Cub Cadet 7000 7360SS Compact Tractor Service manual

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SERVICE MANUAL

SERIES 7000

COMPACT TRACTOR

Model Number

7360SS

CUB CADET • P.O. BOX 368023 • CLEVELAND, OHIO 44136-9723

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


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

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3

4

6

7

8

9

10

11

12

13

13

14

15

15

19

21

21

23

25

25

28

34

44

79

100

107


5. CLUTCH

5-1 DISASSEMBLING

5-2 REASSEMBLING

5-3 ADJUSTMENT

6. TRANSMISSION

6-1 CLUTCH HOUSING DISASSEMBLING

6-2 CENTER CASE 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


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


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

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153

153

155

158

159

164

166

167

168

170

139

141

141

142

144

146

147

150

152

123

126

126

126

127

128

111

113

115

117

118

121

129

130

131

132

132

135

108

108

108

109

111

I. GENERAL


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1. SAFETY


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2. LOCATION OF ENGINE MODEL, ENGINE SERIAL NO.

AND TRACTOR SERIAL NO. IDENTIFICATIONS

(1) ENGINE MODEL

Engine model is relieved on right side of

cylinder block . Enter this model and engine

serial number

(See next paragraph) for ordering parts.

(3) TRACTOR SERIAL NO.

Tractor Serial No. is punched on right side of transmission center case.

(2) ENGINE SERIAL NO.

Engine serial No. is punched on right side of

engine block by the injection pump.

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3. SPECIFICATION AND DATA

Capacities

Engine oil capacity with filter change ———————————————— 4.5 liters 4.8 QTS

NOTE :

Oil filter capacity is 0.5 liters (0.13 US Galls)

Cooling capacity ————————————————————————— 7.1 liters 7.9 QTS

Transmission & Hydraulic oil———————————————————— 43 liters 45.9 QTS

MFD Axle ———————————————————————————— 6.5 liters 6.9 QTS

Fuel Tank ———————————————————————————— 35 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

Cloud Point (Wax Appearance Point) (Max)—————————————— 21 C

140 F

5.8 F

Pour Point (Max)————————————————————————— 26 C 14.8 F

Distillation Temperature, 90% Point ————————————————282 to 338flC 539 to 640flF

Viscosity at 38flC

Centistokes ——————————————————————————— 2.0 to 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) —————————————————————— 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

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4. POWER TRANSMISSION DIAGRAM

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5. TIGHTENING TORQUES

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6. PRECAUTIONS FOR DISASSEMBLY

Place snap ring that square side face to force

Slit

Slit

Shaft movement

Shaft movement

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7. GENERAL INFORMATION

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II. ASSY REMOVAL AND REINSTALLATION

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1. FRONT AXLE ASSY REMOVAL AND REINSTALLATION

1-1 FRONT AXLE ASSY REMOVAL

(1) 4WD SHAFT REMOVAL

1. Remove cover A

2. Remove the snap ring at joint (rear side) from

the shaft groove.

3. Move the joint to front side and remove the

4WD shaft.

(2)STEERING HOSE REMOVAL

1.Remove the two hoses from steering cylinder

(3) BATTERY CODE DISCONNECTION

1. Disconnect Battery Code (Negative) and

loosen fixing bolts of bracket.

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(4) FRONT & REAR HOLDER REMOVAL

1. Remove mounting bolts of front holder.

2. Remove mounting bolts of rear 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 readjust it if necessary.

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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.

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.

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(2) PANEL REMOVAL

1. Disconnect the clutch rod and brake rods

(Left and right brake rods).

(Lever side)

2. Disconnect the shuttle wire.

(Transmission side)

3. Disassemble the operator seat area.

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4. Disconnect the connectors of harness B.

5. Remove the steering hoses from the flow

divider and transmission case.

6. Remove the fixing bolts at column cover .

Lift up the panel assy .

(Flow divider)

Column cover

Bolt Bolts

(Transmission case)

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(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.

8. Remove the suction and pressure pipe from

pump I and II.

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.

6. Remove the fuel tank bracket and fuel tank.

7. Remove the muffler 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.

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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

clutch 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 lbf.ft (8.5~9.5 kgf-m)

4. Tightening torque of chassis mounting bolts

68.7~83.2 lbf.ft (9.5~11.5 kgf-m)

5. Tightening torque of power steering hose at

transmission side.

36.2~43.4 lbf.ft (5~6 kgf-m)

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6. Shuttle wire installation.

1) Set the length of wire at transmission side to

5.8 in (147 mm).

8. Clutch pedal free play

[0.787~1.181 in.]

9. After reinstall the harnesses and tachometer

cable, clamp them not to touch the muffler,

manifold and fan belt.

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)

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).

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3. CLUTCH HOUSING, TRANSMISSION CASE, REAR AXLE

CASE AND HYDRAULIC LIFT CASE REMOVAL AND

REINSTALLATION

3-1. HOUSINGS REMOVAL

2. Remove the main shift lever linkages.

3. Lift the center case and remove it from

transmission case.

(1) CLUTCH HOUSING REMOVAL

1. Remove the fixing bolts between clutch

housing and center case.

2. Lift the clutch housing and remove it from

center case.

(2) CENTER CASE REMOVAL

1. Remove the fixing bolts between center

case and transmission case.

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(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.

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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.

3-2. HOUSING REINSTALLATION

3. Lift the rear axle case and remove the

mounting bolts.

*Reinstall the housings 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.

61.5~68.7lbf.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 lbf.ft (8.5 ~ 9.5 kgf-m)

4. Remove the rear axle assy.

4. Tightening torque of the top link bracket

mounting bolts.

86.8~97.6 lbf.ft (12 ~ 13.5 kgf-m)

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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.

(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. Tightening torque of the clutch housing fixing

bolts.

86.8~97.6 lbf.ft (12 ~13.5 kgf-m)

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4. ENGINE

4-1. DETERMINING WHEN TO

OVERHAUL THE ENGINE

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)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 improperly 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.

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)If the gauge reading is below the limit,

overhaul the engine.

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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 important to measure the compression

pressure at regular intervals to obtain the

data on the gradual change of the

compression pressure.

4. The compression pressure would be slightly

higher than the standard in a new or

overhauled engine owing to breaking-in of

the piston rings, valve seats, etc. It drops as

the 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,

(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 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.

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(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)

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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)Items to be checked for ahead

• Clogged air cleaner

• Poor quality fuel

(2)Inspection procedure

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Problem 2 : Overheating

(1) Items to be checked for ahead

Overheating might also be caused by abnormal operating conditions. If the engine is overheating but its cooling system is not contributing to this trouble, it is necessary to check the difference between the ambient temperature 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.

• Insufficient coolant and exterior coolant leaks

• Loose fan belt

• Radiator core openings plugged with dirt


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Problem 3 : Black exhaust smoke





Problem 4 : Erratic idle speeds


• Maladjusted engine control

• Wrong oil grade for weather conditions



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Problem 5 : Low power or loss of power


• Stuck running parts

• Wrong oil grade for weather conditions



• Restricted exhaust line

• Faulty power take-off


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Problem 6 : Starting system troubleshooting

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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

(1)Remove the bolts that hold the rocker

stays in position and remove the rocker

shaft assembly.

(2)Remove the valve caps.

2.Rocker shaft disassembly

Put identification on each rocker arm as to its

location on the rocker shaft.

3.Cylinder head bolt removal

Loosen the cylinder head bolts in two or three

steps in the sequence shown.

If any parts on the cylinder head are faulty,

check the cylinder head bolts for tightness

with a torque wrench before loosening them.

Cylinder head bolt loosening sequence.

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4.Cylinder head assembly removal

Lift the cylinder head straight up with a hoist.

6.Valve stem seal removal

Remove the valve stem seals with pliers.

If the gasket is seized and the cylinder head

cannot be separated from the cylinder block,

tap around the thick side portion of the

cylinder head with a plastic hammer.

Do not reuse the valve stem seals.

5.Valve and valve spring removal

(1)Compress the valve spring with a valve

lifter and remove the valve lock.

(2)Remove the retainer, spring and valve.

The valves, retainers, springs and valve

locks must be set aside separately in groups,

each tagged for cylinder number, for correct

installation.

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(2) TIMING GEAR•FLYWHEEL

(1) Flywheel

(2) Rear plate

(3) Oil seal case

(4) Tappet

(5) Speedometer driven gear

(6) PTO gear

(7) Crankshaft pulley

1.Flywheel removal

(1)Have someone hold the crankshaft pulley

with a wrench to prevent the flywheel

from rotating.

(2)Remove one of the bolts that hold the

flywheel in position.

(8) Timing gear case

(9) Idler gear

(10) Valve camshaft gear

(11) Thrust plate

(12) Valve camshaft

(13) Pump camshaft gear

(14) Bearing

(15) Pump camshaft

(16) Oil pump

(17) Front plate

(3)Install a safety bar(M12x1.25)into the

threaded hole in the flywheel from which

the bolt was removed in Step(2). Remove

the remaining bolts.

(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.

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2.Rear plate removal

The rear plate is doweled in position. Pull the

plate as straight as possible when removing it.

5.Speedometer driven gear removal

Remove the lock plate and speedometer

driven gear in that order.

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.

Unless the speedometer driven gear is

removed, the camshaft cannot be removed.

Do not cause damage to the oil seal.

4.Tappet removal

Remove the tappets from the cylinder block

with a valve push rod.

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

bars to hold the crankshaft to prevent it

from rotating.

(2)Remove the crankshaft pulley.

The tappets will fall into the oil pan if the

camshaft is removed before the tappets are

removed.

When removing the crankshaft pulIey, be

prepared to stop the job in case the bar slips

off the crankshaft to prevent injury.

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7.Timing gear case removal

Remove the bolts that hold the timing gear

case in position and remove the case.

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.

Item

Standard

Crankshaft gear and idler gear

Idler gear and camshaft gear

0.04 to 0.12

(0.0016 to 0.0047)

Limit

Idler gear and fuel injection pump camshaft gear

0.30

(0.0118)

Camshaft gear and P.T.O. gear

0.08 to 0.19

(0.003 to 0.0075)

Fuel injection pump camshaft gear and oil pump gear

0.007 to 0.20

(0.0028 to 0.0079)

9.Idler gear removal

To remove the idler gear, rotate the gear in a

direction of the helix of the teeth to pull it out

of mesh.

8.Timing gear backlash measurement

Measure the backlash of each gear and

keep a record of it for correct installation.

Replace the gears if the backlash exceeds

the limit.

10.Camshaft removal

(1)Remove the bolts that hold the thrust plate.

(2)Pull the camshaft out of the cylinder block.

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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.

12.Gear removal(when required)

To remove the gears from the camshaft and

fuel injection pump camshaft, use an arbor

press.

13.Oil pump removal

Remove the bolts that hold the oil pump to the

cylinder block and remove the pump.

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(3) CYLINDER BLOCK,

CRANKSHAFT,PISTONS AND

OIL PAN DISASSEMBLY

(1)Oil pan

(2)Oil screen

(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


(upper)

(12)Main bearing cap

(13)Main bearing(lower)

(14)Crankshaft

(15)Main bearing(upper)

(16)Cylinder block

1.Oil 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.

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.

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2.Oil screen removal

Loosen the nut that holds the screen in

position and remove the screen.

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.

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 thrust clearance for connecting rod big end

Standard

0.10 to o.35

(0.0039 to 0.0138)

Limit

0.50

(0.0197)

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.

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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.

8.Crankshaft removal

Remove the crankshaft.

Do not cause damage to the bearings.

Unit:mm(in.)

Item

End play for crankshaft end play

Standard

0.050 to 0.175

(0.00197 to 0.00689)

Limit

0.500

(0.01969)

Put identification on each main bearing as

to its location in the engine.

9.Piston separation from connecting rod

(1)Use Piston Pin Setting Tool (31A9100100)

(special tool)to separate the piston from the

connecting rod.

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 Do not attempt to remove the piston pin by

tapping. Replace a piston pin which needs

a greater force for removal.

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(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.

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4-4. REASSEMBLING

(1) CYLINDER HEAD REASSEMBLING

* Reassemble the cylinder head with reverse

procedure of disassembling. Use the following

values as adjustment and service standard.

1.Cylinder head bottom face cleaning

Scrape the gasket from the bottom face of the

cylinder head.

(1) Rocker cover (7) Valve Lock

(2) Rocker shaft assembly (8) Valve retainer

(3) Valve push rod (9) Valve spring

(4) Cylinder head bolt

(5) Cylinder head

(10) Valve

(11) Valve stem seal

(6) Cylinder head gasket (12) Valve cap

2.Valve stem seal installation

Using Box 12, install the valve stem seal in

position in the valve guide. After installation,

make sure the seal is in its correct position.

After scraping the gasket, rub off gasket

remnants from the face with an oilstone

smeared with engine oil and thoroughly

clean the face.

Improper stem seal installation can cause a

failure to seal against downward flow of oil

along the stem.

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3.Valve spring installation

Install the valve spring with the white

enameled end up.

(3)Put new cylinder head gasket in position

on the cylinder block, making sure the

guide bolts are all in alignment with their

respective holes in the gasket.

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.

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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.

Tightening torque

9 0.5 kgf•m

(65 4 lbf•ft)

[88 5 N•m]

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.

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(2) TIMING GEAR•FLYWHEEL REASSEMBLING

(

1) Flywheel

(2) Rear plate

(3) Oil seal case

(4) Tappet

(8) Timing gear case

(9) Idler gear

(5) Speedometer driven gear (10) Valve camshaft gear

(6) PTO gear

(7) Crankshaft pulley

(11) Thrust plate

(12) Valve camshaft

* 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 block

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.

(13) Pump camshaft gear

(14) Bearing

(15) Pump camshaft

(16) Oil pump

(17) Front plate

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.

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3.Engine turning

(1)Install two bolts (M12x1.25)in the flywheel

bolt holes in the crankshaft.

(2)Put a bar between the bolts and turn the

crankshaft to bring No.1 piston to the top

center as shown in the illustration.

(2)Put the camshaft(with gear)in position in

the cylinder block.

Do not cause damage to the lobes and

journals when the camshaft is installed.

4.Fuel injection pump camshaft installation

(1)Put the camshaft(with bearing and gear)

in position in the cylinder block.

(2)Hit the gear with a plastic hammer to fit

the bearing in position.

(3)Make sure the camshaft rotates freely.

(4)Tighten the stopper bolt.

(3)Tighten the bolts that hold the thrust plate

to the specified torque.

Tightening torque

1.1 0.1 kgf•m

(8 0.7 lbf•ft)

[10.8 1 N•m]

(4)Make sure the camshaft rotates freely.

Check the end play for the camshaft.

5.Camshaft installation

(1)Lubricate the lobes and journals with

engine oil.

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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).

(2)Tighten the crankshaft pulley nut to the

specified torque.

Tightening torque

17.5 2.5 kgf•m

(127 18 lbf•ft)

[172 25N•m]

Check the strength of the bolts and bar

used for holding the crankshaft.

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.

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.

8.Crankshaft pulley nut tightening

(1)Install two bolts(M12x1.25)in the

flywheel bolt holes in the crankshaft and

hold the crankshaft.

10.Speedometer driven gear installation

(1)Install the O-ring in the groove in the driven

gear sleeve.

(2)Install the speedometer driven gear in position

in the cylinder block while rotating it or the

camshaft.

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(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.

Tightening torque

6.5 1 kgf•m

(47 7 lbf•ft)

[64 10 N•m]

11.Tappet installation

Lubricate the tappets with engine oil and put

them in position in the cylinder block.

Install the starter to the rear plate before

installing the plate to the cylinder block for

convenience of rear plate installation.

12.Oil 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.

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.

13.Rear plate installation

(1)Put a new gasket in position on the rear

plate.

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(5)Have someone hold the crankshaft pulley

with a wrench to prevent the flywheel

from rotating.

(6)Tighten the four bolts that hold the

flywheel to the specified torque.

Tightening torque

13.5 0.5 kgf•m

(98 4 lbf•ft)

[132 5 N•m]

11.Valve clearance adjustment

Make reference to“VALVE CLEARANCE”

(page 100)

Always signal each other to prevent

possible personal injury.

10.Rocker shaft assembly installation

(1)Install the valve caps in position on the top

of the valves.

(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

Tightening torque

1.5 0.5 kgf•m

(11 4 lbf•ft)

[14.7 5 N•m]

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.

Tightening torque

1.15 0.15 kgf•m

(8.3 1.1 lbf•ft)

[11.3 1.5 N•m]

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(3) CYLINDER BLOCK, CRANKSHAFT,PISTONS AND OIL PAN REASSEMBLING

(1)Oil pan

(2)Oil screen

(3)Connecting rod cap


(lower)

Reassemble 5 thru 10

(5)Connecting rod

(6)Piston pin

(7)No.1 ring

(8)No.2 ring

(9)Oil ring

(10)Piston


(upper)

(12)Main bearing cap

(13)Main bearing(lower)

(14)Crankshaft

(15)Main bearing(upper)

(16)Cylinder block

*Reassemble the cylinder block, crankshaft,

pistons and oil pan with reverse procedure

of disassemble. Use following values for

reassembling as adjustment and service

standard.

(2)Install the flanged bearing in the No.3

journal.

(3)Lightly lubricate the inside surfaces of the

bearings with engine oil.

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.

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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.

Install the front and bearing caps in

position so their end faces are even with the

end faces of the cylinder block.

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.

(4)Tighten the bolts holding the main

bearing caps in steps to the specified

torque.

Tightening torque

5.25 0.25 kgf•m

(38 2 lbf•ft)

[51.5 2.5 N•m]

(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.

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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.

(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

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.

5.Piston assembling to connecting rod

(1)Set Piston Setting Tool(31A91-00100)

(special tool)in a hydraulic press.

(2)Put the connecting rod on the tool and

lubricate the bore in the rod for the piston

pin with engine oil.

Observe the indicator of the press when

pressing the piston pin. If the force of the press

is ready to exceed 110 lbf (50 kgf) [490 N], stop

pressing the pin and check the bores in the

piston and connecting rod for alignment.

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(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.

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

end gap 180 apart from the coil spring joint.

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

of the piston toward the front(timing gear

case side) of the engine.

(6)Using a piston guide (commercially available),

put the piston and connecting rod into the

cylinder from the top of the cylinder block.

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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.

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.

(4)Tighten the connecting rod cap nuts in

steps to the specified torque.

Tightening torque

3.55 0.25 kgf•m

(25.7 2 lbf•ft)

[34.8 2.5 N•m]

(5)Check the thrust clearance for the

connecting rod big end.

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 side.

9.Oil screen installation

(1)Lay the cylinder block with the bottom

(oil pan side) up.

(2)Install the oil screen in position.

The oil screen must be installed in position

so that it is below the oil level line and away

from the oil pan.

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10.Oil pan installation

(1)Clean the mating surfaces of the oil pan and

cylinder block and coat them with Three Bond

1207C.

(2)Tighten the bolts that hold the oil pan to

the cylinder block in a crisscross pattern


Tightening torque

Cast oil pan:

2.8 0.3 kgf•m

(20.3 2.2 lbf•ft)

[27.5 3 N•m]

Plate oil pan:

1.15 0.15 kgf•m

(8.3 1.1 lbf•ft)

[11.3 1.5 N•m]

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.

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(4)COOLING SYSTEM

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.

3.Water pump assembly removal

Remove the water pump assembly.

Keep the spacers with the for installation.

2.Thermostat case removal

Remove the thermostat case assembly

containing thermostat.

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(5)FUEL SYSTEM DISASSEMBLY

REMOVAL

1.Fuel injection pipe removal

Disconnect the fuel injection pipes and fuel

leak-off pipe from the fuel injection pump and

nozzles.

3.Governor assembly 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.

(3)Remove the governor assembly.

Put plugs or caps on the openings of the

injection pump and nozzle connectors.

2.Fuel injection nozzle removal

Loosen the fuel injection nozzles with a

wrench. Remove the nozzles and gaskets from

the cylinder head.

4.Governor weight removal

(1)Remove the sliding sleeve.

(2)Remove the sliding sleeve shaft and

governor weights.

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.

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(6)AIR INLET AND EXHAUST SYSTEM

DISASSEMBLY REMOVAL

1.Exhaust manifold removal

Remove the exhaust manifold from the cylinder

head.

(3)Remove the fuel injection pump.

Keep a record of the thickness of shims for

installation.

2.Air inlet cover removal

Remove the air inlet cover from the cylinder

head.

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(7)LUBLICATION SYSTEM REMOVAL

3.Oil pressure switch removal

Remove the oil pressure switch with Oil

1.Oil 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.

Pressure Switch Socket Wrench(MD998054)

(special tool).

2.pressure relief valve removal

Remove the pressure relief valve from the

cylinder block.

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(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

(10)stopper ring

(11)stopper

(12)pinion

(13)spring

(14)pinion shaft

(15)lever

(16)front bracket

(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.

Keep the rear bracket with washer for

installation.

(2)Rear bracket removal

Remove the through bolts(two) and the bolts

(two) that hold the brush holder in position.

Remove the rear bracket.

(3)Brush holder removal

With the brushes (two) kept apart from the

commutator, remove the yoke and brush

holder assembly. Remove the armature.

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Any time the pinion is removed, a new

stopper ring must be installed.

(4)Cover removal

Remove the cover and remove the snap ring

and washer.

(7)Pinion shaft removal

Remove the spring, lever, reduction gear and

pinion shaft from the front bracket.

(5)Center bracket removal

Remove the bolt and remove the center

bracket. Remove the washer for adjusting the

end play for the pinion shaft.

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.

(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.

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2. Alternator

(1)through bolts

(2)pulley

(3)rotor

(4)rear bearing

(5)bearing retainer

(6)front bearing

(7)front bracket

(8)stator core

(9)brush holder

(10)rectifier

(11)rear bracket

(3)Stator core and rectifier removal

(a)Unsolder the leads from the rectifier and

remove the stator core from the rectifier.

Disassembly procedure

(1)Stator core separation from front bracket

(a)Pry the stator core off the front bracket

with a screwdriver as shown in the

illustration.

Be careful not to insert the screwdriver too

deep. Damage to the stator core can be the

result.

(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 the leads as quickly as possible to

prevent damage to the diodes in the rectifier.

(b)Remove the screws that hold the

rectifier in position and remove the

rectifier.

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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

Low idle speed

Test method

Use a tachometer.

Criteria

Standard farm engine:

Exhaust smoke

Orifice discharge pattern

1)Check by quickly increasing

engine speed under no-load

condition.

2)Check by staring load.

Remove injection nozzle and

reinstall it with orifice toward

outside of engine. Look at

discharge pattern by cranking

the engine with starter.

Not too much black or gray

smoke

Good discharge pattern

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(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

(3)Pinion shaft end play adjustment

The maximum 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.

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.

(4)Lever installation

Install the lever in correct position.

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(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.

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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

portion 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.

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3. Shutoff solenoid installation

(a)Remove the tie rod cover.

(b)Coat the threads of the stop solenoid

with thread sealant(three Bond 1212).

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.

(f)Back off the shutoff solenoid 30•to 45•

turn(the clearance between the control

rack and plunger will be 0.0059 to 0.0070ı 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.

Do not allow cleaning solvent to contact any

solenoid parts.

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.

(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 plunger will be rotated by

the shutoff solenoid being turned in.)

It will take about 5 minutes to restart an

engine which was shut down by the key

shutoff device.

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(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.

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.

4.Thermoswitch and thermounit

combination installation

Coat the threads of the combination with Three

Bond 1104. Put the combination in position and

tighten it to the specified torque.

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.

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REINSTALLATION

1.Glow plug installation

Install the glow plug in position in the

precombustion chamber and tighten in to the

specified torque.

Tightening torque

1.75 0.25 kgf•m

(12.7 1.8 lbf•ft)

[17.2 2.5 N•m]

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] force (10 to 12)

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(12)LUBLICATION SYSTEM

REINSTALLATION

1.Pressure relief valve installation

Put the relief valve in position on the cylinder

block and tighten in to the specified torque.

Tightening torque

5 0.5 kgf•m

(36 4 lbf•ft)

[49 5 N•m]

3.Oil pressure switch installation

Coat the threads of the switch with thread

sealant (Three Bond 1102). Use Oil Pressure

Switch Socket Wrench(MD998054)(special

tool) to install the oil pressure switch.

a)Put the sealant on the threads only.

b)Do not over-tighten the oil pressure

switch when it is installed.

2.Oil 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.

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(13)FUEL SYSTEM REINSTALLATION

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 kgf•m

(40 4 lbf•ft)

[54 5 N•m]

4.Sliding sleeve installation

Install the sliding sleeve on the sliding sleeve

shaft and make sure the sleeve moves freely.

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.

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.

3.Flyweight assembly installation

Put the flyweight assembly in position on the

rear end of the fuel injection pump camshaft

and tighten the sliding sleeve shaft to the

specified torque.

Tightening torque

5.5 0.5 kgf•m

(40 4 lbf•ft)

[54 5 N•m]

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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

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DISASSEMBLY REMOVAL

1.Starter

1.1Testing before disassembly removal

(1)Clearance between pinion and housing

(pinion clearance)

(a)Connect the starter to a 12 volt battery

as shown in the illustration to cause the

pinion to shift into cranking position and

remain there.

(b)Close the switch to make sure the pinion

shifts into cranking position properly

and the starter runs at speeds higher than

is specified. If the current draw and / or

operating speed is out of the standard,

disassemble the starter for inspection

and repairs.

Due to the amount of current being passed

through the solenoid series winding, this test

must be made within 10 seconds.

(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

to it by adding or removing the packings

on the magnetic switch. Adding the

packings will decrease the clearance.

(2)No-load characteristics

(a)Connect the starter to a 12 volt battery

with an ammeter capable of indicating

several hundred amperes as shown in the

illustration.

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

shifting of the pinion.

Item Standard

Model M2T5622 M2T50381

Nominal output, V-kW 12-2.0 12-1.6

Terminal voltage, V 11 11.5

Current draw, A 130, maximum 100, maximum

Speed, rpm 3850,minimum 3000, minimum

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(3)Magnetic switch

(a)disconnect the connector from the M

terminal of the magnetic switch.

(b)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.







(d)Connect the magnetic switch to a 12 volt


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.




(c)Connect the magnetic switch to a 12 volt


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.

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.

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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

Series resistor or winding open-circuited

Alternator drive belt loose

Voltage regulator setting too low

Alternator output low

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 battery.

(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.

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(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.

-

(6)Increase the engine speed. Measure the

maximum output current at the specified

alternator speed when the voltmeter

reading is 13.5 volts.

Standard

Item Model

Terminal

voltage / Speed

currents

13.5 V / 33 A

A7T02071

13.5 V / 47 A

2500 rpm, maximum

5000 rpm, maximum

Connections for testing voltage setting

Item Standard

Voltage setting

[at 20 C (68 F)] 14.7 0.3V

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.

2.4.Testing output characteristics

(1)Disconnect the battery ground(negative)

cable

(2)Connect one ammeter lead to the B

terminal of the alternator 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.

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4-5. INSPECTION

(1) CYLINDER HEAD AND VALVE

MECHANISM

1.cylinder head

Using a heavy accurate straight edge and a

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.

Unit:mm(in.)

Item Standard Limit

Warpage of 0.05(0.0020) 0.10

cylinder head maximum (0.0039)

bottom face

3.Valve springs

Check the squareness and free length. If the

squareness and /or free length exceeds the

limit, replace the spring.

Item Standard Limit

Free length 47(1.85) 46(1.81)

Squareness 1.5 maximum

Length under 13.9 0.7

test force: (30.6 1.5)

39.1(1.54) [136 7]

Length under 29 2 -15%

test force: (64 4.4)

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

shaft to find the clearance between the arm

and shaft. If the clearance has reached the

limit, replace the rocker arm. If it exceeds the

limit, replace both arm and shaft.

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 to 0.00197 0.00787

rocker arm and shaft (0.012 to 0.050) (0.200)

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4.Valve push rods

Using V-blocks and a dial indicator, check for

bend. If the bend exceeds the limit, replace the

push rod.

Unit:mm(in.)

Item Limit

Bend(dial indicator reading) 0.3(0.012)

of valve push rod maximum

(2)Clearance between valve stem and valve

guide.

The valve guide wears more rapidly at its both ends than at any other parts. Measure the bore in the guide for the stem at its ends with an inside micrometer caliper to find the clearance between the stem and guide. If the clearance exceeds the limit, replace the guide or valve whichever is badly worn.

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

beyond the limit, or if it is abnormally worn,

replace the valve.

Unit:mm(in.)

Item

Diameter of valve stem

Inlet valve

Nominal Standard Limit size

6.6

(0.260)

6.565to

6.580

Exhaust 6.6

valve (0.260)

(0.25846to 6.500

0.25905) (0.25591)

6.530to

6.550

(0.25709to

0.25787

Unit:mm(in.)

Item Nominal Standard Limit

size

0.02 to

Clearance Inlet 0.05 0.10

between valve (0.008to (0.0039)

valve stem 0.0020)

and valve 0.05to

guide Exhaust 0.085 0.15

valve (0.0020to (0.0059)

0.00335)

Height to 9.5to10.5

top of valve 10(0.39) (0.374to

guide 0.413)

Before measuring the valve guides, clear the

guides of lacquer and carbon.

(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.

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(b)Install a new guide into the cylinder

head by pushing it with 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

freely.

(d)After the valve guide has been replaced,

check the valve contact with its seat.

(4)Valves

(a)Put a small amount of Prussian blue or

read lead on the valve face. Hold the

valve with a valve lapping tool(com-

mercially available)and press it against

the seat to check its contact.

(c)If the valve margin(valve lip thickness)

exceeds the limit, replace the valve.

Unit:mm(in.)

Item Standard Limit

Valve margin 1.0(0.039) 0.5(0.020)

(lip thickness)

(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.

Unit:mm(in.)

Item Standard Limit

Valve sinkage

(dimension from 0.05 0.25 1.5

top of closed (0.020 0.0098) (0.059)

valve to face

of head)

(b)The width of contact must be uniform all

the way around both seat and valve. If

the contact is bad, reface the valve and

seat.

(5)Valve refacing

(a)Set the valve refacer at an angle of 45

and grind the valve.

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(b)The valve margin must be not less than

the limit. If the margin seems to be less

than the limit when the valve is refaced,

replace the valve.

(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

clearance between the valve and guide,

and replace the guide if necessary.

(b)Cut the valve seat with a valve seat

cutter(commercially available), or grind

it with a valve seat grinder, and finish

the width of valve seat and the angle of

seat face to the correct values.

a)Do not put lapping compound on the

valve stem.

b)Use a lapping compound of 120 to 150

mesh for initial lapping and a compound

of finer than 200 mesh for finish lapping.

c)Mixing the compound with a small

amount of engine oil will help put the

compound on the valve face uniformly.

(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

seat 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.

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(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.

(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.

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(2)TIMING GEARS AND FLYWHEEL

1.Camshaft

(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

bushing.

Unit:mm(in.)

Item Standard

Clearance between

camshaft journal 0.15(0.0059)

and bushing

(b)Installation

Install a new bushing in position with its

oil holes in alignment with those of the

oil gallery.

(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.

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Unit:mm(in.)

Item Standard Limit

Lobe height 35.72 34.72

of camshaft (1.4063) (1.3669)

2.Fuel injection pump camshaft

Measure the lobe height and base circle as

shown in the illustration. Subtract the base

circle from the height to find the lobe life.

If the lobe lift exceeds the limit, replace the

camshaft.

Unit:mm(in.)

Item Standard Limit

Lobe height of

fuel injection 44(1.73) 43(1.69)

pump camshaft.

(2)Clearance between tappet and cylinder

block

Measure the diameter of the tappet and the bore in the cylinder block for the tappet to find the clearance. If the clearance exceeds the limit, replace the tappet.

Unit:mm(in.)

Item Standard

Clearance between 0.15(0.0059)

tappet and cylinder block

3.Tappets

(1)Cam contact face

Check the cam contact face of each tappet for

abnormal wear. Replace the tappet if the face

is defective.

4.Idler 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.

Unit:mm(in.)

Item Standard Limit

Clearance between 0.03 to 0.0 0.20

idler gear and shaft (0.0012 to 0.0028) (0.0079)

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(2)Idler shaft replacement

Install a new idler shaft to the cylinder block

so that its dimension from the face of the block

is 26.5 0.5 mm(1.043 0.020 in.).

(a)Removal

Heat the ring gear evenly with an

acetylene torch. Tap the ring gear all the

way around with a bar and a hammer as

shown in the illustration to remove it

from the flywheel.

(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 the 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.

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(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 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 between average 5(0.18)

weight of all pistons in one

engine, g(oz)

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)

(b)If the clearance still exceeds the limit

after new piston rings have been

installed, replace the piston.

(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.

(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.

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Inside diameter of gauge

0.25 mm(0.0098 in.)oversize:

+0.03

78.25 mm(3.08 in.)

0.50 mm(0.0197 in.)oversize:

78.50 mm(3.09 in.)

0

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)

ends of 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)

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)

(4)Clearance between 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.

(b)Generally, a connecting rod aligner is

used to check the connecting rod for

bend or twist.

To check the rod for bend, install the cap to

the connecting rod and tighten the cap nuts


Unit:mm(in.)


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)

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(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 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”).

(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.)


Diameter 48 47.950to

of crankpin (1.89) 47965

(standard) (1.88779to

1.88838

Clearance 0.025to

between 0.072

crankpin and (0.00098to 0.150

connecting 0.00283 (0.00591)

rod bearing

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 kgf•m

(25.7 1.8 lbf•ft)

[34.8 2.5 N•m]

(c)If the clearance exceeds the limit, install

a new bearing and check the clearance

again.

(d)If 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

-0.035

-0.050

(0.0098) (1.8799 )

-0.035

0.50 47.50

-0.050

-0.00197

-0.035

0.75 47.25

-0.050

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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.).

(2)Clearance between journal and main

bearing

(a)Install the main bearing(upper and

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.

Tightening torque

5.25 0.25 kgf•m

(38 1.8 lbf•ft)

[51.5 2.5 N•m]

Unit:mm(in.)


Diameter 52 51.985to

of journal (2.05) 52.000

(standard) (2.04665to

2.04724

clearance 0.030 to

between 0.077

journal and (0.00118to 0.100

main bearing 0.00303 (0.00394)

(c)If the clearance exceeds the limit, install a

new bearing and check the clearance again.

(d)If the clearance still exceeds the limit,grind

the journal to 0.25 mm(0.0098in.), 0.50

mm(0.0197 in.)or 0.75 mm(0.0295 in.)

undersize and use undersizemain bearing.

Journal undersize

Unit:mm(in.)

Item Undersize Finish

0.25 51.75

0

-0.015

(0.0098) 2.0374

0.50 51.50

0

-0.00059

0

-0.015

(0.0197) 2.0276

0.75 51.25

0

0

-0.00059

-0.015

(0.0295) 2.0177

0

-0.00059

(b)Measure the diameter of the journal as

shown in the illustration to find the

clearance between the journal and main

bearing.

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.).

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(5)Crankshaft gear installation

(a)Install 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.

(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.

Do not remove the gear unless the gear or

crankshaft is defective.

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Unit:mm(in.)

Piston and piston ring Bore

Size Size code Standard Limit

Standard STD 78

+0.03

0

+0.0012

(3.07 )

Taper and 0.01(0.0004)

out-of-round 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

Warpage of cylinder 0.05(0.0020) 0.10

block top face maximum (0.0039)

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(4)COOLING SYSTEM

1.Water pump

Check the impeller and shaft for rotation. If

they do not rotate freely or have noise, replace

the water pump assembly.

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.

Resistance at 120 C 30m

(248 F)

Temperature at which 111 3.5 C

switch is turned ON (232 6.3 F)

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)

Temperature at which 95 C

valve lift is 8 mm(0.3 in.) (203 F)

Water in the pan is hot. Any contact can

cause severe burns.

Oil in the pan is hot. Any contact can

cause severe burns.

4.Thermounit(standard)

Hang the thermounit in the pan of antifreeze

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,

replace the thermounit.

50 C(122 F):80 10

Standard 80 C(176 F):29.5 2.5

120 C(248 F):10 0.3

Antifreeze in the pan is hot. Any contact

can cause severe burns.

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(5)LUBRICATION SYSTEM

1.Oil pump

Visually check the pump for rough rotation or

other defects. Replace the pump assembly if

defective.

2.Oil 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)Insert 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 2 (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 2

opening pressure (50 7psi)

[343 49kPa]

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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.

(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.

(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(lbf)[N]

Item Standard Limit

Brush spring 3.0(6.6)[29.4] 1.8(4.0)[17.7]

tension

(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.)

ltem Standard Limit

Runout of 0.03 0.10

commutator (0.0012) (0.0039)

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(b)Diameter of commutator

Measure the diameter of commutator.

If it exceeds the limit, replace the armature.

Unit: mm (in.)

Item Standard Limit

Diameter of 32(1.26) 31(1.22)

commutator

(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

(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.

(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.

(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.

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(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)Bearings

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.

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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.

(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 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.

(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.

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(4)Brushes

(a)Make replacement of brushes that have

been worn down to,or beyond, the wear

limit line.

(c)To install the new brushes, put them in

position in the brush holder and solder

the leads to the brushes.

(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.

3.Glow plug

Test for continuity between the terminal and

body as shown in the illustration.

Item Standard

Resistance 0.55

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4-6 ADJUSTMENT

(1)VALVE CLEARANCE


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.

Tightening torque

9 0.5 kgf•m

(65 4 lbf•ft)

[88 5 N•m]

(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)

(2)Find top dead center compression 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.

(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 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

100

the valve clearance is correct.

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


(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.

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.

(3)The fuel injection timing is correct if IT

mark on the crankshaft pulley is aligned

with the mark on the timing gear case

when fuel stops from the injection pipe.

Fuel injection timing 17 (standard)

(BTDC)

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.

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3.Adjustment

(1)If the fuel injection timing is incorrect,

change the thickness of shims under the

fuel injection pump. An increase or

decrease of the shims by 0.1 mm(0.004

in.)will vary the timing by 1.

(2)Increase the thickness of the shims to

retard the timing or decrease it to advance

the timing.

Adjustment range Standard 1.5

Four kinds of shims are available in

thicknesses 0.2 mm(0.0079 in.), 0.3 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.

Apply sealant to both faces of each shim to

prevent oil leaks.

(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.

Tightening torque

9 0.5 kgf•m

(65 4 lbf•ft)

[88 5 N•m]

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(3)IDLER R.P.M SETTING


Make sure that the valve clearance and

injection timing are correct and that the fuel

injection nozzles have no defect.

(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 rpm. Tighten the lock nut.

(3)To set the high idle rpm, loosen lock

nut for the high-idle set bolt and turn the

set bolt to make the engine run at the

specified rpm. Tighten the lock nut.

Disassembly sequence and inspection points

(1)Tie rod spring

(2)Tie rod

(3)Speed control lever

(4)Spring pin

(5)Grooved pin

(6)Governor shaft

(Remove (7) thru (11) as an assembly.)

(7) Governor lever

(8) Start spring

(9) Tension lever

(10) Governor spring

(11) Governor spring lever

(12) Governor case

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(4)INJECTION NOZZLE

1.Inspection

(1)Injection Pressure (valve opening pressure)

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.

An increase or decrease of washer thickness

by 0.1 mm (0.004 in.) will vary injection

pressure by 10 kgf/cm 2 (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.).

(c)If the injection pressure is incorrect,

disassemble the nozzle and change the

thickness of the washer.

+5

Injection pressure 140 kgf/cm 2

+490

Standard [13729 kPa]

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.

(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 handle at a speed of

one stroke per second to make sure the

discharge is straight.

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(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

valve in the body in clean diesel fuel.

Keep the needle valves with their respective bodies

(b)After cleaning the tip, install it in the

nozzle and tighten the retaining nut to

the specified torque.

Tightening torque

9 0.5 kgf•m

(65 4 lbf•ft)

[88 5 N•m]

(c)If the injection nozzle is still bad after

the tip has been washed, replace the tip.

Do not hit the tip when removing it from the

injection nozzle.

a)Do not touch the sliding surface of the

needle valve.

b)When installing the new nozzle tip,

remove synthetic resin film from the tip

and slide the needle valve in the body in

clean diesel fuel to wash off inhibitor

completely.

Disassembly sequence and inspection points

(1) Retaining nut

(2) Nozzle tip assembly

(3) Piece

(4) Pin

(5) Spring

(6) Washer

(7) Body

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(5)FAN BELT

(1)Measure the deflection of the belt. Apply

10 kgf (22 lbf)[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)

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4-7.SPECIAL TOOLS


In addition these special tools. commercially available tools such as bearing puller , valve seat

cutting tool , valve guide installing tool , valve spring compressing tool , oil filter wrench , etc .

are necessary.

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5. CLUTCH

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 .

2. Remove cotter pin, clevis pin and release

lever.

3. Pull out the clutch lever with removing the

release lever.

2. Take out cover assy and disk assy.

5-2. REASSEMBLING

(1) REASSEMBLING CLUTCH LEVER

1. Reassemble the clutch lever, release lever,

release hub with reverse procedure of

disassembling. Use the following values as

adjustment and service standard for the

installation.

*For the installation of release bearing,

depress the inner hub.

(2) DISASSEMBLING CLUTCH LEVER

1. Remove the release hub with release bearing

by moving the clutch lever.

2. Make sure the direction of release lever and

release hub for the reassembling.

3. Apply the lithium grease inside of release hub

before assembling.

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(2) REASSEMBLING CLUTCH ASSY

1. Reassemble the clutch assy with reverse

procedure of disassembling. Use following

values as adjustment and service standard

for the assembling.

2. Set the clutch disk surface which spline boss

sticking out longer face to clutch housing

5-3 ADJUSTMENT

(1) CLUTCH PEDAL ADJUSTMENT

1. Depress the clutch pedal by hand and

measure the amount of pedal free play at

pedal.

Pedal free play : [0.79~1.18in.] ıııı ıııııııı

3. Apply the lithium grease to the spline of clutch

disk.

2. In case that the free play is out of standard

value, adjust the rod length by turning the

adjust nut.

4. Before installing the clutch assy to engine,

clean flywheel end. Aline the center of clutch

disk ID and flywheel bearing ID.

5. Tightening torque of clutch assy fixing bolts.

[18~21.7 lbf•ft]

*Apply the grease at pivot point of the pedal.

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(2) STOPPER ADJUSTMENT

1. Adjust the stopper length and lock the stopper

by lock nut.

Stopper length : [0.79in.]

2. In case that the measurement is out of the

following limit, replace the clutch disk assy.

Item Standard value Service limit

Depth to rivet 0.05 ~0.075 in. 0.012in.

2. Depress the clutch pedal to the stopper and

make sure the clutch is disengaged

3. In case that the oil is stick to the lining, lining

is carbonized or damaged, replace the clutch

disk and check the cause.

5-4 CHECK AND MAINTENANCE

(1) CLUTCH DISK

1. Measure the depth from clutch lining surface

to rivet.

(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

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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) 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 shaft.

(2) COVER B SUB ASSY DISASSEMBLING

1. Disassemble main shaft

1) Remove snap ring (1)and remove main

shaft from cover B.

3. Remove drive shaft.

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4. Disassemble PTO hydraulic clutch assy.

(1) Case

(2) Piston

(3) Seal ring

(4) Disk assy

(5) Ring set

(6) Spring

(7) Washer

(8) Return plate

(9) Brake disk

(10) Seal ring set

(11) Gear set 40T

(12) Seal ring

(13) Ring

(14) Back plate

(15) Belleville spring

(16) Ring

(3) 4WD SHAFT DISASSEMBLING.

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6-2 CENTER CASE DISASSEMBLING

(1) COVER C SUB ASSY REMOVAL

1. Remove the fixing bolts of main shift lever

holder and remove the holder.

(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.

COVER C

2. Remove stopper,detent ball and spring.

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.

(1) Select shaft

(2) Gear 23T

(3) Gear 26T

(4) Gear 35T

(5) Gear 40T

(6) Retainer A

(7) Retainer B

(8) Retainer A

(9) Hub

(10) Sleeve

(11) Ring

(12) Piece

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(13) Spring

(14) Ball bearing

(15) Ball bearing

(16) Ball bearing

(17) Needle bearing

(18) Snap ring

(19) Snap ring

(20) Liner

(21) Gear 21T

(22) Spacer

(23) Spacer

(24) Gear 28T


(3) DISASSEMBLE SHUTTLE SHIFT CONTROL

1. Disconnect shuttle shift wire from link.

2. Remove link from arm and remove holder.

3. Remove stopper bolt.

(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.

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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.

Shift fork

Differential case assy

6-3 TRANSMISSION CASE DISASSEMBLY

Pinion shaft

Drive shaft

4WD shaft

Counter shaft

(1) REAR DIFFERENTIAL CASE REMOVAL

1. Remove differential 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.

3. Remove fixing bolts of holder L.H. and R.H.

and lock plates. Remove holder L.H. , R.H. and

differential case assy.

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(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.

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.

4.Remove spring pin at lever and remove holder

and arm.

3. Disassemble 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.

(3) COVER E SUB ASSY DISASSEMBLING

1. Disassemble pinion shaft..

1) Remove lock nut from pinion gear and

remove pinion shaft.

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4. 4WD shaft disassembling.

1) Remove 4WD shaft and gear

6-4 CLUTCH HOUSING REASSEMBLING

*Assemble the clutch housing with reverse

procedure of disassembling.

(1) COVER B REINSTALLATION

Reinstall the cover B with reverse procedure

of removal.

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.

(2) COVER B REASSEMBLING

*Reassemble the cover B with reverse


Use following adjustment and service

standards for the reassembling.

1. Counter shaft end play adjustment

Adjust the end play at counter shaft to

[0.002in.~0.008in.] by liner.

2. Drive shaft end play adjustment

Adjust the end play at drive shaft to

[0.002in.~0.008in. ] by liner.

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3. PTO hydraulic clutch reassembling

For the installation of return plate, face the

stamping surface (round edge side)of the

plate to brake disk.

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.

[28.93~32.55lbf•ft]

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.

(3) 4WD SHAFT REASSEMBLING

*Reassemble 4WD shaft with reverse


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(2) COVER C REASSEMBLING

*Reassemble the cover C with reverse


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.

2) Install the sleeve to hub that the bigger

chamfer side of sleeve face to spline step

side of hub.

3) Install the spring with shifting the setting

position of spring between both sides of hub.

2. Select Shaft

1) Adjust the end play at select shaft to

[0.002~0.079in.] by liner.

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(3) COVER D REINSTALLATION

*Reinstall the cover D sub assy with

reverse procedure of removal.

Use following values as adjustment and

service standard for reassembling.

1. Shuttle Shaft

1) Adjust the endplay at (A) and (B) to

[0.002~0.079in.] by shim.

2. Shuttle linkage.

Adjust the wire length. (See page 16)

(4) COVER D SUB ASSY REASSEMBLING

*Reassemble the cover D sub assy with

reverse procedure of dis assembling.

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6-6 TRANSMISSION CASE REASSEMBLING

*Reassemble the transmission case with

reverse procedure of disassembling.

(1) REAR DIFFERENTIAL CASE REASSEMBLING

*Reassemble the rear differential case with

reverse procedure of disassembling. Use

following values as adjustment and service

standard for reassembling.

1. Differential lock pedal

Adjust the stopper bolt that the clearance

between differential case and hub comes to

[0.039~0.059in.] when pedal is fully depressed.

(2) COVER E SUB ASSY REASSEMBLING

*Reassemble the rear differential case with




1. Drive shaft

Adjust the end play at drive shaft to be

[0.002~0.0079in.] by liner.

2. Holders

1) Adjust the backlash at ring gear and pinion

gear to [0.004~0.012] by adjusting shim

thickness at left holder.

2) Adjust the clearance between side of

differential case assy and transmission case

to [0~0.004in.] by adjusting shim thickness at

right holder.

3) Lock the fixing bolts of holders by lock plate.

2. Counter shaft

Adjust the end play at counter shaft to

[0.002~0.0079in.] by liner.

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3. Pinion Shaft www.mymowerparts.com

4. 4WD Shaft

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.

(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.

2. PTO Drive Shaft

Adjust the end play at PTO drive shaft to

[0.002~0.079 in.] by liner.

2) Adjust end play at pinion shaft to

[0.002~0.079 in.] by liner.

3) Adjust the pre-load at pinion shaft to

[0.72~0.94 lbf•ft]by tightening the nut and

calk the nut.

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6-6 CHECK AND MAINTENANCE

(1) DIFFERENTIAL GEAR AND PINION SHAFT

Shifter groove

Shift fork

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.

Pinion shaft

Diffrential ring gear

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.

3. Check the clearance between shift fork and

shifter.

Clearance ;



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.

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5. Check of Double cone Synchromesh

1) outer synchronizer ring ,inner synchronizer

ring ,synchronizer corn

(a) Make sure there is no damage and

scratch on the tooth surface of gear and

cone surface.

(b) Assemble the outer ring ,innner ring and

corn to the gear.

Measure the clearance “A”.

In case that clearance is out of limit,

replace them.

limit : [0.197 in.]

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.

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

Slit

Front

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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 ;



2) Steel plate

Check the flatness of steel plate . In case

that the flatness of steel plate is out of

service limit, replace the steel plate.

Flatness ;

Standard value : Less than [0.0059 in.]


3) Piston and Seal ring

Check the wear of piston and seal ring.

(1) Case

(2) Piston

(3) Seal ring

(4) Disk assy

(5) Ring set

(6) Spring

(7) Washer

(8) Return plate

(9) Brake disk

(10) Seal ring set

(11) Gear set 40T

(12) Seal ring

(13) Ring

(14) Back plate

(15) Belleville spring

(16) Ring

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7. REAR AXLE

7-1. DIFFERENTIAL CASE ASSY

DISASSEMBLING

(1) DIFFERENTIAL CASE ASSY REMOVAL

(See page 21.)

7-2. REAR AXLE DISASSEMBLING

(1) REAR AXLE ASSY REMOVAL

(See page 23.)

DIFFERENTIAL CASE ASSY

(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.

(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.

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(3) BRAKE ASSY REMOVAL

1. Remove fixing bolts of holder (6).

2. Remove arm (3).

3. Remove brake Assy (4-5).


7-3. BRAKE CONTROL DISASSEMBLING

(1) BRAKE (LH) DISASSEMBLING

1. Disconnect the rod (7) between brake link

L.H. (6) and L.H. brake arm.

2. 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 R.H. and brake link R.H.

3. Remove the spring pin and remove the brake

pedal L.H. (2), R.H. and brake shaft (1) from bracket.

4. Remove snap ring from link shaft (5).

5. Remove fixing bolts of link shaft and remove

link shaft (5).

(1)CASE L.H.

(2)LEVER

(3)ARM

(4)COM PLATE

(5)BRAKE DISK

(6)HOLDER

(7)SHAFT

(1)BRAKE SHAFT

(2)ROD

(3)BRAKE PEDAL R.H.

(4)JOINT

(5)LINK SHAFT

(6)BRAKE LINK L.H.

(7)ROD

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6. Disconnect the brake rod between brake link

R.H. and R.H. brake lever.

7. Remove snap ring and remove brake link R.H.

from link shaft.

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.

7-4. DIFFERENTIAL CASE ASSY

REASSEMBLING

*Reassemble the differential case assy with


(1) DIFFERENTIAL CASE ASSY

REASSEMBLING

*Reassemble the differential case assy with


Use following values for reassembling of

differential case assy as adjustment and

service standard.

1. Adjust the backlash between diff. pinion gear

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;

[30.38~36.17lbf•ft]

3. Install the spring pin in the manner that the

direction of slit comes as shown below.

(1)BRAKE SHAFT

(2)ROD

(3)BRAKE PEDAL R.H.

(4)JOINT

(5)LINER

(6)PARKING BRAKE LEVER

(7)BRACKET

(8)BUSHING

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7-5. REAR AXLE REASSEMBLING

* Reassemble the rear axle with reverse


(1) REAR AXLE REASSEMBLING

*Reassemble the rear axle with reverse


values for rear axle reassembling as


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)

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




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7-6. BRAKE CONTROL REASSEMBLING

*Reassemble the brake control with reverse


(1) BRAKE L.H. REASSEMBLING

*Reassemble the brake L.H. with reverse




(2) BRAKE R.H. REASSEMBLING

*Reassemble the brake R.H. with reverse




1. After installation of the grease nipple, fill up

the chassis grease.

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.]

2. Adjust the clearance between bracket (7) and

parking brake lever (6) to be less than

[0.197 in.] by liner.

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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 limit(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

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8. FRONT AXLE

8-1. FRONT AXLE REMOVAL

(1) FRONT AXLE REMOVAL

See page 13.

(2) HOLDER ASSY DISASSEMBLING

(1)REAR BRACKET

(2)FRONT BRACKET

(3)CENTER CASE R.H.

(4)CENTER CASE L.H.

(5)HOLDER

(6)PINION SHAFT

(7)BEARING CASE

(8)SHIM

(9)OIL SEAL

(10)NUT

1. Remove rear bracket (1) from front axle assy.

2. Remove fixing bolts of bearing case (7) and

remove bearing case from front axle assy.

3. Remove nut (10) and remove pinion shaft(6),

bearing, oil seal (9) , collar and shims (8) from

bearing case (7).

4. Remove nut (10) and remove front bracket (2).

5. Remove fixing bolts of holder (5) and remove

holder(5).

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(3) KNUCKLE ARM, FINAL CASE

DISASSEMBLING www.mymowerparts.com

1. Remove fixing bolts of knuckle arm and

remove knuckle arm from gear case.

2. Remove fixing bolts of cover and remove

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.

(4) KING PIN CASE DISASSEMBLING

(1)KING PIN CASE

(2)KING PIN SHAFT

(3)LINER

(4)GEAR 18T

(5)GEAR CASE L.H.

(6)GEAR 14T

(7)LINER

(8)CENTER CASE L.H.

(9)DIFFERENTIAL SHAFT

(10)GEAR 13T

(11)ARM HOLDER

(12)COVER

(13)BEARING

(14)BEARING

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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


(8)GEAR 14T

(9)PINION SHAFT

(10)LINER

(11)LINER

(12)O-RING

(13)DRAIN PLUG

(14)JOINT

(15)BEARING DIFFERENTIAL

CASE

1. Remove gear 14T (8) , bearing (15) and diff.

shaft (7).

2. Remove fixing bolts of center case L.H. (2) and R.H. (1) and divide center case L.H. and

R.H..

4. Disassemble diff. case assy.

1) Remove bearings from diff. case.

2) Remove fixing bolts of ring gear (4) and remove ring gear from diff. case (3).

3) Remove spring pin and remove shaft,

pinions (6), side gears (5) and liners from diff.

case.

3. Remove diff. case assy from center case

R.H. (1).

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8-2. FRONT AXLE REASSEMBLING

*Reassemble front axle with reverse


(1) FRONT AXLE ASSEMBLY

*Reassemble holder assy with reverse


*Special tool for bushing (A) and (B) insullation.

Parts number MA-19619032000 for (A)

MA-19619031000 for (B)

*Use following values for adjustment and service

standard of reassembling.

1. Apply the lithium grease to o-rings for

assembling.

2. Adjust the turning torque of pinion shaft to

[6.51~8.68 lbf•ft] by tightening the nut.

3. Select the shim by calculating the shim

thickness as follows and install between axle

center case and holder.

Shim thickness = H - 28

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(

1)REAR BRACKET

(2)FRONT BRACKET

(3)CENTER CASE R.H.

(4)CENTER CASE L.H.

(5)HOLDER

(6)PINION SHAFT

(7)BEARING CASE

(8)SHIM

(9)OIL SEAL

(10)NUT


3. Tighten the nut until no play is produced but

bracket can be turned lightly.

Use following values for reassembling of

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.].

(2) KNUCLE ARM AND FINAL CASE

REASSEMBLING

*Reassemble knuckle arm and final case with


Fill the grease at pivot of knuckle arm.

4. Adjust backlash between gear 13T and gear

38T to [0.008~0.016 in] by liner.

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(3) KING PIN CASE REASSEMBLING

*Reassemble king pin case with reverse


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). [8.68~12.3lbf•ft]

4. King pin case assembling

Adjust the dimensions as shown in the

drawing by liner (3).

DETAIL B DETAIL C

5. Adjust backlash between gear 14T and gear

18T to [0.0078~0.0157 in.] by liner (7).

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(4) CENTER CASE AND DIFF. CASE

REASSEMBLING

*Reassemble center case and diff. case with


(1)CENTER CASE R.H.

(2)CENTER CASE L.H.

(3)DIFFERENTIAL CASE

(4)RING GEAR

(5)SIDE GEAR

(6)PINION


(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

standard.

1. Apply lithium grease to o-ring.

2. Tightening torque of drain plug (13).

[28.93~57.86 in.]

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

ring gear fixing bolts is; [50.63~57.86 in.]

3) Install the spring pin with direction as shown

below.

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4) Apply heat resistant grease sliding surface.

2. Check the backlash of bevel gears. In case

that the backlash is out of standard, readjust it.

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).

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.

Item 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.

8-3. FRONT AXLE CHECK AND

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.

Item Standard value(in.) Service limit(in.)

Clearance between king 0.00118 0.0079

pin case and bushing ~0.00315


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

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(3) CLEARANCE BETWEEN KNUCKLE ARM

HOLDER AND BUSHING

1. Check the clearance between knuckle arm

holder and bushing. In case that the

clearance 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.


Clearance between holder 0.00197~

and knuckle arm 0.00787

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9. STEERING

9-1. OPERATOR CONTROL AREA REMOVAL

(1) STEERING WHEEL REMOVAL

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.

(1)STEERING UNIT

(2)COLUMN

(3)PLATE

(4)BOLT

(5)NUT

(6)BOOT

(7)SHAFT

(8)STEERING WHEEL

(9)CENTER PAD

(10)NUT

(11)HOSE L (RED TAPE)

(12)HOSE R

(13)TILT LEVER

(14)BOLT

(15)NUT

(16)SPRING

(17)BOLT

(18)DISK SPRING

(19)NUT

(20)LINER

(21)BOLT

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(2) STEERING WHEEL DISASSEMBLING

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

snap ring , liner (20) and shaft (7) from

column (2).

9-2. STEERING UNIT DISASSEMBLING

(1) STEERING UNIT REMOVAL

Remove steering unit fixing bolt and remove

steering unit from column.

(2) STEERING UNIT DISASSEMBLING

(1)DUST SEAL

(2)RETAINING NUT

(3)SEAL GRAND BUSHING

(4)O-RING

(5)OIL SEAL (X-RING)

(6)NEEDLE BEARING KIT

(7)RELEASE BEARING

(8)THRUST NEEDLE

(9)RELIEF VALVE ADJUSTER

(10)O-RING

(11)COLER

(12)SPRING

(13)POPPET

(14)CONTROL PARTS ASSY

(15)HOUSING

(16)CONTROL SLEEVE

(17)CONTROL SLEEVE

(18)FLAT SPRING

(19)CENTERING SPRING

(20)PIN

(21)O-RING

(22)SPACER

(23)DRIVE

(24)ROTA SET

(25)O-RING

(26)SPACER

(27)END CAP

(28)RETAINER SCREW

(29)CHECK VALVE RETAINER SCREW

(30)BALL

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1. Rotary disassembling

1) Remove screw 28 (6 pieces), retainer screw

29 (1 piece) and end cap (27).

2) Remove o-ring (21) from end cap (27).

2. Controls disassembling

1) Remove retaining ring (2) from housing.

2. Remove rota set (24) and o-ring (21)

2) Turn spool (17) and sleeve (16) until pin

(20) comes to horizontal. Push spool (17)

and sleeve (16) and remove seal grand

bushing (3) from housing.

3. Remove drive (23) and spacer plate (22).

4. Remove o-ring from housing.

3) Remove release bearing (7) and thrust

needle (8) from spool (17) and sleeve(16) .

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4) Pull out spool(17)and sleeve(16)from housing.

(Pull them out to opposite side of flange.)

Do not disassemble or adjust the adjust plug

for relief pressure setting at dealer.

5) Remove pin (20) from spool (17) and sleeve

(16) assy.

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.

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.

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3. Disconnect battery negative code and positive

code. Remove battery.

6. Remove chassis and radiator.

7. Remove hydraulic cylinder assy.

4. Remove radiator hoses and air cleaner hose

from engine.

(2) HYDRAULIC CYLINDER ASSY

DISASSEMBLING

1. Remove tie rod end (6) , rod (9), rod end (8)

and packing case (3).

2. Remove cylinder rod (2) from cylinder tube (1).

5. Remove fixing bolts of front holder.

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9-4. OPERATOR CONTROL AREA

REASSEMBLING

*Reassemble operator control area with


(1) STEERING WHEEL REINSTALLATION

*Reinstall steering wheel with reverse

procedure of removal. Use following values as


(1)STEERING UNIT

(2)COLUMN

(3)PLATE

(4)BOLT

(5)NUT

(6)BOOT

(7)SHAFT

(8)STEERING WHEEL

(9)CENTER PAD

(10)NUT

(11)HOSE L (RED TAPE)

(12)HOSE R

(13)TILT LEVER

(14)BOLT

(15)NUT

(16)SPRING

(17)BOLT

(18)DISK SPRING

(19)NUT

(20)LINER

(21)BOLT

1. Adjustment of tilt lever

1) Tighten the bolts (17) until locking the

steering column..

2) Loosen the bolts (17) of L.H. side and R.H.

side equally until tilt force at steering wheel

comes to [21.7~108.5 lbf•ft ] and lock them

by lock nut (19).

3) Check the tilt force at steering wheel after

lock the lock nut (19).

4) Check the tilt amount at steering wheel

which is approximate [0.827 in.] and side

play which should be less than [0.079 in.].

2. Tightening torques [36.17lbf•ft]

Hoses [18.08lbf•ft]

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(2) STEERING WHEEL REASSEMBLING

*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 lbf •ft ]

9-5 STEERING UNIT REASSEMBLING

*Reassemble steering unit with reverse


(1) STEERING UNIT REASSEMBLING

(1)DUST SEAL

(2)RETAINING NUT

(3)SEAL GRAND BUSHING

(4)O-RING

(5)OIL SEAL (X-RING)

(6)NEEDLE BEARING KIT

(7)RELEASE BEARING

(8)THRUST NEEDLE

(9)RELIEF VALVE ADJUSTER

(10)O-RING

(11)COLER

(12)SPRING

(13)POPPET

(14)CONTROL PARTS ASSY

(15)HOUSING

(16)CONTROL SLEEVE

(17)CONTROL SLEEVE

(18)FLATE SPRING

(19)CENTERING SPRING

(20)PIN

(21)O-RING

(22)SPACER

(23)DRIVE

(24)ROTA SET

(25)O-RING

(26)SPACER

(27)END CAP

(28)RETAINER SCREW

(29)CHECK VALVE RETAINER SCREW

(30)BALL

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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 lbf•ft ]

Put the mark (line) at spline end surface of

drive (23) to ensure the position.

Make sure of location for installation of screw (29).

3) Apply grease at o-ring.

4) When hold the flange of housing (15) by vise, do not hold too tight.

7) Install o-ring (21) to rota set (24).

5) Install o-ring (21) to housing (15).

Put spacer plate (22) and aline bolt hole of

plate and tapped hole of housing.

8) Face o-ring groove side of rota set (24) to

spacer plate (22) and aline bottom of star

piece and line B. Make sure the line A

(line between bottoms of star piece),

B, C and D as shown below.

Aline the bolt hole of rota set (24) while

keeping the connection of drive and star

piece of rota.

6) Turn spool (17) and sleeve (16) assy to parallel the pin (20) and port surface of housing (15).

Insert the drive (23) and engage the yoke of drive and pin.

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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.

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.

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.

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9-6. HYDRAULIC CYLINDER ASSY

REASSEMBLING

*Reassemble the hydraulic cylinder assy with


(1) HYDRAULIC CYLINDER ASSY

REASSEMBLING

*Reassemble hydraulic cylinder assy with


following values for reassembling as


1. Packing case tightening torque ; [72.33lbf•ft]

(Apply the threebond #1901 to thread.)

In case of removing the hose, take the

following procedure for air removal

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.

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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) side of tire.

Toe-in = A - B = [0~0.394 in.]

(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

3. If toe-in is out of standard, readjust the toe-in

by adjusting the rod length.

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;

[108.50~122.96lbf•ft]

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.

Bolt head of rod bolt should be set to upper side.

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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 I is supplying hydraulics to hitch

and pump II is supplying hydraulics to

power steering and PTO clutch.

2. Pump I disassembling

(1)HOUSING

(2)BUSHING

(3)DRIVE GEAR

(4)DRIVEN GEAR

(5)BUSHING

(6)BUSHING

(7)O-RING

(8)FRENGE

(9)COVER

(10)O-RING

(11)KNOCK PIN

(12)BACK UP ELEMENT

(13)SEAL ELEMENT

(14)BUSHING

(15)OIL SEAL

(16)C-RING

(17)BOLT

(18)KEY

1) Remove fixing bolts (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).

2) Remove snap ring (16) and oil seal (15)

from flange (8).

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3. Pump II disassembling www.mymowerparts.com

2. Control valve disassembling

1) Remove plug at unload valve and remove

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.

1) Remove fixing bolts (12) and remove cover

(2), gasket (7), gear A (3), gear B (4),

snap ring (10), and oil seal (9) from body (1).

(2) CONTROL VALVE DISASSEMBLING

1. Control valve removal

Disconnect the linkage at control valve spool

and remove fixing bolts of control valve

(3 bolts) and ,lubrication pipe, guide and

control valve.

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10-2. HYDRAULIC LIFT DISASSEMBLING

(1) LIFT SHAFT AND CYLINDER

DISASSEMBLING

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

remove cylinder (14). Remove piston (12).

2. Lift shaft disassembling

1) Remove snap rings and remove lift arms (2).

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).

Do not hit shaft with hammer for removal.

(1)SHAFT

(2)LIFT ARM

(3)BUSHING

(4)BUSHING

(5)O-RING

(6)COLER

(7)SNAP RING

(8)POWER ARM

(9)BUSHING

(10)PISTON ROD

(11)BACK UP RING

(12)PISTON

(13)O-RING

(14)HYDRAULIC CYLINDER

(15)STEEL BALL

(16)SET BOLT

(17)O-RING

(18)LIFT ARM PIN

(19)PIN

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(2) HYDRAULIC LINKAGE DISASSEMBLING

(1)CONTROL VALVE

(2)GUIDE

(3)ROLLER

(4)SPRING

(5)POWER ARM

(6)LINK

(7)LINK H

(8)PLATE

(9)POSITION SHAFT

(10)DRAFT SHAFT

(11)SHAFT

(12)ARM

(13)LEVER B

(14)LEVER A

(15)LINER

(16)NUT

(17)LINK B

(18)LINK J

(19)LINK

(20)LINK E

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 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).

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.

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(3) POSITION CONTROL LEVER REMOVAL

1) Remove piston control lever.

2) Remove rod A.

3) Remove plate (F)

(4) FLOW CONTROL VALVE DISASSEMBLING

1. Loosen lock nuts (3) and remove screw (4),

plate (5), washer and spring (6) .

2. Remove sleeve (8), ball (9) and spring(10).

3. Remove fixing bolts of plate (7) and remove

plate (7), shims(1) and (2).

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10-3. MAIN HYDRAULICS REASSEMBLING

*Reassemble the main hydraulics with


(1) HYDRAULIC PUMPS REASSEMBLING

*Reassemble pump I and II with reverse


values as adjustment and service standard of

reassembling.

1. Tightening torque of pump bolts.

[18.08~21.7 lbf•ft]

2. Apply oil at o-rings and oil seals for the

assembling.

(1)HOUSING

(2)BUSHING

(3)DRIVE GEAR

(4)DRIVEN GEAR

(5)BUSHING

(6)BUSHING

(7)O-RING

(8)FRENGE

(9)COVER

(10)O-RING

(11)KNOCK PIN

(12)BACK UP ELEMENT

(13)SEAL ELEMENT

(14)BUSHING

(15)OIL SEAL

(16)C-RING

(17)BOLT

(18)KEY

(2) CONTROL VALVE ASSEMBLING

*Reassemble and reinstall the control valve

with reverse procedure of the disassembling

and removal. Use followin value for

reassembling and reinstallation of control

valve as adjustment and service standard.

1. Make sure orings are installed on the control

valve before valve installation and apply oil at

o-ring.

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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 lbf•ft

Plug at check valve : 36.17~43.4 lbf•ft

Plug at unloader valve : 50.63~69.1 lbf•ft

Nut at poppet : 13.02~15.91lbf•ft

10-4. HYDRAULIC LIFT REASSEMBLING

*Reassemble hydraulic lift with reverse


(1) LIFT SHAFT AND CYLINDER

REASSEMBLING

*Reassemble the lift shaft and cylinder with


following values for reassembling as


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.

2. Lift shaft reassembling

1) Aline the bolt hole for lock bolt on the power

arm and lift shaft.

Tightening torque of lock bolt

8.68~12.3lbf•ft

2) Aline the punch mark on the lift shaft and lift

arm.

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3) Install the bushing (9) to piston rod (10).

Bushing should be placed with its slit

coming as shown in the following drawing.

4) Install the bushings (3) to lift case. Bushing

should be placed with its seam coming as

shown in the following drawing.

5) Drive in bushing at lift shaft to [0.374~0.394

in.] deep as shown in the following drawing.

6) Apply molybdenum(MoS2) to spline of lift

shaft.

*Special tool for bushing (3) and (4)

insullation.

Parts number 19619021000 and

19619025000 for (3) and (4).

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(2) HYDRAULIC CONTROL LINKAGE

REASSEMBLING

*Reassemble the hydraulic control linkage with




(1)CONTROL VALVE

(2)GUIDE

(3)ROLLER

(4)SPRING

(5)POWER ARM

(6)LINK

(7)LINK H

(8)PLATE

(9)POSITION SHAFT

(10)DRAFT SHAFT

(11)SHAFT

(12)ARM

(13)LEVER B

(14)LEVER A

(15)LINER

(16)NUT

(17)LINK B

(18)LINK J

(19)LINK

(20)LINK E

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.

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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.

3) Aline the punch mark of lever B (13) and

draft shaft (10).

Drawing from 4501 7-53

2) Adjust side play (S) at link H (7) to be less

than [0.0118in.] by liner.

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.

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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.

4. Flow control valve reassembling

1) Adjust the height of plate (7) by shim (1 and

2) to turn the screw (4) smoothly.

2) Tightening torque of sleeve (8)

[61.48~68.71lbf•ft]

3) Adjust the position of plate (5) to obtain the

length of spring (6) to be [0.591~0.669 in.] at

the flow control lock position.

4) Set the clearance between plate (5) and

housing to be [0.236 in.] as shown in the

following drawing.

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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.

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.

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3. Tightening torques of hydraulic line

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10-6. HYDRAULICS CHECK AND

MAINTENANCE

(1) HYDRAULIC LIFT SYSTEM CHECKING

1. Clearance of bushing

1) Measure the outer of diameter of lift shaft

and power arm pin.

2) Measure the inner diameter of bushings

and calculate the clearances.

3) In case that clearance is out of service

limit, replace the parts.

Item Standard Service

value (in.) standard (in.)

Clearance between 0.000984

lift shaft and ~ 0,011811

bushing 0.003504

Clearance between 0.000787

piston rod and ~ 0,011811

bushing 0.003268

Item Standard Service

value (in.) limit (in.)

Clearance between 0.00236~

cylinder and piston 0.00386 0.00787

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. CalcuIate the

clearance between piston and cylinder.

2) In case that clearance is out service limit,

replace the parts.

166

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


167

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

11. ELECTRICS

11-1. ELECTRIC DIAGRAM

168~169


11-2. SPECICATIONS

Electrical System

Type of System ..............................................................................12 Volt, Negative Ground

Battery .....................................................................................................12 Volt, 500 CCA

Group 22F, Top Stud Terminals

Alternator ....................................................................................12 Volt, 50 Ampere Output

Voltage Regulator .................................................................................IC Built in Alternator

Starter Motor ...................................................................12 Volt, 2 kw with Solenoid Switch

Head Lamp .............................................................................................................35 Watt

Flasher Lamp .........................................................................................................23 Watt

Rear Red Lamp ......................................................................................................20 Watt

Panel Lamp ...........................................................................................................3.4 Watt

Turn Indicator Lamp ...............................................................................................3.4 Watt

Indicator Lamp .......................................................................................................3.4 Watt

170

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

Cub Cadet 7000 7360SS Compact Tractor Service manual

Assistant Bot

SERVICE MANUAL

SERIES 7000

COMPACT TRACTOR

Model Number

7360SS

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

2. ENGINE ASSY REMOVAL AND REINSTALLATION

3. CLUTCH HOUSING, TRANSMISSION CASE, REAR AXLE CASE

AND HYDRAULIC LIFT CASE REMOVAL AND REINSTALLATION

4. ENGINE

1

3

4

6

7

8

9

10

11

12

13

15

25

5. CLUTCH

6. TRANSMISSION

7. REAR AXLE

8. FRONT AXLE

9. STEERING

10. HYDRAULICS

11. ELECTRICAL

2

153

167

141

126

132

108

111

I. GENERAL

3

1. SAFETY

4

5

2. LOCATION OF ENGINE MODEL, ENGINE SERIAL NO.

AND TRACTOR SERIAL NO. IDENTIFICATIONS

6

3. SPECIFICATION AND DATA

Capacities

NOTE :

NOTE :

Fuel Specifications

Fuel injectors

7

4. POWER TRANSMISSION DIAGRAM

8

5. TIGHTENING TORQUES

9

6. PRECAUTIONS FOR DISASSEMBLY

Slit

Slit

Shaft movement

Shaft movement

10

7. GENERAL INFORMATION

11

II. ASSY REMOVAL AND REINSTALLATION

12