm 8 to10 Nm 10 to 12 Nm 12 to 14 Nm 9 to 12 5 Ib ft 15 to 18 5 Ib ft 18 5 to 21 5 lb ft 21 5 to 25 Ib ft 8mm 12 to 17 Nm 20 to 25 Nm 25 to 29 Nm 29 to 34 Nm 15 to 21 5 Ib ft 29 to 36 lb ft 36 to 43 5 lb ft 43 5 to 50 Ib ft 10 mm 20 to 29 Nm 39 to 49 Nm 49 to 59 Nm 59 to 69 Nm 32 5 to 40 Ib ft 50 to 58 Ib ft 61 to 68 5 Ib ft 69 to 79 Ib ft 12mm 44 to 54 Nm 69 to 78 Nm 83 to 93 Nm 93 to 107 Nm 47 to 58 lb ft 72 5 to 87 b ft 87 to 97 5 lb ft 97 5 to 108 5 Ib ft 14mm 64 to 78 Nm 98 to 118 Nm 118 to 132 Nm 132 to 147 Nm 65 to 80 Ib ft 94 to 108 5 lb ft 112 to 127 lb f 130 to 144 5 Ib ft 16mm 88 to 108 Nm 127 to 147 Nm 152to 172 Nm 176 to 196 Nm 87 to 101 Ib ft 123 to 136 5 lb ft 152 to 173 5 lb ft 181 to 203 lb ft 18mm 118 to 137 Nm 167 to 185 Nm 206 to 235 Nm 245 to 275 Nm 108 5to123 1b ft 144 5 to 159 5 Ib ft 173 5 to 203 Ib ft 231 to 260 5 lb ft 20 mm 147 to 167 Nm 196 to 216 Nm 235 to 275 Nm si 314 to 353 Nm STANDARD TORQUE DATA FOR REPLACE
44. R AXLE 7 1 DIFFERENTIAL CASE ASSY DISASSEMBLING 1 DIFFERENTIAL CASE ASSY REMOVAL See page 21 aoe 2 DIFFERENTIAL ASSY DISASSEMBLING 1 Remove the differential lock hub 5 and steel balls 2 Remove the fixing bolts 6 of ring gear and remove ring gear 8 from differential case 3 Remove the spring pin 7 and remove the shaft 4 Remove diff side pinion gears diff side gears and liners 126 7 2 REAR AXLE DISASSEMBLING 1 REAR AXLE ASSY REMOVAL See page 23 Axle shaft Gear 59T 2 REAR AXLE ASSY DISASSEMBLING 1 Remove snap ring and remove liner bearing and gear 59T from axle shaft Remove snap ring bearing and axle shaft from rear axle housing Gear 59T Case L Snap ring Bearing d Cg Oil seal 9 Axle shaft K amp T Saw Shop 606 678 9623 or 606 561 4983 3 BRAKE ASSY REMOVAL 1 Remove fixing bolts of holder 6 2 Remove arm 3 3 Remove brake Assy 4 5 Brake assy L H 1 CASE L H 2 LEVER 3 ARM 4 COM PLATE 5 6 7 gt 5 BRAKE DISK 6 HOLDER 7 SHAFT www mymowerparts com 7 1 1 127 4 3 BRAKE CONTROL DISASSEMBLING BRAKE LH DISASSEMBLING Disconnect the rod 7 between brake link L H 6 and L H brake arm Remove the return spring from brake pedal L H 2 and R H Remove joint 4 to discon nect the brake rod from brake pedal L H 2 and brake link L H 6 brake pedal
45. SASSEMBLING 1 Remove steering unit fixing bolts and remove steering unit 1 from column 2 Remove cap 9 nut 10 and washer and remove steering wheel 8 from shaft 7 3 Remove boot 6 with plate 3 and remove 18 snap ring liner 20 and shaft 7 from d 4 column 2 ex Snap 9 2 STEERING UNIT DISASSEMBLING ring ge tf of i 1 STEERING UNIT REMOVAL NI is a 1 14 ba Remove steering unit fixing bolt and remove steering unit from column 2 STEERING UNIT DISASSEMBLING DUST SEAL RETAINING NUT SEAL GRAND BUSHING O RING OIL SEAL X RING NEEDLE BEARING KIT RELEASE BEARING THRUST NEEDLE RELIEF VALVE ADJUSTER O RING COLER SPRING POPPET CONTROL PARTS ASSY HOUSING CONTROL SLEEVE CONTROL SLEEVE FLAT SPRING CENTERING SPRING PIN O RING SPACER DRIVE ROTA SET O RING SPACER 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 END CAP 8 RETAINER SCREW 9 CHECK VALVE RETAINER SCREW 0 r 2 3 4 5 6 7 8 9 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 30 BALL 142 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 1 Rotary disassembling 2 Controls disassembling 1 Remove screw 28 6 pieces retainer screw 1 Remove retaining ring 2 from housing 29 1 piece and end cap 27 2 Remove o ring 21 from end
46. SSEMBLING Reassemble steering wheel with reverse procedure of removal Use following values as adjustment and service standard 1 Apply grease to spline of the shaft 2 Adjust the end play at shaft to be less than 0 0197 in by liner 3 Tightening torque of steering wheel fixing nut 28 93 32 55 Ibf ft 9 5 STEERING UNIT REASSEMBLING Reassemble steering unit with reverse procedure of disassembling 1 STEERING UNIT REASSEMBLING 5 j RAE 7 a tie Snap o ong ring fe ot I a 5 i 1 NS DUST SEAL RETAINING NUT SEAL GRAND BUSHING O RING OIL SEAL X RING NEEDLE BEARING KIT RELEASE BEARING THRUST NEEDLE RELIEF VALVE ADJUSTER O RING COLER SPRING POPPET CONTROL PARTS ASSY HOUSING CONTROL SLEEVE CONTROL SLEEVE FLATE SPRING CENTERING SPRING PIN O RING SPACER DRIVE ROTA SET O RING SPACER JEND CAP RETAINER SCREW CHECK VALVE RETAINER SCREW BALL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 2 2 2 2 2 3 25 26 27 28 29 30 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 1 Rotary reassembling 1 Install o ring 21 to end cap 24 and tighten with screws 28 29 2 Tightening torque of screws 15 19 lbfeft NOT BE Make sure of location for installation of screw 29 3 Apply grea
47. Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 3 DISASSEMBLING 1 CYLINDER HEAD DISASSEMBLY 1 Rocker cover 2 Rocker shaft assembly 3 Push rod 4 Cylinder head bolt 5 Cylinder head 6 Cylinder head gasket 7 Valve lock 8 Valve retainer 9 Valve spring 10 Valve 11 Stem seal 12 Valve cap 1 Rocker shaft assembly removal 3 Cylinder head bolt removal 1 Remove the bolts that hold the rocker Loosen the cylinder head bolts in two or three stays in position and remove the rocker steps in the sequence shown shaft assembly N O T E 2 Remove the valve caps If any parts on the cylinder head are faulty check the cylinder head bolts for tightness with a torque wrench before loosening them 2 Rocker shaft disassembly Put identification on each rocker arm as to its location on the rocker shaft lt 5 Front Cylinder head bolt loosening sequence 34 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 Cylinder head assembly removal 6 Valve stem seal removal Lift the cylinder head straight up with a hoist Remove the valve stem seals with pliers NOTE NOTE If the gasket is seized and the cylinder head Do not reuse the valve stem seals cannot be separated from the cylinder block tap around the thick side portion of the cylinder head with a plastic hammer 5 Valve and valve spring removal 1 Compress the valve sp
48. USHING lift shaft and 0 011811 bushing 0 003504 Clearance between 0 000787 piston rod and 0 011811 bushing 0 003268 BUSHING LIFT SHAFT Check the Shaft and replace it if seized Replace bushing if the inside coating gray color is worn out 2 CLEARANCE BETWEEN CYLINDER AND PISTON 1 Measure the outer diameter of piston and inner diameter of cylinder Calculate the clearance between piston and cylinder 2 In case that clearance is out service limit replace the parts 166 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 167 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com METER PANEL 1 TURN LAMP OPTION FUEL TEMP COMBINATION PTO HAZARD HIGH TON STARTER L R CHARGE OIL GLOW HIGH PTO METER METER sw SW Sw BEEM SW 7 sw PRES BEEM R w o BORN 1 1 ELEC Beis PANEL CAMERA LIGHT TURN psw 3 AW 34W 3 4w 3 AW 3 dw C3 aw 3 aw 3 4wxd i 8o I I ST O Q Q O o 1 Blac 11 1 ELECTRIC DIAGRAM DOO OOO ba ly Jae 1 OOS AF Ja co ala Am
49. YSTEM 1 Starter 1 Brushes a Wear Replace the brushes if they are worn down to the wear limit line which is the bottom of the border for Mitsubishi mark Replace the brush holder assembly if the brushes are worn beyond the wear limit line A Wear limit line b Brush spring tension Test the spring tension using a new brush as shown in the illustration Read the load when the spring just moves off the brush If the tension is below the limit replace the spring Unit kgf Ibf N Item Standard Limit Brush spring 3 0 6 6 29 4 tension 1 8 4 0 17 7 U K amp T Saw Shop 606 678 9623 or 606 561 4983 c Brush holders Test for no continuity between the positive brush holder and brush holder base as shown in the illustration If there is any continuity between them replace the brush holder Also check the brush holder for loose staking 2 Armature a Commutator runout Support the armature in V blocks and measure the commutator runout with a dial indicator If runout exceeds the limit turn the commutator in a lathe The cut should be made within the limit of the commutator diameter Unit mm in Item Standard Limit Runout of 0 03 0 10 commutator 0 0012 0 0039 Commutator www mymowerparts com o Diameter of commutator Measure the diameter of commutator If it exceeds the limit replace the armature Unit mm in Item Standard Lim
50. ad gasket normal gt Cheek the components 4 Yes Is injection timing correct i ah Make adjustment to the timing amp Yes Are lubrication system components oil filter oil No Check the components and oil level pump and oi screen normal and oil level correct gt amp Yes Is governor adjustment correct No Make adjustment to the governor L e Yes Engine is in continuous full load operation 29 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com Problem 3 Black exhaust smoke 1 ltems to be checked for ahead e Clogged air cleaner e Poor quality fuel 2 Inspection procedure Are valve clearance and injection timing correct a Make adjustment to the clearance and timing amp Yes Is injection nozzle discharge pattern normal No Make adjustment to the nozzles Is injection pressure correct not too high gt amp Yes 9 No k Is compression pressure correct 3 Check valves piston rings and cylinder head gasket amp Yes Fuel injection pump is faulty Problem 4 Erratic idle soeeds 1 ltems to be checked for ahead e Maladjusted engine control e Wrong oil grade for weather conditions e Poor quality fuel 2 Inspection procedure Are valve clearance and injection timing correct 25 Make adjustment to the cle
51. ale use of controls belore operating lt is your responsibility to understand and follow manufacturers instructions on machine operation service and to observe pertinant laws and regulations WARNING f you wear clothing that is too loose or do not use the correct safety equipment for your job you can be injured Always wear clothing that will not catch on objects Extra safety equipment that can be required includes hard hats safety shoes ear protection eye or face protection heavy gloves and reflector clothing aa NOTE Operator s and Service Manuals may be ob tained from your dealer 4 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com WARNING Always use heat protective gloves when handling heated parts ALAA CAUTION Lower all attachments to the ground or use stands to safely support the attachments before you do any maintenance or Service ne CAUTION Pin sized and smaller streams of hydraulic oil under pressure can penetrate the skin and result in serious infection If hydraulic oil under pressure does penetate the skin seek medical treatment immediately Maintain all hoses and tubes in good condition Make sure all connections are tight Make a replacement of any tube or hose that is damaged or thought to be damaged DO NOT use your hand to check for leaks use a piece of cardboard or wood JOGA CAUTION When removing hardened pins such as a pivot pin or a hardened shaft u
52. andle at a speed of one stroke per second to make sure the discharge is straight RIID Good nozzle Discharge pattern for orifice with a Use again restriction Recondition or replace 104 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 Nozzle tip washing and replacement a Loosen the retaining nut and remove the tip from the injection nozzle Wash the needle valve and body in clean diesel fuel After washing put the needle NOTE Keep the needle valves with their respective bodies valve in the body in clean diesel fuel b After cleaning the tip install it in the nozzle and tighten the retaining nut to x the specified torque 9 0 5 kgfem Tightening torque 65 4 Ibfeft 88 5 Nem c lf the injection nozzle is still bad after the tip has been washed replace the tip Needle valve Body NOTE a Do not touch the sliding surface of the needle valve Do not hit the tip when removing it from the b When installing the new nozzle tip injection nozzle remove synthetic resin film from the tip and slide the needle valve in the body in clean diesel fuel to wash off inhibitor _ completely E Tightening torque 5 5 0 5 kgf m 4044 lbf ft 5445 N m Ey Cc Cp Check test force and squareness gt Check for wear or damage Check for too much T carbon on tip of nozzle hA
53. arance and timing amp Yes injection pressure constant aN Make adjustment to the nozzles Is injection nozzle discharge pattern normal Is No G Yes Is compression pressure correct no difference No Check valves piston rings and in Compression pressure between cylinders gt cylinder head gasket amp Yes Fuel injection pump is faulty 30 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com Problem 5 Low power or loss of power 1 ltems to be checked for ahead e Stuck running parts e Wrong oil grade for weather conditions e Poor quality fuel e Clogged air cleaner e Restricted exhaust line Faulty power take off 2 Inspection procedure Are valve clearance and injection timing correct Do l Make adjustment to the clearance and timing amp Yes Are fuel lines free from restriction Is fuel pump operat m Check fuel tank fuel filter and fuel lines ing properly when starter switch is in ON position Yes is governor adjustment correct ne Make adjustment to the governor O Yes R ERTA RRE pattern normal ee Make adjustment to the nozzles amp Yes Is compression pressure correct p Check valves piston rings and cylinder head gaskets Q Yes Fuel injection pump is faulty 31 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts co
54. at face Width of 1 3 to 1 8 2 5 valve seat 0 051 to 0 071 0 098 c After refacing the valve seat put lapping compound on the valve face and lap the valve in the valve seat 82 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com c Wash the valve and valve seat with dry cleaning solvent d Apply engine oil to the valve and lap it in the seat e Check the valve face for contact 6 Combustion jet replacement Replace the combustion jets only when they are cracked or defective 1 To remove the jet insert a 6mm 0 24in diameter round bar through the bore in the cylinder head for the glow plug and tap around the jet Round bar Combustion jet 2 To install a new jet put the jet in position in the head with its tangential orifice in alignment with the center of the main chamber and tap it with a plastic hammer 83 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com Camshaf 2 TIMING GEARS AND FLYWHEEL Front of cylinder bushing 1 Camshaft binek 1 Clearance between journal and bushing Measure the diameter of the journal and the bore in the bushing for the shaft to find the clearance as shown in the illustration If the clearance exceeds the limit replace the os i bushing Camshaft Bushing Unit mm in Installer Item Standard Clearance between b Installation camshaft journal 0 15 0 0059 bas bi APEA and bushing Install a new bushing
55. attery 4 Do not attempt to disconnect the lead from the B terminal of the alternator when the engine is running 5 Battery voltage is being applied to the B terminal of the alternator Do not ground it 6 Do not short or ground the terminal of the alternator with a built in IC regulator 7 Do not blow a spray from the steam cleaner nozzle at the alternator 2 3 Testing voltage setting 1 Connect the alternator to a 12 volt battery with an ammeter a voltmeter and a switch as shown in the illustration 77 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 The voltmeter reading must be zero 0 when the starter switch is in OFF position It must be lower than the battery voltage when the switch is in ON position the engine will not start 3 With one ammeter lead short circuited start the engine 4 Read the voltmeter when the ammeter reading is below five amperes and the engine is running at 1800 rpm and also at 2500 rpm with all electrical loads turned off The voltage setting varies with alternator temperature Generally the higher the alternator temperature the lower the voltage setting Ammeter Battery 12 volts Connections for testing voltage setting Item Standard Voltage setting at 20 C 68 F 14 7 0 3V 2 4 Testing output characteristics 1 Disconnect the battery ground negative cable 2 Connect one ammeter lead to the B terminal of the alter
56. aximum permissible limit of the end play thrust gap for the pinion shaft is 0 5mm 0 020 in a Put the pinion shaft reduction gear washer and snap ring in position in the center bracket b Move the pinion shaft in the axial direction to measure the end play If the end play exceeds 0 5mm 0 020 in make adjustment to it by adding adjusting washer ee ca Gx N p Stopper ring ge Pinion stopper Reduction gear Adjusting washer Washer Snap ring End play 0 5 mm 0 020 in maximum 4 Lever installation Install the lever in correct position 66 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com Front bracket Lever Lever spring Packing 5 Pinion clearance adjustment The pinion clearance must be 0 020 to 0 079 in 0 5 to 2 0mm With the pinion held in cranking position lightly push it toward commutator end to measure free movement clearance If the clearance is not correct make adjustment to it Increase the amount of packings if the clearance is too large decrease it if the clearance is too small Pinion clearance 0 5 to 2 0 mm 0 020 to 0 079 in 67 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 Alternator Follow the reverse of disassembly and use the procedure that follows a The rear bearing has a groove for the snap ring Install the snap ring in this groove making sure its tab is in the deep p
57. ble counter shaft 1 Remove bearing 1 and remove gear 18T collar and gear 31T from counter shaft 2 Remove bearing 2 and remove washers gear 24T and needle bearing Peale 24T Bearing 2 Washer cen aa a Gear 31T Counter shaft 116 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 AWD shaft disassembling 6 4 CLUTCH HOUSING REASSEMBLING 1 Remove 4WD shaft and gear Assemble the clutch housing with reverse Geer 24T Gera procedure of disassembling RT A nL 1 COVER B REINSTALLATION Loi PORTRE Reinstall the cover B with reverse procedure ee tee l a 2a a i sa mE fads of removal i Use following adjustment and service Hn standards for the reassembling g TEE H 2 COVER B REASSEMBLING DaS i P en Reassemble the cover B with reverse procedure of disassembling Use following adjustment and service standards for the reassembling 5 PTO shaft removal 1 Remove fixing bolts of bearing cap and remove bearing cap from transmission case 2 Remove PTO shaft and gears 1 Counter shaft end play adjustment Adjust the end play at counter shaft to 0 002in 0 008in by liner Counter shaft g9 Gear 27T oe Liner Xr se Gear 31T Gear 17T 2 Drive shaft end play adjustment Adjust the end play at drive shaft to 0 002in 0 008in by liner 117 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts c
58. ceed 110 Ibf 50 kgf 490 N stop Pore pounectng rod on the tool and pressing the pin and check the bores in the lubricate the bore in the rod for the piston piston and connecting rod for alignment pin with engine oil 54 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 5 After assembling the piston and connecting rod make sure the connecting rod moves freely 6 Piston ring installation Using a piston ring pliers install the piston rings on the piston NOTE a The piston rings must be installed with the side that has the mark T toward the top of the piston b The oil ring must be installed with the ring Sil gap 180 apart from the coil spring pi a Mark to be up No 1 compres sion ring ee No 2 N co ae 55 Coil spring joint 180 Ring end gap 7 Piston and connecting rod installation 1 Lubricate the piston and piston rings with engine oil 2 Move the piston rings on the piston so that the end gaps are apart from a direction parallel to or transverse to the piston pin 3 Install the connecting rod bearing upper half to the rod making sure the tab in the back of the bearing is in the notch of the connecting rod 4 Turn the crankshaft until the crankpin for the piston and connecting rod to be installed is at the top center 5 Hold the piston and connecting rod with FRONT mark arrow head on the top
59. chamfered insufficiently or wrong Ring gear chamfered insufficiently or wrong Ring gear end face badly worn ring gear not hardened properly Tele sy ak T foreign matter il Shift lever jammed Shift lever broken Shift lever spring weak i Pinion gap too large m Contact points close too early coasting Pinion will not shift Pinion metal jammed with dirt Overrunning clutch jammed with Solenoid switch plunger jammed t Pinion shifted excessively Pinion is forced into mesh with ring gear again when starter is Bumed motor coil or switch coil Burned field coil Burned coil in armature Burned motor coil evidence of rubbing Switch will not turn off only when engine fails to fire resulting in damage to motor Burned motor coil This trouble is likely to occur during heating Pinion tooth worn round Wear Ring gear locally _ 7 chipped Four or five teeth chipped Overrunning clutch shell peeled Zin Starter is turned on while engine is running 32 Pinion is chipped as K amp T Saw Shop 606 678 9623 or 606 561 4983 Overrun t Starter faulty r Key switch faulty www mymowerparts com Key not returning completely is Defective contact points m Problems in switch H Shift lever faulty 4 Overrunning clutch jammed Le ba Subswitch faulty and B circu
60. control valve spool TZE POPPET and remove fixing bolts of control valve cyunpeR PING check VALVE 3 bolts and lubrication pipe guide and PORT control valve LIFT CASE a GUIDE BOLT 154 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 10 2 HYDRAULIC LIFT DISASSEMBLING 2 Lift shaft disassembling 1 LIET SHAFT AND CYLINDER 1 Remove snap rings and remove lift arms 2 DISASSEMBLING 2 Remove colors 6 and o rings 5 3 Remove set bolt and washer at power arm 8 and remove lift shaft 1 with bushing 3 1 Cylinder disassembling 1 Remove fixing bolt of pin 19 and remove pin 19 piston rod 10 2 Remove fixing bolts of cylinder 14 and CAUTION remove cylinder 14 Remove piston 12 Do not hit shaft with hammer for removal LIFT ARM HYDRAULIC CYLINDER OL PIPE i FLOW CONTROL uirTcase POWER ARM VALVE STEEL BALL SET BOLT 155 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 HYDRAULIC LINKAGE DISASSEMBLING AR fl_o 28 a CONTROL VALVE 1 Control valve removal 1 Remove snap ring on the pin at plate 8 and disconnect the control valve 1 and link H 7 2 Remove fixing bolts of control valve and remove control valve 1 lubrication pipe and guide 3 Loosen lock nuts 16 and remove plate 8 from control valve 2 Hydraulic linkage removal 1 Remove spring pin at lever
61. de of tire Toe in A B 0 0 394 in LOCK NUT L H LOCK NUT R H A B 0 0 39 IN 3 If toe in is out of standard readjust the toe in by adjusting the rod length h Ya _ aa 7 NUT T NUT 4 For toe in adjustment turn the left side and right side of rods to be equalized dimension C and lock the lock nut Tightening torque of lock nut 108 50 122 96lbfeft NOTE Bolt head of rod bolt should be set to upper side 152 LOCK NUT R D LOCK NUT ROD END 2 STEERING WHEEL FREE PLAY 1 Measure the free play at out side of steering wheel Free play should be as shown below Item Standard value in Steering Wheel free play 1 18 3 15 when stopping engine at Engine 1000 r p m 0 79 1 18 STEERING WHEEL In case that the free play exceeds above value check the oil leakage at cylinder and hoses check for air in the hydraulic line If no leakage and no air are found check steering unit K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 10 HYDRAULICS 10 1 MAIN HYDRAULICS DISASSEMBLING 1 HYDRAULIC PUMP DISASSEMBLING 1 Hydraulic pump removal 1 Remove suction and pressure pipes from pumps 2 Remove fixing nuts and bolts of pumps and remove pumps 3 Pump is supplying hydraulics to hitch and pump II is supplying hydraulics to power steering and PTO clutch 2 Pump disassembling 1 Remove fixing bolts
62. diff case assy 2 Remove fixing bolts of center case L H 2 1 Remove bearings from diff case and R H 1 and divide center case L H and 2 Remove fixing bolts of ring gear 4 and R H remove ring gear from diff case 3 3 Remove spring pin and remove shaft 3 Remove diff case assy from center case pinions 6 side gears 5 and liners from diff R H 1 case 134 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 8 2 FRONT AXLE REASSEMBLING Special tool for bushing A and B Reassemble front axle with reverse insullation procedure of disassembling 1 FRONT AXLE ASSEMBLY Parts number MA 19619032000 for A Reassemble holder assy with reverse MA 19619031000 for B procedure of disassembling 1 REAR BRACKET 2 FRONT BRACKET 3 CENTER CASE R H 4 CENTER CASE L H PINION SHAFT 7 BEARING CASE A 9 OIL SEAL Use following values for adjustment and service standard of reassembling Rear bracket Oil seal 1 Apply the lithium grease to o rings for iF fi i FHH assembling 2 Adjust the turning torque of pinion shaft to 6 51 8 68 lbfeft by tightening the nut 3 Select the shim by calculating the shim thickness as follows and install between axle center case and holder Pinion Shim thickness H 28 135 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 Tighten the nut until no play is produced but Use following values
63. driven gear removal Remove the lock plate and speedometer driven gear in that order NOTE Unless the speedometer driven gear is removed the camshaft cannot be removed 406576 3 Oil seal case removal Remove the bolts that hold the oil seal case in position Remove the case from the cylinder block with a screwdriver or the like CAUTION Do not cause damage to the oil seal 6 Crankshaft pulley removal 1 Install two safety bars M12x1 25 into the threaded holes in the rear end of the crankshaft Put a bar between the safety 4 Tappet removal bars to hold the crankshaft to prevent it Remove the tappets from the cylinder block from rotating with a valve push rod 2 Remove the crankshaft pulley NOTE The tappets will fall into the oil pan if the camshaft is removed before the tappets are removed When removing the crankshaft pulley be prepared to stop the job in case the bar slips off the crankshaft to prevent injury 37 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com Item Standard Limit Crankshaft gear and idler gear p 0 04 to 0 12 m Idler gear and 0 0016 to 0 0047 camshaft gear O Idler gear and fuel injection 0 30 2 pump 0 0118 D camshaft gear E Camshaft gear 0 08 to 0 19 7 Timing gear case removal and PTO gear 0 003 to 0 0075 Remove the bolts that hold the timing gear ae T F
64. e 9 Oil screen installation 1 Lay the cylinder block with the bottom oil pan side up 2 Install the oil screen in position NOTE The oil screen must be installed in position so that it is below the oil level line and away from the oil pan 56 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 10 0il pan installation 2 Tighten the bolts that hold the oil pan to 1 Clean the mating surfaces of the oil pan and the cylinder block in a crisscross pattern cylinder block and coat them with Three Bond to the specified torque US Cast oil pan 2 8 0 3 kgfem 20 3 2 2 lbfeft Tightening torque 27 5 3 Nem Plate oil pan 1 15 0 15 kgfem 8 3 1 1 Ibfeft 11 3 1 5 Nem Squeeze out a 4mm 0 2 in thick bar of sealing compound three Bond from the tube and put it on the flange of the oil pan as shown 57 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 COOLING SYSTEM 3 Water pump assembly removal Remove the water pump assembly DISASSEMBLY REMOVAL 1 Cooling fan removal Hold the fan by one hand remove the four bolts that hold the fan in position Remove the fan and spacers NOTE D Keep the spacers with the for installation 2 Thermostat case removal Remove the thermostat case assembly containing thermostat 58 K amp T Saw Shop 606 678 9623 o
65. e bearings in a bore always remove any metal protrusions in the bore or edge of the bore Before you press bearings into position put petroleum jelly on the inside and outside diameter of the bearings 11 GEARS Check all gears for wear and damage Replace gears that have wear or damage OIL SEALS O RINGS AND GASKETS Always install new oil seals o rings and gaskets Put petroleum jelly on seals and o rings SHAFTS Check all shafts that have wear or damage Check the bearing and oil seal surfaces of the shafts for damage SERVICE PARTS Always install genuine Mitsubishi service parts When ordering refer to the Parts Catalog for the correct part number of the genuine replacement items Failures due to the use of other than genuine Mitsubishi re placement parts are not covered by warranty LUBRICATION Only use the oils and lubricants specified in the Operator s and Service Manuals Failures due to the use of non specified oils and lubricants are not covered by warranty K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com ll ASSY REMOVAL AND REINSTALLATION 12 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 1 FRONT AXLE ASSY REMOVAL AND REINSTALLATION 1 1 FRONT AXLE ASSY REMOVAL 2 STEERING HOSE REMOVAL 1 Remove the two hoses from steering cylinder 1 4WD SHAFT REMOVAL 1 Remove cover A 2 Remove the snap ring at joint rear side from the shaft groove 3
66. e timing gear case when fuel stops from the injection pipe Fuel injection timing 17 standard BTDC 101 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 Adjustment 1 lf the fuel injection timing is incorrect TDC mark change the thickness of shims under the Wye fuel injection pump An increase or l v which fuel decrease of the shims by 0 1 mm 0 004 Angle by which fuel ection aming is in will vary the timing by 1 P e B Mare e i f da ming gear PX 2 Increase the thickness of the shims to case 4 retard the timing or decrease it to advance the timing Adjustment range Standard 1 5 Increase shim Decrease shim thickness thickness Four kinds of shims are available in thicknesses 0 2 mm 0 0079 in 0 8 mm 0 0118 in 0 4 mm 0 0157 in and 0 8 mm 0 0315 in These shims have no identification measure the thickness of each shim with calipers before using it CAUTION Apply sealant to both faces of each shim to prevent oil leaks E Shims 3 After the timing has been adjusted make sure it is correct 4 Close the fuel filter valve and restore the delivery valve and injection pipe to the original state 4 Installation 1 Put the gasket on the injection nozzle 2 Put the nozzle in position in the cylinder head and tighten it the specified torque 9 0 5 kgfem Tightening torque 65 4 Ibfeft 88 5 Ne
67. el injection pump camshaft and tighten the sliding sleeve shaft to the specified torque Tightening torque 5 5 0 5 kgfem 40 4 lbfeft 54 5 Nem 4 Sliding sleeve installation Install the sliding sleeve on the sliding sleeve shaft and make sure the sleeve moves freely 5 Governor assembly installation 1 Install the governor assembly in position while putting the tie rod and spring into position in the injection pump 2 Install the tie rod to the pin of the control rack and secure it with the tie rod spring 3 Install the tie rod cover in position K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 6 Fuel injection line installation 1 Put the fuel leak off line in position and connect it to the fuel injection nozzles 2 Put the fuel injection lines in position and connect them to the fuel injection pump Install the clamps 74 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 13 ELECTRICAL SYSTEM b Close the switch to make sure the pinion DISASSEMBLY REMOVAL shifts into cranking position properly and the starter runs at speeds higher than 1 Starter is specified If the current draw and or 1 1Testing before disassembly removal operating speed is out of the standard oy eiealance poiveempinion ana pausing disassemble the starter for inspection pinion clearance and repairs a Connect the starter to a 12 volt battery as shown in the illu
68. en the bolts holding the main bearing caps in steps to the specified torque 5 25 0 25 kgfem 38 2 lbfeft 51 5 2 5 Nem Tightening torque 5 Make sure the crankshaft rotates freely without binding or catching 6 Measure the end play for the crankshaft Make reference to End play measurement for crankshaft page 42 If the end play is incorrect loosen the bolts holding the main bearing caps once and tighten them again K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 Side seal installation 1 Coat the side seals with Three Bond 1212 2 Insert the side seals between the cylinder block and the front and rear caps and push in them by hand as far as possible with their rounded side toward the outside of the cylinder block Side seals Rounded side Rounded side 3 Put the piston in position on the connecting rod making sure the model identification on the rod is on the same side as the arrow head O O Q Q on the top of the piston 3 Using a flat plate push the seals into position taking care not to bend them 4 Insert the push rod of the Tool into the bore in the piston for the piston pin and press the pin with the press A CAUTION 5 Piston assembling to connecting rod Observe the indicator of the press when 1 Set Piston Setting TOSA RA O0O pressing the piston pin If the force of the press special tool in a hydraulic press is ready to ex
69. ess and or free length exceeds the Item Standard Limit ae l Warpage of 0 05 0 0020 0 10 pel TOPACA tE spring cylinder head maximum 0 0039 bottom face ae Item Standard Limit Free length 47 1 85 46 1 81 Squareness 1 5 maximum Length under 13 9 0 7 S test force 30 6 1 5 39 1 1 54 136 7 amp Length under 29 2 15 S test force 64 4 4 3 30 5 1 20 284 20 2 Rocker arms and rocker shaft Measure the bore in the rocker arm for the rocker shaft and the diameter of the rocker Vy shaft to find the clearance between the arm Squareness Si and shaft If the clearance has reached the S limit replace the rocker arm If it exceeds the T limit replace both arm and shaft Free length D Unit mm in Item Nominal Standard Limit size Bore in rocker 0 744 0 74449 to 0 74527 arm for shaft 18 9 18 910 to 18 930 Diameter of 0 744 0 74331 to 0 74401 shaft for arm 18 9 18 880 to 18 898 Clearance between 0 00047 to0 00197 0 00787 rocker arm and shaft 0 012 to 0 050 0 200 79 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 Valve push rods Using V blocks and a dial indicator check for bend If the bend exceeds the limit replace the 2 Clearance between valve stem and valve guide The valve guide wears more rapidly at its both push rod ends than at any other parts Measure the bore Unit mm in in the guide for the stem at its ends with an
70. for reassembling of bracket can be turned lightly knuckle arm and final case as adjustment and service standard 1 Apply lithium grease to o ring and lip of oil seal for assembling 2 Apply liquid packing threebond 1208D to installation surface of arm holder marked 3 Select the liner that the clearance between arm holder and knuckle arm to be 0 002 0 008 in Calking 2 KNUCLE ARM AND FINAL CASE Arm holder Knuckle arm REASSEMBLING AXLE SHAFT Reassemble knuckle arm and final case with reverse procedure of disassembling Knuckle arm L H y Gear 38T NOTE C Fill the grease at pivot of knuckle arm D 0p oyo a 4 Adjust backlash between gear 13T and gear 38T to 0 008 0 016 in by liner Z an O Axle shaft 136 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 KING PIN CASE REASSEMBLING Reassemble king pin case with reverse procedure of disassembling Use following values for reassembling of king pin case as adjustment and service standard 1 Apply lithium grease at o ring and oil seal 2 Wind seal tape to fixing bolts 15 of arm holder 3 Tightening torque of plug 16 8 68 12 3lbfeft 4 King pin case assembling Adjust the dimensions as shown in the drawing by liner 3 DETAIL B DETAIL C Arm holder Gear 18T Detail B Differential shaft L H 5 Adjust backlash between gear 14T and
71. g torque of the clutch housing fixing bolts 86 8 97 6 lbf ft 12 13 5 kgf m 24 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 ENGINE 4 1 DETERMINING WHEN TO OVERHAUL THE ENGINE 1 DETERMINING WHEN TO OVERHAUL THE ENGINE Generally when to overhaul the engine is to be determined by taking into account a drop in compression pressure as well as an increase in lube oil consumption and excessive blowby gases Lower power or loss of power an increase in fuel consumption a drop in lube oil pressure hard starting and excessive abnormal noise are also troubles These troubles however are not always the result of low compression pressure and give no valid reason for overhauling the engine the engine develops troubles of widely different varieties when the compression pressure drops in it Following are the typical troubles caused by the compression pressure failure 1 Low power or loss of power 2 Increase in fuel consumption 3 Increase in lube oil consumption 4 Excessive blowby through breather due to worn cylinders pistons etc 5 Excessive blowby due to poor seating of worn inlet and exhaust valves 6 Hard starting or failure to start 7 Excessive engine noise In most cases these troubles occur concurrently Some of them are directly caused by low compression pressure but others are not Among the troubles listed above 2 and 6 are caused by a fuel injection pump im
72. gear 18T to 0 0078 0 0157 in by liner 7 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 CENTER CASE AND DIFF CASE REASSEMBLING Reassemble center case and diff case with reverse procedure of disassembling 1 CENTER CASE R H 2 CENTER CASE L H 3 DIFFERENTIAL CASE 4 RING GEAR 5 SIDE GEAR 6 PINION 7 DIFFERENTIAL SHAFT 8 GEAR 14T 9 PINION SHAFT 10 LINER 11 LINER 12 O RING 13 DRAIN PLUG 14 JOINT Use following value for reassembling of center case and diff case as adjustment and service 3 Install the spring pin with direction as shown standard below 1 Apply lithium grease to o ring 2 Tightening torque of drain plug 13 28 93 57 86 in Poe Differential case 3 Diff case assy assembling 1 Make sure the backlash between pinion and side gear is in the range of 0 0004 0 0118in 2 Apply threebond 1374 to tightening torque of ring gear fixing bolts Tightening torque of Pinion shaft ring gear fixing bolts is 50 63 57 86 in Spring pin 138 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 Apply heat resistant grease sliding surface 4 Diff case installation 1 Adjust the backlash between ring gear and pinion shaft to 0 0098 0 0138 in by liner at A 2 Adjust end play of diff case assy to 0 0 004 in by liner at B DIFFERENTIAL ASSY DIFFERENTIAL RING GEAR 35T SHAFT 8 3 FRONT AXLE CHECK AND
73. gs with reverse procedure of the removal Use following values as adjustment and service standard for the installation 1 Rear axle case reinstallation 1 Apply the liquid packing Threebond 1280D to the mating surface of the rear axle case and transmission case 2 Tightening torque of rear axle case mounting bolts 61 5 68 7Ibf ft 8 5 9 5 kgf m 2 Hydraulic lift case reinstallation 1 Apply the liquid packing Threebond 1280D to the mating surface of the hydraulic lift case and transmission case 2 Tighten the top link bracket mounting bolts before tightening the hydraulic lift case fixing bolts 3 Tightening torque of hydraulic case fixing bolts 61 5 68 7 Ibf ft 8 5 9 5 kgf m 4 Tightening torque of the top link bracket mounting bolts 86 8 97 6 Ibf ft 12 13 5 kgf m K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 5 In case of equipping the draft control and disassembling the top link bracket adjust the dimension of stopper bolt to 29 mm 1 14in and lock it by jam nut Stopper S 3 Center case reinstallation 1 Apply the liquid packing Threebond 1208D to the mating surface of the center case and transmission case 2 Tightening torque of center case fixing bolts 86 8 97 6 lbf ft 12 13 5 kgf m 4 Clutch housing reinstallation 1 Apply the liquid packing Threebond 1208D to the mating surface of the clutch housing and center case 2 Tightenin
74. h washer for installation Rear bracket Through bolts 3 Brush holder removal With the brushes two kept apart from the commutator remove the yoke and brush holder assembly Remove the armature K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com Brush holder 4 Cover removal Remove the cover and remove the snap ring and washer 3 8 KOY Washer Snap ring Pe 8g Cover 5 Center bracket removal Remove the bolt and remove the center bracket Remove the washer for adjusting the end play for the pinion shaft Center bracket E74 W Adjusting washer i 6 Pinion removal a Put a pipe shaped tooling on the pinion stopper and hit the stopper with a hammer to expose the stopper ring b Remove the stopper ring with a pliers and remove the pinion NOTE Any time the pinion is removed a new stopper ring must be installed ring ay Pinion PG Pinion stopper Stopper ring 7 Pinion shaft removal Remove the spring lever reduction gear and pinion shaft from the front bracket NOTE Do not mix the sequence of spring lever and reduction gear when the pinion shaft is removed 8 Bearing removal To remove the ball bearings from the ends of the armature use a bearing puller The bearing fitted in the front bracket is not re placeable Replace the front bracket assembly if this bearing is defective Front
75. handle get another person s help and if neces sary use a jack or a hoist 2 Assembly 1 Wash all parts except for oil seals O rings rubber sheets etc with cleaning solvent and dry them with pressure air 2 Always use tools that are in good condi tion and be sure you understand how to use them before performing any job 3 Use only good quality lubricants Be sure to apply a coat of oil grease or sealant to parts as specified 4 Be sure to use a torque wrench to tighten parts for which torques are specified 5 Any time the engine is assembled new gaskets and O rings must be installed 26 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 6 PREPARATION FOR DISASSEMBLY 1 Engine oil draining Remove the drain plug from the bottom of the oil pan and allow the oil to drain Refil capacity 1 19 gal 4 5 L Hot oil and components can cause personal injury Do not allow hot oil or components to contact skin 2 Coolant draining Loosen the drain plug on the right side of the cylinder block and allow the coolant to drain Refill capacitiy 6 6 gal 2 5 L Coolant drain plug r 9 40540 27 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 2 TROUBLE SHOOTING Problem 1 Fuel knock More or less knock occurs in diesel engines This may be caused either by an excessively large delay period or by a too fast rate of fuel injection 1 ltems to
76. hassis and radiator code Remove battery 7 Remove hydraulic cylinder assy BRACKET HYDRAULIC CYLINDER 4 Remove radiator hoses and air cleaner hose 2 HYDRAULIC CYLINDER ASSY from engine DISASSEMBLING HOSE RADIATOR 1 Remove tie rod end 6 rod 9 rod end 8 and packing case 3 2 Remove cylinder rod 2 from cylinder tube 1 Front axle FRONT HO 145 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 9 4 OPERATOR CONTROL AREA REASSEMBLING Reassemble operator control area with reverse procedure of disassembling 1 STEERING WHEEL REINSTALLATION Reinstall steering wheel with reverse procedure of removal Use following values as adjustment and service standard To power steering cylinder To transmission NBKS case fo To flow divider 1 Adjustment of tilt lever 1 Tighten the bolts 17 until locking the 4 Check the tilt amount at steering wheel steering column which is approximate 0 827 in and side 2 Loosen the bolts 17 of L H side and R H play which should be less than 0 079 in side equally until tilt force at steering wheel comes to 21 7 108 5 lbfeft and lock them 2 Tightening torques 36 1 7lbfeft by lock nut 19 Hoses 18 08lbfeft 3 Check the tilt force at steering wheel after lock the lock nut 19 146 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 STEERING WHEEL REA
77. he crankshaft pulley 11 Valve clearance adjustment with a wrench to prevent the flywheel Make reference to VALVE CLEARANCE from rotating page 100 6 Tighten the four bolts that hold the flywheel to the specified torque 13 5 0 5 kgfem Tightening torque 98 4 Ibfeft 132 5 Nem Always signal each other to prevent possible personal injury 12 Rocker cover installation 1 Make sure the gasket is put on the rocker cover 2 Tighten the bolts that hold the rocker cover to the specified torque 10 Rocker shaft assembly installation l l 1 15 0 15 kgf m 1 Install the valve caps in position on the top Tightening torque 8 3 1 1 lbfeft of the valves 11 3 1 5 Nem 2 Put the rocker shaft assembly in position on the cylinder head Tighten the bolts that hold the rocker shaft assembly to the specified torque 1 5 0 5 kgfem Tightening torque 11 4 Ibfeft 14 7 5 Nem v 51 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 CYLINDER BLOCK CRANKSHAFT PISTONS AND OIL PAN REASSEMBLING 1 Oil pan 2 Oil screen 3 Connecting rod cap 4 Connecting rod bearing lower Reassemble 5 thru 10 5 Connecting rod 6 Piston pin 7 No 1 ring 8 No 2 ring 9 Oil ring 10 Piston ee ee n n 11 Connecting rod bearing upper 12 Main bearing cap 13 Main bearing lower 14 Crankshaft 15
78. he illustration to find the flatness If the flatness exceeds the limit grind the face Unit mm in Item Standard Limit Flatness of 0 15 0 0059 0 50 flywheel maximum 0 0197 2 Ring gear replacement Check the ring gear and replace it if its teeth are abnormally worn or chipped 86 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 CYLINDER BLOCK CRANKSHAFT PISTONS AND OIL PAN 1 Pistons Piston Rings and Piston Pins 1 Diameter of piston Measure the diameter of the piston at its skirt in a direction transverse to the piston pin with a micrometer as shown in the illustration If the diameter exceeds the limit replace the piston Select a new piston so that the differ ence between average weight of all pistons in one engine does not exceed the standard Unit mm in Item Standard Limit No 1 comp 0 06 to 0 10 0 30 0 0118 ression ring 0 0024 to 0 0039 No 2 comp 0 05 to 0 09 0 20 0 0079 ression ring 0 0020 to 0 0035 Oil ring 0 03 to 0 07 0 20 0 0079 0 0012 to 0 0028 Unit mm in Item Nominal size Standard Limit 77 93 to Standard 78 00 77 95 77 80 3 0709 3 0681 to 3 0630 3 0689 0 25 78 18to Diameter 0 0098 78 25 78 20 78 05 of piston oversize 3 0807 3 0779to 3 0728 3 0787 0 50 78 43to 0 0197 78 50 78 45 78 30 oversize 3 0905 3 0878to 3 0827 Maximum permissible difference bet
79. hop 606 678 9623 or 606 561 4983 www mymowerparts com 7 Cylinder head bolt tightening 1 Remove the guide bolts and install the bolts that hold the cylinder head to the cylinder block 2 Tighten the bolts in number sequence in two or three steps to the specified torque 9 0 5 kgfem Tightening torque 65 4 Ibfeft 88 5 Nem lt Front 8 Valve push rod installation 1 Put the valve push rod into position through the bore in the cylinder head 2 Make sure the ball end of the push rod has been put into position over the top of the tappet 9 Rocker shaft assembling 1 Install the rocker arms brackets and springs on the rocker shaft Secure the brackets to the shaft by tightening the bolts 2 Make sure the rocker arms move freely 46 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 TIMING GEAR FLYWHEEL REASSEMBLING 1 Flywheel 2 Rear plate 3 Oil seal case 8 Timing gear case 13 Pump camshaft gear 4 Tappet 9 Idler gear 14 Bearing 5 Speedometer driven gear 10 Valve camshaft gear 15 Pump camshaft 6 PTO gear 11 Thrust plate 16 Oil pump 7 Crankshaft pulley 12 Valve camshaft 17 Front plate Reassemble the timing gears and flywheel with reverse procedure of disassembling Use following values for reassembling as adjustment and service standard 1 Front plate installation 1 Scrape the gasket from the cylinder b
80. ider and transmission case Flow divider Transmission case m 17 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 ENGINE REMOVAL 1 Drain the coolant from radiator and drain the transmission oil 2 Remove the 4WD Shaft See Page 13 3 Remove the panel Assy See Page 17 4 Remove the fuel hose at fuel filter and drain the fuel 5 Remove the air cleaner hose radiator hoses 2 hoses and coolant drain hose from engine Air cleaner hose i Radiator hose rai i 6 Remove the fuel tank bracket and fuel tank 7 Remove the muffler from engine Tank bracket Fuel tank 8 Remove the suction and pressure pipe from pump and Il 9 Put the jack under the transmission case to support and remove the chassis mounting bolts 10 Pull the chassis together with front axle assy to front and remove it from engine 11 Lift the engine by hoist and remove the engine mounting bolts between engine rear plate and clutch housing 12 Remove the engine from clutch housing K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com Clutch housing 2 2 ENGINE REINSTALLATION Install the engine with reversed procedure of removal Use following adjustment and service standards for the reinstallation 1 When reinstall the engine to clutch housing apply the liquid packing Threebond 1208D to the mating surface of engine rear plate and cl
81. ing 2 Gear 23T 14 Ball bearing 3 Gear 26T 15 Ball bearing Say 4 Gear 35T 16 Ball bearing 5 Gear 40T 17 Needle bearing 6 Retainer A 18 Snap ring 7 Retainer B 19 Snap ring 8 Retainer A 20 Liner 9 Hub 21 Gear 21T Shift fork 10 Sleeve 22 Spacer 11 Ring 23 Spacer 12 Piece 24 Gear 28T 113 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 DISASSEMBLE SHUTTLE SHIFT CONTROL 1 Disconnect shuttle shift wire from link 2 Remove link from arm and remove holder 3 Remove stopper bolt Shattle rail Shattle wire 4 COVER D REMOVAL Remove fixing bolts of cover and remove cover from center case 5 COVER D SUB ASSY DISASSEMBLING 1 Disassemble drive shaft 1 Remove drive shaft with bearing and synchronized gears 2 Remove bearing 10 and remove synchronize gears and hubs from drive shaft Needle Gear Q D h Ring assy iy Needle K Da assy we Ball A ae E A Aa Shaft bearing Bushing Cover Liner 114 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 Disassemble reverse shaft 1 Remove plate and remove reverse shaft from cover D 2 Remove snap ring washer gear 17T and needle bearings from reverse shaft Plate Snap ring D gt Washer iaa AN oo Back shaft sk Gear 17T Cover D 6 3 TRANSMISSION CASE DISASSEMBLY Pinion shaft 1 REAR DIFFERENTIAL CASE REMOVAL 1 Remove differentia
82. it Diameter of 32 1 26 31 1 22 commutator i X e il j i c Mica undercut Measure the undercut of mica insulation between the adjacent segments If undercut exceeds the limit recondition the mica or replace the armature Unit mm in Item Standard Limit Undercut 0 5 0 020 0 2 0 008 of mica Undercut Segment Mica d Testing for short circuit Place the armature on growler and slowly rotate it with a hacksaw blade held above the armature core The hacksaw blade vibrates against the core when it is above a slot containing a shorted winding A shorted armature should be replaced 96 Growler e Testing for grounded circuit Test the armature for grounded circuit as shown in the illustration If there is any continuity between commutator segment and coil the armature is grounded and should be replaced 2 SS CQ E gt Zvi Gi omens F i A P f Testing for open circuit Test the armature for open circuit as shown in the illustration If there no continuity between the segments the armature is open circuited and should be replace J a K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 Field coils Replace the yoke assembly if a There is any continuity between the brush and yoke b There is no continuity between the brushes c The pole piece or coil is loosen 4 Bea
83. it replace the clutch disk assy Item Standard value Service limit Depth to rivet 0 05 0 075 in 0 012in 3 In case that the oil is stick to the lining lining is carbonized or damaged replace the clutch disk and check the cause 2 CLUTCH DISK BOSS AND MAIN SHAFT 1 Install the clutch disk to main shaft 2 Check the backlash at circumference of clutch disk 3 In case that the backlash exceed from the following value replace the clutch disk Item Standard value Service limit Backlash at out side of 0 016 0 039in 0 787in disk diameter Backlash at out side of disk diameter K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 6 TRANSMISSION 6 1 CLUTCH HOUSING DISASSEMBLING 1 COVER B SUB ASSY REMOVAL 1 Remove the fixing bolt of cover B and remove cover B sub assy cover B 2 COVER B SUB ASSY DISASSEMBLING 1 Disassemble main shaft 1 Remove snap ring 1 and remove main shaft from cover B Main shaft Drive shaft A a Snap ring 4 02 O 2 Remove snap ring 2 from main shaft and remove gear 22T and bearing 3 3 Remove snap ring 4 and remove drive shaft A 2 Disassemble counter shaft 1 Remove snap ring 1 and remove gear 30T from counter shaft 2 Remove counter shaft from cover A 3 Remove gear 31T with needle bearing and washers 4 Remove snap ring 2 3 and remove gear 27T from counter
84. ith an arbor press from the upper side of the head until the specified height to the top of the guide is obtained c Insert a new valve into the guide and make sure the valve slides in the guide Bad freely around the complete d After the valve guide has been replaced circumference check the valve contact with its seat c If the valve margin valve lip thickness E exceeds the limit replace the valve Unit mm in Valve guide pa Item Standard Limit z Valve margin 1 0 0 039 0 5 0 020 Cylinder head Uipinierness 15 mm 0 59 in d If the valve sinkage the dimension from the top of a closed valve to the face of cylinder head exceeds the limit recon dition the valve seat or replace the cylinder head assembly 4 Valves Unit mm in a Put a small amount of Prussian blue or Item Standard Limit read lead on the valve face Hold the Valve sinkage valve with a valve lapping tool com dimension from 0 05 0 25 1 5 mercially available and press it against top of closed 0 020 0 0098 0 059 the seat to check its contact valve to face of head Valve lapping Valve sinkage Valve margin Prussian blue b The width of contact must be uniform all the way around both seat and valve If 5 Valve refacing the contact is bad reface the valve and a Set the valve refacer at an angle of 45 seat and grind the valve 81 K amp T Saw Shop 606 678 96
85. its shorted External load connected to S circuit i Incorrect wiring Broken retum spring Sticking Machining fault of parts Key not finished to close tolerances External obstacle Rust due to moisture Pull in and hold in coils unbalance in number of windings Pull in or hold in coil layer shorted Contact points defective Plunger jammed Machining fault of parts Lever pivot jammed Machining fault Sliding part jammed Sliding surface dirty Machining fault of lead Burned contact points Assembly fault resulting ap in failure to return Starter is energized for hours resulting in 1 Burned hold in coil 2 Burned armature and field coils 3 Burned subswitch if so equipped 1 Burned motor coil 2 Burned pull in and hold in coils minor defect 3 Plunger fails to return when voltage is applied to circuit between M and terminals and plunger is pushed in with switch off starter Switch will not turn off only when engine fails to fire resulting in burning of motor coil 1 Burned motor coil 2 Burned pull in and hold in coils Dotted lines indicate failure of contact points to close Sticking pinion metal Burned hold in coil and motor coil Make reference to Pull in and hold in coil unbalance Make reference to Key not returning completely Other possibility is sticking pinion metal in case of overrun trouble 33 K amp T
86. l lock pedal fixing bolt and remove the pedal 2 Remove spring pin 1 washer and spring pin 2 3 Pull out the shaft and remove shift fork cum and spring at shaft 115 Spring pin 2 ___ Shift fork Pedal ey g i i Shaft Spring pin 1 3 Remove fixing bolts of holder L H and R H and lock plates Remove holder L H R H and differential case assy a Differential case assy Holder R H a 7 6 Lock plate A Shim N Lock plate Shim K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 COVER E SUB ASSY REMOVAL 1 Remove 4WD rod and remove fixing bolt of plate 2 Remove spring pin at link and remove link and arm 3 Remove fixing bolts of cover E and remove cover E assy from transmission case Rod Arm O LAN Link 4 Remove spring pin at lever and remove holder and arm 7 fork goin rail Spring pin Holder Lever 3 COVER E SUB ASSY DISASSEMBLING 1 Disassemble pinion shaft 1 Remove lock nut from pinion gear and remove pinion shaft Gear 36T y Pinion shaft Gear 38T 2 Disassemble drive shaft 1 Move snap ring 3 and remove gear 23T and 35T from pipe shaft 2 Remove bearing 1 snap ring 2 from pipe shaft and remove washers gear 18 28T and needle bearing Pipe shaft Cover E ae 23T SS oe j Drive shaft Snap ring 2 Gear 18 28T Collar Snap ring 3 3 Disassem
87. learance is out of service standard replace it Item Standard value in Service limit in Clearance between 0 00118 0 0079 holder and bushing 0 00236 4 CLEARANCE BETWEEN HOLDER AND KNUCKLE ARM Check the clearance between holder and knuckle arm In case that the clearance is out of standard value adjust it by liner Item Standard value in Clearance between holder 0 00197 and knuckle arm 0 00787 140 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 9 STEERING 9 1 OPERATOR CONTROL AREA REMOVAL 1 STEERING WHEEL REMOVAL Steering To power steering cylinder To transmission NBKS case fo To flow divider 1 Remove fixing screws of rear cover and remove rear cover 2 Remove fixing bolts 4 and nuts 5 of plate 3 3 Disconnect the wire of engine control lever and shuttle lever 4 Remove fixing bolts of bracket and remove bracket and levers 5 Remove lock nut 18 column fixing bolts 17 disk spring 18 Bothsides and column 2 6 Remove spring 16 lock nut 15 tilt lever fixing bolt 14 and tilt lever 13 7 Remove hose L 11 R 12 P and return hose from steering unit HOSE L RED TAPE HOSE R TILT LEVER BOLT NUT SPRING BOLT DISK SPRING NUT LINER BOLT x rere rer aS Se Se Se Se we K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 STEERING WHEEL DI
88. lift case Bushing shaft should be placed with its seam coming as Special tool for bushing 3 and 4 shown in the following drawing insullation Parts number 19619021000 and 19619025000 for 3 and 4 LIFT SHAFT LIFT CASE LIFT ARM O RING LIFT SHAFT S LOCK BOLT G o SLIT OF BUSHING 160 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 HYDRAULIC CONTROL LINKAGE REASSEMBLING Reassemble the hydraulic control linkage with reverse procedure of disassembling Use following values as adjustment and service standard for reassembling 1 CONTROL VALVE 2 GUIDE 3 ROLLER 4 SPRING 5 POWER ARM 6 LINK CONTROL VALVE 1 Control valve installation 1 After install the control valve adjust the dimension M to 132 2 132 8 mm with pushing the spool to make 0 0118 0 0354 in of clearance at T by adjusting position of plate 8 2 Sticking out amount N of screw on plate 8 should not exceed 0 039in from valve plate 161 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 After adjustment of plate position lock the all three nuts 16 2 Control linkage installation 1 O ring installation to shafts Fit the draft shaft 10 and shaft 11 in the housing and pull it out until o ring groove comes to out side of housing Fit the o ring in the groove apply grease and pull in the shaft Drawing from 4501 7 53 2 Adjust side play S at link H 7 to be le
89. lly handle the hydraulic parts during disassembly not to contaminate with dust metal chips etc 5 For disassembling the electrical parts remove the negative battery cable first 6 Pay attention to mark on assemblies components and parts for their positions or directions Put on marks if necessary to aid assembly 7 Carefully check each part or component for any sign of faulty condition during removal or cleaning The part will tell you how it acted or what was abnormal about it more accurately during removal or cleaning 8 When lifting or carrying a part too heavy or too awkward for one person to handle get another person s help and if necessary use a jack or a hoist 2 Assembly 1 Wash all parts except for oil seals O rings rubber sheets etc with cleaning solvent and dry them with pressure air 2 Clean up the parts before checking the installation parts 3 Use genuine parts for replacement to keep machine performance and safety 4 Replace the packing and O ring for reassembling Apply grease to O ring and oil seal for their installation 5 Use Three bond 1208D as liquid packing Remove the old packing completely before applying the new packing Apply new packing with 1 to 2 mm thickness without gap Assemble the parts within 10 minutes after applying the liquid packing Pour the oil etc after 30 minutes of assembling with liquid packing 6 Install the snap ring as shown below Force
90. lock and front plate 2 Coat the gasket contact surface of cylinder block with adhesive and put a new gasket in position making sure the holes in the gasket are all in alignment with the holes in the cylinder block 3 Put the front plate in position Install four bolts and tighten them 2 Oil pump installation 1 Make sure the packing has been put in position on the oil pump 2 Put the oil pump in position on the cylinder block Install three bolts and tighten them evenly 3 Make sure the oil pump gear rotates freely K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 Engine turning 2 Put the camshaft with gear in position in 1 Install two bolts M12x1 25 in the flywheel the cylinder block bolt holes in the crankshaft G D 2 Put a bar between the bolts and turn the CAUTION crankshaft to bring No 1 piston to the top Do not cause damage to the lobes and center as shown in the illustration journals when the camshaft is installed 3 Tighten the bolts that hold the thrust plate to the specified torque 4 Fuel injection pump camshaft installation 1 Put the camshaft with bearing and gear in position in the cylinder block 1 1 0 1 kgf m 2 Hit the gear with a plastic hammer to fit Tightening torque 8 0 7 Ibfeft the bearing in position 10 8 1 Nem 3 Make sure the camshaft rotates freely 4 Tighten the stopper bolt 4 Make sure the camshaft r
91. ls j r Qo O x 8 3 j My Mm i 2 D l of oO o wo Ou J 1 l i mn LR cL TURN LAMP Gece aie i OPTION zj Ol gt o Oe Qt amp wy wt Ay WI wm j amp W ol N Q F gt 3 0 al 3 f E oF ai a Fo af Of pa m te om oO oO m N o Djo Q m gt OL k Mg aoe lt j a ee a oO a 3 m Erz 2g o FJ FOS 30 gt m S505 8 i Meg 0 F D a o A F x e oO gt FREER 7 S500CCA GLOW RELAY GLOW TIMER Zo sg Se Read aa fede Ps FLEC fo My M y oo v oL TEMP GLPW PLUG TEMP prescun sw MAGNET BATTERY MOTOR SOLENOID sw PUMP MOTOR ALTERNATOR 1 68 1 69 FUSE BOX K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 11 2 SPECICATIONS Electrical System Type OT SV SUSI aieia sce ER van east ay caw hele sks Pes EEEE crude aa aware 12 Volt Negative Ground BINEN ssc tes eve rerert ace EEEE EARE EEEE EAr rane char suace eranuebar goer AAEE EE S 12 Volt 500 CCA Group 22F Top Stud Terminals PMS RIVAL OR gy de acm circa a enee SEEE TAE EE EEE AAA EEEE EEEE steven 12 Volt 50 Ampere Output VOlt ge Regulator sar eenen E e O sete rant AE E O EEEE EIRAN IC Built in Alternator Starter MOTOT cccccccccc cc enirere ce eeeeeeeeeeaueeaeeeaeeseeauaneeuees 12 Volt 2 kw with Solenoid Switch Head Camp eae aaeeeo ee R EEE E sa rsame cast ee narouse one se erst espe eae EE 35 Watt Flasher MESO asians se es rier saree se eaten netece cost axane case ene stneane rats es
92. m 102 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 IDLER R P M SETTING NOTE Make sure that the valve clearance and injection timing are correct and that the fuel injection nozzles have no defect High idle position Low idle position 1 Start and run the engine at low idle until the coolant temperature above 60 C 140 F 2 To set the low idle rpm loosen the lock nut for the idling set bolt and turn the set bolt to make the engine run at the specified rom Tighten the lock nut 3 To set the high idle rom loosen lock nut for the high idle set bolt and turn the set bolt to make the engine run at the specified rom Tighten the lock nut Idling set bolt Lock nuts High idle set bolt Make move a Check weights for wear Check sliding sleeve for wear or damage Make sure it moves freely Check spring for damage Check sliding sleeve contact face for wear Disassembly sequence and inspection points 1 Tie rod spring 7 Governor lever 2 Tie rod 8 Start spring 3 Speed control lever 9 Tension lever 4 Spring pin 10 Governor spring 5 Grooved pin 11 Governor spring lever 6 Governor shaft 12 Governor case Remove 7 thru 11 as an assembly 103 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 INJECTION NOZZLE 1 Inspection 1 Injection Pressure valve opening pressure
93. m Problem 6 Starting system troubleshooting Burned starter No cranking Faulty A starter bess motor F Prolonged cranking E Excessive load Pinion fails to p shift Pinion shifts but will not spin Pinion butts ring gear instead of meshing Overruns at low speed Make reference to Overrun Burned contact points in switch Layer shorted or grounded field coil Layer shorted or grounded armature coil Mechanical problems Misaligned armature t Machining fault of parts Worn bearings Pinion gap too large Hard starting at low temperatures Wrong starting system High resistance in main circuit Poor quality fuel Mechanical problems in engine Very low ambient temperature Troubles in engine No fuel Engine directly coupled to load Reverse torque due to incorrect injection timing Mechanical problems in engine Starter abused for moving equipment m Battery run down Loose battery terminals Defective key switch Poor S connector contact S connector missing Open circuit in engine switch coil m Worn starter brushes Defective contact points in auxiliary switch Open circuit in auxiliary switch coil m High resistance in S circuit Voltage applied to starter too high Contact points defective in starter switch Pinion and ring gear improperly chamfered Battery rating too high Pinion
94. mm 88 to 108 Nm 127to 147 Nm 152 to 172 Nm 176 to 196 Nm 87 to 101 Ibft 123 to 136 5 lb ft 152 to 173 5 Ib ft 181 to 203 Ib ft 18mm 118to 137 Nm 167 to 185 Nm 206 to 235 Nm 245 to 275 Nm 108 5 to 123 Ib ft 144 5 to 159 5 Ib ft 173 5 to 203 Ib ft 23 to 260 5 lb ft 20 mm 147 to 167 Nm 196 to 216 Nm 235 to 275 Nm 314 to 353 Nm Torque Specifications 10 SIZE GRADE 8 8 GRADE 10 9 5mm 4 Ib ft 5 5 Nm 5 5 Ib ft 7 5 Nm 6mm 7 Ib ft 9 Nm 9 Ib ft 12 5 Nm 8 mm 17 Ib ft 22 5 Nm 23 Ib ft 31 5 Nm 10 mm 32 5 Ib ft 44 Nm 46 Ib ft 62 Nm 12 mm 57 Ib ft 77 5 Nm 81 Ib ft 110 Nm 14 mm 88 5 Ib ft 120 Nm 125 5 Ib ft 170 Nm 16 mm 140 Ibft 190 Nm 196 Ib ft 265 Nm 18mm 192 Ib ft 260 Nm 269 5 Ib ft 365 Nm 165 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 10 6 HYDRAULICS CHECK AND Item Standard Service MAINTENANCE value in limit in 1 HYDRAULIC LIFT SYSTEM CHECKING Clearance between 0 00236 1 Clearance of bushing cylinder and piston 0 00386 0 00787 1 Measure the outer of diameter of lift shaft and power arm pin 2 Measure the inner diameter of bushings and calculate the clearances CYLINDER PISTON ROD 3 In case that clearance is out of service limit replace the parts Item Standard Service value in standard in Clearance between 0 000984 PISTON B
95. n shaft to 0 72 0 94 lbfeft by tightening the nut and calk the nut 4 AWD Shaft Gear 24T Gear 27T TO Gear SIT i iA ear is 3 PTO SHAFT REINSTALLATION Reinstall the PTO shaft with reverse procedure of removal Use following values as adjustment and service standard for reinstallation 1 PTO Shaft 1 Adjust the end play at PTO shaft to 0 002 0 079 in by liner PTO shaft 2 PTO Drive Shaft Adjust the end play at PTO drive shaft to 0 002 0 079 in by liner Drive shaft Drive shaft 122 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 6 6 CHECK AND MAINTENANCE 1 DIFFERENTIAL GEAR AND PINION SHAFT Shifter groove e m Shift fork Pinion shaft m Sa 7a 1 Checking the gear contact pattern 1 Clean the contact area of gear thoroughly and coat with Prussian blue or red lead 2 Rotate ring gear more than 2 3 turn to check the gear contact pattern If contact pattern is abnormal adjust the pinion shaft setting by shim with following the chart below Contact is seen at about 80 of entire tooth area from tooth end and the contact is uniform Counter measure and adjustment a ral eae is Bring pinion seen only shaft closer COP at tooth eo Adjust back N4 crest lash by moving ring gear away Contact Move pinion seen only shaf
96. nator and the other lead to the positive terminal of the battery Connect one voltmeter lead to the B terminal and the other lead to the ground 3 Connect the battery ground cable 4 Start the engine 5 Turn on all electrical loads 78 6 Increase the engine speed Measure the maximum output current at the specified alternator speed when the voltmeter reading is 13 5 volts Ammeter Alternator indicator Standard Item Model Terminal voltage Speed currents a 13 5V 33Aa 700 Tpm 5 A7T02071 o 25 13 5V 47A ea maximum OS 2 5 Removal 1 Disconnect the battery cables 2 Disconnect the lead from the B terminal of the alternator 3 Disconnect the connector from the alternator 4 Loosen the brace and support bolts Move the alternator toward the engine and remove the drive belt 5 Remove the alternator K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 5 INSPECTION 1 CYLINDER HEAD AND VALVE MECHANISM cylinder head Using a heavy accurate straight edge anda feeler gauge check the bottom face for warpage in three positions lengthwise two crosswise and two widthwise as shown in the illustration If warpage exceeds the limit reface the bottom face with a surface grinder 3 Valve springs Check the squareness and free length If the Se squaren
97. ng Use following 1 BRAKE L H REASSEMBLING values for rear axle reassembling as adjustment and service standard Reassemble the brake L H with reverse procedure of disassembling Use following values for rear axle reassembling as adjustment and service standard BRAKE ASSY L H 1 Adjust the free play of brake pedal L H and R H by joint 4 Difference of pedal height between brake pedal L H and R H must be adjusted less than 0 118 in 1 After installation of the grease nipple fill up the chassis grease 2 Adjust the clearance between bracket 7 and parking brake lever 6 to be less than 0 197 in by liner E 7 SE BRAKE PEDAL L H BRAKE ROD L H TEE z BRAKE PEDAL R y j l j HAT A 0 975 1 365 IN Bs 130 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 7 7 CHECK AND MAINTENANCE 1 BACKLASH 1 Check the backlash at differential case assy and side clearance In case that the values are out of the following standard adjust them Item Standard in Backlash at differential case assy 0 004 0 015 Side clearance at differential case assy 0 0 004 Backlash between diff ring gear and pinion shaft 0 004 0 012 2 Check the backlash between diff shaft and final gear 59T In case that the backlash is out of following standard replace them Item Standard in Service limi
98. nger will be rotated by the shutoff solenoid being turned in f Back off the shutoff solenoid 30 to 45 turn the clearance between the control rack and plunger will be 0 0059 to 0 00701 in 0 15 to 0 20 mm and tighten the nut to the specified torque g Start the engine and make sure the engine stops when the plunger is pushed all the way h Install the rubber cap in position with the arrow head toward up with the side that has a water drain hole down as shown in the illustration CAUTION Do not allow cleaning solvent to contact any solenoid parts Rubber cap Inspection after assembly a For the schematic of the key shutoff system see page 168 b Start the engine and make sure the engine stops when the starter switch key is turned to OFF position c Start the engine and make sure the engine stops when the oil pressure switch terminal is shorted to the switch body NOTE It will take about 5 minutes to restart an engine which was shut down by the key shutoff device 69 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 10 COOLING SYSTEM REINSTALLATION 1 Water pump installation Put a new gasket in position on the water pump flange Install the water pump in position on the cylinder block 4 Thermoswitch and thermounit combination installation Coat the threads of the combination with Three Bond 1104 Put the combination in position and tighten
99. of the crankpin into the bore in the big end of the rod and measure A and B with a dial indicator Subtract A from B to find the bend C 3 Crankshaft 1 Clearance between crankpin and connect ing rod bearing a Install the bearing upper and lower halves and cap to the big end of the connecting rod and tighten the cap nuts to the specified torque Measure the bore in the bearing for crankpin as shown in the illustration Tightening torque 3 55 0 5 kgfem 25 7 1 8 lbfeft 34 8 2 5 Nem Measuring diagram 3 5540 25 kgfm 25 741 8 Ibf ft 34 8 2 5 N m b Measure the diameter of the crankpin as shown in the illustration to find the clearance between the crankpin and connecting rod bearing Unit mm in Item Nominal size Standard Limit Diameter 48 47 950to of crankpin 1 89 47965 standard 1 88779to 1 88838 Clearance 0 025to between 0 072 crankpinand _ 0 00098to 0 150 connecting 0 00283 0 00591 rod bearing 89 Measuring diagram c If the clearance exceeds the limit install a new bearing and check the clearance again d lf the clearance still exceeds the limit grind the crankpin to 0 25 mm 0 098 in 0 50 mm 0 0197 in or 0 75 mm 0 0295 in undersize and use undersize connecting rod bearing Crankpin undersizes Unit mm in Item Undersize Finish 0 25 47 75 020
100. of the piston toward the front timing gear case side of the engine Oil ring Se l by ring and oil ring coil spring joint Front of engine No 1 compres sion ring 6 Using a piston guide commercially available put the piston and connecting rod into the cylinder from the top of the cylinder block K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 Tighten the connecting rod cap nuts in steps to the specified torque Do not hit the piston with a hammer to install the piston and connecting rod This will put force on the piston and connecting rod and cause damage to the piston rings and crankpin 3 55 0 25 kgfem Tightening torque 25 7 2 lbfeft 34 8 2 5 Nem 5 Check the thrust clearance for the connecting rod big end 8 Connecting rod cap installation 1 Push the piston into position until the big end of the connecting rod is put into position over the crankpin Then turn the crankshaft 180 while pushing on the top of the piston 2 Install the lower halt of the connecting rod bearing in the connecting rod cap making sure the tab in the back of the bearing is in the notch of the cap 3 Install the bearing cap to the connecting rod NOTE a Make sure the number on the cap is the same as the number on the connecting rod b In case of a new connecting rod having no cylinder number install the cap to the rod with the notches on the same sid
101. om 3 PTO hydraulic clutch reassembling For the installation of return plate face the stamping surface round edge side of the plate to brake disk Liner PTO hydrauric clutch Cy Gear 41T 3 4WD SHAFT REASSEMBLING Reassemble 4WD shaft with reverse procedure of disassembling INL x a Bush Sleeve Cover C 6 5 CENTER CASE REASSEMBLING Reassemble the center case with reverse procedure of removal 1 COVER C SUB ASSY REINSTALLATION Reinstall the cover C sub assy with reverse procedure of removal Use following values as adjustment and service standard for reassembling 1 Apply liquid packing three bond 1208D at the mating surface of center case and lever holder 2 Tightening torque of fixing bolts of lever holder 28 93 32 55lbfeft 3 Install the stopper to set 0 079 0 118in clearance between stopper and adaptor and make sure the lever could be move smoothly in the guide Stopper Lever Adapter 3 4 0 117 in Lever holder 118 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 COVER C REASSEMBLING Reassemble the cover C with reverse procedure of disassembling Use following values as adjustment and service standard for reassembling 1 Drive Shaft 1 Adjust the end play at drive shaft to 0 002 0 079in by liner Pipe shaft Gear 23T Gear 29T 2 Select Shaft 1 Adjust the end play at select shaft to 0 002 0
102. oove in the driven gear sleeve 2 Install the speedometer driven gear in position in the cylinder block while rotating it or the camshaft K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 11 Tappet installation Lubricate the tappets with engine oil and put them in position in the cylinder block 12 0il seal case installation 1 Put new gasket in position on the oil seal case 2 Lubricate the oil seal lip with engine oil and install the oil seal in position in the cylinder block 13 Rear plate installation 1 Put a new gasket in position on the rear plate 2 Put the rear plate in position on the cylinder block with its dowel holes in alignment with the dowels Tighten the bolts that hold the rear plate to the specified torque 6 5 1 kgfem Tightening torque 47 7 Ibfeft 64 10 Nem NOTE Install the starter to the rear plate before installing the plate to the cylinder block for convenience of rear plate installation 14 Flywheel installation 1 Install a safety bar M12x1 25 in the rear end of the crankshaft 2 Put the flywheel in position in alignment with the safety bar 3 Install three of four bolts in the flywheel and tighten them finger tight only 4 Remove the safety bar Install the last bolt in the flywheel and tighten it finger tight only K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 5 Have someone hold t
103. orce 10 to 12 71 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 12 LUBLICATION SYSTEM 3 Oil pressure switch installation REINSTALLATION Coat the threads of the switch with thread 1P iiet valve Th tailati sealant Three Bond 1102 Use Oil Pressure E E Switch Socket Wrench MD998054 special Put the relief valve in position on the cylinder H tool to install the oil pressure switch block and tighten in to the specified torque 5 0 5 kgfem CAUTION ning 0 ry a Put the sealant on the threads only 49 5 Nem l b Do not over tighten the oil pressure switch when it is installed MD998054 To be coated with thread sealant 2 0il filter installation 1 Lightly lubricate the gasket with engine oil 2 Install the new filter element by hand When the gasket contacts the base tighten one turn more 72 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 1 fuel injection nozzle installation 1 Put the gasket on the nozzle 2 Put the nozzle assembly in position in the cylinder head and tighten it to the speci fied torque Tightening torque 5 5 0 5 kgfem 40 4 lbfeft 54 5 Nem 2 Fuel injection pump installation Put the pump in position on the cylinder block and tighten the bolts that hold the pump to the specified torque Put the flyweight assembly in position on the rear end of the fu
104. ortion of the groove b When installing the new rear bearing put it in position with the side that has a groove toward the slip rings of the rotor c To install the rear bearing in the rear bracket heat the rear bracket d Before installing the rotor in the rear bracket insert a wire shaped tooling into the hole in the rear bracket to lift the brushes off the slip rings Remove the tooling after the rotor has been installed in position Wire shaped tooling Wire shaped tooling 68 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 Shutoff solenoid installation a Remove the tie rod cover b Coat the threads of the stop solenoid with thread sealant three Bond 1212 NOTE Coat the length of the threads to be turned in the governor case c Temporarily install the shutoff solenoid and nut in the governor case d Move the injection pump control rack all the way to the non injection shutoff position Tightening torque 4 5 0 5 kgf m 32 5 3 6 lbf ft 4445 N m Threads To be coated with thread sealant Plunger 0 0079 in NOTE Do not allow thread sealant to contact Do not allow cleaning solvent to enter the solenoid through B e Turn the shutoff solenoid in the governor case while pushing the plunger toward the control rack until the shaft is in touch with the tie rod At this time clearance C must be 0 mm Under this condition the plu
105. otates freely Check the end play for the camshaft 5 Camshatt installation 1 Lubricate the lobes and journals with engine oil 48 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 6 Idler gear installation 1 Lubricate the idler gear with engine oil 2 Install the idler gear in position with its 3 2 and 11 marks in alignment with the 33 mark on the fuel injection pump camshaft gear the 22 mark on the camshaft gear and the 1 mark on the crankshaft gear respectively 3 Check the backlash of the gears Make reference to Timing gear backlash measurement page 38 7 Timing gear case installation 1 Coat the gasket with adhesive and put it in position the front plate 2 Lubricate the oil seal lip with engine oil 3 tighten the bolts that hold the timing gear case 8 Crankshaft pulley nut tightening 1 Install two bolts M12x1 25 in the flywheel bolt holes in the crankshaft and hold the crankshaft 2 Tighten the crankshaft pulley nut to the specified torque 17 5 2 5 kgfem Tightening torque 127 18 lbfeft 172 25Nem Check the strength of the bolts and bar used for holding the crankshaft 9 P T O gear installation Install the P T O gear in position in the timing gear case with the side that has no oil hole toward the rear of the engine 10 Speedometer driven gear installation 1 Install the O ring in the gr
106. packing case calk the packing case of both sides DUST SEAL 2 HYDRAULIC CYLINDER ASSY REINSTALLATION Install the hydraulic cylinder assy with reverse procedure of removal Use following values for reinstallation as adjustment and service standard 1 Install the hose with red tape winded to lower port Tightening torque of hose 18 08 Ibfeft e aE a Pie gph T a 2 Turn the steering wheel to left and check the tire is turning to left 3 There is liner between chassis and front bracket See page 14 1 Tightening torque of front bracket 61 48 68 71 lbfeft 2 Tightening torque of chassis 61 48 68 71 lbfeft dr HYDRAU LIC CYLINDER The 4 Installation procedure of hydraulic cylinder assy 1 Set the length B of rod end cylinder side to 1 693 1 772 in 2 Set the length A of rod end knuckle side to 5 906 in 3 Adjust the toe in by turning the rod L H and R H equally See page 152 4 Check the cylinder stroke and steering angle Cylinder stroke should be 8 898 in and steering angle should be 48 50 Steering angle can be set by set bolt Set length of set bolt is 0 906 in K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 9 7 CHECK AND MAINTENANCE 1 TOE IN ADJUSTMENT 1 Set the tire pressure to 22 335 psi 2 Set the front tire to straight ahead Measure the distance between left and right tire center at front B and rear A si
107. portant to measure the compression pressure at regular intervals to obtain the data on the gradual change of the compression pressure higher than the standard in a new or overhauled engine owing to breaking in of ee engine components wear down 3 BASIC PRECAUTION FOR DISASSEMBLY AND ASSEMBLY This section outlines basic precautions recommended by Mitsubishi that should always be observed 1 Disassembly 1 Always use tools that are in good condition and be sure you understand how to use them before performing any job 2 Use an overhaul stand or a work bench if necessary Also use bins to keep engine parts in order of removal 3 Parts must be restored to their respective components from which they were removed at disassembly This means that all parts must be set aside separately in groups each marked for its component so that the same combination or set can be reproduced at assembly 4 Pay attention to marks on assemblies components and parts for their positions or directions Put on marks if necessary 4 The compression pressure would be slightly the piston rings valve seats etc It drops as A 5 Carefully check each part or component for any sign of faulty condition during removal or cleaning The part will tell you how it acted or what was abnormal about it more accurately during removal or cleaning 6 When lifting or carrying a part too heavy or too awkward for one parson to
108. properly adjusted with respect to injection quantity or injection timing worn injection pump plungers faulty injection nozzles or poor care of the battery starter and alternator The trouble to be taken into account as the most valid reason for overhauling the engine is 4 in actually determining when to overhaul the engine it is reasonable to take this trouble into account in conjunction with the other ones 2 COMPRESSION PRESSURE MEASUREMENT 1 Inspection Check to make sure 1 The crankcase oil level is correct and the air cleaner starter and battery are all in normal condition 2 The engine is at the normal operating temperature 2 Measurement 1 Move the control lever to a position for shutting off fuel supply 2 Remove all glow plugs from the engine Install the compression gauge and adaptor ST332270 combination to a cylinder on which the compression pressure is to be measured 3 Turn the engine with the starter and read the gauge pressure at the instant the gauge pointer comes to stop 4 lf the gauge reading is below the limit overhaul the engine LN Soy x oy K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com NOTE 1 Be sure to measure the compression pressure on all cylinder 2 The compression pressure varies with change of engine r p m This makes it necessary to check engine r p m at the time of measuring the compression pressure 3 It is im
109. r 606 561 4983 www mymowerparts com 3 Magnetic switch a disconnect the connector from the M terminal of the magnetic switch o Connect the magnetic switch to a 12 volt battery with a switch as shown in the illustration to test the pull in coil Close the switch to see if the pinion shifts If the piston fails to shift the magnetic switch is faulty CAUTION Due to the amount of current being passed through the solenoid series winding this test must be made within 10 seconds Battery 12 volts Connector disconnected c Connect the magnetic switch to a 12 volt battery with a switch as shown in the illustration to test the hold in coil Close the switch and pull the pinion away from the commutator end by hand Release the pinion to see if it remains there If the pinion returns the magnetic switch is faulty Connector disconnected 12 volts CAUTION Due to the amount of current being passed through the solenoid series winding this test must be made within 10 seconds d Connect the magnetic switch to a 12 volt battery with a switch as shown in the illustration to make a pinion return test Close the switch and pull the pinion away from the commutator end by hand Release the pinion to see if it returns immediately when released If the pinion fails to so return the magnetic switch is faulty Due to the am through the solenoid series winding thi
110. r 606 561 4983 www mymowerparts com 5 FUEL SYSTEM DISASSEMBLY 3 Governor assembly removal REMOVAL 1 Remove the tie rod cover 2 Remove the spring from the tie rod with a pliers to disconnect the tie rod from the 1 Fuel injection pipe removal Disconnect the fuel injection pipes and fuel leak off pipe from the fuel injection pump and nozzles fuel injection pump 3 Remove the governor assembly NOTE Put plugs or caps on the openings of the injection pump and nozzle connectors 4 Governor weight removal 1 Remove the sliding sleeve 2 Remove the sliding sleeve shaft and re oud governor weights 2 Fuel injection nozzle removal Loosen the fuel injection nozzles with a wrench Remove the nozzles and gaskets from the cylinder head NOTE Remove the gaskets from the cylinder head with a screwdriver or the like Discard defective gaskets 5 Fuel injection pump removal 1 Remove the tie rod cover 2 Remove the spring from the tie rod with a pliers to disconnect the tie rod from the fuel injection pump 59 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com J _ 6 AIR INLET AND EXHAUST SYSTEM k DISASSEMBLY REMOVAL 1 Exhaust manifold removal Remove the exhaust manifold from the cylinder head 3 Remove the fuel injection pump NOTE Keep a record of the thickness of shims for installation 2 Air inlet cover removal Remove
111. r others in the area can be injured 4B 35 DANGER Batteries contain acid and explosive gas Explosions can result from Sparks flames or wrong cable connections To connect the jumper cables correctly to the battery of this machine refer to the Operators Manual Failure to follow these instructions can cause serious injury or death K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 LOCATION OF ENGINE MODEL ENGINE SERIAL NO AND TRACTOR SERIAL NO IDENTIFICATIONS 1 ENGINE MODEL 3 TRACTOR SERIAL NO Engine model is relieved on right side of Tractor Serial No is punched on right side of cylinder block Enter this model and engine transmission center case serial number See next paragraph for ordering parts RUAA Location of serial No Right hand side of Center case 2 ENGINE SERIAL NO Engine serial No is punched on right side of engine block by the injection pump 406544 6 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 SPECIFICATION AND DATA Capacities Engine oil capacity with filter change __ 4 liters 4 8QTS NOTE Oil filter capacity is 0 5 liters 0 13 US Galls Cooling capacity H aa _ H ____ ____ 7 1 liters 7 9 QTS Transmission amp Hydraulic oi _ 46g liters 45 9 QTS MFD Axle 65 liters
112. re of disassembling 1 HYDRAULIC PUMPS REASSEMBLING Reassemble pump and II with reverse procedure of disassembling Use following values as adjustment and service standard of reassembling 1 Tightening torque of pump bolts 18 08 21 7 Ibfeft 2 Apply oil at o rings and oil seals for the assembling 1 HOUSING 2 BUSHING 3 DRIVE GEAR 4 DRIVEN GEAR 5 BUSHING 8 FRENGE 9 COVER 10 O RING KNOCK PIN 2 CONTROL VALVE ASSEMBLING Reassemble and reinstall the control valve 1 Make sure orings are installed on the control with reverse procedure of the disassembling valve before valve installation and apply oil at and removal Use followin value for O ring reassembling and reinstallation of control valve as adjustment and service standard 158 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com LIFT CASE VALVE WASHER BOLT 2 Valve neutral adjustment 1 Put the air nozzle to pump port of valve and send the air to pump port Move spool and find the spool position to start to come out the air from cylinder port This position is neutral position of spool Dimension A is 0 386 0 394 in 2 Adjust clearance between nut and plate dimension T to 0 3 0 6 mm at neutral position of spool and lock the nuts 3 Tightening torques Plug at poppet 50 63 69 1 Ibfeft Plug at check valve 36 17 43 4 Ibfeft Plug at unloader valve 50 63 69 1 Ibfeft
113. ression for No 1 piston by using the procedure that follows a Turn the crankshaft until TDC mark on the crankshaft pulley is aligned with the mark on the timing gear case b With No 1 piston at top dead center on the compression stroke the rocker arms will not be moved when the crankshaft is turned approximately 20 in both directions c If the rocker move No 1 piston is at top dead center on the intake or exhaust stroke In such a case turn the crankshaft 360 in the direction of engine rotation again No 1 piston is now at top dead center on the compression stroke 100 3 Loosen the lock nut for the adjusting screw With a feeler gauge inserted between the rocker arm and valve cap adjust the valve clearance by turning the adjusting screw Unit mm in Item Standard Valve clearance both inlet and exhaust valves 0 25 0 0098 TDC top dead center mark for No 1 and No 4 pistons Mark on timing gear case IT injection timing mark TDC mark for No 2 and No 3 pitons HAY P a hl 4 Hold the adjusting screw and tighten the lock nut 5 After the valve clearance on the valves for No 1 cylinder has been adjusted turn the crankshaft 180 in the direction of engine rotation and adjust the valve clearance on the valves for the remainder of the cylinders in firing order injection sequence Firing order Crankshaft rotation angle injection sequence S4L
114. ring with a valve lifter and remove the valve lock 2 Remove the retainer spring and valve NOTE The valves retainers springs and valve locks must be set aside separately in groups each tagged for cylinder number for correct installation ANRATA 35 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 TIMING GEAR FLYWHEEL 1 Flywheel 8 Timing gear case 13 Pump camshaft gear 2 Rear plate 9 Idler gear 14 Bearing 3 Oil seal case 10 Valve camshaft gear 15 Pump camshaft 4 Tappet 11 Thrust plate 16 Oil pump 5 Speedometer driven gear 12 Valve camshaft 17 Front plate 6 PTO gear 7 Crankshaft pulley 1 Flywheel removal 1 Have someone hold the crankshaft pulley 3 Install a safety bar M12x1 25 into the with a wrench to prevent the flywheel threaded hole in the flywheel from which from rotating the bolt was removed in Step 2 Remove 2 Remove one of the bolts that hold the the remaining bolts flywheel in position 4 Hold the flywheel by hands and withdraw it from the crankshaft Joggling the flywheel back and forth will facilitate removal When removing the flywheel wear heavy gloves to avoid hand injury 36 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 Rear plate removal The rear plate is doweled in position Pull the plate as straight as possible when removing it 4NRS7A 5 Speedometer
115. rings Replace the bearings if they are noisy or fail to run freely 5 Overrunning clutch Replace the overrunning clutch assembly if a The pinion is not locked when spun freely when spun in the reverse direction clockwise b The pinion is worn or chipped Do not wash the overrunning clutch with cleaning solvent 6 Front bracket Replace the front bracket assembly if the ball bearing is noisy or fails or rotate freely 7 Reduction gears Replace the reduction gears if they are worn or damaged 97 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 Alternator 1 Diodes a Test the resistance between the diode and heat sink First touch the positive prod of an ohmmeter to the diode then the negative prod If the resistance is infinite in both cases the diode is open If it is nearly zero in both cases the diode is shorted Do the same step for the remainder of the diodes If any diode is open or shorted replace the rectifier 3 Stator core a Test for continuity between the leads as shown in the illustration No continuity shows there is an open circuit in the stator core Replace the stator core A NEA N CN UE IGRU lt VD 2 Field coil a Test for continuity between the slip rings as shown in the illustration No continuity shows there is an open circuit in the field coil Replace the field coil b Test for no continuity between each
116. s test must be made within 10 seconds Connector disconnected 1 2 Removal 1 Disconnect the battery wires Disconnect the negative wire first 2 Disconnect wire 1 from the starter 3 Loosen bolts 2 two holding starter 3 in position and remove the starter 76 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 Alternator 2 1 Inspection before removal The correct diagnosis of the charging system requires a careful inspection with the alternator on the engine to determine whether or not it is necessary to remove the alternator from the engine for further inspection The following chart in which two troubles are listed with four possible causes of each will help locate the cause of the trouble Voltage regulator setting too high Ground return circuit defective Wiring incorrect Alternator charge too high Series resistor or winding open circuited Alternator drive belt loose Voltage regulator setting too low Alternator output low gives no charge Alternator Brushes worn 2 2 Precautions for removal Following is a list of basic precautions that should always be observed for removal 1 When installing the battery care must be used to make sure the negative termi nal is grounded 2 Do not use a megger an instrument for high resistance of electrical materials 3 Disconnect the battery cables before charging the b
117. se a soft head brass or bronze hammer or use a driver made from brass or bronze and use a steel hammer q4 17 CAUTION When using a hammer to remove and install pivot pins or seperate parts using compressed air or using a grinder wear eye protection that completely encloses the eyes approved goggles or other approved eye protection 4614 CAUTION Use suitable floor service jacks or chain hoists to raise wheels off the floor Always block machine in place with suitable safety stands JOT A 5 CAUTION When servicing or repairing the machine Keep the shop floor and operator s compartment and steps free of oil water grease tools etc Use an oil absorbing material and or shop cloths as required Use safe practices at all times 408 CAUTION Some components of this machine are very heavy Use suitable lifting equipment or additional help as instructed in this Service Manual inte DANGER Engine exhaust fumes can cause death if itis necessary to start the engine ina closed place remove the exhaust fumes from the area with an exhaust tube extension Open the doors and get outside air into the area 48 5b DANGER When the battery electrolyte is frozen the batlery can explode if 1 you try to charge the battery or 2 you try to jump start and run the engine To prevent battery electrolyte from freezing try to keep the battery at full charge If you do not follow these instructions you o
118. se at o ring 4 When hold the flange of housing 15 by vise do not hold too tight CAUTION Put the mark line at spline end surface of drive 23 to ensure the position O RING 8 Face o ring groove side of rota set 24 to spacer plate 22 and aline bottom of star 5 Install o ring 21 to housing 15 P p l oe l piece and line B Make sure the line A line between bottoms of star piece B C and D as shown below NOTE Aline the bolt hole of rota set 24 while keeping the connection of drive and star piece of rota Put spacer plate 22 and aline bolt hole of plate and tapped hole of housing GROOVE OF ROTA SET STARE SURFACE OF DRIVE 6 Turn spool 17 and sleeve 16 assy to a p parallel the pin 20 and port surface of N housing 15 Pair D Insert the drive 23 and engage the yoke of drive and pin 148 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 9 Install retaining ring to housing groove Make sure that the retaining ring is completely dropped in the groove 10 Install dust seal and X ring seal to seal grand bushing 3 and insert spool 17 as shown below DRIVER DUST SEAL RETAINING NUT SEAL GRAND BUSHING X RING SEAL NOTE Make sure that seal grand bushing is contacting to bearing race 7 1 Assemble the spool and sleeve that the groove for spring is alined GROOVE FOR CO
119. ss than 0 0118in by liner 7 3 Aline the punch mark of lever B 13 and draft shaft 10 OON E DRAFT SHAFT 4 Install link H 7 that the side of linkage plate touches lightly to guide 2 Make sure linkage H 7 can move parallel to the cylinder K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 Position control lever reassembling 1 Fix the handle stopper and place the position control lever to the highest position 2 Adjust the play Fat top position of lift arm to be 0 197 0 394in by adjusting the rod A length POSITION CONTROL LEVER LOCK NUT SHIM 1 4 Flow control valve reassembling 1 Adjust the height of plate 7 by shim 1 and SCREW 4 2 to turn the screw 4 smoothly PLATE 7 Q ETCAEE 2 Tightening torque of sleeve 8 Aa 61 48 68 7 1 lbfeft PEA bin 3 Adjust the position of plate 5 to obtain the Sr a SHIM 2 XS length of spring 6 to be 0 591 0 669 in at ae the flow control lock position P7 N SPRI 4 Set the clearance between plate 5 and oS PARER housing to be 0 236 in as shown in the 9 SLEEVE following drawing ney PEPING PLATE 5 163 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 10 5 HYDRAULIC LINE CHECKING 1 During the installation 1 Apply oil to o rings and install them not to stick out 2 Assemble the parts with care not to get contamination to the hydraulic ports
120. st it if necessary K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 ENGINE ASSY REMOVAL AND REINSTALLATION 2 1 ENGINE ASSY REMOVAL 1 HARNESSES REMOVAL 1 Remove front grille bonnet side covers and panel cover 2 Disconnect battery cable Disconnect negative cable first and then disconnect positive cable 5 Disconnect the harnesses at oil pressure sensor fuel cut solenoid electric fuel feed pump and fuel gauge E Flectrical pump i g 3 Disconnect the harnesses at alternator and starter motor Disconnect the tachometer cable 6 Disconnect the engine control wires 2 wires at governor side Disconnect the engine control wire for foot accel pedal from step Remove the power steering hoses 2 hoses from steering cylinder 4 Disconnect the harnesses at water temperature gauge water temperature sensor and glow plug 15 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 PANEL REMOVAL 1 Disconnect the clutch rod and brake rods Left and right brake rods Lever side Brake rod LH 2 Disconnect the shuttle wire 3 Disassemble the operator seat area Transmission side Shuttle wire DETAIL A 16 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 4 Disconnect the connectors of harness B 6 Remove the fixing bolts at column cover Lift up the panel assy 5 Remove the steering hoses from the flow div
121. stration to cause the pinion to shift into cranking position and remain there Swilch CAUTION Due to the amount of current being passed through the solenoid series winding this test must be made within 10 seconds Tachometer g b Push the pinion toward the commutator end by hand to measure its free movement pinion clearance c The pinion clearance must be 0 020 to 0 079 in 0 5 to 2 0mm If the clearance is out of this range make an adjustment CACAUTION to it by adding or removing the packings on the magnetic switch Adding the packings will decrease the clearance a The size of wires used for this test must be as large as possible Tighten the terminals securely b This starter has a reduction gear Do not confuse gear noise with some abnormal noise else c When measuring the starter speed at the end of the pinion be ready for accidental Push in pinion shifting of the pinion 0 5 to 2 0 mm Battery k 0 020 to 0 079 in 12 volts Starter 2 o Item Standard 2 No load characteristics Model M2T5622 M2T50381 a Connect the starter to a 12 volt battery Nominal output V kW 12 20 12 16 with an ammeter capable of indicating D several hundred amperes as shown in the Bn Terminal voltage V 1 11 5 MUSIANO 5 g Current draw A 130 maximum 100 maximum SS gs Speed rom 3850 minimum 3000 minimum 75 K amp T Saw Shop 606 678 9623 o
122. t away ee at tooth I Adjust backlash E i root by bringing o ring gear closer 2 Contact Bring ring seen only gear closer ras H N at outer gt Adjust back Xe end Bsa lash by moving pinion shaft away Contact Move ring seen only gear away A o gt at inner 5 Adjust backlash Nk end Dha by bringing pinion shaft closer Checking the tooth contact pattern 123 2 Check the backlash of differential ring gears Backlash Standard value 0 004 0 008 in Service limit 0 012 in Replace the gear if backlash is out of service limit 3 Check the clearance between shift fork and shifter Clearance Standard value 0 008 0 023 in Service limit 0 039 in Replace the fork or shifter if the clearance is out of service limit 4 Check the synchromesh gear 1 Check the abrasion or flaw at mating surface of synchronizer ring hub and sleeve 2 Check the decay of spring and abrasion of piece Synchronizer Synchronizer sleeve Ring Synchronizer Hub K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 5 Check of Double cone Synchromesh 1 outer synchronizer ring inner synchronizer Outer ring Inner ring ring synchronizer corn a Make sure there is no damage and scratch on the tooth surface of gear and O cone surface b Assemble the outer ring innner ring and corn to the gear Measure the clearance A In case that
123. t in Backlash between final 0 004 0 012 0 02 gear and diff shaft 2 BRAKE DISK 1 Check the worn out of brake disks In case that the measurement value is out of standard replace the disks Item Standard in Service limit in Thickness 0 134 0 126 of brake disk 3 BRAKE PEDAL 1 Check the clearance between inner diameter of bushing on brake pedal R H and outer diameter of brake shaft In case that the clearance is out of service limit replace the bushing Item Standard in Service limit in Clearance between inner diameter of 0 0016 0 197 bushing and outer 0 0047 diameter of shaft 131 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 8 FRONT AXLE 8 1 FRONT AXLE REMOVAL 1 FRONT AXLE REMOVAL See page 13 2 HOLDER ASSY DISASSEMBLING REAR BRACKET FRONT BRACKET 3 CENTER CASE R H 4 CENTER CASE L H 6 PINION SHAFT 7 BEARING CASE 8 SHIM 9 OIL SEAL 10 NUT 1 Remove rear bracket 1 from front axle assy 4 Remove nut 10 and remove front bracket 2 2 Remove fixing bolts of bearing case 7 and 5 Remove fixing bolts of holder 5 and remove remove bearing case from front axle assy holder 5 3 Remove nut 10 and remove pinion shaft 6 bearing oil seal 9 collar and shims 8 from bearing case 7 132 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 KNUCKLE ARM
124. te E E A 23 Watt Meal ROO MAM PD cespertncttevstacapete NEE e E E e cat ten une cone vara iO Er o e E E N tenes 20 Watt Pane lCamp eerren ra E aE E paa eee teas e aaa r e 3 4 Watt Tarmdmdicator Lampea npa n a E O EE 3 4 Watt INGIC ATOM Camp wecesirncade co cteciss tes degeneeecies TETEE EEEO EEEE EE OTER ETR EREE TRAS 3 4 Watt 170 K amp T Saw Shop 606 678 9623 or 606 561 4983
125. the direction of slit comes as shown below Ring gear Differential Spring pin case Pinion shaft 128 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 7 5 REAR AXLE REASSEMBLING Reassemble the rear axle with reverse procedure of disassembling 1 REAR AXLE REASSEMBLING Reassemble the rear axle with reverse procedure of disassembling Use following values for rear axle reassembling as adjustment and service standard O Liner o a Gear 59T Case L 1 Apply lithium grease at lip of oil seal and install axle shaft carefully not to damage lip 2 Make sure snap ring is completely installed in the groove 3 Adjust the end play of axle shaft to 0 002 0 008 in by liner 2 BRAKE ASSY REASSEMBLING Reassemble the brake assy with reverse procedure of disassembling Use following values for rear axle reassembling as adjustment and service standard 1 Make sure that the snap ring is completely installed in the groove 2 Pull the brake lever 3 for making sure that the brake is functioning properly 3 Aline the hole of the two brake disks on each side when assembled For lubrication purpose 129 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 7 6 BRAKE CONTROL REASSEMBLING 2 BRAKE R H REASSEMBLING Reassemble the brake control with reverse Reassemble the brake R H with reverse procedure of disassembling procedure of disassembli
126. the air inlet cover from the cylinder head 60 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 7 LUBLICATION SYSTEM REMOVAL 1 0il filter removal 1 Put a container under the oil filter to catch the oil 2 Remove the oil filter from the cylinder block with a filter wrench 2 pressure relief valve removal Remove the pressure relief valve from the cylinder block 3 Oil pressure switch removal Remove the oil pressure switch with Oil Pressure Switch Socket Wrench MD998054 special tool z MD998054 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 8 ELECTRICAL SYSTEM DISASSEMBLY 1 Starter disassembly 1 magnetic switch 2 rear bracket 3 brush holder assembly 4 yoke 5 armature 6 cover 7 center bracket 8 gear 9 spring set stopper ring stopper pinion spring pinion shaft lever front bracket 10 11 12 13 14 15 16 1 Magnetic switch a Loosen the nut that holds the connector to the M terminal of the magnetic switch and disconnect the connector from the magnetic switch b Remove the bolts two that hold the magnetic switch in position and remove the magnetic switch 2 Rear bracket removal Remove the through bolts two and the bolts two that hold the brush holder in position Remove the rear bracket NOTE Keep the rear bracket wit
127. the seal is in its correct position NOTE Improper stem seal installation can cause a failure to seal against downward flow of oil along the stem NOTE After scraping the gasket rub off gasket remnants from the face with an oilstone smeared with engine oil and thoroughly clean the face 44 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 Valve spring installation 3 Put new cylinder head gasket in position Install the valve spring with the white on the cylinder block making sure the enameled end up guide bolts are all in alignment with their respective holes in the gasket White enameled end Do not use any gasket adhesive or other substances on the top face of the cylinder block 4 Valve block installation Put compression on the valve spring with a valve lifter and install the block in position on the valve top Do not put excessive compression on the valve spring This can cause the retainer to hit and damage the stem seal 6 Cylinder head installation Put the cylinder head in position on the cylinder block making sure the guide bolts are all in alignment with their respective bolt holes in the head 5 Cylinder head gasket installation 1 Thoroughly clean the top faces of the cylinder block and pistons 2 Install two guide bolts M10x1 25 in the bolt holes in the cylinder block 45 K amp T Saw S
128. ts that hold the oil pump to the cylinder block and remove the pump 39 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 CYLINDER BLOCK CRANKSHAFT PISTONS AND OIL PAN DISASSEMBLY 1 Oil pan 2 Oil screen 3 4 3 Connecting rod cap 4 Connecting rod bearing lower Remove 5 thru 10 as an assembly 5 Connecting rod 6 Piston pin 7 No 1 ring 8 No 2 ring 9 Oil ring 10 Piston 11 Connecting rod bearing upper Main bearing cap Main bearing lower Crankshaft Main bearing upper Cylinder block aS a oor W ND 1 0il pan removal 1 Turn the engine upside down 2 Tap the bottom corners of the oil pan with a plastic hammer to remove the oil pan ACAUTION Do not attempt to pry off the oil pan by inserting a screwdriver or a chisel between the oil pan and cylinder block Damage to the oil pan can be the result 40 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 2 0il screen removal Loosen the nut that holds the screen in position and remove the screen 3 Thrust clearance measurement for connecting rod big end Install the connecting rod to its crankpin and tighten the cap nuts to the specified torque Measure the thrust clearance with a feeler gauge If the clearance exceeds the limit replace the connecting rod Unit mm in Item Standard Limit thrust clearance 0 10 to 0 35 0 50
129. tween piston pin and piston Measure the diameter of the piston pin and the bore in the piston for the pin as shown in the illustration to find the clearance If the clearance exceeds the limit replace the piston or pin whichever is badly worn Unit mm in Item Nominal size Standard Limit 22 994 to Diameter of 23 23 000 piston pin 0 91 0 90527 to 0 90551 Clearance 0 0006to between 0 018 0 050 piston pin 0 00024to 0 00197 and piston 0 00071 2 Connecting rods Check the connecting rod for bend or twist as follows a Measure C and L If C exceeds0 05 mm 0 0020 in per 100 mm 3 94in of L straighten the connecting rodwith a press Unit mm in Item Standard Limit Bend or twist of 0 05 100 0 0020 0 15 100 connecting rod 3 94 maximum 0 0059 3 94 unit mm in Cc P 0 05 0 002C L 100 3 94 l 0 05 0 0020 10 3 94 C Twist b Generally a connecting rod aligner is used to check the connecting rod for bend or twist NOTE To check the rod for bend install the cap to the connecting rod and tighten the cap nuts to the specified torque 88 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com c To check the connecting rod fitted to the piston for bend put the connecting rod and piston on the surface plate as shown in the illustration insert a round bar having a diameter equal to that
130. uel injection case in position and remove the case pump camshaft 0 007 to 0 20 gear and 0 0028 to 0 0079 oil pump gear The front plate is bolted inside the timing gear case Do not attempt to remove this plate along with the timing gear case by tapping 9 Idler gear removal To remove the idler gear rotate the gear ina direction of the helix of the teeth to pull it out of mesh ANAKAN 8 Timing gear backlash measurement Measure the backlash of each gear and keep a record of it for correct installation 10 Camshaft removal Replace the gears if the backlash exceeds 1 Remove the bolts that hold the thrust plate the limit 2 Pull the camshaft out of the cylinder block i Ly amp ti 38 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com Do not cause the damage to the lobes or bearing journals when removing the camshaft 11 Fuel injection pump camshaft removal 1 Remove the stopper bolt 14 Front plate removal Remove four bolts that hold the front plate in position Tap the plate lightly with a plastic hammer to separate the gasket 2 Tap the rear end of the camshaft with a copper bar to push it out of the front side of the cylinder block 406587 12 Gear removal when required To remove the gears from the camshaft and fuel injection pump camshaft use an arbor press 13 0il pump removal Remove the bol
131. utch housing 2 When installing the engine make sure that main shaft and clutch center is aligned 3 Tightening torque of engine mounting bolts 61 5 68 7 Ibf ft 8 5 9 5 kgf m 4 Tightening torque of chassis mounting bolts 68 7 83 2 Ibf ft 9 5 11 5 kgf m 5 Tightening torque of power steering hose at transmission side 36 2 43 4 Ibf ft 5 6 kgf m 19 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 6 Shuttle wire installation 8 Clutch pedal free play 1 Set the length of wire at transmission side to 0 787 1 181 in 5 8 in 147 mm 9 After reinstall the harnesses and tachometer cable clamp them not to touch the muffler Shuttle wire manifold and fan belt Brake pedal L H e 2 Set the length of wire at shuttle lever side to 6 5in 164 mm Amount of screw into the ball joint must be 0 32 in 8 mm Ball joint Shuttle wire 3 After set of the wire lengths adjust the wire length by nut to obtain the shuttle shift lever neutral position at lever guide In the neutral position shuttle shift lever can be move side to side 7 Brake pedal adjustment See page 127 Free play 0 99 1 39in 25 35 mm Adjust the left and right brake pedal height difference to be less than 0 12in 3 mm 20 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 CLUTCH HOUSING TRANSMISSION CASE REAR AXLE CASE AND HYDRAULIC LIFT CASE REMOVAL AND REINSTALLATION
132. values as adjustment and service Adjust the andplay aEANye shaft to be standard for reassembling 0 002 0 0079in by liner 1 Differential lock pedal Pipe shaft Adjust the stopper bolt that the clearance Sault between differential case and hub comes to Lo EF f i Liner N 0 039 0 059in when pedal is fully depressed ee a k o Gear 23T Drive shaft j NS Snap ring 2 Gear 18 28T Collar Snap ring 3 Gear 35T 2 Counter shaft Adjust the end play at counter shaft to 2 Holders 0 002 0 0079in by liner 1 Adjust the backlash at ring gear and pinion gear to 0 004 0 012 by adjusting shim thickness at left holder a 24T O Bearing 2 e 2 Adjust the clearance between side of Liner an differential case assy and transmission case ay 4 sa to 0 0 004in by adjusting shim thickness at right holder 3 Lock the fixing bolts of holders by lock plate oA Gear 31T N Counter shaft 121 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com 3 Pinion Shaft Gear 21T Gear 36T N Gear 38T Sleeve 1 Adjust the distance between center of differential case and rear end of pinion gear teeth to 4 21 0 002in by shim At least one 0 031in thickness of shim is installed at factory 1961 9010 000 Special Tool parts No Differential case assy Pinion shaft 2 Adjust end play at pinion shaft to 0 002 0 079 in by liner 3 Adjust the pre load at pinio
133. ween average 5 0 18 weight of all pistons in one engine g 0z Direction transverse to on pin 2 Clearance between piston ring and groove a Measure the clearance between the groove and piston with a straight edge and a feeler gauge as shown in the illustration If the clearance exceeds the limit replace the ring b If the clearance still exceeds the limit after new piston rings have been installed replace the piston No 1 compression ring clearance No 2 compression ring clearance 3 Clearance between ends of piston ring Put the piston ring in a gauge or in the bore in a new cylinder block and measure the clear ance between the ends of the ring with a feeler gauge as shown in the illustration If the clearance exceeds the limit replace all the rings K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com Inside diameter of gauge Standard 78 9 mm 3 07 9 0012 in 0 25 mm 0 0098 in oversize 78 25 9 mm 3 08 9 17in 0 50 mm 0 0197 in oversize 78 50 mm 3 09 2 0012in NOTE Put the piston ring in the gauge or cylinder squarely with piston Unit mm in Item Standard Limit Clearance No 1 comp 0 15 to 0 30 between ression ring 0 0059 to 0 0118 endsof No 2 comp 0 15 to 0 35 1 50 piston ring ression ring 0 0059 to 0 0138 0 0591 Oil ring 0 20 to 0 40 0 0079 to 0 0157 4 Clearance be
134. www mymowerparts com Cub Cadel SERVICE MANUAL SERIES 7000 COMPACT TRACTOR Model Number 7360SS CUB CADET P O BOX 368023 CLEVELAND OHIO 44136 9723 K amp T Saw Shop 606 678 9623 or 606 561 4983 www mymowerparts com INDEX 1 GENERAL 1 SAFETY 2 LOCATION OF ENGINE MODEL ENGINE SERIAL NO AND TRACTOR SERIAL NO IDENTIFICATIONS 3 SPECIFICATION AND DATA 4 TRANSMISSION DIAGRAM 5 TIGHTENING TORQUES 6 PRECAUTIONS FOR DISASSEMBLY 7 GENERAL INFORMATION 2 ASSEMBLY REMOVAL AND REINSTALLATION 1 FRONT AXLE ASSY REMOVAL AND REINSTALLATION 1 1 FRONT AXLE ASSY REMOVAL 1 2 FRONT AXLE ASSY REINSTALLATION 2 ENGINE ASSY REMOVAL AND REINSTALLATION 2 1 ENGINE ASSY REMOVAL 2 2 ENGINE ASSY REINSTALLATION 3 CLUTCH HOUSING TRANSMISSION CASE REAR AXLE CASE AND HYDRAULIC LIFT CASE REMOVAL AND REINSTALLATION 3 1 HOUSING REMOVAL 3 2 HOUSING REINSTALLATION 4 ENGINE 4 1 DETERMINING WHEN TO OVERHAUL THE ENGINE 4 2 TROUBLE SHOOTING 4 3 DISASSEMBLING 4 4 REASSEMBLING 4 5 INSPECTION 4 6 ADJUSTMENT 4 7 SPECIAL TOOLS K amp T Saw Shop 606 678 9623 or 606 561 4983 13 13 14 15 15 19 21 21 23 25 25 28 34 44 79 100 107 www mymowerparts com 5 CLUTCH 5 1 DISASSEMBLING 5 2 REASSEMBLING 5 3 ADJUSTMENT 6 TRANSMISSION 6 1 CLUTCH HOUSING DISASSEMBLING 6 2 CENTER CAS

SERVICE MANUAL - K&T Parts House Lawn Mower Parts & Chain

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SERVICE MANUAL - K&amp;T Parts House Lawn Mower Parts &amp; Chain

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SERVICE MANUAL - K&T Parts House Lawn Mower Parts & Chain