FRONT MOWER

CM284
CM364

WORKSHOP MANUAL

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 Introduction

Shibaura developed a front mower incorporating new technology for more

improved passenger mowing garden tractor.
This manual describes the structure, functions, maintenance and service of
models CM284 and CM364 so that their functions are fully exhibited in actual
operation.
Please read this carefully to promote sales and service, to improve the service
techniques and guide users for proper operation of Shibaura tractors.

Figures or other conditions in this manual may be changed without notice in

order to improve the performance or for other objects.

Ishikawajima-Shibaura Machinery Co., Ltd.

Tractor Division
Quality Assurance Department

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 INDEX

Chapter 1. GENERAL ············································ 3 Chapter 6. REAR AXLE ASSEMBLY ··············149

1-1 Specifications & Performances ······························ 4 1. DESCRIPTION AND OPERATION ·················· 150
1-2 Precautions Before Servicing ································· 5 2. REAR AXLE REMOVAL ································· 151
1-3 Basic Understanding on Servicing ························· 5 3. INSTALLATION··············································· 151
4. DISASSEMBLY ··············································· 152
Chapter 2. ENGINE ················································ 7 5. INSPECTION ··················································· 154
2-1 Engine Removal ···················································· 8 6. ASSEMBLY······················································ 155
2-2 Disassembly, Inspection and Reassembly ··············· 9 7. INSTALLATION··············································· 156
1. Disassembly ·························································· 9
2. Disassembly, Inspection and Reassembly Chapter 7. HYDRAULIC LIFT SYSTEM ·······157
of Engine Main Parts ··········································· 13 1. DESCRIPTION AND OPERATION ·················· 158
3. Engine Reassembly ············································· 36 2. OIL FLOW························································ 159
2-3 Electrical Units ···················································· 46 3. OVERHAUL····················································· 162
1. Alternator ···························································· 46
2. Starting Motor ····················································· 53 Chapter 8. IMPLEMENT DRIVE ·····················167
3. Glow Plug ··························································· 68 1. DESCRIPTION AND OPERATION ·················· 168
4. Thermometer and Thermosensor ·························· 69 2. POWER FLOW ················································ 169
5. Buzzer Alarm Warning System ···························· 70 3. AUTOMATICALLY PTO
6. Oil Pressure Switch ············································· 71 DISENGAGE SYSTEM ···································· 171
7. Engine Stop Solenoid ·········································· 72 4. ADJUSTMENT AND SPECIFICATION ··········· 172
8. Fusible Link ························································ 72 Chapter 9. MAINTENANCE
9. Wiring Harness···················································· 72
2-4 Trouble Shooting ················································· 73 STANDARDS TABLE ·····················173
2-5 Engine Maintenance Standard Table····················· 75 Maintenance Standards Table ·································· 174
Chapter 3. TRANSMISSION AND BRAKE ······ 83 Chapter 10. ELECTRICAL SYSTEM ··············177
1. DESCRIPTION AND OPERATION ···················· 84 1. DESCRIPTION ················································· 178
2. TRANSMISSION UNIT ····································· 88 2. COMPONENT LOCATION AND FUNCTION · 178
1) Removal ························································ 88 3. FUNCTION INSPECTION
2) Front Transmission Unit ································· 93 AND ADJUSTMENT········································ 181
3) Rear Transmission Unit ································· 101
4) PTO Clutch Unit ··········································· 105 Chapter 11. MOWER ··········································207
5) Front Wheel Shaft and Brake Unit ················· 108 11-1 Sectional Vier: FM60SD ···································· 208
6) Two Way Clutch Unit···································· 110 11-2 Specifications ···················································· 209
7) Differential Gear Unit ··································· 111 11-3 Disassembly ······················································ 210
11-4 Reassembly and Adjustment ······························ 216
Chapter 4. HST SYSTEM ·································· 117
1. OIL FLOW ························································ 118
2. HST UNIT REMOVAL ······································121
3. PRECAUTIONS BEFORE DISASSEMBLY ······124
4. DISASSEMBLY ················································124
5. INSPECTION ····················································125
6. REASSEMBLY ··················································126
7. ASSEMBLY·······················································126
8. ADJUSTMENT ·················································128
9. TROUBLE SHOOTING AND
SPECIFICATIONS ·············································132
Chapter 5. POWER STEERING ······················· 135
1. OIL FLOW ························································136
2. CONTROL VALVE ASSEMBLY ·······················141
3. POWER STEERING CYLINDER ······················145
4. PIPING ······························································146
5. TROUBLE SHOOTING·····································147

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 Chapter 1. GENERAL

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 1-1 Specifications & Performances
Model CM284 CM364
Model J843 N843L
Type Water-Cooled 4-Cycle Vertical Diesel Engine
Number of Cylinders 3
Engine

Total Stroke Volume 1330 cc 1662 cc

Maximum Output 20.8 kW (28 HP)/2700 rpm 26 kW (35 PS)/2700 rpm
Compression Ratio 22.5 : 1
Fuel Diesel Fuel Oil
Starting Method By Starting Motor
Overall Length 2415 mm
Overall Height 1390 mm
Overall Width 1220 mm (narrow), 1370 mm (wide)
Weight 730 kg 750 kg
Front Wheel 23 × 10.5 – 12
Tire
Rear Wheel 20 × 8.00 – 10
Maine Body

No. of Running Speeds 2 Forward Speeds, 2 Reverse Speeds (Continuously variable speed)
Transmission System L/H Switching, All Hydraulic Continuously Variable Speed (HST)
Brake Wet Disc Brake
Lift Control Valve Relief Set Pressure 9.8 MPa {100 kgf/cm2}
Relief Set Pressure/ Steering 5.88 – 6.56 MPa {60 – 67 kgf/cm2}/ Full Hydraulic Power Steering
Forward: L 0 – 10.0 km/h
Forward: H 0 – 17.2 km/h
Running Speed
Reverse: L 60 – 70 % of Forward Speed
Reverse: H 60 – 70 % of Forward Speed
Fuel Tank 50.5 ℓ
Capacity

Engine Oil 4.6 ℓ (Including oil filter) 5.6 ℓ (Including oil filter)
Transmission Gear Oil Front 20 ℓ, Rear 2.3 ℓ
Cooling Water 5.1 ℓ 5.3 ℓ
Battery 75 D 26 L
Starting Motor 12 V – 1.7 kW 12 V – 2.0 kW
Electric Units

Alternator 12 V – 40 A
Head Light 23 W
Monitor Lamp 3W
Dash Panel Lamp 2W
Light Switch Lamp 1.4 W

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 1-2 Precautions Before Servicing
1. Have the tractor washed clean and have the oil, fuel, and cooling water drained out as would be required by
the work to be performed.
2. Service shop should always be kept clean to prevent dust from rising and should be well lighted.
3. The disassembled parts shall have the oil and grease washed off and arranged on a stand separated by groups.
4. Clothing, service tools and equipments shall be checked to ensure safety in performing the operations.

1-3 Basic Understanding on Servicing

1. Engine, transmission, and hydraulic apparatus have been specially manufactured to high accuracy so that
care shall be exercised to maintain them in clean state and not to do any unnecessary disassembly.
2. Defective parts due to wear and other causes shall be discarded and new parts ordered with the tractor model,
serial No., code No., and part name clearly defined. (Keep the defective parts on hand to enable showing it to
the customer.)
3. When assembling, it is essential to have oil applied to all moving parts so that they will be provided with
initial oil film until normal lubrication takes place.
4. Unless specially instructed, bolts and nuts shall be tightened by proper tools to the proper tightening torque.

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 GENERAL METRIC BOLT TORQUE SPECIFICATION TABLE
USE THE FOLLOWING TORQUES WHEN SPECIAL TORQUES ARE NOT GIVEN

NOTE : These values apply to fasteners as received from supplier, dry, or when lubricated
with normal engine oil. They do not apply if special graphited or molly disulphide grasses
or other extreme pressure lubricants are used.

Coarse Thread Fine Thread

Bolt Size Grade No. Pitch (mm) Newton Meters Pitch (mm) Newton-Meters
4T 4.9 – 6.9
M6 7T 1.0 8.3 – 11.3 – –
10T 11.7 – 15.7
4T 12.7 – 16.7 15.2 – 20.1
M8 7T 1.25 22.6 – 28.4 1.0 26.5 – 34.3
10T 28.5 – 36.3 30.4 – 40.2
4T 25.5 – 33.3 28.4 – 36.2
M10 7T 1.5 44.1 – 55.9 1.25 49.0 – 62.8
10T 54.0 – 69.6 57.9 – 73.5
4T 37.3 – 47.1 43.1 – 54.9
M12 7T 1.75 65.7 – 83.4 1.25 74.5 – 94.1
10T 92.2 – 116 99.0 – 127
4T 62.8 – 80.4 69.6 – 87.3
M14 7T 2.0 104 – 131 1.5 117 – 148
11T 139 – 175 147 – 186
4T 86.3 – 110 91.2 – 115
M16 7T 2.0 149 – 184 1.5 157 – 192
11T 206 – 255 221 – 270
4T 114 – 141 131 – 163
M18 7T 2.0 196 – 235 1.5 230 – 279
11T 275 – 333 299 – 368
4T 144 – 179 172 – 211
M20 7T 2.5 240 – 289 1.5 275 – 333
11T 363 – 441 397 – 485

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 Chapter 2. ENGINE

NOTE:
Due to Pollutant Regulations, some of parts relating to Engine exhaust are not
available for spares as an individual part.

Engine Model Tractor Model

J843 CM284
N843L CM364

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 2-1 Engine Removal
1) If necessary, remove bolts and nuts and the bonnet.

2) Remove the muffler and stay from the engine.

3
3) Disconnect the wiring from the air cleaner clogging
sensor. 1
2 5
4) Disconnect the wiring from the water temperature
sensor and water temperature switch.

5) Remove the radiator hoses from the engine. 4

6) Disconnect the wiring from the alternator.

7) Disconnect the wiring from the starting motor. 002X

① Water temperature switch ④ Alternator
8) Remove the bolt and ground wire from the cylinder
② Water temperature sensor ⑤ Starting motor
head.
③ Radiator hose
9) Disconnect the fuel return hose from the fuel return
pipe.

003X
① Air cleaner clogging sensor ③ Glow plug connector
② Ground wire ④ Fuel return hose

10) Disconnect the wiring from the engine oil pressure

switch.

11) Disconnect the wiring from the glow plug connector.

12) Disconnect the wiring from the engine stop solenoid.

3
13) Disconnect the fuel pipe from the injection pump.
2
1 5
14) Remove the accelerator wire from the engine.
4
15) Disconnect the drain hose from the drain cock.

16) Disconnect the oil hoses from the hydraulic oil pump. 6
004X
17) Remove the engine attaching nuts and hoist the ① Engine stop solenoid ⑤ Hydraulic oil pump
engine from the flame. ② Accelerator wire ⑥ Engine attaching nut
③ Fuel hose
④ Drain cock

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 2-2 Disassembly, Inspection and Reassembly
1. Disassembly

005X

Order Disassemble Parts Name

1 Alternator
2 Starting motor
3 Oil filter
4 Relief valve
5 Oil level gauge · Gauge guide
6 Engine stop solenoid · Seal washer
7 Injection pipe
8 Injection pump
NOTE:
1. Remove the injection pipes and engine stop solenoid before remove the injection pump.
2. Raise the injection pump and disconnect the governor link from the control rack by remove
the snap pin.
3. Injection timing has been adjusted by the shims between injection pump and cylinder block.
Take note of their thickness and number when removing the injection pump.

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 006X

Order Disassemble Parts Name

9 Return pipe
10 Injection nozzle · Gasket
11 Oil transfer pipe · Eye bolt · Seal washer
12 Connector · Glow plug
13 Oil pressure switch
14 Thermostat case · Gasket
15 Head cover · O-Ring · Intake manifold · Spacer
16 Rocker arm assembly · O-Ring · Cap
NOTE: Remove the caps from intake valves and exhaust valves.
17 Push rod
18 Cylinder head assembly · Head gasket
NOTE:
1. Untighten the cylinder head bolts in several steps and remove the cylinder head assembly.
19 Tappet

10

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 007X

Order Disassemble Pats Name

20 V-belt · Cooling fan · Fan holder · Fan pulley
21 Water pump assembly · Gasket
22 Crankshaft pulley
23 Hydraulic oil pump, Cover, Drain cock.
24 Timing gear case assembly · Gasket
NOTE: Remove the engine stop solenoid and injection pump assembly at first.
25 Idle gear · Oil pump assembly
26 Cam shaft assembly · Plate
NOTE: Remove the bolts and plate at first, and draw out the cam shaft assembly.
27 Front plate · Gasket

11

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 008X

Order Disassemble Parts Name

28 Oil pan · Gasket · Suction filter · Suction pipe
29 Fly wheel
30 Rear plate
31 Oil seal
32 Piston and connecting rod assembly
NOTE:
1. Before extracting piston, remove the carbon deposit from the TDC in the cylinder.
2. Place the connecting rod, cap and bearing removed in order of the cylinders.
33 Crank shaft and bearing holder assembly
NOTE: Remove the four bolts, and draw out the crank shaft and bearing holder assembly as a
set.

12

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 2. Disassembly, Inspection and Reassembly of Engine Main Parts

★ Cautions before start

1) Check the cylinder block and cylinder head for wear, leakage and damage.
2) Remove deposit in oil holes of each part with air and check for clogging.
3) Wash each part well to remove dust, contaminated oil, carbon, and other foreign matter.
4) Remove carbon deposite on the piston, cylinder head, valves, etc. carefully not to damage parts. (Great care is
necessary specifically for aluminum alloy parts.)
5) Valves, pistons, connecting rods, metals and other parts which are to be combined as specified should be
attached match marks beforehand to prevent confusion.

1) Rocker arm ass’y

Disassembly

(1) Extract the screw from the rocker arm bracket.

(2) Screw in a M8 bolt from the front side of the rocker
arm bracket and extract the rocker arm shaft.
(3) Take out the spring and rocker arm from the rocker
arm bracket.

1. Screw
2. Rocker arm shaft
3. Rocker arm
4. Spring
5. Shim

009X
Inspection and service

(1) Rocker arm shaft

Measure the outside diameter of the rocker arm shaft

with a micrometer and replace if the result is bellow
the service limit.

Rocker arm shaft diameter (ø)

Standard assembling value Service limit 010X
J843 11.65 – 11.67 11.57
N843L 14.95 – 14.97 14.87

13

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 (2) Clearance between rocker arm and rocker arm
shaft

a. Measure the rocker arm bore.

b. Measure the clearance between the rocker arm
and rocker arm shaft, and replace if the service
limit is exceeded.

Clearance between rocker arm and rocker arm shaft

(mm) 011X
Standard assembling value Service limit
0.032 – 0.068 0.2

(3) Inspection of rocker arm

Check the valve cap-contact surface for uneven wear

and streaks. Correct the curved surface with an oil
stone or grinder correctly if insignificant.

Reassembly

Reassembly parts reversely to disassembly.

2) Cylinder head ass’y

Disassembly

(1) Compress the valve spring with a valve spring

replacer and remove the valve cotter, retainer, spring
and valve.
(2) Remove the valve guide seal, if required.
013X
1. Valve 4. Valve cotter
2. Spring 5. Valve guide seal
3. Retainer

Inspection and service

(1) Distortion of cylinder head bottom surface.

Apply a straight edge to the bottom surface of the

cylinder head, and insert a thickness gauge at 6 points
from A to F in the right figure and measure distortion.
If the distortion exceeds the repair value, correct with
surface grinder or the like.

Distortion at cylinder head bottom surface (mm) 014X

Standard assembling value Repair value
Less than 0.05 0.12

015X

14

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 (2) Intake and exhaust valves and valve guide

a. Check the head and stem of each valve and

replace if burnout, wear or deformation is
remarkable.
b. Measure the outside diameter at the position I, II,
and III on the valve stem with a micrometer and
replace if the result is less than the service limit.
016X
Valve stem diameter (mm)
Intake valve Exhaust valve
Standard Standard
Service Service
assembling assembling
limit limit
value value
6.955 – 6.97 6.89 6.94 – 6.95 6.84

c. Replace a valve if its head thickness is less than

service limit.

Valve head thickness (mm)

Standard assembling value Service limit
0.775 – 1.075 0.5
017X

d. Replace the valve if the clearance between the

stem and guide exceeds the service limit.

Clearance between valve stem and valve guide (mm)

Intake valve Exhaust valve
Standard Standard
Service
assembling Service limit assembling
limit
value value
0.045 –
0.03 – 0.06 0.2 0.25
0.075 018X

15

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 (3) Valve seat

a. Since the valve seat is corrected according to the

valve guide, be sure to check the valve guide for
wear condition first before correcting the seat.

b. Correct the seat using a seat cutter of 15°, 45°

and 75° so that the contact width is the standard
assembling value.

Valve seat contact width (mm)

Standard assembling value Repair value 019X
Intake 1.66 – 1.87
2.5
Exhaust 1.66 – 1.73

c. When the seat recess exceeds the service limit,

replace the valve seat or valve.

Valve seat recess (mm)

Standard assembling value Service limit
0.85 – 1.15 1.8

020X

d. Coat the valve seat surface with compound and

lap the contact surface turning the valve.
e. Check that the valve contact surface is within the
standard value and the contact position is even.

021X

16

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 (4) Valve spring

a. Check the valve spring visually for damage.

b. Measure the squareness of the spring using a
square on a surface plate and replace if the
service limit is exceeded.
c. Check the free length and spring force with a
spring tester and replace if the service limit is
exceeded.

Standard
Service limit
assembling value
Squareness (mm) 1.2 2
Free length (mm) 35 33.5
Spring force (when
compressed to 30.4 8.1 7 022X
mm)

(5) Inspection of combustion chamber

Check and clean the inside of the combustion

chamber.

Reassembly

Reassemble parts in the order reverse to disassembly taking care for the following points.
(1) When assembling the valve, spring, retainer and cotter, be careful not to damage the valve guide seal.
(2) Tighten the glow plug with the tightening torque of 14.7 – 19.6 N·m {1.5 – 2.0 kgf·m}.

17

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 3) Cylinder block Distortion on cylinder block top surface (mm)

Inspection and service Standard assembling value Repair value

Less than 0.05 More than 0.12
(1) Check for crack, damage and distortion on the top of
the block in the same way as in the cylinder head.

(2) Measurement of cylinder bore

a. There should be apparent scratches, rust,

corrosion, etc. on the cylinder bore.
b. Measure the cylinder bore at the top, center and
bottom respectively in the crankshaft direction
(A) and the direction at right angle to it (B). If
the repair value is exceeded, replace engine long
block assembly.

122V

Standard assembling
Model Repair value
value
Replace engine long block assembly.
J843
More than
· φ84 – φ84.019
φ84.2
N843L

18

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 4) Piston and piston ring

Disassembly

(1) Remove the piston ring using a piston ring tool.

(2) Remove the snap ring and extract the piston pin.

Inspection

(1) Piston 024X

a. Check the piston for crack, streak and burnout

on the outside surface and replace if remarkable.
b. Measure the longer diameter at 10 mm above the
lower end of the piston skirt and bore of the
cylinder in the thrust direction, calculate the
clearance, and replace if the repair value is
exceeded.

Clearance between cylinder and piston (mm)

Standard
Model Service limit
assembling value
J843·N843L 0.0375 – 0.0715 0.25

Piston skirt bottom longer dia. (mm)

Standard
Model Service limit
assembling value
J843·N843L φ83.9475 – 83.96 φ83.7

Model Piston size Skirt bottom longer dia.

025X
J843 S.T.D 83.9475 – 83.9625
N843L S.T.D 83.9475 – 83.9625

d. Measure the piston pin hole diameter and piston

pin outside diameter and replace if the clearance
exceeds the service limit.

Clearance between piston pin hole and piston pin (mm)

Standard assembling value Service limit
-0.001 – +0.007 0.02

026X

19

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 (2) Piston ring

a. Replace worn out or damaged piston ring, if any.

b. Insert a ring at a right angle to the least worn out
skirt of a cylinder, measure the clearance of ring
end gap with a thickness gauge and replace if the
end gap exceeds the service limit.

Piston ring end gap (mm)

Standard assembling
Service limit
value
Top ring 0.2 – 0.35 1.0
Second ring 0.2 – 0.4 1.0
Oil ring 0.2 – 0.8 1.2
027X

Clearance between piston ring groove and ring (mm)

c. Measure the clearance between the piston ring
groove and ring and replace if the service limit is Standard assembling
Service limit
exceeded. value
Top ring 0.07 – 0.11 More than 0.25
Second ring 0.04 – 0.08 More than 0.25
Oil ring 0.03 – 0.13 More than 0.25

Model Piston ring size Part code No.

d. Piston and piston ring kits of the following part J843 S.T.D. 115107840
No. is available.
N843L S.T.D. 115107290
Piston/piston ring kit
Model Size Part code No.
J843 S.T.D. 115017390
N843L S.T.D. 115017310

e. Piston ring installing procedure

Install the piston ring to the piston as shown in
the right figure.

028X

(3) Piston pin Piston pin outside dia. (φ)

Model Standard assembling value Service limit

Measure the outside diameter of the piston pin and
replace if the service limit is exceeded. J843 24.996 – 25.0 24.98
N843L 27.996 – 28.0 27.98

20

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 5) Connecting rod

Inspection
Torsion and parallelism of connecting rod (mm)
(1) Check for torsion, parallelism and damage.
Measure the torsion and parallelism using a Standard
Repair value
connecting rod aligner and correct or replace if the assembling value
repair value is exceeded. Torsion (per 100 mm) Less than 0.08 More than 0.2

1. Gauge Parallelism (per 100 mm) Less than 0.05 More than 0.15
2. Piston pin
3. Torsion
4. Flat part of aligner
5. Pin

(2) Measure the bore of the connecting rod small end

bush and replace if the clearance to the piston pin
exceeds the service limit.

(3) Install the connecting rod to the crankshaft, measure

the axial play and replace the connecting rod if the 029X
service limit is exceeded.
Clearance between bush and piston pin (mm)
Standard assembling value Service limit
0.010 – 0.025 More than 0.08

Axial play of connecting rod and crank pin (mm)

Standard assembling value Service limit
0.1 – 0.3 More than 0.7

6) Connecting rod metal

Clearance between crank pin and connecting rod metal
Inspection (oil clearance) (mm)
(1) Check the metal and if peeling, melting, uneven wear, Standard assembling value Service limit
improper contact or other damage is noticed, replace J843 0.035 – 0.083 0.2
the metal.
(2) Measure the oil clearance of the crank pin and metal N843L 0.035 – 0.085 0.2
using plasti-gauge.
a. Remove oil dust or other foreign matter stuck to
the metal and crank pin.
b. Cut plasti-gauge to the length same as the metal
width and place it on the crank pin in parallel
with the crankshaft avoiding the oil hole.
c. Install the connecting rod metal and connecting
rod cap and tighten with the specified tightening
torque.

49 – 53.9 N·m
Tightening torque Set a plasti-gauge. Measure the oil clearance
{5.0 – 5.5 kgf·m}
030X 031X
NOTE: Never turn the connecting rod at this time.

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 d. Remove the connecting rod cap and measure the Crankshaft pin
plasti-gauge width with the scale printed on the outside dia.
gauge envelope. Models Metal size Metal code No. Finishing
dimension
NOTE: Measure the widest part of the (φ)
plasti-gauge. J843 S.T.D. 198517180 43.964 – 43.975

(3) If the oil clearance exceeds the service limit N843L S.T.D. 198517250 51.964 – 51.975
according to the result of the measurement, replace
the metal.

Reassembly (piston and connecting rod)

(1) Heat the piston to about 100°C with a piston heater or

the like and install it aligning the SHIBAURA mark
in the piston and match mark at Ⓐ of the connecting
rod.
(2) Care should be taken to the figure match mark at Ⓐ
of the connecting rod.
(3) Install the piston ring to the piston facing the stamp at
the end surface of the ring end gap upward.
(4) When the connecting rod or piston and piston pin are
replaced, weight variation among cylinders with the
rod, piston and piston ring installed should be within
10 g. 032X

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 7) Bearing holder

Disassembly and inspection

Clearance between crankshaft center journal and metal
Center bearing (metal) (oil clearance) (mm)
Models Standard assembling value Service limit
(1) Remove the bearing holder, and replace the metal if
peeling, melting, uneven wear, or improper contact is J843
· No2, 3 0.044 – 0.116 0.2
noticed. and 4
N843L
(2) Measure the oil clearance of the crankshaft center
journal and metal using a plasti-gauge.
(3) If the oil clearance exceeds the service limit
according to the result of the measurement, replace
the metal or/and crank shaft.

033X

Metal Metal code No.

size J843 N843L
198517210 (Upper) 198517230 (Upper)
S.T.D.
198517200 (Lower) 198517240 (Lower)

Finished dimensions of crankshaft journal

Journal (φ)
size
J843 N843L
S.T.D. 57.957 – 57.970 67.957 – 67.970

Thrust washer

Check the thrust washer and replace if wear, improper

contact, seizure, or other damage is noticed, or thickness Thrust washer thickness (mm)
exceeds the service limit. Standard assembling value Service limit
2.95 – 3.0 Less than 2.8

034X

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 Reassembly

(1) Install the metal with oil groove to the upper bearing
holder and the metal without oil groove to the lower
bearing holder
(2) With the stepped area of the bearing holder facing the
front side, install the bearing holder to be fitted with
thrust washer on the flywheel side and the bearing
holder with identification cutting mark at the center.

49 – 53.9 N·m
Bearing holder tightening torque
{5 – 5.5 kgf·m}

(3) Install the thrust washer facing the oil groove towards
the crankshaft thrust surface.

NOTE: Be sure to confirm that the oil hole of the

bearing holder and that of the cylinder
block are in the same direction.

035X

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 8) Crankshaft bearing (bush)

Inspection

(1) Check the bearing (bush) and replace if peeling,

melting, uneven wear, improper contact, or other
damage is notice.
(2) Measure the oil clearance of the bearing (bush) and
crankshaft journal using a cylinder gauge and 036X
micrometer.
(3) If the oil clearance exceeds the service limit
according to the result of measurement, replace the
bearing (bush) or/and crank shaft.

Clearance between crankshaft journal and bearing (bush)

(oil clearance) (mm)
Standard assembling value Service limit
0.044 – 0.116 0.2

Bush size Bush code No.

J843 N843L
S.T.D. 037X
198517190 198517220

Crankshaft journal outside dia. Finishing

Bush size
dimension (φ)
J843 N843L
S.T.D.
57.957 – 57.970 67.957 – 67.970

NOTE:
1. Measure the dimensions in the A and B directions
at the position 1 and 2 in the right figure avoiding
the oil hole of the bearing (bush) and calculate
difference from the maximum value of the
crankshaft journal (oil clearance).
2. When replacing the bush, push it up using a
press or the like. At this time, align the oil holes
and push it up until the bush end surface
becomes level with the outside machined surface
of the cylinder block (see the arrow mark in the 038X
right figure).

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 9) Crankshaft

Inspection

(1) To measure run-out of the crankshaft, support the Crankshaft run-out (mm)
crankshaft using a V block as shown in the right
Standard assembling value Service limit
figure, apply a dial gauge to the crankshaft center
journal, read the indication on the dial gauge rotating Less than 0.03 0.06
the shaft one turn gently. If the service value is
exceeded, correct or replace.
(2) Check the crankshaft oil seal for damage or wear on
the contact surface and oil hole clogging.

039X

(3) Check the crankshaft journal and pin for damage,

irregular wear (ellipticity, conicalness) and shaft
diameter. If the service limit is exceeded, replace the
bearing (bush) and/or crankshaft. Measure the
dimensions of the journal and pin in the AA and BB
directions at the position 1 and 2 avoiding the oil
holes.

Irregular wear limit of crankshaft journal and pin

0.05 mm

040X

Model J843
Journal and pin size Shaft dia. at crankshaft journal (φ) Shaft dia. at crankshaft pin (φ)
Outside dia. Outside dia. finishing
finishing Repair value dimension Repair value
S.T.D.
dimension
57.957 – 67.970 Less than 57.90 43.964 – 43.975 43.90

Model N843L
Journal and pin size Shaft dia. at crankshaft journal (φ) Shaft dia. at crankshaft pin (φ)
Outside dia. Repair value Outside dia. finishing
finishing dimension Repair value
S.T.D.
dimension
67.957 – 67.970 Less than 67.90 51.964 – 51.975 Less than 51.90
* Replace the crankshaft if diameter is below the repair value.

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 10) Flywheel and ring gear

Inspection

Check the ring gear and replace if damage or remarkable

wear is noticed.
When the wear is limited to a small area, remove the, ring
gear, turn it about 90 degrees and shrinkage-fit to reuse it.
To shrinkage-fit the ring gear, heat it to 120 – 150°C to
allow it to expand.

042X

11) Cam shaft ass’y

Inspection

(1) Check the journal and cam for wear and damage and
replace if the service limit is exceeded.
(2) Correct insignificant uneven wear or scars on the cam
surface using oil stone or the like.

A. Height of intake/exhaust valve cams (mm)

Standard assembling value Service limit
34.441 – 34.5076 34.1
B. Height of injection pump cams (mm)
Standard assembling value Service limit 043X
42.99 – 43.01 42.8

12) Timing gear

Inspection

(1) If pitting or remarkable wear is observed on the tooth

face of gears, replace the gear.
(2) Measure the backlash of gears and replace if the
service limit is exceeded.

Timing gear backlash (mm)

Standard assembling value Service limit
0.08 More than 0.25

044X

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 13) Oil flow

045X

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 14) Oil pump

Disassembly

Removal from engine

(1) Remove the snap ring.

(2) Take out the collar, spring and shim.
(3) Take out the idle gear, vane, and oil pump cover
together.
(4) Extract the rotor and thrust washer.
(5) Extract the oil pump cover from the idle gear.

046X
Inspection and reassembly

(1) Check the oil pump cover, rotor and vane and replace
if worn out or damaged remarkably.
(2) Check the clearance between the rotor and vane and
replace if the service limit (0.25 mm) is exceeded.
(3) Reassemble in the order reverse to disassembly.
a. Install the crankshaft gear and idle gear aligning
the match mark.
b. Adjust the side clearance of the rotor and vane to
0.1 – 0.15 mm. (Refer to Fig. 071X.)

047X
15) Oil filter

Structure and Functions

(1) The cartridge type oil filter is excellent in filtering

performance.
(2) Since it is of the full-flow type, when the filter is
clogged, the safety valve is opened to allow the oil to
flow, preventing seizure or other troubles.
(3) The oil fed under pressure with the oil pump enters
Ⓐ, is filtered by the element, and supplied to each
part from Ⓑ.
When the element is clogged, the oil is supplied to
each part without passing through the element.

Replacement

(1) Replace the oil filter every 200 hours of operation.

(2) Coat the filter mounting surface with oil and tighten
the filter by hand. 048X
(3) Do not reuse the filter if it is removed once.

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 16) Water pump ass'y

Disassembly

(1) Remove the set plate gasket.

NOTE: The pump main body is aluminum die cast

and should be replaced as ass’y if subjected
to water leakage or other troubles.

049X
1. Water pump ass’y
2. Gasket
3. Set plate
17) Radiator and reserve tank

Specifications and structure

Structure

Radiator cap of the pressure type (closing-up type) is

employed for better cooling efficiency. When the cooling
water temperature in the radiator rises (pressure also
increases), the pressure valve is pushed open to release
excessive pressure (cooling water) from the overflow pipe
(white arrow) and the water is stored in the reserve tank.
When the cooling water temperature in the radiator
decrease and the internal pressure becomes negative, the
cooling water in the reserve tank is returned into the
radiator. (black arrow)

Specifications
Fin type Corrugated
5.1 ℓ (J843), 5.3 ℓ
Cooling water volume
(N843L)
050X
Pressure valve starting 2
0.75 – 1.05 kgf/cm
pressure
Negative pressure valve
Less than 0.05 kgf/cm2
starting pressure
Heat radiation volume 28,400 kcal/h

Inspection

a. Check the radiator, pipe, and reserve tank for water leakage and repair or correct if any.
b. Check the radiator fin and remove dust, mud, or other foreign matter clogging in the air passage, if any.
c. Check the pressure valve and negative pressure valve of the radiator cap for valve opening pressure and sealing
condition. Replace of defective.
d. Check the radiator hose and replace if damaged or aged.
e. If the net is clogged, remove and clean.
f. The cooling water level in the reserve tank should be always between FULL and LOW.

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 18) Fuel filter

Fuel passage

The fuel flows as shown in the figure from the tank,

pressurized by the injection pump to high pressure, and fed
to the nozzle and injected to the combustion chamber.
The fuel after lubricating the nozzle needle is returned to
the tank through the overflow pipe.

051X
1. Tank 4. Injection pump
2. Nozzle and holder 5. Fuel pump
3. Fuel filter

Inspection

If water, dust, or other foreign matter is observed in the transparent plastic case, clean and replace the filter if necessary.

Disassembly and reassembly

(1) Remove the filter turning the filter ring nut.

NOTE: Take care to the O-Ring fitted between the ring nut and filter body, coat with grease before tightening.

(2) Apply the grease to the element attaching place of the filter body, and install the element by hand.

19) Governor

Structure and functions

Governor

This governor is a mechanical all-speed governor. It is

installed in the gear case. The fly weight ass’y is installed
to the cam shaft and its movement is transmitted to the
control rack of the injection pump through the slider
control lever link. The spring which controls the
movement of the fly weight is hitched to the arm COMPL
and tension lever. The spring tension is changed by
changing the governor lever so as to control the engine
speed.

052X

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 20) Injection pump

Specification

Engine Model Part Code No. Manufacturer and Injection Pump Type
BOSCH AUTOMOTIVE SYSTEM CORPORATION
J843 131017700
104134 – 3050
BOSCH AUTOMOTIVE SYSTEM CORPORATION
N843L 131017770
104135 – 3050

Disassembly, Inspection and Reassembly

(1) Disassembly, inspection, and reassembly of injection pump. If the trouble has been verified to be in the injection
pump, do not disassemble other than at shop specializing in this operation.

Trouble-shooting

Trouble Possible Cause Check or Remedy

1. Engine does start. (1) Fuel Shortage or air mixed (1) Replenish fuel, check air entering part, bleed air
in.
(2) Defective engine stop (2) Check and replace the electric system
solenoid.
2. Engine starts but (1) Filter or pipes clogged. (1) Replace or clean out.
will not stop at (2) Air mixed in. (2) Check fuel pipe and connections.
once. (3) Fuel tank filter cap air (3) Wash
breathe clogged.
(4) Short-circuit or disconnected (4) Inspect and repair.
wire of electric system of
engine stop solenoid.
3. Engine output (1) Air mixed in. (1) Check fuel pipe and connections.
unstable (2) Water mixed in fuel. (2) Replace fuel, replace filter.
NOTE: Due to possibilities of other troubles, refer to 2 – 5 Trouble Shooting

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 21) Nozzle and holder

Specifications

Model J843 (CM284) N843L (CM364) Model J843 (CM284) N843 (CM364)
Part code No. 131406440 131406360 Needle valve dia. φ4
Pintle dia. φ1
Ass’y No. 105148 – 1210 105148 - 1170 11.76 MPa 14.7 MPa
Valve opening
{120 kgf/cm2} {150 kgf/cm2}
Nozzle holder 105078 - 0100 Injection angle 4°
Nozzle 105007 – 1170 (NP-DN4PDN117) Nozzle type Throttle type

Structure and functions

The nozzle is finished super-precisely to inject the fuel

which is fed from the injection pump under pressure to the
combustion room in good condition. Components as
shown in the right figure are incorporated.
The fuel is fed under pressure from the oil hole of the
nozzle holder main body to the nozzle body. When the
pressure exceeds the specified value, it pushes the spring,
injected from the nozzle, and at the same time lubricates
and cools the nozzle and nozzle body.
The oil leaking at this time is returned to the tank by the
return pipe.

053X

054X

Disassembly and inspection

(1) Place the nozzle holder (body) in a vice and disassemble turning the nozzle nut.

NOTE: Take care not to allow the needle valve to drop when removing the nozzle.

(2) Wash the nozzle and needle valve and check for seizure and sticking of the nozzle and fuel leakage on the seat surface.
Correct fuel leakage of the seat by lapping.
(3) Check the distance piece upper and lower contact areas and correct to be stuck closely.
(4) Check the push rod for wear on the nozzle needle valve contact surface and check the spring seat for crack.

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 Reassembly and adjustment

(1) When assembling a new nozzle ass’y, heat light oil to

50 – 60°C and remove the rust preventive oil in it.
Slide the body and needle valve to ensure that they
slide lightly.
(2) Invert the body, place the shim, spring, rod, piece and
nozzle on it in this order, cover the nozzle nut and
tighten.
(3) After assembly, check for the nozzle injection
pressure.
a. Adjust by the adjusting washer (shim) so that the
injection is started at 11.76 MPa {120 kgf/cm2}
on Model J843 and 14.7 Mpa {150 kgf/cm2}
on Model N843L using a nozzle tester.
b. The pressure increases or decreases about 0.98
MPa {10 kgf/cm2} by a washer of 0.1 mm.
(4) Injection condition
a. Small drops should not be mixed in the spray.
b. The oil should be injected describing a cone by
straight lines toward the center line of the
nozzle.
c. Place white paper at about 30 cm from the
nozzle and confirm that the spray is
approximately circular when injected.
d. Keep the oil pressure lower by 1.96 MPa {20
kgf/cm2} than the specified value 11.76 MPa
{120 kgf/cm2} on Model J843 and 14.7 Mpa
{150 kgf/cm2} on Model N843L and check that 055X
the test oil does not drop form the nozzle end.

22) Air Cleaner

Structure and functions

(1) The air cleaner is connected to the cylinder with the

air cleaner hose.
(2) The air cleaner is of the cyclone type incorporating
filter element and removes dust from the intake air.

035X

Inspection and replacement

(1) Take out the element every 100 – 200 hours and blow compressed air (less than 7kgf/cm2) from the inside and clean.
(Clean the dust deposit on the dust pan also.)
(2) If soot or oil has sticked to the element, immerse it in neutral detergent for about 15 minutes and then wash by shaking
several times. Rinse in clean water sufficiently and dry naturally.
(3) When the air cleaner is used in dust place, clean it earlier.
(4) After cleaning 6 times or once every year, replace the element with new one.
(5) After completion of cleaning, apply light from the inside of the element. It should be replaced with new one if
puncture, pin hole, and especially thinner part is observed or if the gasket is broken.
(6) Do not use the element before drying completely.

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 23) Thermostat

Disassembly

(1) Remove the bolt fixing the thermostat cover from the
thermostat case.
(2) Remove the thermostat and gasket from the
thermostat case.

1. Thermostat cover
2. Gasket
3. Thermostat
4. Thermostat case

057X
Specifications and inspection

Thermostat

Replace if the valve is opened even only slightly at normal

temperature.
Immerse the thermostat in water, increase the water
temperature gradually and check the valve opening
temperature and valve lift.

Specifications

Type Wax pellet

Opening temperature 80º – 84ºC
Full-opening temperature 95ºC
Valve lift
8.0 mm
(at water temperature 95ºC)
058X

NOTE: 3 to 5 minutes are required until the valve

is operated.

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 3. Engine Reassembly

★ Cautions before assembly

1) Wash parts to be installed. (Especially wash oil passage, bearing, piston and cylinder bore carefully.)
2) Coat the sliding and rotating parts of the cylinder bore, piston, bearing and other parts with new oil before
installing.
3) Replace the gaskets with new ones. If necessary, use liquid packing to prevent oil leakage.
4) Do not tighten bolts and nuts for aluminum alloy parts excessively. Tighten them with specified torque.

Reassembly

1. Relief valve assembly with O-Ring.

Relief valve tightening torque.

Relief valve tightening torque

59 – 69 N·m {6.0 – 7.0 kgf·m}

2. Crank shaft and bearing holder assembly

Cylinder block to bearing holder tightening torque

Bolts fixing bearing holder

Hexagon socket 25 – 29 N·m
A
head blot {2.5 – 3.0 kgf·m}
49 – 54 N·m
B Hexagon bolt
{5.0 – 5.5 kgf·m}

NOTE:
1. Take care not to damage the bush in the cylinder
block by the crank shaft gear when install the
crank shaft and bearing holder assembly.
2. Install the two hexagon socket head bolts for the
fly wheel side bearing holder. 059X

3. Measure the end play of crank shaft.

Crankshaft end play

Standard value 0.1 – 0.4 mm
Service limit 0.5 mm

060X

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 3. Oil seal

4. Rear plate
061X
NOTE: Apply the liquid gasket to around the M8
screw holes for rear plate.

Rear plate tightening torque:

22.6 – 28.4 N·m {2.3 – 2.9 kgf·m}

062X
5. Fly wheel

Align the hole to the roll pin on the crankshaft.

Fly wheel tightening torque

69 – 78 N·m {7.0 – 8.0 kgf·m}

063X

6. Piston and connecting rod assembly

① Coat the metal surface, piston and piston ring with

engine oil.

064X

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 ② Turn the ring to allow the oil to ensure the ring
groove sufficiently, and set the ring end gaps at 90°
respectively avoiding piston pin direction and the
direction at a right angle to the piston pin.
③ Insert the ring facing the connecting rod figure
match mark toward the injection pump side, using
ring pliers.

NOTE: Place the smallest connecting rod figure

match mark to the front side so that the
figures increase gradually.

④ Tighten the connecting rod cap with the specified

torque and check for the axial play.

Connecting rod tightening torque

49 – 54 N·m {5.0 – 5.5 kgf·m} 065X

NOTE:
1. After tightening, confirm that the crankshaft
moves lightly.
2. The connecting rod should move 0.1 – 0.3 mm in
the axial direction.

7. Suction pipe · Suction filter

① Fit an O-Ring to the suction pipe and insert the

suction pipe to the cylinder block.
② Place the suction pipe end into the suction filter and
fix the suction filter.

Suction filter tightening torque

9 – 13 N·m {0.9 – 1.3 kgf·m}

066X

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 8. Oil pan

Start tightening the bolts of the oil pan from the

center, then tighten the opposing bolt on opposite side
on the diagonal and specified torque.

Bolt tightening torque

10 – 12.7 N·m {1.0 – 1.3 kgf·m}

067X

9. Oil level gauge · Gauge guide

Install the oil level gauge and gauge guide using 2

O-Rings.

10. Front plate

Install the front plate together with the gasket.

11. Cam shaft ass’y · Tachometer shaft · Plate

① Install the tachometer shaft.

② Install the cam shaft ass’y (taking care to the
bearing).
③ Fix the tachometer shaft and cam shaft ass’y with
the plate.

Plate tightening torque

9 – 13 N·m {0.9 – 1.3 kgf·m}

068X
NOTE: Install the timing gear case taking care so
that the slider is not dislocated from the
guide pin.

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 12. Idle gear · Oil pump ass’y

① Install a thrust washer to the idle gear shaft.

② Install the idle gear ass’y.
③ Align the match marks of the idle gear, crankshaft
gear and cam shaft gear and install it to the idle
gear shaft.
④ Install the rotor.
⑤ Install the oil pump cover, shim, spring and collar
and fix with a snap ring.

NOTE:
1. Coat the rotor and vane both sides with grease
before installing them.
2. Never turn the crankshaft until the timing gear
case is installed. 069X
3. Turn the oil pump cover clockwise and
counterclockwise, fix the hole at the center of the
spring pin inserting hole moving distance, and
then install the gear case.

070X
⑥ Adjust the shims so that the oil pump, rotor and
vane side clearance is 0.1 – 0.15 mm.

071X
13. Timing gear case · Cover

① Untighten the lock nut and remove the low idle set
bolt.
② Install the start spring between the timing gear case
and governor link.
③ Inserting the link into the cylinder block hole while
turn the governor lever to clockwise and hold it,
and then install the timing gear case.
④ Reinstall the low idle set bolt and secure the lock
nut.
⑤ Install the covers.

072X

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 14. Crankshaft pulley

Fit the key to the crankshaft, install the crankshaft

pulley, and tighten with the nut.

Crankshaft pulley tightening torque

274 – 333 N·m {28 – 34 kgf·m}

15. Injection pump assembly

073X
① Fit the shim which has been removed at the time of
disassembly, connect the control rack of the
injection pump and link, and fix with the snap pin.
② Tighten the injection pump with bolts and nut.

Injection pump tightening torque

13 – 17 N·m {1.3 – 1.7 kgf·m}

16. Injection timing adjustment 074X

Usually the injection timing is adjusted properly by

the step of the order 15.
When the injection pump, cam shaft assembly or
cylinder block is replaced, adjust the injection timing
in the following procedure.

① Install the injection pump inserting a shim of 0.5

mm in thickness according to the procedure of
order 15.
② Remove the delivery valve holder on the injection
pump front side (radiator side).
③ Extract the delivery valve (IN) and install the spring
and delivery holder.

NOTE: When installing the delivery holder, adjust

the delivery valve (OUT) to the correct 075X
position with a wire.

④ Move the governor lever in the fuel increasing

direction and flow the fuel near 25° before
compression TDC of the No. 1 piston (front side)
and then the fuel flows out of the delivery valve
holder.
⑤ Turn the crankshaft gently clockwise from the
condition of above ④, and then the fuel flowing
out of the delivery holder stops. Read the piston
position before TDC at this time. If it is late more
than 18° decrease the shim thickness and if earlier
more than 20° increase the shim thickness.

076X

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 Injection timing adjusting shim Injection timing (before TDC) 18 – 20°
Part code Piston displacement (before TDC)
Thickness (mm)
J843·N843L J843 2.594 – 3.187 mm
0.2 131437540 N843L 3.195 – 3.932 mm
0.3 131437550
0.4 131437560 Model
Crankshaft angle
0.5 131437570 J843 N843L

0.5 *131437580 17º 2.320 2.854

* Without beading 18º 2.594 3.195

19º 2.884 3.554
NOTE: 20º 3.187 3.932
1. When shim is not required, coat liquid parking
before installing. 21º 3.505 4.328
2. The injection timing varies about 2º with 0.3 mm
22º 3.837 4.741
of shims.
3. Mix assemble a shim (0.5 mm) with beading and
a shim (0.5 mm) without beading when you need
adjusting shims more than 1.0 mm.

⑥ Install the delivery valve (IN)

Delivery holder tightening torque

39.2 – 44.1 N·m {4.0 – 4.5 kgf·m}

077X

17. Drive gear ass’y (for hydraulic pump) · Hydraulic pump ass’y

Install the drive gear ass’y to the hydraulic pump and then install it to the gear case..

18. Oil filter

Coat the mounting surface with a small quantity of oil and tighten by hand.

19. Engine stop solenoid

Tighten the engine stop solenoid lightly with pliers.

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 20. Cylinder head ass’y

① Set the piston at the TDC and measure the injection

beyond the cylinder block with a depth gauge or
dial gauge.

NOTE:
1. Measure holding the piston lightly by hand.
2. Use the cylinder with the largest projection
distance among the 3 cylinders as the reference.
The variation of the projection should be within
0.1 mm.

② Select a head gasket according to the measured

value.
078X

Measured value (mm) Head gasket part code No. Thickness when tightened
More than 0.6 – under 0.7 111147490 t = 1.3
More than 0.7 – less than 0.8 111147500 t = 1.4

NOTE: Four smallest digits of the part code No. are stamped on the top surface of the head gasket.

③ Tighten the cylinder head in several steps in the

order as shown in the right figure and tighten with
the specified torque finally.

Cylinder head tightening torque

98 – 103 N·m {10 – 10.5 kgf·m}

NOTE:
1. Take care to the spring pin which positions the
cylinder head ass’y. 079X
2. Coat the thread with grease containing disulfide
molybdenum.

21. Cap · Push rod · Rocker arm ass’y

① Install the cap to the valve steam end.

② Install the push rod and rocker arm ass’y.

Rocker arm ass’y tightening torque

J843 20 – 25 N·m {2.0 – 2.5 kgf·m}
N843L 27 – 39 N·m {2.8 – 4.0 kgf·m}

080X

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 22. Valve clearance adjustment

Untighten the nut of the intake and exhaust valves

and adjust the clearance to 0.2 mm.

NOTE:
1. Adjust the valve clearance while cold.
2. Set the No. 1 cylinder at the compression TDC,
adjust the valve clearance of the No. 1 intake and
exhaust valves, and No. 2 exhaust valve, turn the
crankshaft 240° counterclockwise when viewed
from the front side, and adjust the No. 2 intake,
and No. 3 intake and exhaust valves.

Lock nut tightening torque

11.8 – 15.7 N·m {1.2 – 1.6 kgf·m}

081X

23. Oil pressure switch

Oil pressure switch tightening torque

15 – 20 N·m {1.5 – 2.0 kgf·m}

24. Oil pipe

Eye bolt tightening torque

M8 10 – 13 N·m {1.0 – 1.3 kgf·m}

082X
25. Water pump ass’y · Bypass hose

① Install and tighten the gasket and water pump ass’y.

② Connect the thermostat case and water pump case
with bypass hose.
③ Install the radiator hose.

26. Connector
083X

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 27. Head cover · Filler pipe

Tighten the head cover and filler pipe evenly taking

care to the O-ring.

Head cover tightening torque

J843 8 – 12 N·m {0.8 – 1.2 kgf·m}
N843L 12 – 16 N·m {1.2 – 1.6 kgf·m}

28. Nozzle and holder ass’y

Tighten the nozzle and holder ass’y with specified

torque using a nozzle holder socket.

Nozzle and holder tightening torque

59 – 69 N·m {6 – 7 kgf·m}

29. Return pipe COMPL · Injection pipe

Install the return pipe and then injection pipe.

Injection pipe tightening torque

15 – 25 N·m {1.5 – 2.5 kgf·m} 085X

30. Intake manifold · Spacer · Exhaust manifold

① Install the gasket, spacer, gasket, and intake

manifold in this order.
② Install the exhaust manifold.

086X
31. Alternator

Install the alternator taking care to the direction of the

adjusting plate.

32. V belt · Fan pulley · Cooling fan

① Install the fan pulley and cooling fan and then V

belt.
② Adjust the belt tension with the alternator so that it
is deflected 5 – 10 mm at the middle point between
the crankshaft pulley and alternator pulley when
depressed by a finger (about 5 kgf) and tighten.

Cooling fan tightening torque

087X
9 – 13 N·m {0.9 – 1.3 kgf·m}

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 2-3 Electrical Units
1. Alternator
(No. 185046320 – A007T03877)

1) Disassembly
088X
① Make both brackets and the stator with a scribe mark
for assembly.
② Remove the four through bolts. Pry between the
stator and front bracket with blade of a screw driver.
Carefully separate the front bracket, pulley and rotor
assembly away from the stator and rear bracket
assembly.
③ Place the rotor in a vice with soft jaws and remove
the pulley nut, washer, pulley spacer and front
bracket from the rotor.

089X

④ Unsolder three stator leads and remove the stator.

⑤ Remove the voltage regulator assembly and rectifier
assembly as a set.

090X

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 2) Inspection of parts
(1) Rotor

① Inspection of slip ring surface.

Correct stain or scratches on the slip ring surface
with a sand paper of about 400 – 600 #.
A badly roughened slip ring or a slip ring worn
down beyond the service limit should be replaced.

② Check for continuity between both the slip rings. If 091X

there is no continuity, the field coil is defective.
Replace the rotor assembly.

092X
③ Check for continuity between the slip ring and shaft
(or core).
If there is continuity, it means that the coil or slip
ring is grounded.
Replace the rotor assembly.

(2) Stator
093X
① Check for continuity between the leads of the stator
coil.
If there is no continuity, the stator coil is defective.
Replace the stator assembly.

094X

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 ② Check for continuity between any stator lead and
stator core.
If there is continuity, it means that the coil is
grounded.
Replace the stator assembly.

(3) Rectifier Assembly 095X

① Positive Heatsink
Check for continuity between the positive (+) heat
sink and stator coil lead connection terminal with a
circuit tester.
If there is continuity in both directions, the diode is
short-circuited.
Replace the rectifier assembly.

096X

② Negative Heatsink
Check for continuity between the negative (-) heat
sink and stator coil lead connection terminal with a
circuit tester.
If there is continuity in both directions, the diode is
short-circuited.
Replace the rectifier assembly.

097X

③ Diode Trio
Using a circuit tester, check the three small diodes
for continuity in both directions.
If there is either continuity or an open circuit in
both directions, the diode is defective.
Replace the rectifier assembly.

098X

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 ④ Brush and Brush spring

a. Check the length of the brush.

A brush worn down to the wear limit line should
be replaced.
b. Check the brush spring pressure and make sure
the brush moves smoothly in the brush holder.

099X

3) Reassembly

Reverse the disassembly procedure except for the

following:

(1) Installing rotor.

Push brushes into brush holder, insert a wire to hold
them in raised position before install the rectifier and
regulator assembly.
Install rotor and remove wire.

NOTE: Since rear bearing and rear bracket fitting

is tight, heat the bearing box in the rear
bracket to 50 – 60ºC {122 – 140ºF} before
installing rotor. 100X
(2) Lubrication to bearing box for bearing with resin
band, grease should not be applied.
Remove oils completely if found on the bearing box
in the rear bracket.

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 4) Bench Check
To check the alternator on a test bench, proceed as follows:

(1) Make connection as shown in the Figure 101X except leave the load resistor disconnected.
(2) Slowly increase the alternator speed and observe the voltage.
(3) If the voltage is uncontrolled with speed and increases above 15.5 V, check the alternator.
(4) If voltage is below 15.5 V, connect the load resistor as shown in the Figure 101X.
(5) Operate the alternator at 2500 rpm and adjust the load resistor as required to obtain maximum output.
(6) Measure the output current. The output must be within the limits shown in the section on “Service Specifications”.
If the output is less than specified value the alternator should be disassembled and checked.

101X

5) Precautions

(1) Reversed battery connections will damage the alternator and/or wiring.
(2) When connecting a booster battery, make certain to connect negative battery terminals together and positive battery
terminals together.
(3) When a fast charger is used to charge the battery, the equipment battery cables should be disconnected.
(4) Grounding of the alternator output terminal will damage the alternator and/or circuit.
(5) Do not connect a load of over 1A to the terminal “L”.
(6) If the alternator is operated with the terminal L and B short-circuited, if may damage the diode trio.

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 6) Service Specifications

Item
A007T03877 (MITSUBISHI)
Model Name
Nominal output (V-A) 12 – 40
Polarity Negative ground
Weight (kg) Approx. 3.7 {8.2 lb}
Rotational direction (Viewed from the pulley) Clockwise
Terminal voltage (V) 13.5
Load characteristics (cold) Current (A) Min. 30
Revolution number (rpm) 2500
Original (mm) 18.5
Brush length
Limit (mm) 5.0
Original (N) 4.6 – 5.8 {470 – 590 gf}
Brush spring tension
Limit (N) 2.6 {270gf}
Rear side ECSC8
Bearing
Front side 6303DDG
Original (mm) 22.7
Slip ring diameter
Limit (mm) 22.1
To be repaired (mm) 0.05
Slip ring diameter eccentric wear
Allowable limit (mm) 0.2
If dirty or damaged correct with emery
Slip rings surface condition
cloth.
Rotor shaft bending To be repaired (mm) 0.07
Field coil resistance (Ω/at 20ºC) 2.8
Adjusting voltage (V)(at 5000 rpm) 14.4 – 15.0

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 7) Fault Finding

Trouble Parts Cause Remedy

Wiring, ammeter Disconnection, short circuit, loosened connection Correct
Disconnection of coils, earth, short circuit Replace
No charging Alternator Defective rectifier Replace
Disconnection of RF resistor Replace
Regulator Defective regulator Replace
Wring Disconnection, short circuit, loosened connection Correct
Loosened alternator bolt Correct
Layer short of rotor coil Replace

Insufficient Alternator Layer short of stator coil Replace

charging Defective rectifier Replace
Insufficient contact of brush, stained slip ring Correct
Regulator Defective regulator Replace
Battery Defective battery Replace
Battery Internal short circuit Replace
Over charge
Regulator Defective regulator Replace
Wiring Disconnection or breakage of wire Replace
Slackened alternator drive belt Replace
Short of rotor coil, breakage of wire Replace

Unstable charging Shortage of stator coil, breakage of wire Replace

Alternator
current Insufficient contact of brush, stained brush and slip ring Correct
Broken brush and spring Replace
Insufficient contact of terminals Correct
Regulator Defective regulator Replace
Incorrect installation of alternator Correct
Defective bearing. Replace
Abnormal noise of
Alternator Rotor core and stator core in contact Correct
alternator
Defective diode Replace
Short of stator coil Replace

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 2. Starting Motor (For Engine Model J843:CM284) (No. 185086551 1.7kW)

1) Straucture

This starter features a reduction mechanism of planetary gearing system and permanent magnets for magnetic field
induction.
Its reduction mechanism comprises internal gear, three planetary gears, gear shafts (with overrunning clutch fitted by
spline) and armature shaft gear.
The structure is different from that of direct drive type, but the electrical wiring is the same between two types.
The magnetic field is produced by six permanent magnets. The magnets are mounted in the yoke and positioned according
to polarity. They are permanently attached to the yoke and are not removable.

① Rear Bracket ⑦ Overrunning Clutch ⑬ Planetary Gears

② Armature ⑧ Front Bracket ⑭ Rubber Cover
③ Switch ⑨ Bearing ⑮ Magnets
④ Internal Gear ⑩ Pinion ⑯ Yoke
⑤ Lever Packing ⑪ Gear Shaft ⑰ Brushes
⑥ Lever ⑫ Ball ⑱ Sleeve Bearing

102X

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 2) Disassembly
Reference Figure 104X

NOTE:
1. Before disassembling starter, be sure to put
match marks at two locations (switch and yoke)
so that any possible mistake can be avoided.
2. Do not clamp yoke in a vise or strike it with a
hammer during repair operations. Permanent
magnets attached to yoke could be broken and
yoke dented or deformed if mishandled.

① Remove switch terminal nut (1) and disconnect

connecting wire (2).
Remove screws (3) securing switch and remove
switch and plunger (4).
② Remove brush holder securing screws (5) and
through bolts (6). 103X
Remove rear bracket (7) but do not remove
brush holder (8).
③ Install a socket (outer diameter 30mm) on the
armature commutator, see Figure 103X.
Then slide the brush holder (8) onto the socket.
Leave the socket in position in the brush holder
for inspection and reassembly.

104X

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 ④ Slide yoke (9) away from front bracket (10).
⑤ Remove armature (11) and ball (12).
Do not lose ball when removing the armature.
⑥ Remove rubber cover (13) from planetary gear
assembly (23) and remove lever packing (14) and
plate (15).
⑦ Remove planetary gears (16).
Remove gear shaft/overrunning clutch assembly
(18) and lever (19) as a unit from front bracket (10).
⑧ To remove overrunning clutch (18).
a. Remove plastic cap (20). If the cap is too badly
distorted or cracked, it will be necessary to use a
new one on reassembly.
b. Slide a piece of pipe of suitable size over shaft
against stop ring (21).
Then tap the pipe with a hammer to remove the
stop ring and expose snap ring (22).
Remove the pipe from the shaft.
c. Remove the snap ring and the stop ring and
separate the over running clutch (18) from the
gear shaft (17). 105X
If the snap ring is distorted, it will be necessary
to use a new one on reassembly.

3) Inspections

(1) Armature

① Inspect the armature coil for short-circuit with a

growler tester.
Replace armature if shorted.
② Inspect armature coil for ground with a circuit
tester.
Replace grounded armature.

106X

③ Inspect commutator for wear. If below the limit,

replace armature.
④ Inspect commutator for insulator depth.
Correct if below the limit.
⑤ Check gear teeth for wear or damage, and replace
armature as necessary.

107X

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 (2) Permanent magnets

Check permanent magnets for crack, damage and looseness, replace yoke assembly as necessary.

(3) Brushes

① Check brushes for wear. Replace brushes if below

the limit.
② Check brush spring pressure to make sure brush
moves smoothly in brush holder.
③ To check brush holder assembly for grounds, touch
one probe of a circuit tester to holder plate and the
other probe to each of insulated holders. Replace
brush holder assembly if any continuity is noted.

108X

(4) Over running clutch and pinion gear.

While holding clutch housing, rotate pinion.

Pinion should rotate smoothly in one direction (not necessarily easily), but should not rotate in opposite direction.
If the clutch does not function properly, replace it. If pinion gear is worn or burred, replace it.

NOTE: Overrunning clutch should not be cleaned with grease dissolving solvents, since these would dissolve the
lubricant in the clutch mechanism.

(5) Front bracket

Replace front bracket as an assembly including ball bearing if the bearing fails to rotate smoothly or it is noisy.

(6) Rear bracket

Replace rear bracket as an assembly including sleeve bearing if the hearing is badly worn.

(7) Internal gear and planetary gears

Replace the gears if their teeth are badly.

(8) Switch

Check continuity between M terminal and body (ground).

Replace the switch if no continuity is noted.

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 4) Reassembly and Adjustment

To reassemble the starter, follow the reverse of disassembling procedure, and observe the following precautions:

(1) Apply grease to the following parts during assembly.

① Sleeve bearing and ball.

② Sleeve bearing in internal gear.
③ Sleeve bearing in rear bracket.
④ Gear shaft.
⑤ Sliding surface of lever and overrunning clutch.
⑥ Armature shaft gear, internal gear and planetary
gears.
⑦ Sliding surfaces of pinion and front bearing.

109X
(2) Armature shaft end play

No adjustment.

(3) Pinion position adjustment.

After completing reassembly, check pinion position

to be sure that it is between 0.5 and 2.0 mm.
To adjust, proceed as follows:

① Connect the starter to a battery, as shown in Fig.

110X.
Close switch. This will shift pinion into cranking
position.

110X

② Push pinion back by hand and measure the amount

of the pinion movement as shown in Fig. 111X.
If the amount does not fall within limit, adjust it by
adding or removing shims which are located
between switch and front bracket.
Adding shims decreases the amount of the
movement.

111X

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 5) Non-Load Test

① After adjusting pinion position, from a test circuit

with a volt meter and an ammeter, as shown in
Figure 112X.

NOTE: Use wires as thick as possible and tighten

each terminal fully.

① Close the switch and compare the R.P.M., current

and voltage readings with the Service
Specifications.

② If any abnormality is noted, check it according to

the inspections. 112X

6) Service Specifications

Item Standard Value or Service Limit

Volts 11
No-load Characteristic Amps. 110 Max.
RPM 2400/min.
Outer Dia. 29.4 mm
Commutator
Service Limit 28.8 mm
Length 17.5 mm
Brush
Service Limit 10 mm
Tention 22.5 – 32.5 N {2.3 – 3.3 kgf}
Brush spring
Service Limit 10 N {1.02 kgf}
Pinion Movement (Pinion Gap) 0.5 – 2.0 mm
Part No. 185086551 (MITSUBISHI 1.7 kW)

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 7) Troubleshooting

(1) Pinion does not advance even though the key switch is turned ON.
Unit Cause Remedy
Disconnected wire, untightened battery and switch terminals, or
Wiring Correct and retighten
improper contact of the inserting part.
Correct or replace the contact
Key switch Improper contact preventing flow of current.
part
Helical spline of the pinion shaft is scored and prevents the pinion
Starting motor Replace or correct
from moving.
Improper movement of the plunger of the magnet switch or
Magnet switch Correct or replace
disconnected wire or short circuit of the coil.

(2) Though the pinion is engaged and the motor rotates, the rotation is not transmitted to the engine.
Unit Cause Remedy
Defective clutch. Replace
Starting motor
Broken reduction gear. Replace

(3) Though the pinion is engaged with the ring, the starting motor does not start.
Unit Cause Remedy
Disconnected wire, connecting the battery and magnet switch.
Repair, retightening, or
Wiring Insufficient tightening of the lead wire connecting the magnet switch
replace the wire.
and motor.
Locked ball bearing. Replace
Improper installation. Install properly.
Worn out brush, improper contact of brush spring. Replace
Starting motor
Stained commutator. Correct
Defective armature or field coil. Correct or replace
Insufficient tightening of connections of the field coil and brush. Retighten
Broken holding coil Replace
Magnet switch Improper contact of contact Replace
Roughened contact surface of contact Replace
Battery Discharged Charge

(4) Motor starts rotating before the pinion is engaged with the ring gear.
Unit Cause Remedy
Improper sliding of pinion shaft Replace
Starting motor Worn out pinion tooth top Correct
Improper pinion pushing position Replace
Engine Worn out ring gear Replace
Magnet switch Defective magnet switch Replace

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 Starting Motor (For Engine Model N843L:CM364)

1) Specifications and Performance

Part code No. 185086530 Pinion ejecting voltage (V) Less than 8
Type RA (228000-5121) Terminal voltage (V) 11.5
Continuous operation (second) 30 Unloaded Current (A) Less than 100
Output (V-kW) 12 – 2.0 Speed (rpm) More than 4000

Rotating direction Terminal voltage (V) 7.6

Clockwise
(viewed from pinion) Current (A) Less than 400
Loaded
Clutch type Overrunning
Torque N·m {kgf·m} More than 16.7 {1.7}
Engaging type Magnetic shift

2) General Description

The newly developed reduction starter is a positive shift type starter and consists of the motor, reduction gear, overrunning
clutch and pinion magnetic switch.
The magnetic switch and sliding pinion mechanism are arranged on the same axis as shown below.

3) Structure

113X

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 4) Disassembly

Disassembly of yoke O.D. 76 mm type

114X
(1) Remove the nut ① and disconnect the lead wire ② from the magnetic switch ③.

(2) Remove the through bolts ④ from the rear end frame⑤.

(3) Remove the yoke ⑥ from the magnetic switch ③.

(4) Remove the screw ⑦ from the rear end frame ⑤.

(5) Remove the rear end frame ⑤ from the yoke ⑥.

(6) Using the long-nose pliers, take off the brushes and pull out the brush holder ⑧.

(7) Remove the armature ⑨ from the yoke ⑥.

(8) Remove the screws ⑩ from the drive end frame ⑪.

(9) Remove the drive end frame ⑪ from the magnetic switch ③.

(10) Remove the over running clutch ⑫ from the drive end frame ⑪.

NOTE: If the pinion is installed on the drive end frame (externally attached to overrunning clutch shaft), it will
be necessary to remove pinion prior to removing overrunning clutch.

(11) Remove the steel ball from the overrunning clutch ⑫.

(12) Remove the idle gear ⑭ from the drive end frame ⑪.

(13) Remove the retainer ⑮ and rollers ⑯ from the drive end frame ⑪.

(14) Remove the return spring ⑰ from the magnetic switch ③.

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 5) Inspection and Repair

Inspect the following items and repair or replace if necessary. Test method is as same as the conventional type.

● Armature ● Brush holder

a) Armature short circuit test a) Check brush spring

b) Armature winding ground test b) Brush holder insulation test
c) Commutator run-out test
d) Measurement of segment mica depth ● Overrunning clutch test

● Yoke

a) Field windings ground test

b) Measurement of brush length

6) Reassembly

Reverse the order of disassembly to reassemble the starter. However attention should be paid to the following operations.

(1) Lubrication

Before reassembling, apply the recommended grease as follows:

● Retainer and rollers

● Overrunning clutch
Nippondenso No. 50 grease or ● Steel ball
equivalent (Esso beacon 325) ● Return spring
● Armature bearing
● Felt washer

(2) Fixing torque

Item Torque N·m {kg-m}

Throught blot 8.82 – 11.76 {0.9 – 1.2}
Drive end flame fixing screw 8.82 – 11.76 {0.9 – 1.2}
C-terminal nut 9.8 – 13.72 {1.0 – 1.4}

(3) Cautions for installation

● Do not forget to assemble the steel ball and return

spring

● Install the negative brush (brush holder side) to the

brush holder negative hole (not insulated), and the
positive brush (yoke side) to the brush holder
positive hole (separated from plate with insulator).
Then make sure that the positive brush lead wires
are not grounded.

● When assembling the brush holder to the yoke, take

care not to damage and get oil on it.

115X

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 ● When installing the rear end frame to the yoke,
engage the tab on the rear end frame with the lead
wire grommet.

● When installing the yoke to the magnetic switch,

engage the tab on the yoke with the notch in the
magnetic switch.

● Securely put the rubber boot over the C-terminal.

116X

(4) Magnetic switch test

The following tests should be performed without

the armature assembly.

NOTE: Each test should be performed a short time

(3 to 5 sec.) to prevent the magnetic switch
winding from burning.
Each test should be performed with
specified voltage is applied.

● Pull-in test
Connect the test leads as shown in Figure.
When connecting terminal C and M. T are closed,
the pinion should jump out. 117X

● Hold-in test
With the same condition as in the pull-in test, open
the connecting terminal C. The pinion should
remain in jumped out position.

● Return test 118X

With the same condition as in the hold in test, open
the connecting terminal 50. The pinion should
return immediately.

119X

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 7) Performance test

The following test should be carried out after reassembling

the starter. If suitable equipment is not available, at least
the No-load test should be carried out.

(1) No-load test

With the starter securely clamped in a vice, and using

a battery and suitable ammeter, connect the positive
lead of the battery, and the ammeter to the “50”
terminal.
Connect the negative lead to the starter body.
The starter should show smooth and steady rotation
immediately after jumping out of the pinion and
should draw less than the specified current.

120X

121X

(2) Load test

Read the ammeter and voltmeter when the specified torque is applied. The ammeter should indicate less than the
specified current, and the tachometer should indicate more than the specified speed.

(3) Lock torque test

Read the torque meter and ammeter when the tachometer reading becomes 0 rpm after applying the load. The torque
meter should indicate more than the specified torque and the ammeter should indicate less than the specified current.

8) Diagnosis and test for starting system

Use the diagnostic charts as a guide when you are repairing the starting system. Before diagnosis, be certain the battery is
fully charged and inspect the starter and battery cables for clean and tight connections.

Precaution:
● Do not operate the starter longer than 30 seconds.
● Do not disconnect or short any lead wire while starter is operating.
(Continue)

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 Diagnostic chart
Key switch “START” position

Engine does not start Engine starts, but pinion does not disengage

Go to diagnosis 3
Starter does not Starter cranks engine,
crank engine but very slowly

Go to diagnosis 1 Go to diagnosis 2

Diagnosis 1
Turn key switch to “START” position

Does magnetic switch click?

GOOD NO GOOD
Perform test 2 (on next page) Perform test 1 (on next page)

GOOD NO GOOD
GOOD NO GOOD

Remove starter Replace magnetic Repair or replace Replace magnetic

from engine and switch the key switch, switch
repair it relay and wiring

Diagnosis 2
Check starting system circuit

GOOD NO GOOD
Is battery in good condition

Clean and retighten

GOOD NO GOOD cable and wire

Remove starter Recharge or

and repair replace battery

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 Diagnosis 3
Check the operation of starting switch and relay

GOOD NO GOOD

Remove starter and Repair or replace if

repair necessary

TEST 1

(1) Disconnect the cable from “C” terminal.

(2) Connect a jumper wire to positive terminal of battery.

(3) Briefly touch jumper wire to “50” terminal of

magnetic switch.
If the magnetic switch operates, probable cause of
starter failure is in the wiring, starting switch or relay.

122X
TEST 2

(1) Disconnect the cables from C.T., M.T. and 50

terminal.

(2) Using an ohmmeter, touch one probe to the “50”

terminal and the other to the starter body.
There should be continuity.
If there is no continuity, the hold-in winding is
open-circuited.
Replace the magnetic switch if open circuited.

123X
[Discrimination of starter terminals]

Each terminal can be discriminated as follows:

M.T. ·············· Main terminal to which the main cable from battery is connected.
C.T. ··············· C-terminal to which the lead wire from the yoke is connected.
50· ················ 50-terminal to which the lead wire from the starting switch or starter relay is connected.

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 9) Service Specification

Part code No. 185086530

Type RA (228000-5121)
Output (V-kW) 12 – 2.0
Yoke outside diameter Ø78
Standard value mm 35.0
Commutator outside diameter
Repair value mm 34.0
Standard value mm 0.55 – 0.85
Commutator insulation depth
Repair value mm 0.2
Standard value mm 0.02
Commutator irregular wear
Repair value mm 0.05
Standard value mm 15.0
Brush length
Repair value mm 12.0
① End frame bolt 2.94 – 4.7 {30 – 48}
② Through bolt 8.82 – 11.76 {90 – 120}
③ Magnetic switch cover bolt 3.63 – 4.6 {37 – 47}
Tightening torque N·m {kgf·cm} ④ M terminal nut (Inside) 13.7 – 19.6 {140 – 200}

⑤ M terminal nut (Outside) 5.88 – 9.8 {60 – 100}

⑥ C terminal nut 9.8 – 13.7 {100 – 140}
⑦ Housing bolt 8.82 – 11.76 {90 – 120}

124X

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 3. Glow Plug

IQS super-high speed heating type glow plug is used for this tractor. Refer to paragraph 3-8, Electrical parts and accessories
for the IQS system.

1) Specifications and structure

Part code No. 185366190 Rated voltage 12 V (DC)

Model Y-701RS Standard resistance 0.8 Ω (At normal temperature)

The heat wire (heating unit) is enhoused in the stainless

steel sheath. Coiled thin heat wire is placed in sintered
magnesium oxide powder.
One end of this heat wire is welded to the sheath end and
another end is welded to the center electrode. By setting
the key switch at the heat (H) and start (START) positions,
power is supplied, heats the air in the combustion chamber
and preheats the heat wire.

125X
2) Circuit diagram

126X
3) Inspection

(1) Disconnect the connector.

(2) Connect the circuit tester to the center electrode of the glow plug and cylinder head and measure the resistance.

Measured value Judgment

At 0 Ω Short-circuit
At ∞ Disconnected wire

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 4. Thermometer and Thermosensor

1) Specifications (thermosensor) and structure

Part code No. 385720011

Operating range 50°C – 120°C

35°C → 670±80
Standard resistance value (Ω)
80°C → 118±6
(The resistance rating is
measure on the special
105°C → 54.5±2.7
circuit.)
115°C → 4.2±2.5

Electric thermosensor composed of a receiver and

transmitter is used for this tractor. 127X
The receiver employs a thermister in which electric
resistance varies according to temperature to increase the
current flowing the circuit when the cooling water
temperature rises and indicator of the receiver indicates the
corresponding position.

2) Inspection

(1) Thermosensor

a. Remove the thermosensor from the thermostat case.

b. Connect a circuit tester to the thermosensor.
c. Measure the resistance value at each temperature
while heating with a heater.

128X

(2) Thermometer

a. Disconnect the wiring from the themosensor.

b. Turn the key switch to “ON” position. (No start the
engine).
c. Connect the wiring for thermosensor to ground.
d. If the pointer for the thermometer moves to “C” to
“H” after a while, the thermometer is normal. If the
pointer does not move, the wiring or the
thermometer is defective.

129X

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 5. Buzzer Alarm Warning System

The buzzer is alarmed when the engine is over heated

and/or engine oil pressure is too lowered.

1) Over heat warning alarm system

The thermos-switch is located on the themostat case.

Relay and buzzer are located on the fire wall
compartment. The buzzer is alarmed with the
thermos-switch and relay.

130X
The thermos switch is closed at 107ºC to 113ºC, and
is opened at 103ºC.
If buzzer is alarmed, clean the radiator front screen
and radiator screen, and inspect the coolant quantity
after coolant temperature become cold.

131X

(2) Engine oil pressure warning alarm system

The oil pressure switch is located on the cylinder

head. Relay and buzzer are located on the fire wall
compartment. The buzzer is alarmed with the oil
pressure switch and relay. The switch is closed when
oil pressure is low 0.29 MPa {0.3 kgf/cm2}.

If buzzer is alarmed, stop the engine and inspect the

engine oil level.

132X

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 6. Oil Pressure Switch

Structure

This oil pressure switch is used to warn engine oil pressure. When the pressure increases more than specified, the oil
pressure lamp lights up warning the trouble, Diaphragm and contact points are combined in the oil pressure switch.

a. Oil pressure switch lamp lights up at pressure less than 0.2 – 0.4 kgf/cm2.

7. Battery

1) Specifications

CM284 Electrolyte specific gravity

Model 75D26L 1.28/When charged fully
CM364 (at 20ºC)

Capacity 75 AH Charging current 7A When charged normally

2) Specific gravity of electrolyte and charging condition

The specific gravity of electrolyte decreases approximately

lineally in proportion to the discharged electricity of
battery. By measuring the specific gravity of the electrolyte
using a hydrometer, residual capacity of the battery can be
known.
The specific gravity value measured by the hydrometer
should be compensated with respect to temperature. The
specific gravity of battery electrolyte is based on the
temperature of 20°C. As the temperature varies 1°C, the
specific gravity value increases or decreases 0.0007.
Therefore measured values can be compensated by the
following equation.
133X
S20 = St + 0.0007 (t – 20)
Electrolyte temperature in
Specific gravity Discharged Residual capacity
measured value
(20°C) electricity (%) (%)
Measured specific gravity
1.280 0 100
Specific gravity converted to
the value at 20°C 1.225 25 75
The right figure shows how to read the hydrometer and the 1.170 50 50
table indicates relation between the specific gravity values 1.116 75 25
and battery residual capacity.
1.060 100 0

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 7. Engine Stop Solenoid

Inspection

Connect (+) side of the battery to the terminal of the

engine stop solenoid and (-) side to the main body. If the
plunger is sucked into the main body, the engine stop
solenoid is normal.

134X
135X
8. Fusible Link

Inspection
The fusible link is installed between the battery and fuse
box to protect such parts that could not be protected by
fuses or a circuit (starter circuit) to which large current
flows instantaneously. Check the continuity with a circuit
tester.

NOTE:
1. If a fusible link is burnt out again immediately
after it is replaced, short circuit of the wiring can
be considered as the reason. Check the wiring
harness in such a case.
2. Never use a substitute wire or the like when the
fusible link is burnt out.
136X

9. Wiring Harness

Inspection and service

(1) Disconnect the negative cord of the battery when inspecting or servicing the wiring harness.
(2) Check each wiring for damage of sheathing due to wiring or for some other reason, or looseness at the connecting
parts at the time of its inspection or service. If there is some defective point, repair the insulation or replace the wiring
harness. (The band becomes breakable when becoming old. Be sure to substitute in such a case.)
(3) After completion of service for the tractor, etc., protect wiring at the plugging parts with vinyl tube, use clamping
fixtures with vinyl cover, and check that the figures are not in direct contact with wiring. (Replace uncovered
fixtures.) Especially check carefully where wiring may be caught between something.
(4) Check very carefully where positive current flows constantly and confirm sheathing is free form troubles.
1) Starting motor
2) Alternator
3) Key switch
(5) After check, protect the wiring with corrugated tube or the like.

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 2-4 Trouble Shooting
Condition Cause Remedy

Defective key switch Connect or correct contact points properly.

Insufficient charging or completely discharged Charge.
battery.
No fuel. Replenish the fuel.
Air mixed in the fuel system. Correct points allowing the air to enter the
fuel.
Clogged fuel filter. Replace the fuel filter.
Engine does not start.
Irregular of improper fuel supply. Trouble of injection pump. Have corrected
in work specified by Nippon Denso.
Defective glow plug. Replace.

Improper viscosity of lubricating oil. Check and change.

Clogged air cleaner. Clean the air cleaner.

Not compressed. Check and correct each part.

Defective engine stop solenoid. Check or replace wiring.

Air mixed in the fuel system. Discharge air from the fuel.
Uneven fuel injection. Trouble of injection pump. Have corrected
or replaced in a work specified by Nippon
Denso.
Irregular engine speed
Replace the fuel filter.
Clogged fuel filter.
Check and adjust.
Trouble of speed governor.
Overhaul, check and correct each part.
Improper function of engine main body.

No fuel in fuel tank. Replenish fuel.

Clogged fuel filter. Replace the filter.
Engine stops during
Air mixed in the fuel system. Correct points to allow the air to enter the
operation
fuel system.

Improper functions of engine main body. Check and correct each part.

Insufficient cooling water. Replenish the cooling water, and check and
repair water leaking points.
Loosened or slipping fan belt. Clean oil dust, etc. and retighten.
Failure of fan belt. Replace.
Clogged radiator. Clean the radiator.
Engine overheat Clean.
Clogged radiator fin.
Cooling water passage clogged with dust, fur, etc. Wash.
Improper function of thermostat. Check and replace
Insufficient lubricating oil. Replenish.
Overload. Decrease the load.

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 Condition Cause Remedy

Improper color of Too much engine oil. Check and adjust the quantity.
engine exhaust Too low viscosity of engine oil. Check and change.
Improper injection timing. Too late. Correct.

Improper fuel. Check and change.

Improper engine Excessive fuel injection. Check and adjust.
exhaust (black or dark Improper function of engine main body. Check a correct each part.
gray) Overload. Reduce the load.
Clogged air cleaner. Clean the element.

Loosened fan belt. Correct belt tension.

Trouble in wiring of each part. Check and repair.
Improper charging.
Defective battery. Replace.
Defective alternator. Replace.

Loosened or disconnected wiring of each part. Check and install or tighten.

Dropped battery voltage. Charge the battery.
Starting motor does not
Defective safety switch. Replace.
operate.
Trouble in starting motor. Check and correct the starting motor.
Disconnected wire of fusible link. Replace.

Insufficient engine oil. Replenish to specified gauge level.

Trouble in oil pressure switch. Replace the switch.
Oil pressure lamp does Oil leakage from lubricating system. Check and retighten.
not go out. Clogged oil filter. Replace with new one.
Short circuit wiring between oil pressure lamp Repair.
and mano contact.

Oil pressure lamp does Burnt out lamp. Replace the lamp.
not light up with the Disconnected wire between battery and oil Repair.
key switch turned ON. pressure lamp.
(While engine stops.)

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 2-5 Engine Maintenance Standard Table
1. J843
* Unit for values without unit in the column of inspection item is mm.
Standard Standard Service
Part Inspection Items Repair Value Remarks
Dimension Assembling Value Limit
Cylinder compression pressure More than 2.94 Engine speed
2.45 {25}
MPa {kgf/cm2} {30} at 200 rpm
Cylinder head tightening torque Coat
98 – 103
N⋅m {kgf⋅m} Molycoat
{10.0 – 10.5}
grease.
Distortion of cylinder head bottom surface
Less than 0.05 0.12
(mounting surface)
Cylinder head

Valve seat recess (intake/exhaust)

Valve sheet
0.85 – 1.15 1.8
angle 45°

137X
Intake 1.66 – 1.87 2.5
Valve seat contact width
Exhaust 1.66 – 1.73 2.5
Cylinder
block

Bore φ84 φ84 – 84.019 φ84.2 φ84.2

Distortion on cylinder block top surface Less than 0.05 0.12
φ83.9475 –
Longer dia. at skirt φ83.955 φ83.7
83.96
Piston

Clearance to cylinder 0.0375 – 0.0715 0.25 At 20°C

Clearance between piston pin hole and pin -0.010 – +0.007 0.02
φ24.996 –
Pin outside dia. φ25 φ24.98
25.0
Piston
pin

0.010 –
Clearance between rod small end bush and pin. 0.08 Oil clearance
0.025
Clearance between Top ring 0.07 – 0.11
piston ring groove and 0.25
ring 2nd ring 0.04 – 0.08
Oil ring 0.03 – 0.13 0.25
Top ring 2
Piston ring

Ring width 2nd ring 1.5

Oil ring 4
Top ring 0.20 – 0.35 1.0
Piston ring end gap 2nd ring 0.20 – 0.40 1.0
Oil ring 0.20 – 0.80 1.2

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 Standard
Standard Repair Service
Part Inspection Items Assembling Remarks
Dimension Value Limit
Value
Torsion of large end and small end holes Less than More than
(per 100 mm) 0.08 0.2
Parallelism of large end and small end holes Less than More than
(per 100 mm) 0.05 0.15
Connecting rod

Longitudinal play of connecting rod and crank pin 0.1 – 0.3 0.7
Clearance between connecting rod bearing and crank 0.035 – Oil
0.2
pin 0.083 clearance
Connecting rod bearing (bore x width) φ44×19.8
Connecting rod tightening torque N⋅m {kgf⋅m} 49.0 – 53.9
{5.0–5.5}
Weight variation of piston after assembly (g) Less than 10
φ57.957 –
Journal dia. φ58 φ57.90
57.97
φ43.964 –
Crank pin dia. φ44 φ43.90
43.975
Journal and pin finishing accuracy 1.6Z
Less than
Run-out of crankshaft 0.06
0.03
Axial play of crankshaft 0.1 – 0.4 0.5
Crank shaft

Thrust washer thickness 3 2.95 – 3.00 2.8

Bush (journal metal) bore × outside dia. φ58×φ62
Clearance between crank journal and bush (journal 0.044 – Oil
0.2
metal) 0.116 clearance
Center bearing (bore × outside dia.) φ58×φ62
0.044 – Oil
Clearance between crank journal and center bearing 0.2
0.116 clearance

Bearing holder (upper and lower) tightening torque 49 – 53.9

N⋅m {kgf⋅m} {5.0 – 5.5}

For intake and

34.441 –
exhaust valves 34.1
34.5076
Camshaft

For injection 42.99 –

42.8
138X pump 43.01
Cam shaft runt 0.03 0.1
Cam gear backlash 0.08 0.25
Intake valve stem 6.97 6.955 – 6.97 6.89
Exhaust valve stem 6.95 6.94 – 6.95 6.84
Intake 0.03 – 0.06 0.2
Clearance between valve stem and valve
0.045 – at cold
guide Exhaust 0.25
0.075
Valve

0.775 –
1.0 0.5
1.075

139X

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 Standard Standard Service
Part Inspection Items Repair Value Remarks
Dimension Assembling Value Limit
Valve clearance
0.2 0.5 When cold
(both intake and exhaust)
Spring force (when installing
length is compressed to 30.4 8.1 7
mm)
Valve spring

High 35 33.5
Valve

1.2 2.0

140X

Intake Opening angle before TDC 13°

valve Closing angle after BDC 43°
Exhaust Opening angle before BDC 43°
valve
Closing angle after TDC 13°
Overall length 174.3 174.1 – 174.5
Push
rod

Outer diameter φ6.3

Wear of rocker arm shaft φ11.66 φ11.65 – 11.67 φ11.57
Rocker
arm

Oil
Clearance between rocker arm and shaft 0.032 – 0.068 0.2
clearance

Oil pressure switch 19.6 – 39.2

29.4 {0.3}
working pressure kPa {kgf/cm2} {0.2 – 0.4}
Relief valve 24.5 – 34.3
Oil pump

opening pressure kPa {kgf/cm2} {2.5 – 3.5}

At replacing
Lubrication oil volume (ℓ) 4.6
filter
Tip clearance (between rotor and vane) 0.01 – 0.15 0.25
Side clearance (between rotor and cover) 0.1 – 0.15 0.2
Type 104134 - 3050 BOSCH
Injection pump

Pump plunger dia.

Pump plunger stroke
Before T.D.C. 18° – 20°
Injection
timing Piston displacement
2.59 – 3.187
(before T.D.C.)

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 Standard Standard Service
Part Inspection Item Repair Vlue Remarks
Dimensions Assembling Vlue Limit
Type (Nozzle) 105007 - 1170 (NP-DN4PDN117) BOSCH
Injection nozzle

12.25 – 13.23
Injection pressure MPa {kgf/cm2}
{125 – 135}
Injection angle 4°
Nozzle and holder tightening torque 58.8 – 68.6
N·m {kgf·m} {6 – 7}

Reserve tank
Cooling water amount (ℓ) 5.1
0.6 ℓ
Thermostat operating temperature
82 80 – 84
(°C)
Cooling conditions

Thermostat full open temperature

95
(°C)

V belt (fan) looseness (load at center Dimension A

5 – 10
49 N {5 kgf }) 36.5
Start to open pressure of radiator cap
73.5 {0.75} 88.2 {0.9}
pressure valve kPa{kgf/cm2}
Start to open pressure of radiator cap
Less than
negative pressure valve 4.9 {0.05}
4.9 {0.05}
kPa{kgf/cm2}
Model M001T66081
No. of teeth of pinion gear 9
Starting motor

Pinion gear shifting method Magnetic shifting

Wear of commutator dia. φ29.4 φ28.8
Brush length 17.5 10
22.5 – 32.5
Brush spring pressure N {kgf} 10 {1.0}
{2.3 – 3.3}
Type A007T03877 12 V – 40 A
Diameter φ22.7 22.1
Slip
ring
Alternator

Correct with cloth file if

Surface condition
stained or damaged
Brush length 18.5 5
4.6 – 5.8
Brush spring pressure N (gf) 2.6 {270}
{470 – 590}

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 2. N843L
* Unit for values without unit in the column of inspection item is mm.
Standard Standard Service
Part Inspection Items Repair Value Remarks
Dimension Assembling Value Limit
Cylinder compression pressure More than 2.94 Engine speed
2.45 {25}
MPa {kgf/cm2} {30} at 200 rpm
Cylinder head tightening torque Coat
98 – 103
N⋅m {kgf⋅m} Molycoat
{10.0 – 10.5}
grease.
Distortion of cylinder head bottom surface
Less than 0.05 0.12
(mounting surface)
Cylinder head

Valve seat recess (intake/exhaust)

Valve sheet
0.85 – 1.15 1.8
angle 45°

141X
Intake 1.66 – 1.87 2.5
Valve seat contact width
Exhaust 1.66 – 1.73 2.5
Cylinder
block

Bore φ84 φ84 – 84.019 φ84.2 φ84.2

Distortion on cylinder block top surface Less than 0.05 0.12
φ83.948 –
Longer dia. at skirt φ83.955 φ83.7
83.963
Piston

Clearance to cylinder 0.0375 – 0.0715 0.25 At 20°C

Clearance between piston pin hole and pin -0.010 – +0.007 0.02
φ27.996 –
Pin outside dia. φ28 φ27.98
28.0
Piston
pin

0.010 –
Clearance between rod small end bush and pin. 0.08 Oil clearance
0.025
Clearance between Top ring 0.07 – 0.11
piston ring groove and
ring 2nd ring 0.04 – 0.08 0.25
Oil ring 0.03 – 0.13
Top ring 2
Piston ring

Ring width 2nd ring 1.5

Oil ring 4
Top ring 0.20 – 0.35 1.0
Piston ring end gap 2nd ring 0.20 – 0.40 1.0
Oil ring 0.20 – 0.80 1.2

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 Standard
Standard Repair Service
Part Inspection Items Assembling Remarks
Dimension Value Limit
Value
Torsion of large end and small end holes Less than
0.2
(per 100 mm) 0.08
Parallelism of large end and small end holes Less than
0.15
(per 100 mm) 0.05
Connecting rod

Longitudinal play of connecting rod and crank pin 0.1 – 0.3 0.7
Clearance between connecting rod bearing and crank Oil
0.035 – 0.083 0.2
pin clearance
Connecting rod bearing (bore x width) φ44×19.8
Connecting rod tightening torque N⋅m {kgf⋅m} 49.0 – 53.9
{5.0–5.5}
Weight variation of piston after assembly (g) Less than 10
φ67.957 –
Journal dia. φ68 φ67.90 φ67.9
67.97
φ51.964 –
Crank pin dia. φ52 φ51.90 φ51.9
51.975
Less than
Run-out of crankshaft 0.06
0.03
Axial play of crankshaft 0.1 – 0.4 0.5
Crank shaft

Thrust washer thickness 3 2.95 – 3.00 2.8

Bush (journal metal) bore × outside dia. φ58×φ62
Clearance between crank journal and bush (journal Oil
0.044 – 0.116 0.2
metal) clearance
Center bearing (bore × outside dia.) φ58×φ62
Oil
Clearance between crank journal and center bearing 0.044 – 0.102 0.2
clearance

Bearing holder (upper and lower) tightening torque 49 – 53.9

N⋅m {kgf⋅m} {5.0 – 5.5}

For intake and

34.441 –
exhaust valves 34.1
34.5076
Camshaft

For injection
42.99 – 43.01 42.8
142X pump
Cam shaft runt Less than
0.1
0.03
Cam gear backlash 0.08 0.25
Intake valve stem 6.97 6.955 – 6.97 6.89
Exhaust valve stem 6.95 6.94 – 6.95 6.84
Clearance between valve stem and valve Intake 0.03 – 0.06 0.2
guide Exhaust 0.045 – 0.075 0.25
Valve

1.0 0.775 – 1.075 0.5

143X

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 Standard Standard Service
Part Inspection Items Repair Value Remarks
Dimension Assembling Value Limit
Valve clearance
0.2 0.5 When cold
(both intake and exhaust)
Spring force (when installing
length is compressed to 30.4 8.1 7
mm)
Valve spring

Free height 35 33.5

Valve

Less than
2.0
1.2
144X

Intake Opening angle before TDC 13°

valve Closing angle after BDC 43°
Exhaust Opening angle before BDC 43°
valve
Closing angle after TDC 13°
Overall length 174.3 174.1 – 174.5
Push
rod

Outer diameter φ6.3

Wear of rocker arm shaft φ14.95 – 14.97 φ14.87
Rocker
arm

Oil
Clearance between rocker arm and shaft 0.032 – 0.068 0.2
clearance

Oil pressure switch 19.6 – 39.2

29.4 {0.3}
working pressure kPa {kgf/cm2} {0.2 – 0.4}
Relief valve 24.5 – 34.3
Oil pump

opening pressure kPa {kgf/cm2} {2.5 – 3.5}

At replacing
Lubrication oil volume (ℓ) 5.6
filter 5.0 ℓ
Tip clearance (between rotor and vane) 0.01 – 0.15 0.25
Side clearance (between rotor and cover) 0.1 – 0.15 0.2
Type 104134 – 3050 BOSCH
Injection pump

Pump plunger dia.

Pump plunger stroke
Before T.D.C. 18° – 20°
Injection
timing Piston displacement
3.195 – 3.932
(before T.D.C.)

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 Standard Standard Service
Part Inspection Item Repair Vlue Remarks
Dimensions Assembling Vlue Limit
Type (Nozzle) 105007 - 1170 (NP-DN4PDN117) BOSCH
Injection nozzle

15.20 – 16.18
Injection pressure MPa {kgf/cm2}
{155 – 165}
Injection angle 4°
Nozzle and holder tightening torque 58.8 – 68.6
N·m {kgf·m} {6 – 7}

Reserve tank
Cooling water amount (ℓ) 5.3
0.6 ℓ
Thermostat operating temperature
82 80 – 84
(°C)
Cooling conditions

Thermostat full open temperature

95
(°C)

V belt (fan) looseness (load at center Dimension A

5
49 N {5 kgf }) 36.5
Start to open pressure of radiator cap
73.5 {0.75} 88.2 {0.9}
pressure valve kPa{kgf/cm2}
Start to open pressure of radiator cap
Less than
negative pressure valve 4.9 {0.05}
4.9 {0.05}
kPa{kgf/cm2}
Model RA(228000 – 5121)
No. of teeth of pinion gear 9
Starting motor

Pinion gear shifting method Magnetic shifting

Wear of commutator dia. φ35.0 φ34.0
Brush length 15 12

Type A007T03877 12 V – 40 A
Diameter φ22.7 22.1
Slip
ring
Alternator

Correct with cloth file if

Surface condition
stained or damaged
Brush length 18.5 5
4.6 – 5.8
Brush spring pressure N (gf) 2.6 {270}
{470 – 590}

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 Chapter 3.
TRANSMISSION
AND BRAKE

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 1. DESCRIPTION AND OPERATION

1) Removal
The transaxle assembly consists of a two-speed gearbox, a
differential assembly, PTO clutch assembly, PTO shaft and
inboard brake.

300X

Transaxle Assembly

1. Transmission 5. Fixed Gears

Gearbox (2-Speed) 6. Pinion Drive Gear
2. Differential 7. Rear Wheel Drive
Assembly Output Shaft and
3. Input Gear Cluster Two Way Clutch
4. Sliding Gears 8. PTO Clutch Assembly
9. PTO Shaft

The front axle, consists of differential lock linkage, axles,

and brakes.

301X
Transaxle Assembly

1. Differential Lock 3. Axle Housing

Lever 4. Inboard Brake
2. Differential 5. Drive Axle
Assembly

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 The range gearbox housing also supports the differential
assembly, Figure 301X. The two-speed transmission
gearbox consists of constant mesh spur gears and sliding
gears. The range gearbox also contains a four wheel drive
output shaft and two way clutch.

The range selector lever is located on the left-hand panel

adjacent to the operator’s seat. The range selector lever can
be shifted when the HST pedals are in neutral. The range
selector lever and Four-Wheel-Drive (FWD) selector lever
are activated by the same lever.

The range selector lever has three positions; forward (high

range) mid-position (neutral) and rear ward (Low range).
In high range “H” forward speed ranges from 0 – 16.6
km/h and low range from 0 – 9.7 km/h. In reverse the high 302X
speed ranges from 0 – 10.7 km/h and in low range from 0 Range Gear and Differential Housing
– 6.3 km/h.
1. Differential Lock 3. PTO Shaft
Coupler 4. Gearbox Housing
2. Differential

The differential assembly consists of a differential lock

coupler, pinion differential and two bevel side gears
splined directly to the axle shafts.

2) Brakes

The brakes are located in the front axle housing. The

brakes are wet type disc brakes and consists of stator, disc,
steel ball, spring, actuate plate and brake lever. The brakes
are mechanically applied by individual pedals located on
the left side of the steering column (Dealer option).

A master brake pedal, located on the right side, applies

both brakes evenly.

303X
Brakes

1. Brake Disc 4. Spring

2. Stator 5. Actuator Plate
3. Steel Ball 6. Pin
7. Brake Lever

3) Differential Lock
A differential lock is provided to lock the differential so
that both front wheels rotate when power is provided by
the transmission even though one wheel may lose traction.
The differential lock control pedal is foot operated and is
located on the left side of the steering column.

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 4) Power Flow (Range gear)

304X

305X

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 5) Power Flow (PTO)

306X

307X

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 2. TRANSMISSION UNIT
The transaxle assembly must be separated from the
commercial mower to perform service work on the HST,
transmission gearbox, four wheel drive output shaft
differential.

1) Removal

1. Disconnect the negative battery cable.

2. Remove the grip, ①, side cover ②, and fender
③.
3. Disconnect the seat safety switch connectors
under the seat floor and remove the seat assembly,
④, from the seat floor.

308X

4. Pull up the lever and open the floor, and remove

the split pin ①, and separate the damper ②
from the frame.
5. Remove the floor and floor bracket from the
upper frame.

309X

6. Disconnect the parking brake wire ④ from the

both brake levers.
7. Remove the split pin, washer and pin, and
disconnect the brake rod ①, from the both brake
levers.
8. Remove the split pin and pin, and disconnect the
differential lock control rod ② , from the
differential lock lever.

310X

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 9. Disconnect the power steering oil pipes ①, from
the power steering cylinder.
10. Place the safety stands under the main frame.
11. Remove the rear axle bearing holders ②, from
the frame and remove the rear axle assembly ③,
pipe, drive shaft and coupling from the tractor.

311X
12. Remove the fire wall sealed from under the
radiator.
13. Remove the bolt ①, from the universal joint ②,
and disconnect the joint from the HST input shaft
by slide the joint to rearward.

312X

14. Disconnect the wire connector from the HST

neutral switch ①.

313X

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 15. Remove the split pin ① , and washer and
disconnect the lift arm feed back (PTO safety
stop) wire ②, from the R.H. lift arm.
16. Remove the bolt ③, and pin ④, and separate the
hydraulic cylinder ⑤, from the lift arm.

314X

17. Untighten the hose bands ①, and disconnect the

return hose ② , from the vent hose on the
transmission housing.
18. Disconnect the fork joint ③, by remove the split
pin and pin for the PTO clutch control lever ④.
19. Remove the spring ⑤ , from the PTO clutch
control lever ④.

315X

20 Disconnect the oil pipe ①, from HST charge

pump to power steering control valve.

316X

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 21. Untighten the hose band ①, and disconnect the
suction hose ②, for the hydraulic oil pump.

317X
22. Remove the split pin, washer and disconnect the
HST speed control rood ① , from the HST
control lever.
23. Remove the U-nut, and remove the damper ②,
from the HST control lever.
24. Unhook the spring ③, from under the HST speed
control lever.

318X

25. Remove the splits pin, washer and disconnect the

four-wheel drive control rod ①, and range gear
control rod ②, from the change lever.

319X
26. Remove the banjo bolt and clamp ①, for the oil
cooler return pipe, and disconnect the return pipe
②, from the oil cooler.
27. Use the two wrenches, and disconnect the feed
pipe ⑥, for the HST on the top of the HST unit,
Fig. 315X.

320X

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 28. Hold the front flame, with the chain block.
29. Remove the rear frame ①, attaching bolts ②,
and nuts ③.

321X
30. Remove the bolts ① , for attached front axle
housing.
31. Remove the front axle and transmission housing
assembly ②, from the main frame.

322X
32. Remove the rear frame ① , from the rear
transmission housing.

323X
33. Un hook the spring ④, remove the shift arm ①,
and shift guide ②, as a set from the transmission.
If necessary, remove the control lever ③, from
the HST unit.

324X

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 2) Front Transmission Unit

(1) Disassembly

1. Remove the side PTO unit from the transmission

housing and HST unit.

325X

2. Remove the HST unit ① , from the transmission

assembly.

① HST Unit
② O-Ring
③ O-Ring
④ Bolt

326X

3. Remove the L.H. wheel shaft housing ①, and bearing

holder ②.

NOTE: Note the total amount of shims and

thickness used between differential bearing
and bearing holder.

327X

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 4. Remove the L.H. wheel shaft housing ②, the bearing
holder ③, and differential assembly ①.

NOTE: Note the total amount of shims and

thickness used between differential bearing
and bearing holder.

328X

5. Separate the rear transmission housing ①, from the

front transmission housing ②.

329X

6. Remove the seal cover ①, with oil seal ②, and

O-Ring ⑧, from the transmission housing.
7. Drive out the PTO shaft ③, and remove the fixed gear
④, snap ring ⑤, bearings ⑥ and ⑦, from the
transmission housing.

330X

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 8. Remove the PTO clutch assembly ① , and thrust
bearing ②.
9. If necessary, remove the plate ③, from the
transmission housing.

331X

10. Untighten the lock nut ①, on the drive pinion shaft

②.
11. Remove the washer ⑤, and fixed gear ④, from on
the drive pinion shaft ②.

332X

12. Pull out the drive pinion shaft ①, thrust washer ④,

and shims ⑤ , to the front of the transmission
housing.
13. Remove the bearings ② and ③ from the housing.
14. If necessary, drive out the seal cover ⑥, for inspect
the ring gear backlash.

333X

15. Remove the snap ring ①, and pull out the counter
shaft ②, with bearing ③, and collar 4.
16. Take out the fixed gear ⑤, and bearing, ⑥, from the
housing.

NOTE: Put the identity make on the fixed gear by

paint.

334X

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 17. Remove the snap ring ①, and pull out the counter
shaft ②, with bearing ③.
18. Take out the collar ④, fixed gear ⑤, and bearing ⑥,
from the housing.

335X

19. Heat the two bolts ①, by burner and remove them,

and pull out the PTO clutch shaft ②.
20. Take out the clutch fork ③, from the housing.
21. Remove the drive shaft ④, with snap ring ⑤.
22. Take out the fixed gear ⑥, and bearing ⑦.

336X

(2) Inspection

1. Wash all components with a suitable cleaning solvent 4. Inspect the transmission case for cracks, worn bearing
and air dry. bores or other damage.
2. Inspect all bearings for excess wear, score marks, 5. Inspect all for excess wear, chipped teeth, or other
discoloration from overheating, or other damage. damage.
Rotate the bearings by hand and check for roughness 6. Inspect the shift forks for excess wear, bends or other
while slowly rotating the inner and outer races. damage.
3. Lubricate all bearings with a clean lubricant before
installation.

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 (3) Assembly

Reassembly generally follows the disassembly procedure

in reverse.

Be sure all components are free of dirt and foreign matter

and lubricate all components with clean hydraulic oil on
assembly.

During assembly observe the followings:

1. Remove the oil stained from the bolts ①, thread and

thread holes of clutch shaft ②, with the solvent, and
then apply the thread sealant to threads when install
the clutch fork ③.
337X

2. Position the lever ①, of clutch shaft as shown figure

before install the PTO clutch assembly.

338X

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 3. The identity mark fixed gear ①, when removed is
installed position A.

339X
4. The shims ①, are installed between thrust washer ②,
and bearing ③, on the drive pinion ④.
5. Adjust the pinion bearing pre-load using a strong cord
wrapped around the pinion shaft spline and a pull
scale. Tighten the pinion nut to obtain the specified
pounds of constant pull to rotate the pinion assembly.

Pinion Bearing Pre-Load Constant Pull 196 N {20

kgf}

NOTE: Turn drive pinion several times by hand

before performing pull scale test.

340X

6. Bend the lock nut flange by the chisel at the ditch of

the pinion shaft after adjust the pre-load.

341X

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 7. If removed, use care the plate ①, direction for brake
disc of PTO clutch assembly.
8. Align the brake disc projection ②, of PTO clutch in
the plate ①.

9. Apply the grease to the 18 mm inside diameter of 342X

bearing race ①, and ball bearings ②, and install
them on the PTO clutch drive shaft.
The 17 mm inside diameter of bearing race ③, is
installed to the coupling with apply the grease in the
rear transmission housing.

342-1X

10. Apply requid gasket to the matching surfaces of both

transmission housing.
11. PTO cluch separater plates tooth are lined up before
install rear transmission housing.

343X

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 12. Install the guide stick (special tool) to the transmission
housing, and align the each part as follows while
sliding the rear transmission housing.

● Align the drive pinion shaft and center to 4WD

one way clutch center.
● Align the PTO clutch sepatater plates with
coupling of rear transmission housing.
● Align the fixed gear on the drive pinion shaft and
fixed gear on the range counter shaft while
rotating the mainshaft.

344X

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 3) Rear Transmission Unit

(1) Disassembly

1. Heat the two bolts ①, by burner and remove them and

pull out the shaft ②, from the rear transmission
housing, on 4WD model.
2. Take out the shifter fork ③, with tips ⑨, from the
housing on 4WD model.
3. Remove the thrust washer (thick) ④, two way clutch
assembly ⑤, thrust washer (thin) ⑥, drive shaft ⑦,
with bearing ⑧, from the rear transmission housing,
on 4WD model.

346X

4. Remove the snap ring ①, shifter rod ②, steel ball ③,

spring ④, and range shifter fork ⑤.

WARNING:
Hold a shop towel over the top of the shift fork
to restrain the detent ball when the rail is
removed from the fork. The detent ball will be
expelled with considerable force when it is
released.

5. Drive out the roll pin ⑥, and remove the change lever
⑦.
6. Remove the bolt ⑧, and plate ⑨, and pull out the
shift arm ⑩, in the transmission. 347X

7. Remove the snap ring ①, and fixed gear ② from

range gear counter shaft ③.
8. Remove the snap ring ④, and pull out the range gear
counter shaft ③, with bearing ⑤.
Take out the range slide gear ⑥, and bearing ⑦.
9. Remove the plate ⑧, with magnets ⑨.
10. Remove the snap ring ⑩, and drive out the main shaft
(gears) ⑫, with bearings ⑪ and ⑬.

348X

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 11. Remove the nut ①, and washer ⑧, drive out the
countershaft ②, with O-Ring ③, from the housing.
12. Take out the collar ⑦, and the counter gear ④, with
bearing ⑤, and snap ring ⑥.

349X

13. Remove the thrust bearing ⑤, and drive out the

coupling ①, with needle bearing ⑥.
14 Take out the collar ④, bearings ② and ③, from the
transmission housing.
15. If necessary, remove the plate ⑦, from the housing.

350X

(2) Inspection

1. Wash all components with a suitable cleaning solvent 5. Check the detent springs for wear, chipped or weak
and air dry. spring extension.

2. Inspect all bearings for excess wear, score marks, 6. Inspect the detent balls for excess wear or damage.
discoloration from overheating, or other damage.
Rotate the bearings by hand and check for roughness 7. Inspect the shift rail detent grooves for excess wear.
while slowly rotating the inner and outer races.
8. Inspect all gears for excess wear, chipped teeth, or
3. Lubricate all bearings with a clean lubricant before other damage.
installation.
9. Inspect the shift forks for excess wear, bends or other
4. Inspect the transmission case for cracks, worn bearing damage. See “Wear Specifications,” this Chapter.
bores or other damage.

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 (3) Assembly

Reassembly generally follows the disassembly procedure

in reverse.

Be sure all components are free of dirt and foreign matter

and lubricate all components with clean hydraulic oil on
assembly.

During assembly observe the followings:

351X
1. Install the range shift arm ①, in the rear transmission
housing at first.

2. Install the range slide gear shifter fork ②, as follows:

● Install the spring ④, and steel ball ③, in the shifter

fork ②, and press them.
● Assemble the stick (out side diameter is Ø14 –
Ø14.5, length is 45 – 50 mm) ⑤, in the hole of
shifter fork.
● Place the assembled shifter fork ②, on the range
sliding gear in the rear transmission housing.
● Install the shifter rod ⑥, through the housing and 352X
shifter fork ②, and secure with snap ring ⑦.
● Take out the stick ⑤.

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 3. Install the two way clutch assembly (4WD only) as
follows:

● Install the oil seal ① , and bearing ② , in the

housing.
● Install the 4WD drive shaft ③, in the housing.
● Install the small thrust washer ④, on the 4WD
drive shaft with the oil ditch toward the two way
clutch assembly ⑤.

● Install the two way clutch assembly ⑤, on the

drive shaft.

NOTE: Align the notch of the two way clutch

assembly to pin in the housing.

● Install the large thrust washer ⑥, on the two way

clutch assembly with the oil ditch toward the two
way clutch assembly. 353X

● Remove the oil stained from the bolt thread ⑦, and

thread holes of shaft ⑧, with the solvent, and then
apply the thread sealant to threads when install the
shifter fork ⑨.

354X

NOTE: Take care the direction of the tips on the

shifter fork as shown Figure 354-1X.

354-1X
4. Installation of the rear transmission housing to the front
transmission housing generally follows the “Front
Trans Mission Assembly”.

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 4) PTO Clutch Unit

(1) Disassembly

Remove the PTO clutch assembly. See in this chapter 3.

1. Remove the snap ring ①, back plate ②, disc plates ③,

and separator plates ④.

355X

2. Press the washer ⑤, by jig and remove the snap ring

⑥.
3. Release the washer ⑤, and remove the jig, washer and
spring ⑦.

NOTE: The spring is installed under the washer.

Use care when removing the snap ring as
the spring will be expelled with
considerable force when released. Cover
the PTO clutch with a shop towel to
contain the spring while removing the snap
ring.

356X

4. Press the clutch lifter ⑧, and remove the snap ring ⑪.

NOTE: Never remove the six bolts ⑯ Figure 358X,

because they will be broken by fixed them
thread sealant.

357X

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 5. Remove the pressure plates ⑫, and ⑬, and brake disc
⑭, from the housing.

358X

6. Remove the stop ring ⑯, release hub ⑰, and release

bearing ⑱, from the clutch lifter ⑧.

359X

(2) Inspection

1. Wash all parts in a suitable solvent and air dry.

2. Inspect the separator plates, disc plates and brake disc
thickness and any damage. If either is defective,
replace the PTO clutch assembly.

Standard Wear Limit

Disc Plate Thickness 2.0 mm 1.4 mm
Brake Disc Thickness 3.0 mm 2.2 mm

(3) Assembly

Prior to assembly coat the clean hydraulic oil to each parts.

Assembly of the PTO clutch generally follows disassembly
procedures in reverse, however, the following must be
observed:
360X
● When install the snap ring, it's gap avoid from the
groove of the housing.

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 ● When install the snap ring ⑪, for brake disc, it’s
gap position as shown illustration.

361X
● Use care the thrust bearing order when install it. The
small inside diameter race is installed on the release
hub ⑰, and the large inside diameter race is
installed in the clutch lifter ⑧.

362X

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 5) Front Wheel Shaft and Brake Unit

(1) Disassembly

1. Remove the brake discs ①, stators ②, and the anchor

pin ⑥ from in the housing.
2. Remove the springs ③, and brake disc ④, take out the
steel balls ⑤.
3. Remove the snap ring ⑦, and pull out the brake cam
⑧, from the housing.

363X

4. Remove the snap ring ①, and drive out the wheel shaft
②, from the wheel shaft housing.
5. Remove the bearings ③ and ④, and oil seal ⑤, from
wheel shaft housing.

364X

6. Drive out the roll pin ①, and draw out the diff-lock
shaft ②, from the bearing holder (L.H.) ③.
7. Remove the spring ④, diff-lock fork ⑤, and diff-lock
clutch ⑥, from the bearing holder.

365X

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 (2) Inspection

1. Inspect the brake discs for excess wear or damage.

Using a micrometer, measure the brake disc lining

groove depth. Replace the brake disc if the lining
groove depth is less than 0.1 mm.

Brake Disc Wear Check

① Minimum Groove Depth – 0.1 mm
366X

2. Inspect the stators for excess wear or damage.

Replace the stator if contact surfaces are scored or

worn by the brake disc.

Using a micrometer, measure the level difference of the

stator, and replace it if the level difference is more than
0.1 mm.

3. Component Wear:

Check the brake cover, steel balls, actuating cam and

springs, and replace any found abnormal.

Brake Stator Wear Check

① Level Difference – 0.1 mm
367X

(3) Assembly (4) Brake Adjustment

Reassembly generally follows the disassembly procedure 1. Check the brake pedal free travel and if necessary
in reverse. adjust the brake control rod to obtain 35 – 45 mm free
travel at the pedal.
During assembly observe the following:
NOTE: Be sure to test drive the tractor to make
1. Be sure all components are free of dirt and foreign sure the braking action on both wheels is
matter and lubricate all components with clean equal. If necessary, adjust the outer brake
hydraulic oil on assembly. rod to equalize the free-play travel.
2. Install the oil seal at the steel face to outward.
2. Tighten the clevis locknuts securely.

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 6) Two Way Clutch Unit (3) Assembly
(SENSITRACK DISASSEMBLY) Reference – Figure 368X

(1) Disassembly 1. Install thrust washer ⑩, driven cam ⑨, compression

Reference – Figure 368X spring ⑧, and center cam ⑦, in the one-way clutch
assembly housing ⑪.
1. If installed remove the thrust washers ① and ②. 2. Install the keeper pins ⑥, in their recess on both sides
2. Remove the sleeve ③. of the housing and insert the drive cam ⑤, in position.
3. Remove the snap ring ④, and remove the drive cam ⑤, 3. Install the snap ring ④, so that the snap ring end gap is
keeper pins ⑥, center cam ⑦, compression spring ⑧, 90º from the keeper pins ⑥, as shown in Figure 369X.
driven cam ⑨, and thrust washer ⑩, from the two-way
clutch ⑪.

(2) Inspection and Repair

1. Inspect the shifter fork blocks. The blocks should be

smooth and free of any nicks or scratches. Minor nicks
or scratches can be removed using fine emory cloth on
a flat surface.
2. Inspect the drive cam, center cam, and driven cam
mating areas for excessive wear. Replace if found
defective.
3. Inspect all thrust washers for excessive wear and
replace if necessary.
4. Inspect the compression spring for distortion. Replace
as required.

369X

4. Install the sleeve ③, and thrust washers ① and ②.

368X

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 7) Differential Gear Unit

(1) Disassembly (2) Inspection

Reference – Figure 370X
1. Inspect gear teeth for excessive wear or damage.
2. Measure the thickness of the differential gear thrust
1. Remove the bearing ①, and shims ②. washers. Replace washers that exceed the minimum
2. Remove the ring gear tightening bolts ⑭, and ring gear thickness. See “Specifications”.
⑫. 3. Inspect the differential pinion shaft and gears for
3. Take out the thrust washer ④, and differential gear ⑤. excessive wear. See “Specifications”.
4. Remove the dowel pins ⑩, pinion shafts ⑦ and ⑨. 4. Inspect the drive pinion to ring gear tooth wear pattern.
5. Take out the pinion gears ⑥, thrust washers ⑧, joint See Figure 377X, for wear indications and shimming
⑪, differential gear ⑤, and thrust washer ④. adjustments.
5. Inspect the bearings for excessive wear or binding
when rotated by hand.

370X

Differential Gear Case Disassembly

1. Ball bearing 6. Gear 12. Ring Gear 17. O-Ring

2. Shim 7. Pinion Shaft 13. Bearing Holder 18. Spring
3. Differential Housing 8. Thrust Washer 14. Bolt 19. Roll Pin
4. Thrust Washer 9. Pinion Shaft 15. Differential Lock Clutch 20. Shifer Fork
5. Differential Gear 10. Dowel Pin 16. Diff-Lock Shaft
(Side Gear) 11. Joint

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 (3) Assembly

NOTE: When the drive pinion and ring gear are

reused, assemble using the same shims as
removed. When the drive pinion and ring
gear are replaced, adjust the shims as
described below. The ring gear and pinion
are serviced only as a matched set and
must be replaced together.

If the drive pinion and ring gear are replaced:

The drive pinion and ring gear are identified by an

assembly number which is stamped into the end of the
drive pinion gear and on the circumference of the ring gear. 371X
In addition, a “Value of Error” number is also stamped into Ring Gear and Pinion Tolerance Identification
the end of the pinion gear.
The tolerance value is no stamped when the tolerance is 1. Assembly Number and Tolerance “Value of Error”
zero. This number is prefixed with a (+) or (-) to indicate Number
the amount of error from zero adjustment. If the value of
error is greater on the new pinion than on the old pinion,
additional shims will be required. If the value of error is
less on the new pinion than on the old pinion, the number
of shims must be decreased.

Example:

Replaced pinion ·················································· -0.2 mm

New pinion························································· ±0.0 mm
-0.2 + 0.0 = -0.2
Decrease the shims by 0.2 mm

(4) Differential ring Gear and Pinion Assembly

1. Assemble the differential pinion shaft, pinion gears,

thrust washers dowel pins and side gears as shown,
Figure 370X.
2. Install the ring gear on the case and tighten new bolts
and additional lock washers to the specified torque.
3. Bend the tabs to secure the bolts.
4. If removed, install the two drive pinion bearings in the
housing.
5. Assemble the thrust washer, shims and pinion shaft
front bearing on the shaft. Insert the pinion shaft into
the housing from the front while installing the rear
bearing, fixed gear, washer and lock nut as shown.
372X

Differential Pinion Assembly

(Four Wheel Drive Shown)

1. Pinion Gear 5. Locknut

2. Shims 6. Thrust Washer
3. Bearings 7. Fixed Gear
4. Washer

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 6. Adjust the pinion bearing pre-load using a strong cord
wrapped around the pinion shaft and a pull scale.
Tighten the pinion nut to obtain the specified pounds
of constant pull to rotate the pinion assembly.

Tighten the locknut and crimp it at the ditch of the

pinion shaft.

Pinion bearing Pre-Load Constant Pull

196 N {20 kgf}

NOTE: Turn drive pinion several times by hand

before performing pull scale test.

373X
Pinion Pre-Load Adjustment

1. Pinion Shaft 3. Pull Scale

7. Install the right hand bearing carrier ①, and wheel 2. String
shaft assembly ②, to the front transmission housing.
8. Position the differential assembly ③, in the housing.

NOTE: When installing the original components,

use the same quantity and thickness shims
on each side as removed during
disassembly.

374X
1. Bearing Carrier 3. Differential Assembly
2. Wheel Shaft Assembly 4. Shims

9. Install the bearing ①, fixed gear ②, PTO shaft ③,

and bearing ④, in the housing.
10. Install the seal cover ⑤, with oil seal ⑥, and O-Ring
⑦, to the housing.

375X

1. Bearing 4. Bearing
2. Fixed Gear 5. Seal Cover
3. PTO shaft 6. Oil Seal
7. O-Ring

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 11. Install the left hand bearing carrier ①, differential
clutch ②, and fork ③, as a set.
12. Install the wheel shaft assembly.

NOTE: Use care the brake stater is easy fall in the

housing.

If new differential components are used, adjust the

backlash and ring gear contact pattern as follows:

Place a dial indicator gauge at a right angle to the top of

the ring gear teeth, Figure 376X from the hole of the seal
cover.
Rock the ring gear back and forth and observe the dial
indicator reading.

Adjust the shims to obtain the correct backlash.

See “Specifications.”
376X
Using Prussian blue on the pinion gear teeth, rotate the Ring Gear and Pinion Backlash Check
pinion gear and check the gear tooth pattern. Adjust the
differential and pinion shims to obtain the correct tooth 1. Dial Indicator 2. Ring Gear
contact.
13. Install the seal cover in the housing after inspect the
ring gear back lash.
14. Complete the assembly and installation following the
disassembly and removal procedure in reverse.

377X

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 (5) 4WD Control Spring

If removed spring from the 4WD change lever, use care to hook the spring at correct direction and position as shown Figure
378X.
If not correct hooking the spring, it will not be properly working the two way clutch assembly.

378X

1. Spring 3. Transmission Assembly

2. 4WD Change Lever

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 116

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 Chapter 4.
HST SYSTEM

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 1. OIL FLOW

1) Neutral Position

Fluid drawn from the transmission reservoir ⑪ is pressurized by the rotor type charge pump ①. The fluid flows from the
charge pump via the power steering control valve ④ and filter ③ to the feed(check) valve ⑨ and ⑤, and returns to the
sump via the charge pump relief valve⑦. The charge pump relief valve maintains 0.49 MPa {5 kgf/c ㎡} pressure to the
feed (check) valves 5 and 9, at all times. Fluid flow past the feed (check) valves pressurizes the passages “A” and “B” and
the pump ⑩ and motor ⑥ cylinder blocks. Because of equal pressures in passages “A” and “B” the motor does not
rotate.

400X

1. Charge Pump 8. Input Shaft

2. Filter 9. Feed (Check) Valve “A”
3. Filter 10. Hydrostatic Pump
4. Power Steering Control Valve 11. Reservoir
5. Feed (Check) Valve “B” 12. High Pressure Relief Valve
6. Hydrostatic Motor 13. Magnet
7. Charge Pump Relief Valve

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 2) Forward Position
When the foot pedal is shifted forward, the pump swash plate is tilted and a quantity of fluid is discharged from the piston
pump ⑩ into passage “A”. When the foot pedal is shifted further forward, increased fluid flows from piston pump ⑩
through passage “A”. Pump pressure on the back of feed (check) valve ⑨ closes the feed (check) valve and all fluid flow
from passage ”A” flows to the hydrostatic motor ⑥ causing the motor to rotate. Fluid is discharged from the hydrostatic
motor ⑥ at “A2” into passage “B2” flows back to the hydrostatic pump ⑩ to complete the cycle. When fluid leakage in
the system causes a drop in pressure on the suction passage “B” and the feed (check) valve ⑤ opens and provides
make-up fluid from the charge pump ①. Excess fluid from the charge pump ① is returned to the sump via the charge
relief valve ⑦ when above 0.49 MPa {5kgf/c ㎡}.

401X

1. Charge Pump 8. Input Shaft

2. Filter 9. Feed(Check) Valve “A”
3. Filter 10. Hydrostatic Pump
4. Power Steering Control Valve 11. Reservoir
5. Feed (Check) Valve “B” 12. High Pressure Relief Valve
6. Hydrostatic Motor 13. Magnet
7. Charge Pump Relief Valve

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 3) Reverse Position
When the foot pedal is shifted rearward, the pump swash plate is tilted in the opposite direction and a quantity of fluid is
discharged from the piston pump ⑩ into passage “B”. When the foot pedal is shifted further rearward, increase fluid flows
from the piston pump through passage “B”. Pump pressure on the back of feed (check) valve ⑤, close the feed (check)
valve and all fluid flow from passage “B” flows to the hydrostatic motor ⑥ causing the motor to rotate in the reverse
direction. Fluid is discharged from the hydrostatic motor ⑥ at “A2” into passage “A” flows back to the hydrostatic
pump ⑩ to complete the cycle.
When fluid leakage in the system causes a drop in pressure on the suction passage “A” and feed (check) valve ⑨ opens
and provides make-up fluid from the charge pump ①.
Excess fluid from the charge pump ① is returned to the sump ⑪ via the charge relief valve when above 0.49 MPa {5
kgf/c ㎡}.

402X

1. Charge Pump 7. Charge Pump Relief Valve

2. Filter 8. Input Shaft
3. Filter 9. Feed (Check) Valve “B”
4. Power Steering Control Valve 10. Hydrostatic Pump
5. Feed (Check) Valve “A” 11. Reservoir
6. Hydrostatic Motor 12. High Pressure Relief Valve

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 2. HST UNIT REMOVAL

403X

1. Suction Filter 7. HPL Supply Line 13. Cooler Return Line

2. Hydraulic Pump 8. Charge Pump Suction Line 14. HST Return to Sump
3. Foot Control Pedal 9. Hyd. Pump Supply Line 15. Power Steering Control Valve
4. Oil Cooler 10. Hyd. Control Valve 16. HST Supply Line (Hose)
5. HST Unit 11. Power Steering Supply Line 17. Power Steering Return Line
6. HST Filter 12. Cooler Supply Line

Separate the HST unit from the transmission housing after

separate the transmission assembly. See the “Chapter 3” , 2.
TRANSMISSION UNIT, 1) Removal.

NOTE: When separating the HST unit ① from

the transmission housing, be careful not to
lose the O-Rings ② and ③.

① HST Unit
② O-Ring
③ O-Ring

404X

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 If remove the HST unit only from the tractor, refer to as
follows:

1. Remove the eye bolt and return oil pipe ① from the
top of the HST unit.

2. Untighten the flare nut and disconnect the oil pipe ②

from the charge pump to power steering control
valve.

3 Use the two wrenches, and disconnect the feed hose

③ from top of the HST unit.

405X
4. Remove the split pin, washer and disconnect the
HST speed control rod ① from the HST control
lever.

5. Remove the U-nut, and remove the damper ② from

the HST control lever.

6. Unhook the spring ③ from under the HST speed

control lever.

406X

7. Disconnect the wire connector from the HST neutral

switch ①.

8. Remove the two bolts ② and remove the HST shift

guide ③ and shift arm ④ as a set.

407X

9. Remove the bolt ① from the universal joint ② and

disconnect the joint from the HST input shaft by slide
the joint to rear ward.

408X

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 10. Remove the eye bolt and clamp ① for the oil cooler
return pipe ② from the oil cooler.

409X

11. Untighten the hose band ③ and disconnect the

suction hose ④ for the hydraulic oil pump.

410X
12. Remove the bolts ② and suction pipe ① from the
HST unit and rear transmission housing.

13. Remove rear axle assembly, pipe and rear drive shaft,
see “REAR AXLE ASSEMBLY” of chapter 6.

14. Remove the rear frame from main frame and rear of
transmission, see “TRANSMISSION AND BRAKE”
of CHAPTER 3.

15. Install the special tool to HST return pipe attaching

hole with hoist.

410-1X

16. Remove the four bolts ① and remove the HST unit
② to slide the rearward and downward from the
transmission housing.

411X

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 3. PRECAUTIONS BEFORE DISASSEMBLY

1) Thoroughly clean the HST unit and plug all openings to prevent contamination from foreign particles.
2) Maintain a clean work area so as not to contaminate or damage any of the HST components.
3) Handle the HST components with care so as to not scratch or otherwise cause damage to the parts.
4) Drain the oil from the HST unit before disassembly.

4. DISASSEMBLY
Reference – Figure 412X

412X

1. Remove the socket head bolts (38), charge pump case (4) and O-Ring (49).
2. Remove the trochoid rotor assembly (25).
3. Remove the pin (34) from the drive shaft (7).
4. Remove the plate (87), O-Ring (45), and pin (86), from the port block (3).
5. Remove the socket head bolts (37), port block (3), and gasket (47).

NOTE: Take care do not fall down the valve plates (９and 10）.

6. Remove the valve plates（９and 10） from the port block.

7. Remove the cylinder block assembly (5) for the pump.
8. Remove the cylinder block assembly (2) for the motor.
9. Remove the swash plate (6) and take out the roller bearing (82), bush (35) and slide metal (24).
10. Remove the thrust plate (80) from the pump swash plate (6).
11. Remove the thrust plate (12) for the motor in the housing.
12. Remove the screws (61) and trunnion cover (57) from the housing.
13. Remove the snap ring (44) and trunnion shaft (15) from the trunnion cover (57).
14. Remove the screws (69), cover (21), O-Ring (46), and pins (39) from the housing.
15. Drive out the drive shaft (input shaft ) (7), by soft jawed hammer.
16. Remove the snap ring (41), from the housing.
17. Drive the screw driver to the seal cover (22), and remove the cover by lever. Discard the seal cover (22).
18. Remove the snap ring (41), from in the housing.
19. Drive out the transmission drive shaft ( input shaft ) (8), by soft jawed hammer.
20. Remove the plugs (29), springs (31), and check and relief valve assembles (26), from the port block.

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 5. INSPECTION

1. Piston assembly

● Replace the piston assembly if the play at the

caulked are as of the piston and shoe exceeds the
service limit.

Standard assembling value Service limit

0.03 mm 0.1 mm

413X
● Replace the piston assembly if the clearance
between the piston and cylinder block exceeds the
service limit.

Standard assembling value Service limit

0.02 mm 0.03 mm

414X

● Replace the piston assembly if the shoe thickness is

below the service limit.

Standard assembling value Service limit

3.00 mm 2.9 mm

415X
2. Charge pump assembly

● Measure the side clearance of the trochoid rotor

and replace if the service limit is exceeded.

Standard assembling value Service limit

0.025 mm 0.055 mm

3. Lapping distance should be less than 0.005 mm, if

each sliding surface is damaged, correct by lapping.
If the fault cannot correct by lapping, replace the
parts.

416X

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 6. REASSEMBLY

Before assembly refer to as follows:

1. Be sure all components are thoroughly cleaned and well coated with clean transmission fluid.
2. Replace the oil seal, O-Ring, gasket and seal cover with new one.
3. Apply the lithium grease to O-Ring and seal lip of oil seal.
4. Tighten the screw and bolt to specified torque.

7. ASSEMBLY
Reference – Figure 412X

1. If removed, install the bush (36) in the housing (1),

and it depth 10.7 mm from the trunnion cover
matching surface.

417X

2. Install the input shaft as follows:

● Install the bearing (19), on the shaft (8), and secure with snap ring (43).
● Install the shaft (7), in the housing and secure with snap ring (74).

3. Install the output shaft as follows:

● Install the bearing (19) on the output shaft (8) and secure with snap ring (43).
● Install the shaft (8) in the housing and secure with snap ring (41).
● Install the new case cover (22) in the housing (1) and secure with snap ring (41).

4. Install the cover as follows:

● Install the O-ring (46) and pins (39) on the housing.
● Install the oil seal (62) in the cover (21) and install them on the housing and tighten the bolt (69) to 17.2 N.m.

5. Install the thrust plate as follows:

● Align the thrust plate’s projection (12) for motor to housing’s ditch.

6. Install the swash plate as follows:

● Install the pins (40) and bush (35) and roller bearing (82) in the housing.
● Install the swash plate sub-assembly (consist of swash plate (6), guide assembly (83), pin (81) and thrust plate (80))
in the housing.
● Inspect the swash plate sub-assembly is moved to smoothly. If not smoothly moved it, check the roller bearing
position.

7. Install the cylinder block sub-assemblies (2 and 5) in the housing as follows:

● Apply the transmission oil to the thrust plate contact surface.
● The cylinder block for pump (2), is brass color of the cylinder block end and the cylinder block for motor (5) is a
gray color of the cylinder block end.

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 8. Install the port block sub-assembly as follows:
● Install the check and relief valve assemblies (26)
and springs (31) in the port block (3) and tighten
the plugs (29) to 63.7 N·m.
● Install the high pressure relief valve check port’s
plug (56) tighten to 29.4 N·m.
● Press in the oil seal (17) to 3mm depth from the
surface in the port block (3) and secure with snap
ring (42).
● Install the needle bearings (20) in the port block
with the marking surface to outside, and protrude
2.5 mm from the matching surface.
● If removed, install the dowel pins on the housing.
● Apply the grease to the spring and install it in the
housing.
● Install the gasket (47) on the housing.
● Apply the grease to the valve plates (9 and 10) and
low pressure relief valve (32) for prevent fall down
and install them to the port block.
● The notch side (V shape ditch) of the pump valve
plate (10), to against the cylinder block assembly. 418X
● The brass color surface of the motor valve plate (9) 3. Port Block 42. Snap Ring
to against the cylinder block assembly. 17. Oil seal
● Apply the mission oil to the cylinder block contact 20. Needle Bearing
surfaces and install the port block assembly (3) to
the housing and tighten the bolts to 49.0 ± 5 N·m.

9. Install the trunnion cover to the housing as follows:

● Install the slide metal (24) and position the pin hole
against the port block direction in the swash plate
sub assembly (6).
● Install the bearing (16) in the trunnion cover (57).
● Install the washer (18) in the trunnion cover.
● Install the oil seal (66) in the housing to 1 mm
depth from the cover surface.
● Install the trunnion shaft (15) in the cover and
secure with snap ring (44).
● Install the trunnion cover sub-assembly with align
the slide metal’s hole to trunnion shaft’s pin, and
tighten the screw to 6.9±0.7 N·m. 419X
10. Install the charge pump as follows:
● Install the O-Ring and pins to the port block.
● Install the plate (87) with the brass color surface to
against the charge pump.
● Position the pin (34) into the input shaft (7), and
install the trochoid rotor sub-assembly (25), on the
input shaft with align the punch marks (1) and pin
center (2).
● Install the new oil seal in the charge pump case and
secure with snap ring.
● Install the charge pump case sub assembly (4) with
align the pins, and tighten the bolts to 49.0 ± 5
N·m.
420X
11. Inspect the both shafts (7 and 8) are rotated smoothly
by adjustable wrench after assembled.

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 8. ADJUSTMENT

1) Link Adjustments

(1) Neutral Position Adjustment

1. Jack up the front and rear wheels off of the ground 4. If the wheels rotate at this time, loosen the bolt (1)
and place jack stands under the axles. and rotate the eccentric sleeve (2) until the wheels
Make sure all four wheels are clear of the ground stop and tighten the bolt, Figure 421X.
and the commercial mower is properly supported.
NOTE: Turning the control lever (3) clockwise will
2. Disconnect the wires from the seat neutral start cause wheels to rotate in forward and
switch and connect a jumper wire between the two turning counterclockwise the wheels will
harness leads. Apply the master brake pedal and rotate in the reverse direction.
start the engine, release the brake pedal.
5. Stop the engine and remove the jack stands.
3. Set the throttle at low speed and place the range Lower the wheels to the ground.
shift lever in the low range position.
6. Re-connect the seat neutral start switch wires.

7. While seated in the operators seat, start the engine

with the range lever in low range, and increase the
engine speed to full throttle. The commercial
mower should not move in either direction.

421X

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 (2) HST NEUTRAL SWITCH ADJUSTMENT

1. Adjust the HST neutral switch (1) after adjusted the neutral position. Untighten the lock nuts (2). Disconnect the
switch wires at the connector and connect the ohmmeter (3) leads across switch, and turn the switch (1) until the
switch become "ON" (continuity) position. Tighten the two lock nuts (2) and recheck the continuity test after move
the speed control rod (4) to forward and reverse several times.

422X

(3) HST SPEED CONTROL PEDAL POSITION ADJUSTMENT

1. Adjust the pedal height by lengthening or shortening the speed control rod (1). Untighten the two lock nuts (2), and
turn the rod (1) by wrench until the forward speed control pedal and reverse speed control pedal (3) are at the same
flat level (same angle from the floor). Tighten two lock nuts (2).

423X

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 2. Adjust the reverse speed control pedal stroke to 60 – 70％ of the forward speed control pedal stroke. Untighten the
lock nuts and adjust the stopper length by turn them as shown illustration.
Forward speed control pedal stopper length is about 20 mm.
Reverse speed control pedal stopper length is about 30 mm.

424X

425X

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 2) Pressure Checks

(1) HIGH PRESSURE RELIEF VALVE

1. Raise the front and rear wheels of the unit off of the
ground and support the axles with jack stands making
sure the wheels are clear of the ground.

2. Remove the plug from port “A”, Figure 426X and

install a 0 – 49 MPa {500 kgf/cm2} gauge and hose.

NOTE: Port “A” will check the high pressure relief

valve for forward travel and port “B” for
reverse.

3. Start the engine and place the range shift lever in high
range.

4. Depress the forward pedal a third of the way down.

426X
5. Increase the engine speed to full throttle.

6. Apply the master brake pedal and read the pressure

on the gauge.

NOTE: Measure the pressure reading in 2 – 3

seconds. The pressure reading must be 34.3
MPa {350 kgf/cm2}. If the pressure is not
within specifications replace the high
pressure relief valve.

7. Stop the engine and install the pressure gauge and

hose into “B” port, Figure 426X.

8. Install the plug to port “A”.

9. Depress the reverse pedal and master break pedal and

read the pressure. The pressure reading must be 49
MPa {500 kgf/cm2}. If pressure is not within
specifications replace the valve assembly.

(2) LOW PRESSURE RELIEF VALVE

1. Disconnect the oil hose ①, from the adapter.

2. Install the adapter ② and ③, and if necessary install

the adapter ④, to the adapter ②.

3. To check the low pressure relief valve, install a 0 –

3.0 MPa {0 – 30 kgf/cm2} pressure gauge to the
adapter.

4. Place the range lever and forward foot pedal in

neutral and start the engine.

5. Increase the engine speed to full throttle and read the

pressure. The low pressure relief setting is 71 psi.
(4.9 bar). If the pressure is low replace the valve (32),
and spring (33), Figure 412X. 427X

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 9. TROUBLE SHOOTING AND SPECIFICATIONS

1) Trouble Shooting

CONDITION POSSIBLE CAUSE REMEDY

1. Output shaft fails to rotate 1. Improper operation of HST Check the trunnion shaft movement and replace
when the HST pedal is set pump or motor. the assembly.
position. 2. Damaged charge pump Measure the charge pressure and replace the
assembly.
3. Charge pump pressure low. Check the low pressure circuit relief valve and
replace defective parts.
4. High pressure relief valve set too Check the high pressure circuit relief pressure.
low. Replace valve if necessary.
5. Defective HST check valve. Replace check valve and spring.
6. Low pressure relief valve set too Check the low pressure circuit relief valve.
low.
7. Air is mixture in the HST oil. Check the suction piping connection and
transmission oil level.
2. Output shaft fails to stop 1. Defective check and high Disassembly and clean. If condition still exists,
rotating with the HST pressure relief valve. replace valve.
pedal in the neutral 2. Linkage out of adjustment. Adjust linkage.
position. 3. Defective the seat of check and Replace the defective parts.
high pressure relief valve.
3. Low power and rpm of 1. Lack of oil in the HST circuit by Replace the oil filter.
output shaft clogged oil filter.
2. Air is mixture in the HST oil Check the suction piping connection and
circuit. transmission oil level.
3. Lack of charge pump capacity Warm up the tractor when too low oil temperature.
by abnormal oil temperature. Stop the engine until the oil temperature become
low when too high oil temperature.
4. High pressure oil leakage due to Wash oil circuit and replace the HST pump and
wear of the pump and motor motor assembly.
assembly.
4. Abnormal sound from the 1. Sucked air in the HST circuit. Check the suction piping connection and
HST transmission oil level.
2. Lack of oil in the HST circuit by Replace the oil filter.
clogged oil filter.
3. Lack of charge pump capacity Warm up the tractor when too low oil temperature.
by abnormal oil temperature. Stop the engine until the oil temperature become
low when too high oil temperature.
4. High pressure oil leakage due to Wash oil circuit and replace the HST pump and
wear of the pump and motor motor assembly.
assembly.
5. Linkage out of adjustment. Adjust linkage.
5. Oil leaks at shaft and seal. 1. Oil leakage due to damaged oil Replace damaged seal or O-ring.
seal or O-ring.
2. HST case internal pressure too Check for worn piston pump or motor and replace
high. if necessary. Case pressure should not exceed 1
MPa {1.0 kgf/cm2}.
3. HST case oil return tube to front Remove and check tube for restrictions.
case plugged.

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 2) Specifications

MODEL CM284 and 364

HST TRANSMISSION

Type ····················································································································· HVFD-18A18-M

Input Speed ················································································································ 0 – 3200 rpm
Output Speed ·············································································································· 0 – 3000 rpm
Swash Plate Tilt Angle ········································································································· 0 – 16º
High Pressure Relief Valve ······································································· 34.3 MPa {350 kgf/cm2}
Charge Pump Pressure ·················································································· 0.49 MPa {5 kgf/cm2}
Case Pressure ················································································0.096 MPa {0.98 kgf/cm2} Max.
Pump Capacity – Variable Type ··············································································· 0 – 18.2 cc/rev.
Motor Capacity········································································································ 0 – 18.2 cc/rev.
Charge Pump Capacity ··································································································· 4.9 cc/rev.

BOLT TORQUES

Swash Plate Covers ···································································· 6.2 – 7.6 N·m {0.63 – 0.76 kgf·m}
Charge Pump Case Screws······························································· 44 – 54 N·m {4.5 – 5.5 kgf·m}
Relief Valve (High Pressure) Check Plug ······················································· 29.4 N·m {3.0 kgf·m}
Check and High Pressure Relief Valve’s Plug ················································· 63.7 N·m {6.5 kgf·m}
Port Block Screws ··········································································· 44 – 54 N·m {4.5 – 5.5 kgf·m}

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 134

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 Chapter 5.
POWER STEERING

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 1. OIL FLOW

Pressurized oil from the HST charge pump flows to the power steering motor and HST transmission. During a turning cycle,
pressurized oil is directed to the steering cylinder for right or left turns.
Return oil from the power steering cylinder is directed by the steering control valve to the HST transmission. The relief
valve in the steering motor protects the system from over loading.

500X

1. Filter 4. Cylinder
2. Charge Pump 5. HST Unit
3. Steering Motor 6. Oil Filter

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 1) Neutral Operation

Pressurized oil from the HST charge pump enters the valve body at port “P” . The oil flows through the check valve (7) past
the relief valve (3) and through the radial holes in the valve spool (1). In the neutral position, the oil flows through the
hollow spool and returns to the HST unit via port “T”.
Passage to ports “L” and ”R” leading to the cylinder are blocked by the spool and sleeve. Oil contained in the tubes and
cylinder is trapped and the cylinder remains in a fixed position. In this position the front wheels hold at a same condition.
The system is fully hydraulic and as such there is no road feel or front wheel reaction transmitted to the steering wheel.

501X

1. Spool 4. Oil Tank 7. Check Valve – Kick Back

2. Sleeve 5. Oil Pump
3. Relief Valve 6. Steering Cylinder

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 2) Left Turning

Turning the steering wheel to the left rotates the valve spool and indexes the grooves in the spool with holes in the sleeve so
that oil from the pump flows through the spool and sleeve and enters the Gerotor gear pump . Since the Gerotor pump is
being turned counterclockwise , the oil flows through the valve body to the port “L”. From port “L” the pressurized oil
flows to the piston side of the power steering cylinder and causes the front wheels to turn left.

502X

1. Relief Valve 4. Steering Cylinder

2. Oil Pump 5. Gear Pump (Gerotor pump)
3. Oil Tank 6. Check Valve – Kick Back

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 3) Right Turning

Turning the steering wheel to the right rotates the valve spool and indexes the grooves in the spool with holes in the sleeve
so that oil from the pump flows through the spool and sleeve and enters the Gerotor gear pump . Since the Gerotor pump is
being turned clockwise , the oil flows through the valve body to the port “R”. From port “R” the pressurized oil flows to the
rod side of the power steering cylinder and causes the front wheels to turn right. The oil contained in the piston side of the
cylinder is forced out and returns to the control valve “L” port and is directed back to the reservoir through port “T”.

503X

1. Relief Valve 4. Steering Cylinder

2. Oil Pump 5. Gear Pump (Gerotor pump)
3. Oil Tank 6. Check Valve – Kick Back

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 4) Manual Operation

In the event of a power steering pump failure or loss of oil pressure, the power steering system can be operated manually. In
this case, turning the steering wheel drive the Gerotor gear pump to force oil into the power steering cylinder to whichever
side of the cylinder required as directed by the rotation of the steering wheel. On the suction side of the Gerotor pump,
return oil flows from the cylinder and is drawn through the check valve (7) to feed the Gerotor. When additional oil supply
is required, as in making a left turn, make-up oil from the valve (7) to feed the Gerotor pump.

504X

1. Relief Valve 4. Steering Cylinder 7. Check Valve

2. Oil Pump 5. Gear Pump (Gerotor Pump)
3. Oil Tank 6. Check Valve - Kick-Back

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 2. CONTROL VALVE ASSEMBLY

1) Removal
1. Disconnect the negative battery cable from the
battery post.
2. Pull the light musk ① to front ward and
remove the bolts ⑥ and lower cover ② from
the floor.
3. Disconnect the four oil pipes ③ from the
control valve.
4. Remove the four bolts ④ and control valve ⑤
from the frame.

505X

2) Disassembly
Reference – Figure 507X.

1. Place the control valve upside down in a vise, and remove the retaining bolts (22) and check valve retainer bolt
(23).

NOTE: Use soft metal jaws on the vise and apply only enough pressure to support the valve assembly. Do not
over tighten or the valve body may become distorted and permanently damaged.

2. Remove the end cap (21), seals (20) and O-Ring (16).
3. Remove the Gerotor gear pump (19) and O-Ring (16).

NOTE: The inner rotor separates easily from the outer pump body rotor. Use care in handling to prevent
damage to these components.

4. Remove the second large O-Ring (16).

5. Remove the drive shaft (18), spacer plate (17) and third large O-Ring (16).
6. Remove the check ball (24).
7. Remove the retaining ring (2).

NOTE: Remove the valve from the vise and

place on a clean lint-free shop towel.
Use care in handling the valve parts
so as not to mar or damage the
precision finishes.

506X

8. Rotate the spool and sleeve to position the pin horizontally. Gently push on the bottom end of the spool and
sleeve forcing the gland (3) out of the valve body.
9. Separate the seals (1) and (5) from the gland (3).
10. Remove the thrust bearing (7) and two bearing races (6).
11. Remove the spool and sleeve as an assembly (13), (14) and (15).
12. Remove the pin (14).

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 13. Push the spool upward out of the sleeve slightly and remove the centering springs (11) and (12).
14. Remove the spool from the bottom side of the sleeve.

NOTE: rotate the spool while pushing it out of the sleeve to prevent binding.

507X

1. Seal-Dust 8. Relief Valve 13. Sleeve 20. Seal Assembly

2. Retaining Ring Assembly 14. Pin 21. End Cap
3. Seal Gland 9. Body 15. Spool 22. Bolts
4. O-Ring 10. Connector 16. O-Rings 23. Check Ball and
5. Oil Seal 11. Centering Spring 17. Spacer Plate Retaining Bolt
6. Bearing Race (Curved) 18. Shaft 24. Ball (Check)
7. Bearing 12. Spring (Flat) 19. Gerotor Pump

3) Inspection
1. Inspect the spool and sleeve for evidence of sticking, scuff marks and any damage. If defective, replace the spool
and sleeve as a matched set.
2. Upon disassembly, replace all seals and O-Rings with new.

4) Assembly
1. Insert the spool in to the sleeve while slowly rotate the spool.

NOTE: Bring the matching marks into register to align the centering spring slots.
Check to be sure the spool rotates freely within the sleeve.

2. With the spring slots lined up insert the special tool in the slots.

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 3. Position the combination of centering springs into the groove of the installer.

NOTE: The springs are arranged with 2 flat springs in the center and 2 curved spring on each side with
the convened side facing the flat spring. Be sure the notched edges of the spring face downward.

4. While gripping the outer end of the spring combination and maintaining pressure against the tool, slide the tool
out of the assembly leaving the springs positioned in the slots.

NOTE: Positioning the spool in a slightly higher than normal position in the sleeve will facilitate this
assembly operation.

5. position the spool and sleeve so that their ends are flush.
6. Install the pin (14) marking its end flush with the sleeve surface.
7. Insert the spool and sleeve assembly into the valve body for the bottom. Position the assembly so that the end is
flush with the valve body.
Check the sleeve rotation to be sure it rotates freely in the housing bore.
8. Install the O-Ring (4) into the valve body.
9. Position the thrust bearing assembly in the bore making sure it seats firmly on the sleeve and spool.
10. Install the dust seal (1) to the gland (3) bushing.
11. Install the oil seal (5) to the gland . Be sure the seal is not cocked in any way.
12. Position the gland assembly in the bore being sure its outer end face is parallel with the valve body end face.
13. Install the retaining ring in the valve body groove.
14. Position the valve body in a soft jawed vise to support the assembly. Do not over grip the valve body as it will
distort the valve body and cause permanent damage to the unit.
15. Position the check ball (24) in to the retainer bolt bore.
16. Position the spool and sleeve assembly so that it is slightly below the bottom face of the valve body.

NOTE: Be sure the matching surface of the components are clean and free of dart and lint.

17. Install the O-Ring (16) and position the spacer plate (17) on the valve body being sure to match the bolt holes and
ports to that of the valve body.

18. Rotate the spool and sleeve to position the pin

slots parallel with the valve body port face.
19. Scribe a reference mark on the splined end of the
drive shaft parallel to the pin slot as shown.
20. Position the drive shaft in the valve
body engaging the slot with the pin.

1. Reference Scribe Mark

2. Pin
3. Drive Shaft

508X

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 21. Install the O-Ring and seal (20) on the rotor (19).

NOTE: Apply a grease type lubricant to the

face of the rotor to make the O-ring
and seal adhere to the rotor surface.

22. Position the rotor in the pump ring and install the
O-ring (16) in the pump groove.
23. Position the gerotor pump assembly onto the
valve body with the seal side up. Align the drive
shaft reference line with a diametrical line
running through the center of the pump gear
valleys as shown.

NOTE: It is important that the pump drive

shaft , gear lobes and valve ports are
in the correct relationship for proper
valve timing as described above and
reference in the parallel lines A, B,C 509X
and D.
A. Gear Lobe Reference
B. Drive Shaft Reference Mark
C. Drive shaft Pin Location
D. Port Face Reference

24. Install the O-ring (16) onto the end cap (21) and
position the assembly on the valve body.
Align the bolt holes and install the retaining
bolts (22).

NOTE: Lubricate the bolt threads and

tighten to specified torque in two
steps to maintain equal pressure on
the valve body. Tighten the bolts in
the sequence as shown.

Tightening torque-----20 N·m {2kgf·m}

Recheck the valve spool to be sure it rotates

smoothly without binding. 510X

25. Install the connector fitting (10) in the valve

pressure port and tighten to the specified torque.

Tightening torque-----69±9 N·m {7±0.9 kgf·m}

26. Install the control valve assembly on the tractor

and complete the assembly following the
removal procedures in reverse.

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 5) Pressure Testing

1. With the tractor engine stopped, disconnect one

of the hydraulic lines which run to the steering
cylinder.
2. Connect the pressure gauge to the end of the line
from the steering control unit and cap the line
leading to the steering cylinder.
3. Start the tractor engine, and allow it to idle.
Observe the gauge, is should read at 0 or near 0
MPa {0 kgf/c ㎡}.
4. Turn the steering wheel so that the line which the
gauge is connected to receives pump oil intended
for the steering cylinder. For instance, if the
gauge is connected to the left side of the cylinder 511X
(as viewed from the operator’s seat) , turn the
steering wheel to the clockwise. Observe the
gauge reading. (Engine speed at approx. 3200
rpm)

● Test results

1. If the pressure gauge reading rises before the steering wheel is turned, it indicates that steering control valve
timing is off and the steering unit will have to be disassembled and inspect.
2. If the pressure gauge reading rises to the relief valve setting 5.9 – 6.6 MPa {60 – 67 kgf/c ㎡} when the steering
wheel is turned, it indicates the pump and relief valve are working properly.

3. POWER STEERING CYLINDER

1) Removal
1. Disconnect the steering hoses to the power
steering cylinder and cap all openings.
2. Remove the cylinder from the tractor.

NOTE: Do not disassemble the power

steering cylinder assembly. If oil
leaking and /or trouble is evident
from cylinder assembly, replace the
cylinder assembly.

513X

2) Inspection
1. Inspect the anchor pins and bushings for excess
wear and excessive clearance. Replace cylinder
assembly and/or pins if the clearance is over 0.5
mm.

517X

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 3) Installation

1. Install the cylinder on the tractor.

2. Connect the power steering hoses to the adapter and tighten to 19.6 – 29.4 N·m {2 – 3 kgf·m}.
3. Start the tractor, operate the steering system, and check for any leaks.

4. PIPING
Replace the oil hoses and pipes if cracks, oil leakage, or other damages are noticed.
Any time a seal is broken, always use sealing tape on the tube fittings to ensure a tight non-leak fit, and torque the fitting to
the specified torque. Don’t taping at the flare nut fitting.

NOTE: When winding seal tape on the thread, be careful not to allow the tape to flow into the hydraulic piping.
Be careful to keep oil hoses and oil pipes off other part. Fix clamps securely.

1) Tightening Torque of Piping

520X

1. Flare nuts of oil pipe for charge pump to steering motor : 29.4 – 39.2 N·m {3 – 4 kgf·m}
2. Flare nuts of oil pipes for steering motor to power steering cylinder “L” and “R” port : 29.4 – 39.2 N·m {3 – 4
kgf·m}
3. Nuts for oil hose to power steering cylinder ”L” and “R” port : 19.6 – 29.4 N·m {2 – 3 kgf·m}
4. Flare nuts of oil pipes for steering motor to HST oil filter : 39.2 – 49.0 N·m {4 – 5 kgf·m}
5. Banjo bolt of oil pipe for steering motor to HST oil filter : 44.1 – 53.9 N·m {4.5 – 5.5 kgf·m}
6. Nuts of oil hose for HST oil filter to HST unit : 29.4 – 39.6 N·m {3 – 4 kgf·m}

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 5. TROUBLE SHOOTING

Most malfunctions in the steering system can usually be 1. Check the pump for proper relief valve action. See
traced to dirt or foreign matter in the system. Dirt can “Pressure Testing”, discussed in this section.
cause such things as stickiness, erratic operation, or hard 2. Jack the rear end of the tractor off the ground and
steering. cycle the steering from stop to stop to check for rear
axle binding.
Before considering the procedures below, follow these 3. Be sure the hydraulic hoses from the
suggested steps: pump-to-control valve and from the control
valve-to-cylinder are hooked up correctly.

NOTE: If the steering system oil continues to overheat above 200º (93ºC), seals in the system can shrink, harden
or crack thus losing steering ability.

CONDITION POSSIBLE CAUSE CORRECTION

Clicking noise 1. Steering components loose and Check and correct.
shifting under load.

Steering wander 1. Tire pressure incorrect. Check tire pressure.

2. Worn tie rod ends. Replace.
3. Steering column shaft binding. Remove and correct.

High steering effort 1. Low pressure. Check pressure.

2. Steering motor binding. Check and repair.

Excessive heat 1. Kinked hose. Check hose routing.

2. Bent tubes. Check tubes.
3. Restricted re-centering of steering Repair as necessary.
motor.

Hard Steering 1. Lack of transmission oil. Fill the transmission oil.

2. ORBITROL (control valve unit) Reposition ORBITROL. (If loosening

(1) ORTITROL not aligned to its mounting bolts lightens the
steering column. handwheel, it means that ORBITROL
was in misalignment).

(2) Spool-and-sleeve combination is Replace.

seized because of foreign matter.

(3) Over tightening of the end cap Re-tighten to the specified torque limit.
bolts.

3. Oil pump (HST Charge Pump)

(1) The pump is stuck and will not Replace oil pump. (HST Charge Pump)
work.

(2) The pump is worn down. Replace oil pump. (HST Charge Pump)

(3) Pumping performance Test pump performance and, if

inadequate. necessary, remove the pump.
Disassemble the pump and replace the
internal seals.

4. Relief valve
(1) The valve is damaged because Replace control valve assembly.
of internal deterioration.

(2) Pressure setting is too low. Replace control valve assembly.

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 CONDITION POSSIBLE CAUSE REMEDY
Steering wheel will not return to neutral 1. ORBITROL
or will turn by itself.
(1) Spool and sleeve combination is Replace control valve assembly.
stuck and will not rotate.

(2) ORBITROL not aligned to Re-align.

steering column.
Cylinder will not follow steering wheel 1. ORBITROL
rotation or will respond sluggishly.
(1) ORBITROL has been Repair.
improperly rebuilt, resulting in
valve mistiming.

2. Steering cylinder

(1) Air is trapped in the cylinder. Bleed air out.

(2) Internal oil leakage because of Replace the seal.

damaged piston seal.
Steering wheel will “kick back" 1. ORBITROL

(1) ORBITROL has been Repair.

improperly rebuilt, resulting in
valve mistiming.
2. Piping

(1) Pipes are improperly connected Correct the pipe connections.

to the four ports of ORBITROL.
Oil leakage

1. From the splined connection of 1. Leaky oil seal Replace the seal.
column to spool.
(1) Dirty hydraulic oil. Change the oil.

2. From mated face joints (valve 2. Damaged O-Ring. Replace.

body, spacer plate, ORBITROL,
end cap).
Stiff or Jerky Steering Action 1. Worn or damaged bearings Inspect and repair.

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 Chapter 6.
REAR AXLE ASSEMBLY

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 1. DESCRIPTION AND OPERATION
The four -wheel drive rear axle is supported by an axle
pivot pin at the rear of the frame.

Range Selector Lever and Four-Wheel Drive (FWD)

Selector Lever are activated by the same lever.
The range selector lever is on the left side of the seat, can
be shifted when the HST foot pedal is in the Neutral
position to select, High range, Low range or Neutral.

● When the lever is located in the position of Range

Selector Lever, the tractor will run in Automatic
mode.

● When the lever is brought to the outer slot, the

tractor will run in Permanent FWD mode.

NOTE: When tractor is in Permanent FWD mode,

only low range is engaged.

600X
1. Ranger Selector Lever

The four-wheel drive output shaft (1) in the range gear box
is contained in a two way clutch assembly (4).
The two way clutch assembly (4) is installed on the front
wheel drive pinion (2). During operation, placing the lever
into the Automatic four wheel drive position will
automatically give the operator full four-wheel drive when
the front wheels lose traction.
Since the rear wheel drive axle gears rotate slightly faster
than the range gears in the transmission, the four-wheel
drive output shaft (1) is free to rotate within the two way
clutch (4).
When one of the front drive wheels starts to spin, the
two-way clutch applies and sends power to the rear wheels
thus giving the operator automatic four-wheel drive.
601X

1. Four-Wheel Drive 3. HST Unit

Out put Shaft 4. Two-Way Clutch Assembly
2. Drive Pinion Shaft 5. Input Shaft

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 602X

1. Engine 5. Two-Way Clutch 8. Drive Pinion 11. Reduction Case

2. HST Unit 6. Permanent FWD 9. Differential Gear 12. Tie Rod
3. Range Slide Gear Shifter Fork Assembly 13. Wheel Shaft
4. Drive Pinion 7. Rear Wheel Drive Shaft 10. Drive shaft

2. REAR AXLE REMOVAL

1. Disconnect the power steering oil pipes from the
power steering cylinder.
2. Place the safety stands under the main frame.
3. Remove the rear axle bearing holders from the
frame ,and remove the rear axle assembly.
4. If necessary ,remove the pipe, drive shaft and
coupling from the transmission.

603X
1. Oil Pipe 3. Rear Axle
2. Bearing Holder Assembly

3. INSTALLATION
Installation generally follows removal procedure in reverse, however the following must be observed:
1. Replace cracked or damaged hoses.

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 4. DISASSEMBLY

Reference Figure 604X.

1. Remove the rear axle as outlined above and then remove the power steering cylinder (1), wheels (2) and tie rod (3)
from the rear axle assembly.
2. Remove the outer case cover (4) and bevel gear (5) as an assembly.
3. Remove the bolts (6), arm (7) and king pin (8).
4. Remove the final case (9), final pinion (10) and drive shaft (11) to downward.

NOTE: If necessary, remove the seal (12) and bearing (13) from the case.

5. Remove the bolts (14) and remove the idler gear case (15) assembly.
6. Remove the snap ring (16), bearings (17) and idler bevel gears (18) from the idler gear case (15).

1. Power steering cylinder 6. Bolt 11. Drive shaft 16. Snap ring
2. Rear wheel 7. Arm 12. Seal 17. Bevel gear
3. Tie rod 8. King pin 13. Bearing
4. Outer case cover 9. Final case 14. Bolt
5. Bevel gear 10. Final pinion 15. Idler gear case
604X

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 Reference – Figure 605X.
7. Remove the bolts (1) on the right side housing and remove the housing (2) and drive shaft (3) as an assembly.

NOTE: Note the total amount of the shims (3) and thickness used between differential bearing (4) and right axle
housing (2).

8. Remove the differential assembly (5) from the left axle housing (6).
9. Remove the bearing holder (7). Remove the lock nut (8) and pry the oil seal (9) and discard.
10. Remove the snap ring (10) and draw out the drive pinion (11), collars (12 and 13) and bearings (14 and 15) as a set.

NOTE: If necessary, remove the bearings (14 and 15), collars (12 and 13), O-ring (17) and spacer (16) from the
pinion shaft (11).

605X

Reference – Figure 606X.

11. Remove the bearing (1) and final gear (2) .
12. Remove the snap ring (3) and drive out the wheel
shaft (4) from the case cover (5).
13. If necessary, remove the oil seal (6) and bearing (7)
from the case cover (5).

606X

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 14. Remove the bolts (11) from the ring gear (2), and
remove the gear, side cover (3), thrust washer (7) and
side gear (5).
15. Remove the pinion shaft (8), pinions (6), thrust
washer (7) and the opposite side gear and thrust
washer.

5. INSPECTION
1. Wash all parts in a suitable solvent and air dry.
2. Check the bearings for discoloration and wear.
3. Discard all seals and O-rings.
608X
4. Check all gears for wear, chips or broken teeth.
5. Measure the thickness of the thrust washers (4). 1. Bearing (6207) 7. Thrust Washer
Replace the thrust washers if thickness is less than
2. Ring Gear 8. Shaft
0.9 mm. 3. Side Cover 9. Case
6. Measure the thickness of the thrust washers (7). 4. Thrust Washer 10. Bearing (6009)
Replace the thrust washers if thickness is less than
5. Side Gear 11. Bolt
0.9 mm. 6. Pinion
7. Measure the outside diameter of the pinion
shaft (8) and inside diameter of the pinion gears (6).
Replace the pinion or gear if clearance is more than
0.5 mm.

8. Measure the outside diameter of the pivot shaft (1)

and inside diameter of the bushings (2).
Replace the pivot shaft or bushing if clearance is
more than 0.3 mm.

609X

1. Pivot Shaft 2. Bush

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 6. ASSEMBLY
Assembly generally follows disassembly procedures in
reverse however the following must be observed:

1. Remove the oil completely from the ring gear thread

and ring gear bolts before reassemble.
2. Coat all ring gear to differential housing bolts with
Locktite sealant and torque to 24 – 30 N·m {2.5 – 3.0
kgf·m}.
3. Install the bearings (2 and 3) and collar (4) on the
pinion shaft (1), and install a new O-ring (5).

1. Drive Pinion Shaft 4. Collar

2. Bearing 5. O-ring
3. Bearing
610X

4. Install the drive pinion (1) as a set and spacer (2)

secure with snap ring (3) in the left axle housing (4).
5. Install the new oil seal (5) in the left axle housing.
6. Install the collar (6) on the drive pinion shaft.
7. Install the lock nut (7) and tighten to 65.7 – 83.3N·m
{6.7 – 8.5 kgf·m}. Stake the nut to the pinion shaft
groove.

611X
1. Drive Pinion Shaft 5. Oil Seal
2. Spacer 6. Collar
3. Snap Ring 7. Lock Nut
4. Left Axle Housing

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 8. Adjust the ring gear to pinion backlash as follows:

● With the drive pinion and left axle installed, place

the differential assembly into the housing.
Measure the distance “A” from bearing to the
housing.
● Measure the depth of the right hand axle housing
“B” from the housing to the bottom of the bearing
bore.

● Select shims so that measurement “A” equals

measurement “B”.
612X
For example: If measurement “B” is 20.5 mm. and
measurement “A” is 20.0 mm, the difference is 0.5
mm.
Place the selected shim(s) into the right axle
housing (1) prior to assembly. This procedure will
give you the collect ring gear to pinion backlash.

7. INSTALLATION
Installation generally follows removal procedure in reverse
however, the following must be observed:
Adjust the toe-in (A - B) with the tie rod to 5 mm.
Fill the rear axle to the level plug with gear oil.

613X

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 Chapter 7.
HYDRAULIC LIFT
SYSTEM

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 1. DESCRIPTION AND OPERATION

The hydraulic system consists of a filter, hydraulic pump, oil cooler, control valve, weight transfer valve, lift cylinders,
tubing, restriction valve and lift arms.
The oil pump is a gear type which is installed on the engine timing gear case.
The control valve consists of a body, valve spool, weight transfer valve, relief valve and float detent assembly.

700X

1. Oil Filter 5. Lift Cylinders

2. Oil Pump 6. Lift Arms
3. Control Valve 7. Cooler
4. Weight Transfer Valve Grip 8. Transmission Reservoir

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 2. OIL FLOW

1) Neutral Position

Pressurized oil flows to enters the “P” port of the control valve. The oil flows through a passage in the spool and is directed
to the “T” port and then to the cooler and transmission. The oil in the lift cylinders port “A” is trapped by the spool and
holds the lift arms in a constant position.

⑦ ⑩

⑥ ④
⑨

⑪ ⑧
③

②
①

701X

1. Oil Filter 5. Restriction Valve 9. Spool

2. HST Unit 6. Lift Cylinder 10. Control Lever
3. Oil Pump 7. Weight Transfer Valve 11. Relief Valve
4. Control Valve 8. Oil Cooler

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 2) Raising Position
When the control valve lever is moved to the raise position (in), the pressurized oil from “P” port flows to A1 and is
directed to the lift cylinder rods side “A” and raises the lift arms. Oil on the piston side “B” is directed to the transmission.
Holding the lift lever in the raised position, with the lift arms fully raised, will cause the relief valve in the control valve to
open and direct the oil to the cooler circuit.

702X

1. Oil Filter 5. Restriction Valve 9. Spool

2. HST Unit 6. Lift Cylinder 10. Control Lever
3. Oil Pump 7. Weight Transfer Valve 11. Relief Valve
4. Control Valve 8. Oil Cooler

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 3) Lowering(Float) Position
When the control lever is moved to the lowering position pressurized oil enters port “P” and is directed to “B1” port. Oil
from “B1” port flows to the weight transfer valve and via the cooler to the transmission.
At the same time oil in port “P” is fed oil from the rod side of the lift cylinders port “A” by the weight of the implement.
The oil then flows through a passage to “B1” port and through the weight transfer valve to the transmission and the
implement lowers.
Turning the adjuster in on the weight transfer valve will reduce the flow rate, and the pressure in the lift cylinder ”A” side
can be changed to reduce the weight of the implement on the gauge wheels. The weight transfer valve contains a drilled
passage to allow oil to flow if the knob is fully closed.

703X

1. Oil Filter 5. Restriction Valve 9. Spool

2. HST Unit 6. Lift Cylinder 10. Control Lever
3. Oil Pump 7. Weight Transfer Valve 11. Relief Valve
4. Control Valve 8. Oil Cooler

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 3. OVERHAUL

1) Control Valve

(1) Removal

1. Remove the R.H. side cover.

2. Remove the weight transfer valve grip.
3. Remove the eye bolt (1) from bottom of the control
valve (4).
4. Disconnect the oil hoses (2 and 3) from under the
control valve.
5. Drive out the roll pin (5) from the spool.
6. Remove the snap pin and pin (6) and separate the
control lever (7) from the control valve.

(2) Disassembly
Reference – Figure 705X
704X
Repair of hydraulic control valve is limited to seal 1. Eye bolt 5. Roll Pin
replacement only. 2. Oil; Hose 6. Pin
1. Remove the bolts (1) and pull the cap (3) and spool 3. Oil Hose 7. Control Lever
(2) with plate (11) as an assembly. 4. Control Valve 8. Bolt
2. Place the control end of the spool in a vice and
remove the snap ring (4).

NOTE: Do not expand the snap ring to far. The

snap ring will become deformed and will
not hold during assembly.

3. Using care not to lose balls (7 and 8), remove the

holders (6) and spring (9) from the spool.

NOTE: Do not remove the stopper (15), spring and

seat from the spool.

4. Remove the sealing plate (11), wiper (12), spacer

(13) and O-ring (14) from the valve body.
705X
(3) Inspection
1. Bolt 9. Spring
1. Wash all parts in a suitable solvent and air dry. 2. Spool 10. Bolt
2. Discard all O-rings and seals. 3. Cap 11. Plate
3. Inspect the control valve spool and valve body bore 4. Snap Ring 12. Wiper
for any damage. If either is defective , replace the 5. Valve Body 13. Spacer
control valve assembly. 6. Holder 14. O-Ring
7. Ball 15. Stopper
8. Ball 16. Lever Support

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 5. If necessary, remove the relief valve assembly (1) as
a set.

NOTE: Do not disassemble the relief valve

assembly.

6. If necessary, remove the weight transfer valve

assembly (2) as a set.

706X
1. Relief Valve Assembly
2. Weight Transfer Valve

(4) Assembly

Prior to assembly coat the valve body bore and spool with
clean hydraulic oil. Assembly of the control valve
generally follows disassembly procedures in reverse,
however the following must be observed:

● Coat all steel balls during grease.

● Install the snap ring (1) with the rounded edge
facing the cap.
● Tighten the sealing plate bolts (10) to 5.5 N·m
(0.55 kgf·m) and check the spool for smooth
operation, Figure 705X.

707X

2) Remote Valve

On units equipped with a remote valve the repair procedure are the same as the control valve.
The remote valve does not utilize a detent (float) position and it is not equipped relief valve assembly and weight transfer
valve assembly. The single action changeover control valve is equipped on the remote valve.

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 3) Lift Cylinder
(1) Removal

1. Remove the both side panels.

2. Place the stands under the tractor and remove the front wheels.
3. Disconnect the high pressure oil hose (1) from the adapter.
4. If necessary, remove the adapter (3) from the cylinder (4) and un-tighten the hose band, and disconnect the breeze
hose (5) from the adapter.
5. Remove the bolts (6) and pins (7), and remove the cylinder (4) from the frame while supporting the lift arms.

NOTE: Do not disassemble the lift cylinder

assembly. If oil leaking and/or trouble is
evident from cylinder assembly , replace
the cylinder assembly.

(2) Inspection 708X

1. Inspect the anchor pins and bushings for excess wear

and excessive clearance. Replace cylinder assembly
and/or pins if the clearance is over 0.5 mm.

709X

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 (3) Pressure Test

1. Remove the side cover and front R.H. wheel.

2. Disconnect the high pressure hose from the adapter.

712X

3. Install the fitting (ISM Part No. 340630260) and 0 –

19.6 MPa {0 – 200 kgf/cm2} pressure gauge to the
high pressure oil hose to the cylinder.
4. Start the engine, and allow it to idle.
Observe the pressure gauge, it should indicate 0 MPa
{0 kgf/cm2}.
5. Push the hand throttle lever to forward and keep the
engine high idle speed.
6. Pull the lift control lever to rearward and read the
pressure gauge immediately.
7. Stop the engine.

TEST RESULT
If pressure rises to the relief valve setting to 9.8 MPa {100
kgf/cm2}, it indicates that the system is operating properly.
713X

1. High Pressure 3. Oil Pressure Gauge

Oil hose
2. fitting (340630260)

NOTE: If removed restriction valve, use care at the

direction of it.
The orifice toward the cylinder.

714X

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 166

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 Chapter 8.
IMPLEMENT DRIVE

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 1. DESCRIPTION AND OPERATION
The implement drive is helical gear driven and wet disc clutch is engaged by a PTO lever on the right side adjacent to the
operator’s seat.
When the PTO lever (1) is moved to the engaged position. It contacts shaft (2) , fork joint assembly (3) and turn the lever
(4) of PTO clutch shaft.
The clutch fork (5) on the PTO clutch shaft is turned, and push the release bearing (6) to rearward, and then the pressure
plate is pressed and engages the clutch disc and plate assembly (7) by spring load, however, if the implement is raise before
highest position of the lift arm (8), the PTO will automatically disengaged.
A cable (9) on the lift arm pulls the bell crank (10) to downward and then shift plate cam (11) is unhooked from the PTO
lever (1) and moved to rearward by spring in the PTO clutch assembly.

800X

1. PTO lever 5. Clutch fork 8. Lift arm

2. Shaft 6. Release bearing 9. Cable
3. Fork joint assembly 7. Clutch disc and 10. Bell crank
4. Lever plate assembly 11. Shift plate cam

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 2. POWER FLOW

1) Front PTO
Power flow from the engine through the HST transmission in put shaft (1) and coupled to the PTO clutch coupling (2).
The PTO lever (3) is in the “OFF” position, the clutch discs and plates (4) are slipped , and then the power flows is
disengaged to the PTO shaft (5).
The PTO lever (3) is in the “ON” position, the clutch fork (6) is turned and push the release bearing (7) then the pressure
plate pressed by the clutch spring (8), and then the clutch discs and plates (4) are engaged and the power flows to PTO shaft
(5) via the helical gears (9).

801X

1. Input Shaft 6. Clutch Fork

2. PTO clutch Coupling 7. Release Bearing
3. PTO Lever 8. Clutch Spring
4. Clutch Disc and Plate 9. Helical Gear
5. PTO Shaft

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 2) SIDE PTO
Power flows from the engine through the HST transmission input shaft (1) and coupled to the PTO clutch coupling (2) and
through the idler gear (3) to fixed gear (4), and then to the PTO counter shaft (5) . The side PTO is live PTO type, then the
side PTO shaft is rotated while engine is running.

802X

1. HST Input Shaft 4. Fixed Gear

2. PTO Clutch Coupling 5. Side PTO Counter Shaft
3. Idler Gear

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 3. AUTOMATICALLY PTO DISENGAGE SYSTEM

The lift arm is lower position and PTO lever is “ON”

position.
The sift plate cam (1) and PTO lever (2) are hooked at the
position “A”, then the PTO shaft can be rotating.

1. Shift Plate Cam

2. PTO Lever

803X
When the lift arm raised near highest position, the pin (3)
of bell crank is pulled bottom ward by the cable (4) and
also pin (5) with fulcrum the pin (6) until unhook the shift
plate cam’s groove (8) from the pin (7) of the PTO lever.

3. Pin
4. Cable
5. Pin
6. Pin
7. Pin
8. Groove

804X

When the lift arm raised highest position, the pin (3) of
bell crank is pulled more bottom ward by the cable (4), the
shift plate cam’s groove (8) is unhooked from the pin (7),
and then the shift plate cam (1) and lever (9) are moved to
“OFF” position by the springs are in the PTO clutch
assembly.
The power flows to PTO shaft is disengaged at the PTO
clutch assembly at the same time.

1. Shift Plate Cam 7. Pin

3. Pin 8. Groove
4. Cable 9. Lever

805X

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 4. ADJUSTMENT AND SPECIFICATION

1) PTO Lever Link System

Inspect the PTO lever moving force is changed position
from soft to hard at first.
If the changed position is not in the 50 ％ of the PTO
lever stroke, adjust as follows:

1. If necessary, disconnect the seat safety switch wire,

and remove the seat and floor from the tractor.
2. Untighten the lock nuts (1) and (2) on the rod (3).
3. Turn the rod (3) and inspect the PTO lever moving
force is changed position from the soft to hard is in
the 50％ of the PTO stroke.
4. Tighten the lock nuts (1 and 2), and recheck the
position. 806X
1. Lock Nut 3. Rod
2. Lock Nut

2) PTO Release Cable

1. Place the hydraulic lift control lever into the down
position and manually push down the lift arms.
2. If necessary, remove the side cover.
3. Untighten the lock nuts (1 and 2) , and release the
wire cable (3).
4. Start the engine, and raise the lift arms to the highest
position.
5. Move the PTO lever (5) to the locking position.
6. Turn the lock nut (1) until the cable is stretched and
the shift plate cam (6) is disengaged position.
7. More additional two turns the lock nut (1) and secure
tighten the lock nut (2).
8. If removed , install the side cover.

807X

1. Lock Nut 4. Lift Arm

2. Lock Nut 5. PTO Lever
3. Cable 6. Shift Plate Cam

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 Chapter 9.
MAINTENANCE
STANDARDS TABLE

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 Maintenance Standards Table
* Unit for values without unit in the column of inspection item is mm
Standard
Standard Repair Service
Unit Part Inspection Item Assembling Remarks
Dimensions Value Limit
Value

Gear backlash 0.04 – 0.16 0.6

Transmission

Slide gear-shifter fork clearance 0.2 – 0.4 1.0

Differential pinion – pinion shaft clearance 0.1 0.5

Differential pinion-thrust washer thickness 1.2 1.2 0.9
Differential gear-thrust washer thickness 2.0 1.7
Differential gear/differential pinion backlash 0.1 – 0.2 0.4
Differential/PTO

46.1 – 57.9
Ring gear tightening torque N·m {kgf·m}
{4.7 – 5.9}
Load when
pulled with
Drive pinion preload N {kgf} 196 {20}
string wound
on spline
Drive pinion/ring gear backlash 0.1 – 0.2 0.4
Tractor main body

PTO shaft end run-out Less than 0.1 0.3

Gear oil quantity ℓ 20
Rim run-out 3 5
wheel
Front

Wheel rug height

Tire size 23 × 10.50 – 12 4PR
Brake lining groove depth 0.1 0
Level difference to stator (on lining contact
0 0.1
surface)
Brake

Pedal shaft-bush clearance 0.05 – 0.35 1.0

More
Pedal play 35 – 45
than 50
Pedal shaft bush bore Ø25 Ø25.8
2
Relief valve working pressure MPa {kgf/cm } 9.8 {100}
Arm shaft-bush clearance 0.025 – 0.1 0.5
Hydraulic lift

Engine stop.
Hydraulic oil natural settlement (lower link end) Load 350 kg.
30/5 100/5
mm/min Hydraulic oil
60 – 70ºC
Hydraulic cylinder – piston clearance 0.7
Piston rod – Cylinder head clearance 0.3

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 Standard
Standard Repair Service
Unit Part Inspection Item Assembling Remarks
Dimensions Value Limit
Value
Differential pinion – pinion shaft clearance 0.03 – 0.1 0.4
Differential pinion thrust washer thickness 1.2 1.1 – 1.2 0.9
Differential gear thrust washer thickness 0.9
Differential gear/differential pinion backlash 0.2 – 0.3 0.4
24 - 30
Ring gear tightening torque N·m {kgf·m}
{2.5 – 3.0}
Drive pinion/ring gear backlash 0.10 – 0.2 0.3
4WD rear axle

Pivot shaft bush

Front 0.02 – 0.15 0.3
clearance

-10 -
Toe in -5 - +5
+10
Rim run-out 3.0 5.0
Wheel rug height
Tractor main body

Tire size 20 × 8.00 – 10 4PR

Differential chamber 1.3
Gear oil (ℓ) 0.5 on one
Gear chamber
side
5.88 – 6.56
Relief valve working pressure MPa {kgf/cm2} At 16 ℓ/min
{60 – 67}
Common use
Oil quantity ℓ 20
Power Steering

HST oil
Oil type ISO VG32 Hydraulic oil
Hydraulic cylinder – piston clearance 0.7
Cylinder head bush – piston rod clearance 0.3
Pin – bush (piston rod cylinder tube) clearance 0.5
Steering wheel peripheral play 20 – 40 50
Model HVFD-18A18-M
2
High pressure relief valve MPa {kgf/cm } 34.3 {350}
HST

2
Low pressure relief valve MPa {kgf/cm } 0.49 {5}
Charge pump capacity {cc/rev.} 4.9

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 Chapter 10.
ELECTRICAL SYSTEM

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 1. DESCRIPTION
The electrical system is a 12-volt negative ( – ) ground system consisting of wiring harness.

2. COMPONENT LOCATION AND FUNCTION

Reference – Figure 1000X

1. Battery
Battery is located on right side of the frame.

2. Fusible Link
Fusible link is located on left side of engine, near the starting motor. It controls current flow for the entire tractor.

3. Parking Brake Switch

Parking brake switch is located under the parking brake lever, and actuates with the parking brake is engaged.

4. Alternator
Alternator provides current flow to the battery.

5. Safety Start Switches

5A. HST Neutral Switch is located on the left side of the HST unit. It is “ON” position when the HST hoot pedals
are released.
5B. PTO Neutral Switch is located on the PTO control linkage. It is “ON” position when the PTO lever is in the
“OFF” position.
5C. Brake Switch is located right side under the floor. It is “ON” position when the master brake pedal is
depressed .
5D Seat Switch is located under the seat. It is “ON” position when operator is seated. The tractor can be started
when the above all switches are “ON” position.

NOTE: The tractor can be started without seated and/or master brake pedal is not depressed when the parking
brake lever is locked.

6. Fuel Level Sending Unit

Fuel level sending unit is located inside the fuel tank, it sends a signal indicating fuel level to the instrument panel.

7. Engine Coolant Temperature Sensor

Engine coolant temperature sensor is located in the thermostat housing of front left side of the engine cylinder head.
This sender regulates a variable resistance to ground with translates into the movement of the temperature gauge.

8. Engine Coolant Temperature Switch

Engine coolant temperature switch is located in the thermostat housing of front left side of the engine cylinder head.
This switch is open under normal operating temperatures and closes when operating temperatures reach higher than
normal limits 107 – 113℃.

9. Starter
Starter is located to the left side of the engine. It rotates the engine for starting.

10. Head Light Switch

Head light switch is located under the instrument panel. It controls current to head lamp.

11. Key Switch

Key switch is located on the right side of the instrument panel.

12. Engine Oil Pressure Sending Unit

Engine oil pressure sending unit is located in front of the cylinder head. It provides waning of low engine oil pressure
with indicates the oil pressure lamp and alarms the buzzer.

13. Head Light

Head light is located front under of the instrument panel and it is controlled by head light switch.

14. Instrument Panel

Instrument panel is located in the center of the dash. It monitors tractor functions.

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 15. Fuel Shutoff Solenoid
Fuel shutoff solenoid is located on the right side of the engine. It shuts off fuel flow to the injection pump to stop the
engine.

16. Glow Plug

Glow plug is located on the right side of the cylinder head adjacent to the fuel injectors. It aid in engine startup by
warming the air in the combustion chamber.

17. Fuse Blocks

Fuse blocks are located on the left side of the compartment fire wall. They control current flow for individual circuit.

18. Relays
Five relays are standard installed and one optional relay installed on the left side of the compartment fire wall. Four
relays (for starter, for engine stop solenoid, for over heat warning buzzer, for engine oil pressure warning buzzer) and
one optional relay (for cruise control) are interchangeable. The relays each connector‘s color are different for
discrimination.

19. Alarm Buzzer

Buzzer is located on the left side of the compartment fire wall. The buzzer is alarmed when the engine oil pressure is
lower and/or engine is over heated.

20 Air Cleaner Restriction Sending Unit

Air cleaner restriction sending unit is located on the top of the engine. It warns when the air cleaner element is
clogged.

21. Electric Fuel Pump

Electric fuel pump is located on right side of the battery stand. It supplies fuel under pressure to the fuel injection
pump.

22. Cellular Phone Socket

Cellular phone socket is located on the plate of the left side of the screen.

23. Cruise Control Switch (optional)

Cruise control switch is located on the right side of the dash board. It controls current to the speed control magnet.

24. Cruise Control Magnet (optional)

Cruise control magnet is located on the control lever of the left side of the HST unit.
It locks the HST linkage in place to set constant speed.

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 1000X

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 3. FUNCTION INSPECTION AND ADJUSTMENT

1. Battery

Disconnect the negative (–) battery cable at first and disconnect the positive (＋) battery cable.

WARNING: ALWAYS CHECK THE ELECTROLYTE LEVEL WITH THE TRACTOR ENGINE OFF, AS AN
EXPLOSIVE GAS IS PRODUCED INSIDE THE BATTERY WHEN THE ALTERNATOR IS
CHARGING. DO NOT USE AN EXPOSED FLAME AND DO NOT SMOKE WHEN CHECKING
THE BATTERY ELECTROLYTE LEVEL.

2. Fusible Link
A fusible link wire is used to protect the tractor’s entire electrical system. If too much amperage passes through this wire it
will melt down so that it will no longer allow current to pass (similar to the way a fuse works). The fusible link wire is a red
wire that goes to a connector that links into the main wiring harness.

3. Parking Brake Switch

The switch is normally close. The switch is closed at the
parking brake lever is locked position and is opened the
lever is released position.

a. Inspection
Use an ohmmeter to test the parking brake switch.
● With the button at the “OUT” position, there will
be continuity across the terminal leads.
● With the button at the “IN” position, there will be
no continuity across the terminal leads.
If test result are not outlined above, replace the
parking brake switch.

1001X

b. Adjustment
Using an ohmmeter and check to be sure the contacts open when the parking brake is released position, and closes
when the parking brake lever is the raised up position.

4. Alternator
Alternator provides current flow to the battery. See ”CHAPTER 2 ELECTRICAL UNIT”.

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 5. Safety Start Switches
5-A. HST Neutral Switch

HST Neutral Switch is “ON” position when the HST

hoot pedals are released. HST Neutral Switch and
PTO Neutral Switch are interchangeable.

a. Inspection
Use an ohmmeter to test the HST neutral switch.
● With the button at the “IN” position, there will be
continuity across the terminal leads.
● With the button at the “OUT” position, there will
be no continuity across the terminal leads.
If test result are not outlined above, replace the
HST neutral switch.

b. Adjustment
Using an ohmmeter and check to be sure the contacts
open when the HST pedal is pushed position, and
closes when the HST pedal is the released position,
adjust by turn the switch position.
1002X

5-B. PTO Neutral Switch

PTO Neutral Switch is “ON” position when the PTO

lever is in the “OFF” position.

a. Inspection
Use an ohmmeter to test the PTO neutral switch.
● With the button at the “IN” position, there will be
continuity across the terminal leads.
● With the button at the “OUT” position, there will
be no continuity across the terminal leads.
If test result are not outlined above, replace the
PTO neutral switch.

1003X

b. Adjustment
Using an ohmmeter and check to be sure the contacts open when the PTO control lever is pushed “ON” position, and
closes when the PTO lever is the “OFF” position , adjust by turn the switch position.

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 5-C. Brake Switch

Brake Switch is “ON” position when the master brake pedal is depressed.

a. Inspection
Use an ohmmeter to test the brake switch.
● With the button at the “OUT” position, there will
be continuity across the terminal leads.
● With the button at the “IN” position, there will be
no continuity across the terminal leads.
If test result are not outlined above, replace the brake
switch.

b. Adjustment
Using an ohmmeter and check to be sure the contacts
open when the brake pedal is “Released position”,
and closes when the brake pedal is the “Depressed
position”, adjust by turn the switch position.

1004X
5-D Seat Switch

Seat Switch is closed when operator is seated.

The tractor can be started when the above all switches are “closed”.

NOTE: The tractor can be started without seated and/or master brake pedal is not depressed when the parking
brake lever is locked.

a. Inspection
Use an ohmmeter to test the seat switch.
● With the seated, there will be continuity across the terminal leads.
● With the unseated, there will be no continuity across the terminal leads.
If test result are not outlined above, replace the seat switch.

b. Adjustment
The seat switch is non-adjustable.

6. Fuel Level Sending Unit (sensor) and Fuel Gauge

Fuel level sending unit sends a signal indicating fuel

level to the fuel gauge in the instrument panel.

a. Inspection
Use an ohmmeter to test the resistance of the fuel
level sending unit at the fuel tank empty and full.
Attach one of the meter leads to the center terminal A
of the sensor.
Attach the other meter lead to post B.

Test result
● 103 – 117 ohms at the empty in the fuel tank
● 1 – 5 ohms at the full in the fuel tank
1005X
If test results do not in the above replace the fuel level
sensor.

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 7. Engine Coolant Temperature Sensor

Engine coolant temperature sensor is regulates a

variable resistance to ground with translates into the
movement of the temperature gauge.

8. Engine Coolant Temperature Switch

Engine coolant temperature sending switch is opened

under normal operating temperatures and is closed
reach higher than normal limits 107 – 113℃.
If test results is not in the above, replace the sensor.

1006X

9. Starter

Starter rotates the engine for starting. See ”CHAPTER 2 ELECTRICAL UNIT”.

10. Head Light Switch

Head light switch controls current to head lamp.

a. Inspection
Use an ohmmeter to test the continuity of the head light switch connector terminals.

● With the switch in the “OFF” (released) position,

there will be continuity between the terminals B
and C, and D and E.
● With the switch in the “ON” (pushed) position,
there will be continuity between the terminals A
and C, and D and E.

If test results are not outline above, replace the light

switch.

1007X

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 11. Key Switch

The starter switch has four key operated positions

are : OFF, ON, HEAT, and START.
Turning the key from OFF to one of the three
positions will aligned, the circuit is closed and
battery current will flow through the circuit.

Use an ohmmeter to test the continuity of the key 1008X

switch connector terminals.

Conduct continuity test between terminal and the

other terminals (●─●) at each position of the key
switch.

Test results
● A low resistance reading means, the switch is
operating properly.
● A high resistance reading indicates an open
circuit, the start switch need to be replaced.

1009X

12. Engine Oil Pressure Sending Unit

Engine oil pressure sending unit provides waning of

low engine oil pressure and indicates the oil pressure
lamp go on and alarms buzzer.

1010X
13. Head Light

Head light is controlled by head light switch.

14. Instrument Panel

Instrument panel is monitors tractor functions.

Instrument panel is consists proof meter (1), engine coolant temperature gauge (2), fuel gauge (3), glow plug indicator
lamp (4), engine oil pressure warning lamp (5), charge lamp (6), air cleaner restriction warning lamp (7), and parking
brake warning lamp (8), Figure 1011X.

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 1011X

1. Proof meter 5. Engine oil pressure warning lamp

2. Engine coolant temperature gauge 6. Charge lamp
3. Fuel gauge 7. Air cleaner restriction warning lamp
4. Glow plug indicator lamp 8. Parking brake warning lamp

Instrument panel wiring

1012X

NOTE: Do not keep the instrument panel turned upside down while removed, the silicone oil in the gauge will
leak out and the gauges will not move smoothly.

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 Inspection
● Engine coolant temperature gauge
Use an ohmmeter to test the resistance of the engine coolant temperature gauge. Attach one of the meter lead to the
terminal No. ① or ④ of the connector. Attach the other meter lead to the terminal No. ⑩ of the connector.
The measure resistance should be 110 ± 2 ohms.

If the resistance measured is outside the specification, or an open circuit is measured, the instrument panel should be
replaced.

● Fuel gauge
Use an ohmmeter to test the resistance of the fuel gauge. Attach one of the meter lead to the terminal No. ① or ④
of the connector.
Attach the other meter lead to the terminal No. ⑪ of the connector.
The measure resistance should be 110 ± 2 ohms.

If the resistance measured is outside the specification, or an open circuit is measured, the instrument panel should be
replaced.

15. Fuel Shut Off Solenoid

Fuel shut off solenoid is shuts off fuel flow to the

injection pump to stop the engine.
When the solenoid is energized, as when the key
switch is turned to the “ON” and “START” positions,
the solenoid plunger is retracted and the governor
linkage moves the pump control rack rearward into
operating position.

Testing
a. With the solenoid de-energized, measure the 1013X
protrusion distance “A” of the plunger. In the
shut-off position, the plunger protrusion
distance should measure, 25.5 – 26.4 mm.

b. Connect a jumper wire from the solenoid

terminal to the battery positive terminal.
Connect a second jumper wire from the battery
negative terminal to the solenoid body. The
solenoid plunger will retract. Measure the
protrusion distance “B” of the plunger. In the
retracted position, the plunger protrusion
distance should measure 11.5 – 14.5 mm.

1014X

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 16. Glow Plug

Glow plug is aid in engine startup by warming the air

in the combustion chamber.
Use an ohmmeter to test the glow plugs.
Touch one lead to the center electrode.
Place the other lead against the glow plug body.
A meter reading of 0.8 ohms maximum is normal. If
test results are as outlined above, replace the faulty
glow plug.

1015X

17. Fuse Blocks

Fuse blocks are control current flow for individual circuit.

18. Relays

Five relays (for starter, for engine stop solenoid, for over heat warning buzzer, for engine oil pressure warning buzzer
and cruise control) are interchangeable.
The relays each connector‘s color are different for discrimination and as follows:

● Connector color “BLUE” is for safety start relay.

● Connector color “RED” is for engine stop solenoid relay.
● Connector color “GREEN” is for engine over heat warning buzzer relay.
● Connector color “BLACK” is for engine oil pressure warning buzzer relay.
● Connector color “WHITE” is for cruise control relay.

a. Four terminals relay

A relay consists of two parts which work together a
coil and an SPST switch. Terminals “A” and “B” are
connected to a coil. Applying 12 bolts to “A”
terminal energized the coil, turning it into an
electromagnet.
Terminals “C” and “D” are actually part of a single
pole, single throw switch.
When the coil is energized, the switch is thrown, and
terminals C and D are connected.

1016X

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 The SPST switch is spring loaded so terminals C and
D are opened when the coil is not energized.

b. Five terminal relay 1017X

The brake relay is different with four terminal relays.
It has five terminals and connector color is
“BLACK”.
A relay consists of two parts which work together a
coil and an SPDT switch.
Terminals “A” and “B” are connected to a coil.
Applying 12 bolts to “A” terminal energized the coil,
turning it into an electromagnet.
Terminals “C”, “D” and “E” are actually part of a
single pole, double throw switch.

1018X
The SPDT switch is spring loaded so terminals D and
E are opened when the coil is not energized.

When the coil is energized, the switch is thrown, and

terminals C and E are connected.

1. Coil
2. Switch

1019X
INSPECTION

a. Four terminals relay

To test a relay, disconnect it from the circuit.
1. Connect the ohmmeter leads to terminals C and
D.
2. There is no continuity between terminals C and
D if the relay is working properly.

Next use the ohmmeter to verify energized

conditions.

1020X

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 1. Energized the coil by applying 12 volts of
current across terminals A and B.
2. Connect the ohmmeter leads to terminals C and
D.
3. There is continuity between terminals C and D
if the relay is working properly.

1021X
b. Brake relay (Five terminals relay)
To test a relay, disconnect it from the circuit. Use the
ohmmeter to verify non-energized conditions.
1. Connect the ohmmeter leads to terminals D and
E.
2. There is no continuity between terminals E and
D if the relay is working properly.
3. Connect the ohmmeter leads to terminals C and
E.
4. There is continuity between terminals C and E if
the relay is working properly
Next use the ohmmeter to verify energized
conditions.

1022X
1. Energized the coil by applying 12 volts of
current across terminals A and B.
2. Connect the ohmmeter leads to terminals D and
E.
3. There is continuity between terminals D and E if
the relay is working properly.
4. Connect the ohmmeter leads to terminals C and
E.
5. There is no continuity between terminals C and
E if the relay is working properly.

If continuity readings do not match those stated in the

above test procedures, replace the relay.

1023X

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 19. Alarm Buzzer

Buzzer is alarmed when the engine oil pressure is

lower and/or engine is over heated.

INSPECTION
To test a buzzer, disconnect it from the circuit.
Energized the buzzer by applying 12 volts of current
across terminals A and B.

If buzzer is alarmed, it is working properly.

1024X

20. Air Cleaner Restriction Switch

Air cleaner restriction sending unit is warns when the

air cleaner element is clogged.

INSPECTION

To test an air cleaner restriction switch, disconnect it

from the circuit and remove it.
Use an ohmmeter to test the switch. Touch leads to the
both terminals.

● With normally, there will be no continuity.

● With the hole sucked by mouth, there will be
continuity.
If test result are not outlined above, replace the switch. 1025X

21. Electric Fuel Pump

Electric fuel pump is supplies fuel under pressure to

the fuel injection pump.

INSPECTION

If a fuel system malfunction indicates a faulty fuel

pump, a simple shop test of the fuel pump can be
performed using water as the liquid for testing.
To test a fuel pump, remove it from the tractor.

a. Set up the fuel pump, rubber hoses, switch, jumper

cables and clean containers and battery as an
illustration. 1026X
b. Place 3.5 liters of water in a container.
c. Operate the fuel pump using the switch and run the
fuel pump for 15 seconds to charge the system.
Empty the water back into the inlet filled container.
d. Operate the pump for five minutes. Measure the
water in the outlet side container.

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 Test Results
If the pump delivered 2 liters or more the pump is normal.

IMPORTANT:
Before installing water tested fuel pump back on the tractor, place the inlet hose in a small container filled with clean
diesel fuel. Operate the pump until the test water is purged from the pump.

22. Cellular Phone Socket

23. Cruise Control Switch (optional)

Cruise control switch is controls current to the speed

control magnet.

INSPECTION
Remove the switch from the wiring harness.

NOTE: The switch terminals are identified on the

back of the switch. Number 1 and 4 are
blank.

1027X

a. Use an ohmmeter, depress the switch to the “ON”

position and connect the ohmmeter leads across
terminals 5 and 6, then across terminals 2 and 3.
If continuity exists across these terminals, the
switch is operating properly.

1028X
b. Next place the switch in the “STAND BY” (middle)
position and connect the ohmmeter leads across
terminals 2 and 3. If there is continuity, the switch
is good.

1029X

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 c. To test the internal light bulb, connect the
ohmmeter leads across terminals 7 and 8 (the
switch may be placed in any of its three positions).
The reading should be between 55 and 60 ohms.

NOTE: The light is not serviced separately.

If it does not illuminate, replace the switch.
Replace the switch if the correct readings
are not obtained during testing.

1030X
24. Cruise Control Magnet (optional)

Cruise control magnet is locks the HST linkage in

place by switch to set constant speed.

INSPECTION

Use the ohmmeter to test the cruise control magnet.

a. Disconnect the magnet from the tractor wiring

harness and connect the ohmmeter leads to the two
leads coming from the magnet.
b. A meter reading of 11 – 12 ohms is normal.
1031X

c. Disconnect the ohmmeter from the magnet and

apply 12 volts across the magnet leads.
d. The surface will become magnetized and attract any
ferrous object if the cruise control magnet is
working properly.

If the test results are not as outlined above, replace the

cruise control magnet.

1032X

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 1033X

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 1034X

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 1035X

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 1036X

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 1037X

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 1038X

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 1039X

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 1040X

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 1041X

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 1042X

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 1043X

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 1044X

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 Chapter 11.
MOWER

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 11-1 Sectional View : FM60SD

1101X

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 11-2 Specifications
Model EM60 SD
Lifting link 2-point link
Adjustment of mowing height Gauge wheel
Mowing width (mm) 1520
Mowing height (mm) 38 – 115 {7 steps}
Mowing blade speed (rpm) 2899
Mowing blade end speed (m/sec.) 79
No. of mowing blades 3
Standard mowing blade dimensions (T × W × L, mm) 7 × 50 × 518
Gear oil (ℓ) 0.6
Total weight (kg) 175
Applicable models CM284·364

Power flow

1102X

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 11-3 Disassembly
Order Unit Disassembling procedure
1 Belt cover Remove the right and left belt covers.

1103X
2 Belt ① Before removing the belt, untighten
Blade the bolts and nuts of the blade and
pulley.

NOTE:
The pulley nut is threaded
reversely and should be
disassembled carefully.

② Untighten the tension lock reduce the

belt tension, and remove the belt and 1104X
blade.
3 Bearing case ① Remove the nut and take off the
(left and right) pulley.
② Remove the key from the shaft.

1105X

③ Remove the bearing case from the

mower deck (cover).

1106X

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 Order Unit Disassembling procedure
④ Remove the grease nipple and
drive out the rotor shaft
downwards.
⑤ Remove the oil seal, bearing and
collar from the case.

1107X
Components (bearing case)

1. Grease nipple
2. Nut
3. Spring washer (M20)
4. Washer
5. Pulley (B)
6. Bearing (6008Z)
7. Collar
8. Bolt (M 12 × 30)
9. Bearing case
10. Bearing (6206)
11. Oil seal (UE45629)
12. Rotary shaft (B)
13. Key
14. Blade
15. Spacer
16. Spring washer (M18)
17. Bolt

1108X
4 Gear box ass’y ① Remove the gear box and bearing
Bearing case case together from the mower deck.
ass’y ② Drain the gear oil from the gear
box.

1109X

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 Order Unit Disassembling procedure
5 Gear box. ① Remove the cover: joint.
② Remove the grease nipple with
fitting, the right and left stays.

1110X
③ Remove the bolt and take off
the case, shaft, bearing and
bevel gear together.

NOTE:
Note the number of gaskets
(packings) between the gear
box and case.

1111X
④ Remove the bevel gear.

NOTE:
Note the thickness and
number of shims between
the bevel gear and bearing, if
any.
⑤ Remove the Ø62 snap ring.
⑥ Drive out the shaft and bearing
in the arrow mark direction.
⑦ Drive out the oil seal.
1112X
⑧ Remove the box cover.
⑨ Remove the Ø17 snap ring.
⑩ Drive out the shaft downwards
and detach the gear box and
bearing case.

1113X

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 Order Unit Disassembling procedure
⑪ Remove the oil seal by like a
screw driver.
⑫ Remove the Ø52 snap ring,
and remove the bearings (2
pcs.), bevel gear and collar
from the gear case.

1114X

1115X
Components (gear case)

1. Oil seal (UE2545511) 10. Snap ring (Ø62) 19. Bolt (M8 × 12) 28. Bevel gear
2. Case 11. Gasket 20. Washer 29. Gasket
3. Bolt (M8 × 20) 12. Shim: 0.1 mm 21. Packing 30. Plug
4. Bolt (M8 × 25) 13. Shim: 0.2 mm 22. Bolt (M6 × 16) 31. Bearing (6205)
5. Rubber 14. Bolt (M12 × 20) 23. Box cover 32. Snap ring (Ø52)
6. U – nut 15. Spring washer 24. Packing 33. Oil seal (UE25528)
7. Cover; Joint 16. Stay 25. Snap ring (Ø17) 34. Stay
8. Bearing (6305) 17. Gear box 26. Bearing (6303) 35. Vent
9. Shaft 18. Bevel gear 27. Collar 36. Shim
37. Spring
38. Grease nipple

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 Order Unit Disassembling procedure
6 Bearing case ① Remove the Ø25 snap ring.
(center) ② Drive out the shaft
downwards.

1116X
③ Remove the pulley and
bearing together and detach if
necessary.
④ Remove the collar and drive
out the bearing and oil seal.

1117X
Components (bearing case)
1. Bearing case
2. Bearing (6206)
3. Oil seal (UE45629)
4. Shaft
5. Key
6. Collar
7. Bearing (6208Z)
8. Pulley (A)
9. Snap ring (Ø25)
10. Grease nipple
11. Screw pipe
12. Bolt (M6 × 10)

1118X

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 Order Unit Disassembling procedure
7 Tension arm Components
Idler pulley 1. Tension arm ass’y
2. Idler pulley
3. Bearing (6203ZZ or 6203UU)
4. Snap ring (Ø40)
5. Snap ring (Ø17)
6. Grease nipple
7. Snap ring
8. Spacer
9. Bush
10. Spring
11. Rod
12. Nut (M10) 1119X

8 Tail wheel Components

1. Castor arm
2. Washer
3. Gauge wheel ass’y
4. Spacer
5. Bolt (M8 × 14)
6. Grease nipple

1120X

9 Front wheel Components

1. Wheel ass’y
2. Bushing
3. Shaft
4. Washer
5. Snap ring
6. Shaft
7. Spring washer
8. Bolt
9. Spacer
10. Collar
11. Boss
12. Ball bearing
13. Cover
14. Tire
15. Disc wheel
16. Valve ass’y 1121X
17. Grease nipple
10 Roller Components
1. Roller
2. Bolt
3. Shaft
4. Spring washer
5. Cap nut (M10)
6. Washer

1122X

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 11-4 Reassembly and Adjustment
NOTE: Reassemble components in the reverse order to disassembly except for main units, which shall be
reassembled in the following procedure.

Reassembly and adjustment

1. Bearing case (center)

① A single-side shield bearing is used for the pulley.

When installing the bearing to the pulley, care
should be taken not to mistake its direction. (See
the right figure.) (Position the shield surface on the
pulley side.)

1123X
② Put in the oil seal from the case end surface and
install. (Coat the lip with grease.)

1124X

2. Gear box

Adjust the backlash by increasing or decreasing the

shims or gaskets in the following procedure:

① Select shims so that the backlash is 0 (zero).

② Remove shims corresponding to thickness of 0.4 –
0.6 mm from those of above item ① and install
them.

NOTE:
In above item ①, if the shim thickness is below
0.4 mm, add the gasket (t=0.2) and adjust
properly.
1125X
Specified value (0.2 – 0.3 mm) can be obtained by
the above adjustment.

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 3. Adjustment of V-belt tension

Adjust the V-belt tension with the adjusting nut so

that the spring length is 90 mm.

1126X
4. Blade

① Replace the blades if clearance between them

exceeds the specified value. If the clearance is
excessive, mowing operation may not be taken
place.

Clearance between blades (mm)

Standard assembling value (when new) Service limit
1.61 10.0

1127X
② Replace the blade with new one if its bend exceeds
the specified value.

Bend of blade (at end) 0 – 3 mm

1128X
③ Sharpening of blade
Sharpen the blade edge to 45º and the blade end
dimension to 0.4 mm as shown in the right figure.

NOTE:
1. When sharpening the blade, put on protection
glasses and gloves.
2. After completion of sharpening, be sure to adjust
the balance of the blade before installing it.

1129X

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 Reassembly and adjustment

④ Balancing of blade
Fix some suitable bar (below Ø16) to the vice,
install the blade as shown in the right figure and
check that the blade is level. If not, sharpen the
heavier side to balance.

1130X

⑤ Installation of blade
Install the blade, leaf spring, and spring washer in
this order and tighten the bolt with the specified
torque.

132 – 147 N·m

Tightening torque
{13.5 – 15 kfg·m}

NOTE: Install the leaf spring with the recess

positioned on the blade side.

1. Blade 3. Spring washer 1131X

2. Leaf spring 4. Bolt

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