Page 1 www.mymowerparts.com MTD Products, LLC Product Training and Education Department FORM NUMBER 769-00902 K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 2 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 3: Table Of Contents
www.mymowerparts.com CONTENTS CHAPTER 1 GENERAL INFORMATION ..................1-1 1. TRACTOR VIEW ............................... 1-3 2. TIGHTENING TORQUE FOR STANDARD BOLTS AND NUTS ..............1-4 2.1 TIGHTENING TORQUE .......................... 1-4 3. SPECIFICATIONS ............................1-6 4. IDENTIFICATION ............................. 1-8 4.1 ENGINE NUMBER ........................... 1-8 4.2 CHASSIS NUMBER OF THE TRACTOR(CHASSIS NUMBER OF THE MACHINE) .......
Page 4 www.mymowerparts.com 2. CLUTCH ................................3-8 2.1 CHARACTERISTICS ..........................3-8 2.2 LINK STRUCTURE AND CONTROL ..................... 3-9 2.3 TROUBLESHOOTING ........................... 3-10 2.4 SPECIFICATION ............................ 3-11 2.5 TIGHTENING TORQUE ........................3-11 2.6 DISASSEMBLY, MAINTENANCE ......................3-12 CHAPTER 4 TRANSMISSION ......................4-1 1. STRUCTURE ..............................4-3 2.
Page 5 www.mymowerparts.com 10.3 THIRD STAGE (DISASSEMBLY OF 25 GEAR SHAFT AND PROPULSION SHAFT 1) ......4-30 10.4 FOURTH STAGE (DISASSEMBLY OF BEARING COVER ASSEMBLY) .......... 4-30 10.5 FIFTH STAGE (DISCONNECTION OF TRANSMISSION FORK) ............. 4-31 10.6 SIXTH STAGE (DISASSEMBLY OF 22 GEAR SHAFT) ..............4-32 10.7 SEVENTH STAGE (DISASSEMBLY OF MAIN TRANSMISSION COUNTER SHAFT) ....
Page 6 www.mymowerparts.com 5. TIGHTENING TORQUE ..........................7-7 6. DISASSEMBLY, MAINTENANCE ........................7-8 6.1 STRUCTURE ............................7-8 7. DISCONNECTION OF FRONT AXLE GROUP ................... 7-10 7.1 DISASSEMBLY, ASSEMBLY ........................7-10 8. DISASSEMBLY OF FRONT AXLE ........................ 7-12 8.1 FIRST STAGE (DISCONNECTION OF FRONT AXLE CASE AND BEVEL GEAR CASE) ......... 7-12 8.2 SECOND STAGE (DISASSEMBLY OF FRONT AXLE) ..............
Page 7 www.mymowerparts.com 6. OIL FLOW ................................. 8-9 IN NEUTRAL ............................8-9 TURNING TO THE RIGHT ........................8-9 TURNING TO THE LEFT ........................8-10 MANUAL STEERING ..........................8-10 7. TROUBLESHOOTING ........................... 8-11 8. DISASSEMBLY, MAINTENANCE ......................... 8-12 GEAR PUMP ............................8-12 POWER STEERING UNIT ........................8-14 STEERING CYLINDER ........................
Page 8 www.mymowerparts.com 14.TIGHTENING TORQUE ..........................9-24 15.DISASSEMBLY, ASSEMBLY ......................... 9-25 15.1 GEAR PUMP ............................9-25 15.2 MAINTENANCE ............................9-27 15.3 RELIEF VALVE ............................9-27 15.4 HYDRAULIC CYLINDER ........................9-28 15.5 CHECK AND ADJUSTMENT ......................... 9-34 CHAPTER 10 ELECTRIC SYSTEM ....................10-1 1.
Page 9: Chapter 1 General Information
www.mymowerparts.com CHAPTER 1 GENERAL INFORMATION K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 10 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 11: Tractor View
www.mymowerparts.com GENERAL INFORMATION 1. TRACTOR VIEW 615W101A D615-W02 May-2003 K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 12: Tightening Torque For Standard Bolts And Nuts
CHAPTER 1 8354/8404 2. TIGHTENING TORQUE FOR STANDARD BOLTS AND NUTS 2.1 TIGHTENING TORQUE Screws, bolts and nuts whose tightening torques are not specified in this workshop manual should be tightened according to the table below. A. TIGHTENING TORQUE FOR STANDARD BOLTS AND NUTS...
Page 13 www.mymowerparts.com GENERAL INFORMATION B. TIGHTENING TORQUE FOR STUDS 11.7 ~ 15.7 N·m 1.2 ~ 1.6 kgf·m 8.6 ~ 11.5 lbf·ft 24.5 ~ 31.4 N·m 2.5 ~ 3.2 kgf·m 18.0 ~ 23.1 lbf·ft 34.3 ~ 49.0 N·m 3.4 ~ 5.0 kgf·m 25.3 ~ 36.1 lbf·ft C.
Page 14: Specifications
CHAPTER 1 8354/8404 3. SPECIFICATIONS Model 8354 8404 Maximum PTO power 28.3 HP 33.4 HP Engine GROSS power 33.5 HP 40.4 HP Engine Model 3A165D 4A200 Type Indirect injection, vertical, water-cooled, 4-cycle diesel Number of cylinders Bore and stroke 87 ×...
Page 15 GENERAL INFORMATION Model 8354 8404 Synchronized shuttle and transmission Traveling Transmission system 8 forward and 8 reverse speeds (CR: 16 forward and 16 reverse speeds) Brake Traveling Wet disc type Parking Connected with the traveling brake Differential Bevel gear...
Page 16: Identification
CHAPTER 1 8354/8404 4. IDENTIFICATION 4.1 ENGINE NUMBER The engine serial number is stamped on the left side of the cylinder block as shown in the figure. Engine serial number provides important information. 615W102A (1) Engine Serial Number 4.2 CHASSIS NUMBER OF THE...
Page 17: Caution Before Repair
3 ~ 5 mm (0.12 ~ 0.2 in.) on the contact surface after removing the old bond and When replacing parts, use only genuine Cub Cadet parts. cleaning the sealing surface with solvent. Apply sealant on the center of the contact surface for the...
Page 18: Asbestos Parts
CHAPTER 1 8354/8404 5.5 ASBESTOS PARTS Since dust out of asbestos fibrous parts is extremely dangerous to your health, be sure to clean such parts carefully, do not use compressed air. 5.6 ELECTRICAL SYSTEM 1. Check electrical wiring every year for any damage or short circuit at the connections.
Page 19: Tubes And Rubbers
www.mymowerparts.com GENERAL INFORMATION 5.7 TUBES AND RUBBERS 5.8 LUBRICANT 615W111A 615W112A Be cautious of oil or other petroleum products on the When assembling and fixing, apply designated lubri- hoses and rubber parts, this may cause damage. cant where specified in accordance with this repair manual.
Page 20: Regular Check List
CHAPTER 1 8354/8404 6. REGULAR CHECK LIST The first Periodically Since Indicated Hours By Hour Meter Purchased Check Items 1500hr Engine oil change Engine oil filter cartridge change Transmission oil change Hydraulic oil filter change Front axle oil change...
Page 21: Oil & Water Supply List
www.mymowerparts.com GENERAL INFORMATION 7. OIL & WATER SUPPLY LIST Supply Items Capacity Recommended Spec. Fuel (42.3 U.S.gal.) No. 2 - D diesel fuel No. 1 - D diesel fuel if temperature is below - 10 °C (14 °F) Coolant (1.85 U.S.gal.) Fresh clean water with antifreeze 3A165D (2.35 U.S.gal.)
Page 22 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 23: Chapter 2 Engine System
www.mymowerparts.com CHAPTER 2 ENGINE SYSTEM K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 24 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 25: General
www.mymowerparts.com ENGINE SYSTEM 1. GENERAL 1.1 APPEARANCE 615W201A The DAEDONG A series engines are vertical, water- cooled, 4-cycle, three or four cylinders diesel engines, they concentrate DAEDONG’s foremost technologies. With swirl combustion chamber, bosch K type fuel in- jection pump, well-balanced designs, they feature greater power, low fuel consumption, less vibration and noise, and low emission.
Page 26: Specifications
CHAPTER 2 8354/8404 1.2 SPECIFICATIONS Model 3A165D 4A200B Type Vertical, water-cooled, Vertical, water-cooled, 4-cycle diesel engine 4-cycle diesel engine Number of cylinder Bore and stroke 87 x 92.4 mm 83 x 92.4 mm 3.43 x 3.64 in. 3.27 x 3.64 in.
Page 27: Performance Curve
www.mymowerparts.com ENGINE SYSTEM 1.3 PERFORMANCE CURVE 615W203A 615W204A D615-W02 May-2003 K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 28: Dimensions
Replace gaskets or O-rings with new ones when reassembling, and apply grease on a O-ring and the oil seal when reassembling. • When exchanging parts, use Cub Cadet parts to maintain engine performance and safety. • To prevent oil and water leakage, apply non-drying adhesive to the gaskets according to this manual before reassembling.
Page 29: Structure And Function
www.mymowerparts.com ENGINE SYSTEM 2. STRUCTURE AND FUNCTION 2.1 BODY A. CYLINDER HEAD The cylinder head is made of special alloy cast iron which can resist high temperature and pressure caused by combustion. The inlet and exhaust ports are arranged cross-flow type to get high combustion effi- ciency by protecting the suction air from being heated and expanded by heated exhaust air.
Page 30 CHAPTER 2 8354/8404 C. CRANKSHAFT The crankshaft is made of forged steel and the journals, the crankpins and the bearing surface for the oil seal are induction-hardened to increase wear resistance. Each crankshaft journal is supported by the main bear- ing case (3) having a bearing inside.
Page 31 www.mymowerparts.com ENGINE SYSTEM F. CAMSHAFT The camshaft (3) is made of forged steel and its jour- nal and cams are hardened to increase wear resistance. The cams on the camshaft open and close the inlet and exhaust valves with the push rods and rocker arms.
Page 32 CHAPTER 2 8354/8404 I. INLET AND EXHAUST VALVES The valve and its guide of the inlet are different from those for the exhaust. Other parts, such as the spring, spring retainers, valve spring collets, valve stem seals are the same for both the inlet and the exhaust. All contact or sliding surfaces are hardened to increase wear resistance.
Page 33: Lubricating System
www.mymowerparts.com ENGINE SYSTEM 2.2 LUBRICATING SYSTEM A. FLOW OF LUBRICATING OIL The lubricating oil is forced to each journal through the oil passages of the cylinder block, cylinder head and shafts. The oil, splashed by the crankshaft or thrown off from the bearings, lubricates other engine parts such as the push rods (11), tappets (12), camshaft (14), and crankshaft (15).
Page 34 CHAPTER 2 8354/8404 C. OIL FILTER AND RELIEF VALVE The lubricating oil force-fed by the pump is filtered by the filter cartridge, passing through the filter element from the outside to the inside. When the filter element accumulates dirt and the pressure difference between the inside and the outside rises more than 98 kPa (1.0 kgf/cm², 14 psi), the bypass valve (1) opens to...
Page 35: Cooling System
www.mymowerparts.com ENGINE SYSTEM 2.3 COOLING SYSTEM A. FLOW OF COOLING WATER The cooling system consists of a radiator (5), a cen- trifugal water pump (7), a cooling fan (6) and a thermo- stat (2). The water is cooled as it flows through the radiator core, and the fan behind the radiator pulls the cooling air through the radiator core.
Page 36 CHAPTER 2 8354/8404 C. THERMOSTAT The thermostat is wax pellet type, which controls the flow of the cooling water to the radiator to keep the proper temperature. The case has a seat (1) and the pellet has a valve (2). The spindle attached to the case is inserted into the synthetic rubber in the pellet.
Page 37: Fuel System
www.mymowerparts.com ENGINE SYSTEM 2.4 FUEL SYSTEM A. FLOW OF FUEL The fuel is fed from the fuel tank (1) through the fuel feed pump (7) to the injection pump (3) by the fuel filter (2). The injection pump force-feds the fuel through the injection nozzles (5), which inject the fuel into the cylin- ders for combustion.
Page 38 CHAPTER 2 8354/8404 C. FUEL FEED PUMP The diaphragm (6) is linked to the tappet (3) with the push rod (2). The tappet is reciprocated by the eccen- tric cam on the fuel camshaft (7). (A) Inlet Stroke When the diaphragm is pulled down by the spring,...
Page 39 www.mymowerparts.com ENGINE SYSTEM a . Pump Element The pump element (1) consists of a plunger (3) and cylinder (2), their sliding surfaces are precision ma- chined to maintain fuel tightness. The plunger (3) fits in the control sleeve (5) at the driving surface (7). The sleeve is engaged with the control rack, which rotate the plunger in the cylinder to control the amount of fuel delivery.
Page 40 CHAPTER 2 8354/8404 c. Amount of Fuel Delivery (A) No Fuel Delivery At the engine stop position of the control rack (3), the lengthwise slot (1) on the plunger (2) aligns with the feed hole (5). The delivery chamber (4) is led to the feed hole during the entire stroke of the plunger.
Page 41 www.mymowerparts.com ENGINE SYSTEM E. FUEL INJECTION NOZZLE The nozzle is a throttle-type one. It features low fuel consumption and works well with DAEDONG combus- tion chamber. The nozzle valve opening pressure is about 13.7 to 14.7 MPa (140 to 150 kgf/cm², 1991 to 2134 psi), the pressure overcomes the counterforce of nozzle valve spring, and push the valve up instantly, the fuel is then injected in a proper quantity into the swirl-...
Page 42 CHAPTER 2 8354/8404 b. Operation of Governor 1) At start The steel ball (13) has no centrifugal force. As the fork lever 1 (4) is pulled by the start spring (1), the control rack (14) moves to the maximum injection position. At start, the sufficient injection of the fuel enables easy starting.
Page 43 www.mymowerparts.com ENGINE SYSTEM 3) At high speed running with overload When an overload is applied to the engine running at a high speed, the centrifugal force of steel ball (13) be- comes small as the engine speed is dropped, and fork lever 2 (5) is pulled to the right by the governor spring 1 (2) and 2 (3), increasing fuel injection.
Page 44 CHAPTER 2 8354/8404 A. FLOW OF INTAKE AIR AND EXHAUST GAS (a) Intake Air (b) Exhaust Gas (1) Intake Manifold (2) Air Cleaner (3) Cylinder Head (4) Muffler (5) Exhaust Manifold 615W251A B. AIR CLEANER The air cleaner is dry-cyclone type and easy to maintain.
Page 45: Disassembling And Servicing
www.mymowerparts.com ENGINE SYSTEM 3. DISASSEMBLING AND SERVICING 3.1 TROUBLESHOOTING Symptom Probable Cause Solution Engine Does Not Start • Not fuel Replenish fuel • Air in the fuel system Vent air • Water in the fuel system Change fuel and repair or flush fuel system •...
Page 46 CHAPTER 2 8354/8404 Symptom Probable Cause Solution Either White or Blue Exhaust • Excessive engine oil Reduce to the specified level Gas is Observed • Piston ring and bore worn or Repair or replace piston ring stuck • Incorrect injection timing Adjust •...
Page 47 www.mymowerparts.com ENGINE SYSTEM Symptom Probable Cause Solution High Oil Pressure • Improper type of oil Use the specified type of oil • Relief valve defective Replace Engine Overheating • Engine oil insufficient Replenish • Fan belt broken or tensioned Replace or adjust improperly •...
Page 48: Servicing Specifications
CHAPTER 2 8354/8404 3.2 SERVICING SPECIFICATIONS A. ENGINE BODY a . Cylinder Head Item Factory Specification Allowable Limit Cylinder Head Surface Flatness 0.05 mm / 100 mm 0.002 in. / 3.94 in. Top Clearance 0.75 ~ 0.9 mm 0.0295 ~ 0.0354 in.
Page 49 www.mymowerparts.com ENGINE SYSTEM d. Cylinder Bore Item Factory Specification Allowable Limit Cylinder bore inner 3A165D 87.000 ~ 87.022 mm diameter 3.4252 ~ 3.4261 in. 0.15 mm 4A200B 83.000 ~ 83.022 mm 0.0059 in. 3.2677 ~ 3.2690 in. e . Valve Spring Item Factory Specification Allowable Limit...
Page 50 CHAPTER 2 8354/8404 I. Timing Gear Item Factory Specification Allowable Limit Timing gear backlash 0.04 ~ 0.11 mm 0.15 mm 0.0016 ~ 0.0043 in. 0.0059 in. Idle gear side clearance 0.20 ~ 0.51 mm 0.9 mm 0.0079 ~ 0.0201 in.
Page 51 www.mymowerparts.com ENGINE SYSTEM l. Crankshaft Item Factory Specification Allowable Limit Crankshaft Misalignment 0.08 mm 0.0031 in. Clearance between Crankshaft and crank- 0.20 mm 0.040 ~ 0.118 mm shaft bearing 1 0.0079 in. 0.00157 ~ 0.00465 in. Crankshaft O.D 51.921 ~ 51.940 mm 2.04414 ~ 2.04489 in.
Page 52 CHAPTER 2 8354/8404 C. COOLING SYSTEM a . Thermostat Valve opening temperature at beginning 69.5 ~ 72.5 °C (157.1 ~ 162.5 °F) Opened completely (height 8 mm 0.315 in.) 85 °C (185 °F) b. Radiator Radiator tightness No leak at 137 kPa, 1.4 kgf/cm...
Page 53 www.mymowerparts.com ENGINE SYSTEM E. TIGHTENING TORQUES Item Size x Pitch N•m kgf•m lbf·ft Cylinder head screws M11 x 1.25 103.0 ~ 107.9 10.5 ~ 11.0 75.9 ~ 79.6 Head cover nuts M10 x 1.25 8.8 ~ 10.8 0.9 ~ 1.1 6.5 ~ 8.0 * Bearing case screw 1 M9 x 1.25...
Page 54 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 55: Checking, Disassembling And Servicing
ENGINE SYSTEM 3.3 CHECKING, DISASSEMBLING AND SERVICING A. ENGINE DISASSEMBLED VIEW 615WA18A (1) Cylinder Block (7) Cylinder Head (12) Bearing Case Bolt 1 (18) Push Rod (24) Connecting Rod (30) Glow Plug (36) Engine Stop Solenoid (42) Fan Drive Pulley (48) Exhaust Manifold (2) Oil Pressure Switch (8) Head Bolt...
Page 57 www.mymowerparts.com ENGINE SYSTEM B. EXTERNAL COMPONENTS a . Checking and Adjusting 1) Fan belt Measure the deflection, depressing the belt halfway between the fan drive pulley and the alternator pulley at 98 N (10 kgf, 22 lbs) of force. If the deflection is not between the factory specifications, loosen the bolts and nuts, and relocate the alternator to adjust.
Page 58 CHAPTER 2 8354/8404 2) Solenoid 1. Disconnect the stop lever 1 (5) from the engine stop lever (2). 2. Remove the screw (3) and (4). 3. Remove the solenoid (7) with its support. (When reassembling) • Loosen the solenoid mounting screws.
Page 59 www.mymowerparts.com ENGINE SYSTEM C. ENGINE BODY a . Checking and Adjusting 1) Compression pressure 1. Run the engine until warmed up. 2. Stop the engine and remove the air cleaner, the muffler and all nozzle holders. 3. Connect a compression tester to the nozzle holder hole.
Page 60 CHAPTER 2 8354/8404 2) Valve clearance 1. Remove the cylinder head cover and the timing win- dow cover on the flywheel housing and all glow plugs. 2. Turn the flywheel and align the 1 TC or 1.4 TC mark...
Page 61 www.mymowerparts.com ENGINE SYSTEM (B) Heat seal removal procedure 1. Drive screw driver lightly into the heat seal hole. 2. Turn screw driver three or four times each way. 3. While turning the screw driver, slowly pull the heat seal put together with the injection nozzle gasket. If the heat seal drops, repeat the above procedure.
Page 62 CHAPTER 2 8354/8404 (D) Cylinder head 1. Remove the screw in the specified sequence shown in the figure and remove the cylinder head (1) and head gasket. 2. Remove the water flange (2). 3. Take out the tappets from the cylinder block.
Page 63 www.mymowerparts.com ENGINE SYSTEM 1) Timing Gears and Camshafts (A) Injection pump 1. Remove the injection pump cover (3) with the en- gine stop lever (2). 2. Remove the injection pump. (When reassembling) • Apply liquid gasket to the both sides of injection pump cover gasket and install it.
Page 64 CHAPTER 2 8354/8404 (C) Start spring 1. Remove the start spring (1) from the fork lever 1 (2). (When reassembling) • Be careful not to drop the start spring into the gear case. • Hook the start spring so that the longer hook is on the fork lever side.
Page 65 www.mymowerparts.com ENGINE SYSTEM (F) Water pump and relief valve 1. Remove the water pump body (1). 2. Remove the relief valve cover (2) and take out the ball, spring and seat. (When reassembling) • Install the relief valve cover (2) with its mark up. Tightening Relief valve 32.4 ~ 36.3 N·m...
Page 66 CHAPTER 2 8354/8404 (H)Camshaft 1. Align the holes on the cam gear (2) with the crews to loosen them through the holes with a T handle wrench. 2. Draw out the camshaft (1). 3. Remove the cam gear (2).
Page 67 www.mymowerparts.com ENGINE SYSTEM (B) Piston and connecting rod 1. Remove the screws and the connecting rod cap. 2. Push out the rod and piston assembly. (When reassembling) • Apply oil to the crankpin bearing, cylinder wall and connecting rod cap screw. •...
Page 68 CHAPTER 2 8354/8404 (C)Piston ring and piston pin 1. Remove the piston rings with a piston ring replac- ing tool. 2. Remove the piston pin. (When reassembling) • Clean all the parts before assembling. • Heat the piston in approx. 80 °C (176 °F) of oil for 10 ~ 15 minutes, when inserting the piston pin into the piston.
Page 69 www.mymowerparts.com ENGINE SYSTEM (B) Bearing case cover Loosen the screw first inside and next outside, and lift the cover (1) by screwing two screws gradually and evenly, referring to the photo. (When reassembling) • Apply grease to the oil seal lip and take care that it is not rolled when installing.
Page 70 CHAPTER 2 8354/8404 IMPORTANT: • Mark the location line to the bearing case, to pre- vent interchanging. (When reassembling) • Clean the parts and the oil passage of the bearing case. • Apply oil to the journal, bearing inserts and the bear- ing case screws.
Page 71 www.mymowerparts.com ENGINE SYSTEM (C)Valve stem clearance 1. Remove the carbon from the valve guide. 2. Measure the valve stem O.D. with an outside micrometer. 3. Measure the valve guide I.D. of cylinder head, and calculate the clearance. 4. If the measurement exceeds the allowable limit, replace the valve guide of the valve.
Page 72 CHAPTER 2 8354/8404 (F) Valve spring 1. Measure the free length of the spring with venire calipers. 2. Place the spring on a spring compression tester and compress to the specified length, and get the tension. 3. If the measurement is less than the allowable limit, replace the valve spring.
Page 73 www.mymowerparts.com ENGINE SYSTEM 2) Timing gears and camshafts (A) Timing gear backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear. 3. If the backlash exceeds the allowable limit, check the oil clearance of the shafts and the gear.
Page 74 CHAPTER 2 8354/8404 (D)Injection pump gear side clearance 1. Pull the fuel camshaft and pull the injection pump gear (1) to each end. 2. Measure the clearance A between the injection pump gear (1) and the snap ring (2) on the fuel camshaft.
Page 75 www.mymowerparts.com ENGINE SYSTEM (G)Camshaft oil clearance 1. Measure the I.D. of the camshaft bore on the crank- case with an inside micrometer. 2. Measure the O.D. of the camshaft journal with an outside micrometer. 3. If the clearance exceeds the allowable limit, replace the shaft.
Page 76 CHAPTER 2 8354/8404 3) Connecting rod and piston (A) Piston pin bore 1. Measure the I.D. of piston pin bore in piston (length- wise and widthwise of the piston) with a cylinder gauge. 2. If the measurement exceeds the allowable limit, re- place the piston.
Page 77 www.mymowerparts.com ENGINE SYSTEM (D)Piston ring end gap 1. Push down the ring into the cylinder to the lower limit of ring travel in the assembled engine with a piston. 2. Measure the ring gap with a feeler gauge. 3. If the gap exceed the allowable limit, replace the piston ring.
Page 78 CHAPTER 2 8354/8404 (F) Connecting rod alignment 1. Remove the connecting rod bearing and install the bearing cap. 2. Install the piston pin in the connecting rod. 3. Install the connecting rod on the connecting rod alignment tool. 4. Put a gauge over the piston pin and move it against the face plate.
Page 79 www.mymowerparts.com ENGINE SYSTEM (B) Crankshaft alignment 1. Support the crankshaft with V blocks on the surface plate at its front and rear journals and set a dial indicator with its tip on the intermediate journal. 2. Rotate the crankshaft in the V blocks and get the misalignment (half of the measurement).
Page 80 CHAPTER 2 8354/8404 (E) Crankshaft journal and bearing 2 oil clearance 1. Put plastic gauge lengthwise in the center of the journal. 2. Install the bearing cap and tighten the screw to the specified torque once, and remove the cap again.
Page 81 www.mymowerparts.com ENGINE SYSTEM 5) Cylinder bore (A) Cylinder bore diameter 1. Measure the cylinder liner I.D. at sit positions shown in the figure to find the maximum wear. 4A200B 83.000 ~ 83.022 mm 3.2677 ~ 3.269 in. 3A165D 87.000 ~ 87.022 mm 3.425 ~ 3.4261 in.
Page 82 CHAPTER 2 8354/8404 D. LUBRICATING SYSTEM a . Checking (A) Engine oil pressure 1. Remove the oil pressure switch and install adap- tors and pressure tester. 2. Start the engine and run it until it is warmed up, and measure the oil pressure both at idling and rated speed.
Page 83 www.mymowerparts.com ENGINE SYSTEM b. Servicing (A) Rotor and lobe clearance of oil pump 1. Measure the clearance between the outer and in- ner rotor with a feeler gauge. 2. Measure the clearance between the outer and the housing with a feeler gauge. 3.
Page 84 CHAPTER 2 8354/8404 E. COOLING SYSTEM a . Checking Adjusting (A) Fan belt 1. Measure the deflection, depressing the belt half- way between the fan drive pulley and the alternator pulley at 98 N (10 kgf, 22 lbs) of force.
Page 85 www.mymowerparts.com ENGINE SYSTEM b. Disassembling and Assembling (A) Thermostat 1. Remove the thermostat cover (2). 2. Take out the thermostat (1). (When reassembling) • Apply liquid gasket (Three Bond 1215 or equivalent) to the gasket. 615W2D3A (1) Thermostat (2) Thermostat Cover (B) Water pump 1.
Page 86 CHAPTER 2 8354/8404 F. FUEL SYSTEM a . Checking and Adjusting 1) Injection pump (A) Injection term (Injection timing) 1. Remove the injection pipes. 2. Set the speed control lever to the maximum fuel discharge position. 3. Turn the flywheel counterclockwise (facing the flywheel) until the fuel flow through to the hole of the delivery valve holder (1).
Page 87 www.mymowerparts.com ENGINE SYSTEM b. Injection nozzle • Never contact with spraying diesel fuel under pressure, pressure, which can have sufficient force to penetrate the CAUTION skin, causing serious personal injury. • Be sure nobody is in direction of the spray. (A) Fuel injection pressure 1.
Page 88 CHAPTER 2 8354/8404 c. Disassembling and Assembling 1) Injection pump IMPORTANT: • If replacing the pump element, the amount of fuel injection should be adjusted on specified bench. 615W2E0A (1) Pump Body (5) Delivery Valve (2) Control Rack (6) Tappet Roller...
Page 89: Chapter 3 Clutch
www.mymowerparts.com CHAPTER 3 CLUTCH K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 90 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 91: Disassembly And Assembly
www.mymowerparts.com CLUTCH 1. DISASSEMBLY AND ASSEMBLY 1.1 DISASSEMBLY OF PANEL FRAME A. FIRST STAGE 615W301A (1) Side Cover (Left, Right) (3) Front Grill Assembly (2) Bonnet (4) Cover-Low (Left, Right) 1. Disassemble side cover (1), bonnet (2), front grill assembly (3) and cover-low (4). D615-W02 May-2003 K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 92 CHAPTER 3 8354/8404 B. SECOND STAGE 615W302A 615W303A 615W304A (1) Steering Hose Assembly T (7) Accelerator Cable (2) Steering Hose Assembly P (8) Indicator Cable (3) Steering Hose Assembly L (9) Panel Wiring Harness Assembly (4) Steering Hose Assembly R...
Page 93 www.mymowerparts.com CLUTCH C. THIRD STAGE 1. Disengage attaching bolt (2) of frame assembly (1). 2. Disassembly frame assembly. 615W306A (1) Frame Assembly (2) Bolt (When reassembling) • When connecting with power steering unit hoses (1), (2), (3) and (4) make sure hose color and con- necting port to be assembled properly.
Page 94: Disassembly Of Fender And Stepladder Assembly
CHAPTER 3 8354/8404 1.2 DISASSEMBLY OF FENDER AND STEPLADDER ASSEMBLY A. FIRST STAGE 615W308A (1) ROPS (10) Seat Lower Assembly (2) Seat Assembly (11) Differential Clamping Rod (3) Main Shift Knob (12) Spring (4) Knob (Range Lever) (13) Rear Light...
Page 95 www.mymowerparts.com CLUTCH 1. Disconnect ROPS (1). (When reassembling) 2. Disconnect seat assembly (2). Sect. Spec. Tightening Torque 3. Disconnect knobs (3), (4), (5), (6) and (7) of each Stepladder assembly 196 ~ 225 N·m transmission shift lever. and seat lower 20.0 ~ 23.0 kgf·m 4.
Page 96: Clutch
CHAPTER 3 8354/8404 2. CLUTCH 2.1 CHARACTERISTICS 615W310A (1) Clutch Disc Assembly (5) Clutch Release Fork (2) Clutch Cover Assembly (6) Propulsion Shaft Case (3) Release Bearing (7) Main Clutch Lever (4) Clutch Release Hub • Independent PTO method clutch are adapted enable to control the power of Running and the PTO system independently.
Page 97: Link Structure And Control
www.mymowerparts.com CLUTCH 2.2 LINK STRUCTURE AND CONTROL • If working clutch pedal, clutch rod (2) is pulled in the direction of arrow and release hub (5) moves to the direction of arrow through release fork (4). • Release bearing (6) of release hub pushes dia- phragm spring (8) of clutch cover assembly (7), re- leases clutch disc (10) between clutch pressure plate (9) and flywheel (11), and then disconnects...
Page 98: Troubleshooting
CHAPTER 3 8354/8404 2.3 TROUBLESHOOTING Trouble Probable Cause Remedy Remark Clutch trailed • Clutch pedal play excessive Adjust • Clutch disk dirty due to clutch disc Clean assembly • Clutch fork broken Replace • Clutch disc or pressure plate distorted Replace •...
Page 99: Specification
www.mymowerparts.com CLUTCH 2.4 SPECIFICATION Item Reference Allowable Limit Clutch pedal Play 30 ~ 40 mm 1.18 ~ 1.57 in. Stopper bolt setting length Height 27 ~ 29 mm 1.06 ~ 1.14 in. 3 ~ 4 mm Clearance between safety switch and clutch pedal 0.12 ~ 0.16 in.
Page 100: Disassembly, Maintenance
CHAPTER 3 8354/8404 2.6 DISASSEMBLY, MAINTENANCE A. CLUTCH PEDAL CHECK AND ADJUST- MENT a . First Stage (Clutch Pedal Play Adjustment) 1. Press clutch pedal (1) by hand and measure play (A) at the end of pedal. 2. If measurement exceeds the specified, loosen lock nut (3) of clutch rod (2), re-adjust the length of clutch rod, set pedal play and then tighten with lock nut.
Page 101 www.mymowerparts.com CLUTCH B. DISASSEMBLY, ASSEMBLY a . First Stage (Disconnection of Clutch Hous- ing and Flywheel Housing) 1. Support clutch housing (1) and engine with hydrau- lic jack. 2. Disengage clutch housing (1), flywheel housing (2), tightening bolt (3) nut (4). 3.
Page 102 CHAPTER 3 8354/8404 C. MAINTENANCE a . Check of Play Between Clutch Disc Spline Boss and Gear Shaft 1. Attach gear shaft with clutch disc. 2. With the gear shaft locked, rotate the disc slightly and measure the play at O.D. end of disc.
Page 103 www.mymowerparts.com CLUTCH d. Check of Flywheel and Clutch Pressure Plate 1. Check to see if the flywheel and clutch pressure plate are faulty or scored. 2. If a dent or score is found then replace it. 3. Put a straight rule on clutch pressure plate and check the flatness using a gab gauge, if it exceeds the allowable limit, replace it.
Page 104 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 105: Chapter 4 Transmission
www.mymowerparts.com CHAPTER 4 TRANSMISSION K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 106 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 107: Structure
www.mymowerparts.com TRANSMISSION 1. STRUCTURE Sect. Main Shift Shuttle Hi-Lo Shift Creep Speed (*) Transmission Synchro mesh Synchro mesh Constant mesh Constant mesh Fixed method Transmission 4th Stage Forward/ 2nd Stage 2nd Stage 1st Stage stage Reversing (Low/High Speed) (Low/High Speed) Forward: 8th Stage, Reversing: 8th Stage (*:Option,Forward: 16th Stage, Reversing: 16th Stage) 615W401A...
Page 108: Power Transmission
CHAPTER 4 8354/8404 2. POWER TRANSMISSION 2.1 MAIN TRANSMISSION • Consists of full synchro mesh and employs key type as synchro. A. Power Transmission Flow 615W403A (1) 25 Gear Shaft (5) 29 Gear (9) Synchro Hub (13) Shift (2) 26 Gear...
Page 109 www.mymowerparts.com TRANSMISSION B. Synchro Operation 1st Stage • By shifting the main transmission shift lever, shifter (3) and key (2) are moved and the end of the key contacts with cone of gear (6) with synchronizer ring (5) pushed. • By friction power occurred in the cone of synchro- nizer key (2), and synchro hub (1) rotates in a body.
Page 110 CHAPTER 4 8354/8404 Final Stage • When the rotation speed of shift (3) are equal with that of gear (6), the rotation force of synchronizer ring (4), will not affect on shift any longer. The Shift is rotated with the synchronizer ring and gear (6), engaged for perfect transmission.
Page 111: Shuttle
www.mymowerparts.com TRANSMISSION 2.2 SHUTTLE • Employs double synchro mesh type with 8th stage in forward or reverse and improves the transmis- sion shift power and durability as the contacted amount of cone increased twice. Power Transmission Flow Chart 615W407A (1) Shuttle Shaft (7) 16 Gear (2) Spline Hub (8) 18 Gear...
Page 112: Hi-Lo Shift
CHAPTER 4 8354/8404 2.3 HI-LO SHIFT • With High/Low stage, employs selective engage- ment method and when setting the Hi-Lo shift lever to the transmission position, the power will be trans- mitted. Power Transmission Flow 615W408A (1) Hi-Lo Shift Shaft...
Page 113: Mid Pto
The independent PTO method in the 1st stage is the fixed type, and employs a hydraulic clutch. Power Transmission Flow Applicable Model PTO type PTO stage PTO rpm/Engine rpm 8354/8404 Independent PTO 1st stage fixed type 540/2505 615W410A (1) 22 Gear Shaft (PTO) (5) 19 Gear...
Page 114: Creeper Speed (If Applicable )
CHAPTER 4 8354/8404 2.6 CREEPER SPEED (IF APPLICABLE ) • The High/Low stage, employs a gear engagement method and when setting the Hi-Lo shift lever and creep speed lever to the transmission position, the power will then be transmitted.
Page 115: Transmission Shift Link Structure
www.mymowerparts.com TRANSMISSION 3. TRANSMISSION SHIFT LINK STRUCTURE 3.1 MAIN SHIFT • The transmission shift lever (1) is located in left of the driver’s seat and is connected to transmission arm (3), transmission fork (4), and (5). • One transmission shift lever is enabled from the 1st to the 4th stage and is easy to operate.
Page 116: Hi-Lo Shift
(4) Transmission Arm (Aux. Transmission) (5) Transmission Fork (Aux. Transmission) [A] Low [B] High 3.4 SHIFT • 8354 and 8404 models employs 1st stage fixed type and enables manual or auto operation by means of a switch. 3.5 CREEPER SPEED Model:(IF APPLICABLE ) •...
Page 117: Mid Pto Shift
www.mymowerparts.com TRANSMISSION 3.6 MID PTO SHIFT • Mid PTO lever (1) is located to the right of the driver’s seat and connected to the mid PTO lever assembly (2), rod (3), mid PTO lever 1 (4), trans- mission arm (5), and the transmission fork (6). •...
Page 118: Pto Clutch
CHAPTER 4 8354/8404 4. PTO CLUTCH 4.1 CHARACTERISTICS • PTO clutch body is a wet multiplate hydraulic clutch and the clutch valve is set to [ON] or [OFF] to supply the PTO, using PTO switch. • When PTO clutch is set to [ON], it can be selected automatically or manually.
Page 119: Oil Flow
www.mymowerparts.com TRANSMISSION 4.3 OIL FLOW A. With PTO Clutch ON a. If PTO conversion switch is set to [ON], the PTO clutch valve will be operated to flow oil from the hy- draulic pump to PTO clutch “A” port. b. This oil flows to the piston, where it pushes the piston in the direction of arrow with spring compres- sion.
Page 120: Differential Gear
CHAPTER 4 8354/8404 5. DIFFERENTIAL GEAR 5.1 STRUCTURE • Differential gear is a 4 pin type, distributes and pro- vides suitable rpm’s automatically to the left and right wheel for tractor’s turning and efficient run- ning on off road or curve.
Page 121: Operation
www.mymowerparts.com TRANSMISSION 5.2 OPERATION A. Traveling Straight Ahead • Rotation of spiral bevel pinion (1) will be transmit- ted to spiral bevel gear (2) and if road resistance is transmitted to both wheels equally, the differential pinion (4) and differential side gear (5), (6) will be rotated with differential case (3) in a body and dif- ferential gear shaft (7).
Page 122 CHAPTER 4 8354/8404 C. Differential Lock • When the resistance of the right and left tires varies from the ground or work conditions, it could cause the wheels to slip and one wheel will be rotating faster than the other. Therefore, towing power will be decreased.
Page 123: Troubleshooting
www.mymowerparts.com TRANSMISSION 6. TROUBLESHOOTING Trouble Probable Cause Remedy Remark Transmission noise • Lack in transmission oil or unsuitable Re-supply excessive oil used. • Gear worn or backlash improper Replace • Bearing worn or broken Replace • Transmission fork worn Replace •...
Page 124: Maintenance Specification
CHAPTER 4 8354/8404 7. MAINTENANCE SPECIFICATION Item Reference Value Allowable Limit Transmission shift and shift Clearance 0.10 ~ 0.3 mm 0.8 mm groove 0.004 ~ 0.012 in. 0.031 in. Between synchro and spline Clearance 1.35 ~ 1.65 mm 0.5 mm 0.053 ~ 0.065 in.
Page 125: Tightening Torque
www.mymowerparts.com TRANSMISSION 8. TIGHTENING TORQUE The following nut and bolt tightening torque was specified specially. Item Spec N·m Kgf·m lbf·ft Hydraulic hose and joint bolt of front hydraulic block 49.0 ~ 58.8 5.0 ~ 6.0 36.2 ~ 43.4 Hydraulic block support tightening bolt 23.6 ~ 27.4 2.4 ~ 2.8 17.4 ~ 20.2...
Page 126: Clutch Housing
CHAPTER 4 8354/8404 9. CLUTCH HOUSING DISASSEMBLY, MAINTENANCE 615W435A (1) 22 Gear Shaft (PTO) (7) Main Shaft Gear (2) 25 Gear Shaft (8) 24 Gear (3) 23-19 Gear Shaft (PTO) (9) 29 Gear (4) Counter Shaft (PTO) (10) 33 Gear...
Page 127: Transmission Oil Draining
www.mymowerparts.com TRANSMISSION 9.1 TRANSMISSION OIL DRAINING 1. Loosen oil drain plug in the lower of clutch housing and transmission case. 2. Drain transmission oil. 3. Reconnect oil drain plug. (When reassembling) • Disconnect plug from filler neck and then fill oil to the scale of oil gauge.
Page 128 CHAPTER 4 8354/8404 B. Second Stage (Hydraulic Pipe Disconnection) 615W439A (1) Brake Rod (7) Hydraulic Pipe 2 (12) Hydraulic Block (2) Intake Pipe 3 (8) Bolt (13) Hydraulic Block Support (3) Intake Pipe 2 (9) Joint Bolt (14) Washer Holding Bolt...
Page 129 www.mymowerparts.com TRANSMISSION C. Third Stage (Disconnection of Clutch Housing and Flywheel Housing) 1. Support the lower of clutch housing (1) and engine with a hydraulic jack. 2. Loosen tightening bolt (3) and nut (4) of clutch hous- ing and flywheel housing (2). 3.
Page 130 CHAPTER 4 8354/8404 D. Fourth Stage (Transmission Rod Disconnection) 1. Pull out spring pin (2) of transmission shift rod (1) and disconnect the main transmission shift rod 2 (3). 2. Disengage the shuttle transmission arm (4) lock- ing bolt (5) and raise the transmission arm.
Page 131 www.mymowerparts.com TRANSMISSION E. Fifth Stage (Disconnection of Intermediate Case and Clutch Housing) 1. Disengage the shuttle transmission arm (1) lock- ing bolt (2) and pull up transmission arm. 2. Disengage tightening bolt (5) and nut (6) of clutch housing (3) and intermediate case (4). 3.
Page 132: Clutch Housing Disassembly
CHAPTER 4 8354/8404 10. CLUTCH HOUSING DISASSEMBLY 10.1 FIRST STAGE (DISCONNECTION OF MAIN TRANSMISSION COVER) 1. Disengage main transmission cover (1) attaching bolt (2) and disconnect transmission cover. (When reassembling) • Engage transmission rod (3) with transmission arm (4) locking bolt (5) and perform locking both ends of jawed washer firmly to prevent loosening.
Page 133: Second Stage (Disconnection Of Propulsion Shaft Case)
www.mymowerparts.com TRANSMISSION 10.2 SECOND STAGE (DISCONNECTION OF PROPULSION SHAFT CASE) 1. Loosen clutch release fork (1) locking bolt (2) and pull out main clutch lever (3). 2. Disconnect clutch release hub (4) and release bear- ing (7). 3. Loosen propulsion shaft case (5) attaching bolt (6) and using M6 service bolt (two), disconnect propul- sion case.
Page 134: Third Stage (Disassembly Of 25 Gear Shaft And Propulsion Shaft 1)
CHAPTER 4 8354/8404 10.3 THIRD STAGE (DISASSEMBLY OF 25 GEAR SHAFT AND PROPULSION SHAFT 1) 1. Pull out 25 gear shaft (2) from propulsion shaft cover (1). 2. Loosen snap ring (3) for shaft and pull out 26 gear (4).
Page 135: Fifth Stage (Disconnection Of Transmission Fork)
www.mymowerparts.com TRANSMISSION 10.5 FIFTH STAGE (DISCONNECTION OF TRANSMISSION FORK) (When reassembling) 1. Loosen locking bolt (2), (3) from bearing cover (1) and pull out ball (4) and spring (5). 2. Pull out spring pin (8) from transmission fork (6), (7) and disconnect transmission fork and fork rod (9), (10).
Page 136: Sixth Stage (Disassembly Of 22 Gear Shaft)
CHAPTER 4 8354/8404 10.6 SIXTH STAGE (DISASSEMBLY OF 22 GEAR SHAFT) 1. Disengage snap ring (2) for 22 gear shaft (1) and pull out 22 gear shaft from the clutch housing. 2. Loosen snap ring (3) for hole of clutch housing and pull out bearing (4).
Page 137: Seventh Stage (Disassembly Of Main Transmission Counter Shaft)
www.mymowerparts.com TRANSMISSION 10.7 SEVENTH STAGE (DISASSEMBLY OF MAIN TRANSMISSION COUNTER SHAFT) 615W455A (1) Snap Ring (6) Needle Bearing (11) 29 Gear (2) Ball Bearing (7) 24 Gear (12) 33 Gear (3) Ball Bearing (8) 36 Gear (13) Synchronizer Ring (4) Thrust Collar (9) Snap Ring (14) Synchronizer Key (5) Needle Bearing...
Page 138 CHAPTER 4 8354/8404 615W456A (1) Shaft, Counter (9) Ring, Synchronize (17) Bearing, Needle (2) Bearing, Ball (10) Key, Synchronize (18) Cir-clip (3) Cir-clip (11) Spring (19) Collar, Thrust (4) Collar, Thrust (12) Cir-clip (20) Bearing, Ball (5) Gear, 24...
Page 139: Maintenance
www.mymowerparts.com TRANSMISSION 10.8 MAINTENANCE A. Bearing Checking 1. With bearing inner wheel seized, pull in and out outer wheel left and right and check for wear and clearance. 2. Apply bearing ball with transmission oil and with bearing inner wheel seized and outer wheel rotated, check for abnormal noise and operation.
Page 140 CHAPTER 4 8354/8404 D. Synchro Assembly Check 1. Check synchronizer key and spring for damage and replace it if necessary. 2. With synchronizer ring contacted with taper cone of the opposite gear, measure the clearance between synchro spline and opposite gear spline using clearance gauge.
Page 141: Intermediate Case
www.mymowerparts.com TRANSMISSION 11. INTERMEDIATE CASE 615W461A (1) PTO Clutch Assembly (5) 16 Gear (2) 12 Gear Shaft (6) Shuttle Shaft (3) 23-21 Gear (7) 18 Gear (4) 19 Gear D615-W02 May-2003 4-37 K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 142: Disassembly, Assembly
CHAPTER 4 8354/8404 11.1 DISASSEMBLY, ASSEMBLY A. Disconnection of Intermediate Case Group 615W463A (1) Transmission Case (3) Bolt (2) Intermediate Case (4) Nut a. First Stage (Disconnection of Intermediate (When reassembling) Case and Transmission Case) • Make sure PTO clutch assembly and spline hub is 1.
Page 143 www.mymowerparts.com TRANSMISSION B. Disassembly of Intermediate Case a. First Stage (Disconnection of Modulator Valve Assembly) 1. Disengage modulator valve assembly (1) attaching bolt (2) and disconnect valve assembly. (When reassembling) • Check valve assembly, connecting pipe (3), and O- ring (4), (5) and apply the contacted surface with grease.
Page 144 CHAPTER 4 8354/8404 c. Third Stage (Disassembly of Shuttle Fork) 1. Straighten cocking of lock washer (1) and loosen lock bolt (2). 2. Pull out fork rod (4) from bearing cover (3) and dis- assemble transmission fork (5). •...
Page 145 www.mymowerparts.com TRANSMISSION e . Fifth Stage (Disassembly of Shuttle Shaft) 1. Loosen snap ring (1) and disassemble spacer (2). 2. Remove bearing (3), (4) using bearing puller. 3. Disassemble thrust collar (5), needle bearing (6), 19 gear (7) and 16 gear (8). 4.
Page 146 CHAPTER 4 8354/8404 b. Second Stage (Disconnection of PTO Clutch) 1. Disengage snap ring (1) for hole and pull out pres- 2. Disengage snap ring (7) for shaft and pull out sure plate (2), clutch plate (3), clutch disc (4), spline spacer (8), spring (9), piston (10), return plate (11), hub (5) and bearing (6).
Page 147: Maintenance
www.mymowerparts.com TRANSMISSION 11.2 MAINTENANCE A. Bearing Check 1. With bearing inner wheel seized, pull in and out outer wheel left and right and check for wear and clearance. 2. Apply bearing ball with transmission oil and check for abnormal noise or operation, while taking bear- ing inner wheel and rotating outer wheel by hand.
Page 148 CHAPTER 4 8354/8404 2. With synchronizer ring contacted with taper cone of the opposite gear, measure the clearance between synchro spline and opposite gear spline using clearance gage. Sect. Specified Limit Clearance 1.35 ~ 1.65 mm 0.5 mm between 0.053 ~ 0.065 in.
Page 149 www.mymowerparts.com TRANSMISSION F. Checking piston, pressure plate and return plate for flatness 1. Using feeler gage, measure the flatness of piston, pressure plate, and return plate. 2. If exceeds allowable tolerance, replace it. Sect. Specified Allowable Limit Flatness of 0.05 mm 1.5 mm piston 0.002 in.
Page 150: Transmission Case
CHAPTER 4 8354/8404 12. TRANSMISSION CASE 615W478A (1) Aux. Shift Shaft (5) Idle Shaft (2) Spiral Bevel Pinion (6) Mid PTO Shaft (3) Front Drive Shaft (7) PTO Drive Shaft (4) 13 Gear Shaft (8) PTO Shaft (CR option) (9) PTO Drive Shaft 12.1 DISASSEMBLY, ASSEMBLY...
Page 151 www.mymowerparts.com TRANSMISSION b. Second Stage (Disconnection of Hydraulic Cylinder Assembly) 1. Disengage hydraulic cylinder assembly (1) attach- ing bolt (3) and nut (2) and disconnect hydraulic cylinder assembly (1). (When reassembling) • Replace packing. Sect. Spec. Tightening Torque Tightening bolt 48.1 ~ 55.8 N·m 615W481A 4.9 ~ 5.7 kgf·m...
Page 152 CHAPTER 4 8354/8404 d. Fourth Stage (Disconnection of Rear Axle Case) 1. Loosen bolt (1) and nut (2) and disconnect rear axle case (3) in assembly. (When reassembling) • Remove foreign matters or oil from contacted sur- face between brake case and rear axle case and apply it with sealing agent.
Page 153 www.mymowerparts.com TRANSMISSION B. Disconnection of Transmission Case a. First Stage (Disconnection of PTO Shaft) 1. Loosen bearing case (1) attaching bolt (2) and dis- connect PTO shaft (3) and bearing case in assem- bly. 2. Loosen snap ring (4) and pull out PTO shaft with bearing (5).
Page 154 CHAPTER 4 8354/8404 c. Third Stage (Disassembly of Front wheel drive gear assembly/MID PTO Case assembly) 1. Loosen MID PTO case (1) attaching bolt (2) and disconnect case and gear in assembly. 2. Disconnect front wheel drive shaft assembly (3) from transmission case.
Page 155 www.mymowerparts.com TRANSMISSION e. Fifth Stage (Disassembly of Gear Shaft Assembly) 615W495A (1) Nut (7) Pinion Shaft Assembly (2) Bearing Cover (8) Hi-Lo Shift Shaft Assembly (3) Bolt (9) 13 Gear Shaft (Optional) (4) Bearing Case (10) Ball Bearing (5) Shim (11) 27 (30) Gear (6) Taper Roller Bearing Assembly (12) PTO Drive Shaft Assembly...
Page 156 CHAPTER 4 8354/8404 f. Sixth Stage (Disassembly of Spiral bevel pinion shaft) 1. Pull out taper roller bearing (1) using bearing puller and disassemble spacer (2), 25 spur gear (3), and 42-17 gear (4). (When reassembling) • Take care of assembly direction of 25 spur gear.
Page 157 www.mymowerparts.com TRANSMISSION i. Ninth Stage (Disassembly of Creep Speed Shaft) 1. Loosen snap ring (1) and disassemble thrust col- lar (2), 26-20 gear (3), needle bearing (4), and spacer (5). (When reassembling) • Oil groove of thrust collar should be toward gear. •...
Page 158 CHAPTER 4 8354/8404 k. Tenth Stage (Disconnection of Differential Gear Assembly) 615W4A4A (1) Spring Pin (7) Oil Seal (2) Snap Pin (8) Bearing Case (Left) (3) Flat Washer (9) Bearing Case (Right) (4) Pin (10) Bolt (5) Differential Locking Fork Shaft...
Page 159 www.mymowerparts.com TRANSMISSION l. Eleventh Stage (Disassembly of Differential gear) 615W4A5A (1) Taper Roller Bearing (7) Differential Pinion Shaft 1 (2) Taper Roller Bearing (8) Differential Pinion Shaft 2 (3) Differential Locking Shift (9) Differential Side Gear (4) Cap (10) Differential Washer (5) Spiral Bevel Gear (11) Differential Pinion (6) Bolt...
Page 160: Maintenance
CHAPTER 4 8354/8404 12.2 MAINTENANCE A. Bearing Check 1. With bearing inner wheel seized, pull in and out outer wheel left and right and check for wear and looseness. 2. Apply bearing ball with transmission oil and with bearing inner wheel seized and outer wheel rotated, check for abnormal noise and operation.
Page 161 www.mymowerparts.com TRANSMISSION D. Bevel Pinion Shaft and Spiral Bevel Gear Setting 1. When assembling differential gear assembly into transmission case, adjust pre-load of taper roller bearing (1), (2). a. Adjustment Method • Insert datum shim (0.75 mm) in left and right bear- ing case (3), (4) and check bearing pre-load with rotation torque of spiral bevel gear (5).
Page 162 CHAPTER 4 8354/8404 <Good Tooth Contact> • More than 35% tooth contacted. The center is lo- cated between one third and one half from small. 615W4B0A • Decrease shim (7) of bearing case (6) and move bevel pinion shaft (2) in the direction of arrow. Move...
Page 163 www.mymowerparts.com TRANSMISSION E. Check Differential Gear for Worn a. Clearance Check of Differential Case, Cap, and Differential Side Gear Sect. Specified Limit Clearance of 0.050 ~ 0.15 mm 0.35mm differential case, 0.00197 ~ 0.00594 in. differential case 0138in. cap, and differential side gear 40.500 ~ 40.561 mm I.D.
Page 164 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 165: Chapter 5 Rear Axle
www.mymowerparts.com CHAPTER 5 REAR AXLE K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 166 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 167: Structure
MODEL: 8354 / 8404 615W501A (1) Rear Axle Case (4) 10 Gear Shaft(8354)/11 Gear Shaft(8404) (2) Rear Axle (5) Brake Case (3) 55 Gear (8354) / 60 Gear (8404) (6) Differential Gear Assembly D615-W02 May-2003 K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 168: Tightening Torque
CHAPTER 5 8354/8404 2. TIGHTENING TORQUE Item Spec. N·m Kgf·m lbs·ft Rear wheel tightening bolt 260.8 ~ 303.8 26.6 ~ 31.0 192 ~ 224 Brake case and rear wheel case 48.0 ~ 55.9 4.9 ~ 5.7 35.4 ~ 41.2...
Page 169: Service Specification
www.mymowerparts.com REAR AXLE 3. SERVICE SPECIFICATION Application Specified Limit Internal gear and planetary gear Backlash 0.1 ~ 0.2 mm 0.5 mm support 0.0039 ~ 0.0079 in. 0.197 in. Planetary gear and planetary Clearance 0.009 ~ 0.050 mm 0.3 mm gear shaft 0.00035 ~ 0.00197 in.
Page 170: Disassembly, Assembly
CHAPTER 5 8354/8404 4. DISASSEMBLY, ASSEMBLY 4.1 DISCONNECTION OF REAR AXLE GROUP A. First Stage (Disconnection of Rear Wheel) 1. Support the transmission case with a hydraulic jack to raise tire the tires from the ground. 2. Loosen the wheel lug nuts and disconnect the tires from axle.
Page 171 www.mymowerparts.com REAR AXLE C. Third Stage (Disassembly of Planetary Gear) 1. Insert spring pin (1) into planetary gear shaft (2). 2. When pulling out the planetary gear shaft (2), re- move the planetary gear (3), needle bearing (4) and thrust collar (5). 3.
Page 172: Disassembly Of Rear Axle
CHAPTER 5 8354/8404 4.2 DISASSEMBLY OF REAR AXLE 1. Using bearing puller, pull out ball (roller) bearing (2) from the rear axle (1). 2. Straighten cocking of 55 (60) gear (3) locking nut (4). 3. Disassemble 55 (60) gear, spacer barrel (5), and spacer plate (6).
Page 173: Maintenance
www.mymowerparts.com REAR AXLE 5. MAINTENANCE 5.1 BEARING CHECK 1. With bearing inner wheel seized, pull in and out outside of bearing left and right and check for wear and clearance. 2. Apply the bearing ball with transmission oil and ro- tate the inside bearing while holding the outside of bearing still, checking for abnormal noise and operation.
Page 174 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 175: Chapter 6 Brake
www.mymowerparts.com CHAPTER 6 BRAKE K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 176 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 177: Structure
www.mymowerparts.com BRAKE 1. STRUCTURE 615W601A (1) Brake Case (3) Brake Rod (5) Turn Buckle (7) Parking Brake Lever (2) Brake Cam Lever (4) Brake Lever (6) Brake Pedal • For the left and right running brake, an independent mechanical wet disc brake is used and operated through brake pedal by mechanical linkage.
Page 178: Operation
CHAPTER 6 8354/8404 2. OPERATION 615W602A (1) Cam Plate (3) Brake Plate (5) Ball (7) Brake Cam (2) Brake Disc (4) Brake Case (6) Gear Shaft (8) Brake Cam Lever Operational Principle If depressing brake pedal, brake cam lever (8) will be moved in the arrow direction by linkage as shown in the above figure.
Page 179: Troubleshooting
www.mymowerparts.com BRAKE 3. TROUBLESHOOTING Trouble Probable Cause Remedy Remark Brake power is not • Brake pedal clearance is not constant Adjust constant • Brake disc is worn Replace • Cam clutch is bent Replace Brake is trailed • Brake pedal clearance is too small Adjust •...
Page 180: Maintenance Specification
CHAPTER 6 8354/8404 4. MAINTENANCE SPECIFICATION Item Reference Value Allowable Limit Brake pedal Clearance 25 ~ 35 mm (0.98 ~ 1.38 in.) Difference between left and right Deviation 5 mm when not depressing brake pedal (0.197 in.) Brake pedal and stop switch...
Page 181: Brake Pedal
www.mymowerparts.com BRAKE 6. BRAKE PEDAL 6.1 DISASSEMBLY, MAINTENANCE [CHECK AND ADJUSTMENT] A. First Stage (Clearance Adjustment of Brake Pedal) 1. Disengage the brake pedal connection hook (1) and measure the clearance of left and right pedals. 2. If the clearance of left and right pedals exceeds the specified limit, loosen lock nut (2) and adjust clear- ance using a turn buckle (3).
Page 182: Maintenance
CHAPTER 6 8354/8404 6.2 MAINTENANCE Check the clearance between brake lever bush and brake shaft 1. Measure I.D. of brake lever bush. 2. Measure O.D. of brake shaft. 3. Calculate the clearance with the measured value. If exceeding the allowable limit, replace bush.
Page 183: Brake Case
www.mymowerparts.com BRAKE 7. BRAKE CASE 7.1 DISASSEMBLY AND ASSEMBLY A. Disconnection of Brake Case Group a. First Stage (Disconnection of Brake Case) 615W608A (1) Bolt (6) Packing (2) Nut (7) Packing (3) Brake Case (8) Ball Seat (4) Lever Shaft (9) Ball (5) Stud 1.
Page 184 CHAPTER 6 8354/8404 615W609A Bolt, Nut Assembly Position and Tightening Torque Applicable Model: 8354 Assembly Drawing No. Part name Qty. (Bolt) Spec. Tightening torque position (mark) ♣ ♣ ♣ ♣ ♣ 01754 - 51235 Stud. 39.2 ~ 49.0 N·m 37150 - 2735-2 Stud.
Page 185 Make sure assembly position of left and right cam plates is correct CAUTION Model Part name Assembly position 615W613A Cam plate (left) Left of transmission 8354 case 8404 Cam plate Right of (right) transmission case 6-11 D615-W02 May-2003 K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 186: Operation Check Of Brake Cam Lever
CHAPTER 6 8354/8404 7.2 OPERATION CHECK OF BRAKE CAM LEVER A. Operation Check of Brake Cam Lever 1. Move brake cam lever front to rear and check for proper operation. 2. If not operated smoothly, check the parts for dimen- sion.
Page 187 www.mymowerparts.com BRAKE B. Wear Check of Cam Plate 1. Check brake disc contacted surface of cam plate for wear, and measure the flatness using a clear- ance gauge. 2. If it exceeding the allowable limit, replace it. Sect. Specified Allowable limit Flatness of 0.3 mm 0.3 mm...
Page 188 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 189: Chapter 7 Front Axle
www.mymowerparts.com CHAPTER 7 FRONT AXLE K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 190 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 191: Structure
www.mymowerparts.com FRONT AXLE 1. STRUCTURE 615W701B (1) Front Bracket (7) Differential Gear Shaft (12) Bevel Gear (2) Rear Bracket (8) Bevel Gear (13) Front Axle (3) Front Axle Support (9) Bevel Gear (14) Bevel Gear Case (4) Spiral Bevel Pinion (10) Bevel Gear Shaft (15) Front Axle Case (5) Spiral Bevel Gear...
Page 192: Wheel Alignment
CHAPTER 7 8354/8404 2. WHEEL ALIGNMENT To improve control and safety running, front wheel is applied with adequate inclination in the direction of left, right and forward. Camber Angle Caster Angle Camber angle (A) = 2° Caster angle (C) = 1.5°...
Page 193: Troubleshooting
www.mymowerparts.com FRONT AXLE 3. TROUBLESHOOTING Trouble Probable Cause Remedy Reference Left and right inclination • Improper pressure of tire Adjust of front wheel. • Inadequate tow-in adjustment Adjust • Excessive clearance between front axle Replace cast boss and front axle front and rear brackets •...
Page 194: Maintenance Specification
CHAPTER 7 8354/8404 4. MAINTENANCE SPECIFICATION Item Reference Value Allowable Limit Front wheel adjustment Tow in (rear width 2 ~ 8 mm front width) 0.08 ~ 0.32 in. Tire air pressure 7 - 16 1.8 kgf/cm² 25.6 psi 8 - 16 1.6 kgf/cm²...
Page 195: Tightening Torque
www.mymowerparts.com FRONT AXLE 5. TIGHTENING TORQUE Item Spec N·m Kgf·m lbf·ft Tie rod locking nut 368 ~ 431 37.5 ~ 44.0 272 ~ 318 Front wheel steering angle setting lock bolt, nut 123 ~ 147 12.6 ~ 15.0 91.2 ~ 108 Steering hose assembly connection tightening torque 46.6 ~ 50.9 4.8 ~ 5.2...
Page 196: Disassembly, Maintenance
CHAPTER 7 8354/8404 6. DISASSEMBLY, MAINTENANCE 6.1 CHECK AND ADJUSTMENT A. First Stage (Tow-In) 1. Set tire to the specified air pressure. 2. Align front wheel tire in straight driving, measure front width and rear width of front wheel and calcu- late its difference (tow-in).
Page 197 www.mymowerparts.com FRONT AXLE C. Third Stage (Adjustment of Front Axle Rocking Force) 1. Raise the front axle and make sure both tires are off the ground. 2. Using the front bracket adjusting bolt, check for rock- ing force and then tighten with nut. Sect.
Page 198: Disconnection Of Front Axle Group
(3) Draining Front axle oil spec. (2) Oil Level Plug IMPORTANT: • Always use Cub Cadet Industry approved front axle oil. B. Second Stage (Disconnection of Propulsion Shaft) 1. Loosen propulsion shaft cover 1 (1), propulsion shaft cover 2 (2) and attaching bolt (3) and tighten propulsion shaft cover 1 and 2 into inside.
Page 199 www.mymowerparts.com FRONT AXLE C. Third Stage (Disconnection of Steering Cylinder Hydraulic Hose) 1. Loosen steering hydraulic hose (1) and (2). Hose Connection position Steering hose assembly R Right of steering cylinder Steering hose assembly L Left of steering cylinder Sect. Tightening torque Steering hose assembly 46.6 ~ 50.9 N·m...
Page 200: Disassembly Of Front Axle
CHAPTER 7 8354/8404 8. DISASSEMBLY OF FRONT AXLE 8.1 FIRST STAGE (DISCONNECTION OF FRONT AXLE CASE AND BEVEL GEAR CASE) 1. Disengage axle case support (1) attaching bolt (2). 2. Disconnect front axle case (3) from bevel gear case (4), taking care not to drop it.
Page 201: Third Stage (Disassembly Of Front Axle Case)
www.mymowerparts.com FRONT AXLE 8.3 THIRD STAGE (DISASSEMBLY OF FRONT AXLE CASE) 1. Pull out snap ring (1) and disassemble plug (2). 2. Pull out snap ring (3) and disassemble bevel gear (5) and shim (6). (When reassembling) • Make sure the type and number of shim is correct. •...
Page 202: Fourth Stage (Disassembly Of Front Axle Support)
CHAPTER 7 8354/8404 8.4 FOURTH STAGE (DISASSEMBLY OF FRONT AXLE SUPPORT) 615W719B (1) Bevel Gear Case (5) Oil Seal (9) Bevel Gear (13) Spacer Barrel (2) Bolt (6) Ball Bearing (10) Ball Bearing (14) Bevel Gear (3) Plug (7) Snap Ring...
Page 203: Fifth Stage (Disassembly Of Front Axle Support)
www.mymowerparts.com FRONT AXLE 8.5 FIFTH STAGE (DISASSEMBLY OF FRONT AXLE SUPPORT) 615W721A (1) Front Bracket (8) Bevel Pinion Shaft (15) O-Ring (2) Rear Bracket (9) Taper Rolling Bearing (16) O-Ring (3) Center Pin (10) Adjusting Collar (17) Spacer Plate (4) Bolt (11) Snap Ring (18) Thrust Collar (5) Front axle Support...
Page 204: Sixth Stage (Disassembly Of Bevel Pinion Shaft)
CHAPTER 7 8354/8404 • When assembling DX bush (20), (21) into front and rear brackets, align hole of DX bush with assembly hole of grease nipple (19) (See the following CAUTION figure). • Make sure the oil seal assembly di- rection of bevel Pinion shaft is correct (See the following figure).
Page 205: Seventh Stage (Disassembly Of Differential Gear)
www.mymowerparts.com FRONT AXLE 8.7 SEVENTH STAGE (DISASSEMBLY OF DIFFERENTIAL GEAR) 1. Using bearing puller, pull out spiral bevel gear (2) and bearing (1) simultaneously. 2. Loosen bolt (3) and disconnect differential case cover (4). 3. Pull out parallel pin (11) and then disconnect differ- ential pinion shaft (8).
Page 206: Maintenance
CHAPTER 7 8354/8404 9. MAINTENANCE 9.1 CLEARANCE CHECK BETWEEN CENTER PIN, FRONT AXLE SUPPORT BOSS AND FRONT AND REAL BRACKETS 1. Check to see if DX bush of the front and rear brack- ets are worn. 2. If shaft contacted part is worn and bare metal surface, renew it.
Page 207: Check For Bevel Gear Backlash And Tooth Contacted In Bevel Gear Case
www.mymowerparts.com FRONT AXLE 9.3 CHECK FOR BEVEL GEAR BACKLASH AND TOOTH CONTACTED IN BEVEL GEAR CASE A. Backlash Measurement 1. Set the dial gage in bevel gear shaft spline. 2. Lock a gear into the differential gear shaft, move bevel gear shaft by hand and measure the backlash. 3.
Page 208: Check For Backlash And Tooth Contacted Between Bevel Pinion Shaft
CHAPTER 7 8354/8404 9.5 CHECK FOR BACKLASH AND TOOTH CONTACTED BETWEEN BEVEL PINION SHAFT AND SPIRAL BEVEL GEAR A. Backlash Measurement 1. Set dial gage in bevel gear shaft spline. 2. Lock spiral bevel gear, move bevel gear shaft by hand and measure the backlash.
Page 209: Clearance Check Between Differential Pinion Shaft And
www.mymowerparts.com FRONT AXLE 9.6 CLEARANCE CHECK BETWEEN DIFFERENTIAL PINION SHAFT AND DIFFERENTIAL PINION 1. Measure O.D. of differential pinion shaft. 2. Measure I.D. of differential pinion shaft. 3. Check clearance as the measured value and if ex- ceeding allowable limit, renew it. Allowable Sect.
Page 210 CHAPTER 7 8354/8404 9.8 CHECK FOR BACKLASH AND TOOTH CONTACTED BETWEEN DIFFERENTIAL PINION AND DIFFERENTIAL SIDE GEAR 1. Set a dial gauge on the differential pinion gear tooth surface in vertical. 2. Fix differential side gear, move pinion gear by hand and measure backlash.
Page 211: Chapter 8 Steering System
www.mymowerparts.com CHAPTER 8 STEERING SYSTEM K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 212 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 213: Characteristics
www.mymowerparts.com STEERING SYSTEM 1. CHARACTERISTICS 615W802A (1) Hydraulic Filter (5) Hydraulic Block (2) Hydraulic Pump (6) Aux. Control Valve (3) Modulating Valve (7) MLS(Control) Valve (4) Power Steering Unit (8) Power Lift Assembly • Steering system is applied with full hydraulic power steering and installed with two single rod cylinders. •...
Page 214: Hydraulic Circuit Of Power Steering System
CHAPTER 8 8354/8404 2. HYDRAULIC CIRCUIT OF POWER STEERING SYSTEM 615W803B (1) Oil Tank (4) Hydraulic Cylinder (2) Oil Filter (5) Hydraulic Block (3) Gear Pump (6) Steering Unit HYDRAULIC OIL FLOW • When the engine is started, the hydraulic pump will be driven to pass oil in transmission case through a modulator valve to the power steering unit.
Page 215: Gear Pump
www.mymowerparts.com STEERING SYSTEM 3. GEAR PUMP 3.1 PUMP CHARACTERISTICS The power steering hydraulic pumps use the pump hav- ing superior volume efficiency and mechanical efficiency to extract power from engines right cam shaft gear. 3.2 MAJOR SPECIFICATION Gear Rotation Discharge flow rate in engine Attached Type Volume (cc/rev)
Page 216: Operation
CHAPTER 8 8354/8404 3.4 OPERATION a. Hydraulic pump provides constant oil flow to oper- ate the steering wheel, and hydraulic cylinder. The hydraulic pump assembly consists of two pumps having different displacement. b. Two pumps operate equally and use outside gear design to move the amount of fluid determined at each rotation and positive displacement.
Page 217: Power Steering Unit
www.mymowerparts.com STEERING SYSTEM 4. POWER STEERING UNIT 4.1 MAJOR SPEC. Power Steering Unit 51 cc/rev Volume Relief pressure 120 kgf/cm² 8.4 psi 4.2 STRUCTURE AND OPERATION • Power steering controller consists of steering valve and relief valve. • Steering valve is divided into control valve and me- tering device.
Page 218: Steering Cylinder
CHAPTER 8 8354/8404 5. STEERING CYLINDER 5.1 STRUCTURE 615W809A (1) Tube (4) Dust Seal (6) Ring (8) Bearing (2) Packing (5) Rod (7) Housing (9) Snap Ring (3) Bush [A] Rod O.D [B] Tube I.D [C] Tube O.D [D] Stroke 5.2 MAJOR SPECIFICATION...
Page 219: Oil Flow
www.mymowerparts.com STEERING SYSTEM 6. OIL FLOW 6.1 IN NEUTRAL If the steering wheel is not rotated, valve plate (3) keeps in neutral by using a centering spring (4). This time oil flow will be formed between port P (from pump) of control valve and port t of transmission case and all oil supplied from the gear pump will be drained to the port.
Page 220: Turning To The Left
CHAPTER 8 8354/8404 6.3 TURNING TO THE LEFT The steering system operates in the same direction as in rotating to the left, except for flow in and flow out directions to steering cylinder in the opposite when turning to the right.
Page 221: Troubleshooting
www.mymowerparts.com STEERING SYSTEM 7. TROUBLESHOOTING Trouble Probable Cause Remedy Steering wheel is heavy 1. Power steering unit (1) Column and center * Modify (Loosen tightening bolt mismatched. with power steering unit can cause center mismatch (2) Spool and sleeve dirty * Change (3) Excessive tightening torque * Tighten equally into the speci-...
Page 222: Disassembly, Maintenance
CHAPTER 8 8354/8404 8. DISASSEMBLY, MAINTENANCE 8.1 GEAR PUMP A. Tightening Torques Item Reference Value Description Number Clearance between Allowable - Assemble bushing into body. drive gear and body limit: 0.05 mm (0.002 in.) - Assemble drive shaft with idle gear.
Page 223 www.mymowerparts.com STEERING SYSTEM b. Disassembly of Gear Pump 615W815A (1) Snap Ring (9) Bushing (17) Drive Gear Shaft2 (2) Bearing (10) Drive Gear Shaft (18) Passive Gear (3) Cover (Front) (11) Passive Drive Gear (19) Sealing (4) Sealing (12) Coupling (20) Second Pump (5) Pin (13) Cover...
Page 224: Power Steering Unit
CHAPTER 8 8354/8404 8.2 POWER STEERING UNIT A. Disassembly, Assembly a. Disconnection of Power Steering Unit Assembly First Stage (Disconnection of Steering Hose) • Disengage steering hose (1), (2), (3), (4) connect- ing nut and disconnect hose from power steering unit (5).
Page 225 www.mymowerparts.com STEERING SYSTEM B. Disassembly, Assembly of Power Steering Unit 615W818A (1) Screw (12) Sleeve (22) Screw (2) End cap (13) Pin (23) O-Ring (3) O-Ring (14) Centering Spring (24) Inlet Check Valve Assembly (4) Stator (15) Spool (25) Poppet (5) Spacer (16) Stop Ring (26) Spring...
Page 226 CHAPTER 8 8354/8404 C. Disassembly of Power Steering Unit a. Disassembly of GEROTOR 1. With end cap upward, lock port of body housing lightly into vice. 2. Loosen two screws (22) and disassemble housing (21). • Never tighten firmly into vice with rigid plate and etc.
Page 227 www.mymowerparts.com STEERING SYSTEM 7. Disassemble GEROTOR. Make sure rotor not dropped from outer ring of GEROTOR. 8. Pull out spacer plate (8) and O-ring (9). 9. Pull out driver (11). 10. Pull out O-ring from housing. 615W822A (8) Plate (11) Driver (9) O-Ring 11.
Page 228 CHAPTER 8 8354/8404 b. Disassembly of Relief Valve 1. Disassemble retainer screw (1) from plug (29) of housing (20) and pull out retainer pin (2) and ball (3). 2. With flanged surface of housing (20) upward, dis- assemble relief-adjusting plug (29) and pull out O- ring (28).
Page 229 www.mymowerparts.com STEERING SYSTEM • Make sure the number of centering spring is correct, as it is different as input torque spec. of the product. CAUTION 5. While raising spool and from sleeve and com- pressing the opposite end of centering spring by hand, push spool into the groove of sleeve.
Page 230 CHAPTER 8 8354/8404 b. Assembly of Relief Valve 1. Insert poppet (25) into flange of housing with spring guide seized using pincette. 2. Insert spring (26) and damper collar (27). 3. Insert O-ring into relief adjusting plug (29) and tighten to housing.
Page 231: Steering Cylinder
www.mymowerparts.com STEERING SYSTEM 8.3 STEERING CYLINDER A. Check a. Steering Wheel Clearance • After starting engine, wait for the engine to idle. • Rotate the steering wheel by hand and measure clearance. • If clearance exceeding the spec., check steering connection device for link.
Page 232 CHAPTER 8 8354/8404 B. Disassembly, Assembly a. Disconnection of Steering Cylinder Assembly • Disconnect steering hose assembly (1) and (2). • Pull out split pin (3) and disengage nut (4). • With tapping the end of support pin (5) using plastic hammer, pull out support pin from front axle case.
Page 233 www.mymowerparts.com STEERING SYSTEM • After assembling split pin, make sure the end is not fallen. • Apply support pin and grease nipple with sufficient grease. Sect. Spec. Tightening torque 48.0 ~ 55.9 N·m 4.9 ~ 5.7 kgf·m 35.5 ~ 41.2 lbf·ft •...
Page 234 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 235: Chapter 9 Hydraulic System
www.mymowerparts.com CHAPTER 9 HYDRAULIC SYSTEM K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 236 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 237: Hydraulic Circuit Diagram
www.mymowerparts.com HYDRAULIC SYSTEM 1. HYDRAULIC CIRCUIT DIAGRAM 615W901B D615-W03 May-2003 K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 238: Structure
CHAPTER 9 8354/8404 2. STRUCTURE 6305 6305 615W903A (1) Hydraulic Filter (5) Hydraulic Block (2) Hydraulic Pump (6) Aux. Control Valve (3) Modulating Valve (7) MLS(Control) Valve (4) Power Steering Unit (8) Power Lift Assembly The hydraulic system consists of major components as shown in the above figure.
Page 239: Hydraulic Circuit Diagram Of 3-Point Hydraulic System
www.mymowerparts.com HYDRAULIC SYSTEM 3. HYDRAULIC CIRCUIT DIAGRAM OF 3-POINT HYDRAULIC SYSTEM 615W904B (1) Oil Tank (Transmission Case) (6) Front Hydraulic Block (2) Oil Filter (7) Position Control Valve (3) Hydraulic Pump (8) Hydraulic Cylinder (4) Engine (9) Aux. Control Valve (5) Relief Valve (10) Hydraulic Cylinder Block HYDRAULIC OIL FLOW...
Page 240: Hydraulic Pump
CHAPTER 9 8354/8404 4. HYDRAULIC PUMP 4.1 STRUCTURE OF HYDRAULIC PUMP 615W905A (1) Snap Ring (7) Seal Ring (13) Cover (19) Seal Ring (2) Bearing (8) Seal Ring (14) Seal Ring (20) 2nd Pump (3) Cover (Front) (9) Bushing...
Page 241: Oil Filter
www.mymowerparts.com HYDRAULIC SYSTEM 5. OIL FILTER 5.1 STRUCTURE OF OIL FILTER A. Function • Filters particle or sludge from oil. B. Operation • Oil filter consists of filter bracket, magnet assembly and element assembly as intake filter installed at intake side of gear pump. •...
Page 242: Control Valve (Mls Valve)
CHAPTER 9 8354/8404 6. CONTROL VALVE (MLS VALVE) 6.1 STRUCTURE 615W909A 6.2 CIRCUIT DIAGRAM 615W910A D615-W02 May-2003 K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 243: Operation Principle
www.mymowerparts.com HYDRAULIC SYSTEM 6.3 OPERATION PRINCIPLE • Since the control valve of the hydraulic cylinder is available to control oil flowing in and out of the hy- draulic cylinder. It also controls the implement up and down at a constant speed regardless of the implement load.
Page 244 CHAPTER 9 8354/8404 B. Delivery Phase 615W912A (1) Control Spool (18) Annular Duct (2) Regulator Piston (19) Annular Duct (3) Check Valve (20) Hole (6) Fixed Throat (21) Hole (7) Safety Valve (22) Chamber (15) Chamber (23) Cylinder Chamber...
Page 245 www.mymowerparts.com HYDRAULIC SYSTEM C. Discharge Phase 615W913A (1) Control Spool (17) Hole (2) Regulator Piston (18) Annular Duct (4) Exhaust Valve (23) Cylinder Chamber (8) Regulator (24) Hole (15) Chamber (25) Hole (16) Exhaust Hole During this phases the control valve supplies, at the same time, the oil coming from the pump and the oil contained in the cylinder to the discharge causing the lowering of the arms.
Page 246: Relief Valve (Hydraulic Block)
CHAPTER 9 8354/8404 7. RELIEF VALVE (HYDRAULIC BLOCK) • As shown in the figure, a guide is attached at pop- pet (6) and valve chamber D.C (damping chamber) located at the bottom of the guide piston. Intake of valve enable through sliding part of guide and clear- ance of seat (5) to chamber and minimizes valve vibration as damping effect of chamber.
Page 247: Hydraulic Cylinder
www.mymowerparts.com HYDRAULIC SYSTEM 8. HYDRAULIC CYLINDER 615W916A D615-W02 May-2003 9-13 K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 248: Structure And Operation
CHAPTER 9 8354/8404 9. STRUCTURE AND OPERATION 9.1 STRUCTURE 615W917A (1) Lever (11) Shaft (21) Roller 2 (31) Arm (2) Needle Bearing (12) Spring Pin (22) Snap Ring (32) Nut (3) Washer (13) C a m (23) Link 3...
Page 249: Operation
www.mymowerparts.com HYDRAULIC SYSTEM 9.2 OPERATION Operation is Divided Into Position Control, Draft Control and Mixed Operation. A. Position Control 615W918A (1) Position Control Lever (6) Cam 1 (11) Roller 4 (2) Draft Control Lever (7) Lever (12) C a m (3) Shaft (8) Friction Shock Absorber (13) Crank...
Page 250 CHAPTER 9 8354/8404 B. Draft Control (Fig. 225W918A,225W919A) 615W919A (1) Position Control Lever (11) Roller 4 (19) Fly Wheel (2) Draft Control Lever (12) C a m (20) Hitch Point (3) Shaft (15) Crank (21) Shaft (7) Lever (16) Shaft...
Page 251 www.mymowerparts.com HYDRAULIC SYSTEM C. Combined Operation of Positioning and When roller 4 (11) meets the inclined plane of the draw- Drawbar Pull bar pull cam (12), it permits the counterclockwise rota- (Fig. 615W918A,615W919A) tion of lever (7) which by means of shock absorbers (8) To utilize the lifting device in this condition, it is neces- will rotate transmission arm (9) in a clockwise manner sary to observe the following instructions;...
Page 252: Outside Hydraulic Extraction
CHAPTER 9 8354/8404 10. OUTSIDE HYDRAULIC EXTRACTION 10.1 HYDRAULIC BLOCK A: To implement control valve “IN” port B: From implement control valve “TANK” port C: Without attaching implement D: With attaching implement NOTE: • When an implement is not attached, turn the slit on the spool end to the horizontal position fully.
Page 253: Acting Valve
www.mymowerparts.com HYDRAULIC SYSTEM 10.2 ACTING VALVE A. Operation principle A double acting detent type auxiliary control valve is used, and the construction is shown in the figure right. When the auxiliary control valve operating lever is moved to the implement cylinder actuating position, the spool is moved and the oil from the pump port flows into A to B, causing the implement cylinder to operate.
Page 254: Top Link Bracket Device
CHAPTER 9 8354/8404 11. TOP LINK BRACKET DEVICE 11.1 STRUCTURE 615W924A (1) Top Link Holder (6) Hex. Bolt (2) Flange (7) Plate (3) Cover (8) Crank (4) Spring (9) Tie Rod (5) Nut (10) MLS (Control) Valve 11.2 OPERATION...
Page 255: Troubleshooting
www.mymowerparts.com HYDRAULIC SYSTEM 12. TROUBLESHOOTING Trouble Probable Cause Remedy Hydraulic cylinder rises irregularly * Lack in tank (mission case) oil Fill in oil to adequate level. * Intake filter clogged Clean or replace filter. * Intake line mixed with air Check intake pipe, O-ring, and bolt for looseness.
Page 256: Maintenance Specification
CHAPTER 9 8354/8404 13. MAINTENANCE SPECIFICATION 13.1 3-POINT SYSTEM HYDRAULIC PUMP Condition and Point Applicable Model and Item Reference Dimension Allowable Limit Hydraulic pump condition * Engine speed (2700 rpm) * Pressure 16.0 ~ 17.2 Mpa 8354 165 ~ 175 kgf·m/cm²...
Page 257: Hydraulic Cylinder
www.mymowerparts.com HYDRAULIC SYSTEM 13.4 HYDRAULIC CYLINDER Item Reference Dimension Allowable Limit Cylinder bore I.D. 90.000 ~ 90.100 mm 90.150 mm 3.5433 ~ 3.5472 in. 3.5492 in. Relationship Right 0.125 ~ 1.230 mm 0.50 mm between hydraulic are 0.00492 ~ 0.00906 in. 0.0197 in.
Page 258: Tightening Torque
CHAPTER 9 8354/8404 14. TIGHTENING TORQUE Item N·m Kgf·m lbf·ft Hydraulic pipe joint bolt 49.0 ~ 58.8 5.0 ~ 6.0 36.2 ~ 43.4 Hydraulic pipe attaching bolt (M10) 48.1 ~ 55.8 4.9 ~ 5.7 35.5 ~ 41.2 Hydraulic block support attaching bolt (M8) 23.6 ~ 27.4...
Page 259: Disassembly, Assembly
www.mymowerparts.com HYDRAULIC SYSTEM 15. DISASSEMBLY, ASSEMBLY 15.1 GEAR PUMP A. Disconnection of Gear Pump Assembly 1. Disassemble hydraulic pipe (3, 4) and intake pipe (5) assembled into gear pump (1). 2. Disassemble bolt (2). 3. Detach gear pump (1). 615W925A (1) Gear Pump (4) Hydraulic Pipe (2) Bolt...
Page 260 CHAPTER 9 8354/8404 B. Disassembly and Assembly of Gear Pump 615W927A (1) Snap Ring (7) Seal Ring (13) Cover (19) Seal Ring (2) Bearing (8) Seal Ring (14) Seal Ring (20) 2nd Pump (3) Cover (Front) (9) Bushing (15) Seal Ring...
Page 261: Maintenance
www.mymowerparts.com HYDRAULIC SYSTEM 15.2 MAINTENANCE Housing Bore (Depth of Scratch) 1. Check if scratch occurred by gear in the surface of housing. 2. If scratched more than half of inside housing surface, the replace pump assembly. 3. Measure housing I.D. of inside surface without scratch and measure housing I.D.
Page 262: Hydraulic Cylinder
CHAPTER 9 8354/8404 15.4 HYDRAULIC CYLINDER A. DISASSEMBLY, ASSEMBLY a . Pipe, Aux. Control Valve (If Attached) 615W930B (1) Pipe A (9) Quick Coupler (14) O-Ring (2) Pipe B (10) Bolt (15) O-Ring (5) Bracket (11) Seal Washer (16) Flange...
Page 263 www.mymowerparts.com HYDRAULIC SYSTEM b. Hydraulic Cylinder Assembly 1. Disengage joint bolt (1). 2. Disengage the hydraulic cylinder assembly mount- ing bolts [(6), (7), (8), (9)], spring washer (5) and nut (4). 3. Raise and then detach the hydraulic cylinder as- sembly with a nylon rope supported.
Page 264 CHAPTER 9 8354/8404 d. Control Valve 1. Disengage the control valve attaching bolt (1). 2. Detach control valve (3) carefully. (When reassembling) Make sure O-ring not damage. Tightening Attaching 23.6 ~ 27.4 N·m torque bolt 2.4 ~ 2.8 kgf·m 17.4 ~ 20.2 lbf·ft...
Page 265 www.mymowerparts.com HYDRAULIC SYSTEM (When Reassembling) • Taking care of seal (12), insert into piston (11). • Apply the cylinder with transmission oil and insert the piston. • Apply the bottom of the piston that contacts with the connecting rod with grease. •...
Page 266 CHAPTER 9 8354/8404 g. Disassembly, Assembly of MLS Valve 615W938A (1) Adjusting Valve (10) O-Ring (18) Nut (26) Valve Set (2) Valve Body (11) Ball (19) Spring (27) Valve (3) Spool (12) Spacer (20) Valve (28) Pin (4) Valve...
Page 267 www.mymowerparts.com HYDRAULIC SYSTEM h. Top Link Bracket a) Disassembly 1. Before disassembling the top link holder assembly, disassemble the socket support and coupler socket assembly. 2. Disassemble bolt (13), lock washer (14), roller (15), and plate (12). 3. Disassemble nut (21). 4.
Page 268: Check And Adjustment
CHAPTER 9 8354/8404 15.5 CHECK AND ADJUSTMENT A. Hydraulic Cylinder Bore 1. Check the cylinder inside surface for scratches or damage. 2. Using a cylinder gauge, measure cylinder I.D. 3. If the measured exceeds the allowable limits, re- place the hydraulic cylinder block.
Page 269 www.mymowerparts.com HYDRAULIC SYSTEM C. Reaction Spring Assembly Reference Dimension Reaction spring Reference 50 mm assembly initial dimension 1.9685 in. length (L) 615W942A (1) Spring (3) Nut (2) Hex. Bolt D. Dimensional Setting of Position Control Bolt 1. When assembling the control valve (MLS valve) into power lift body, “A”...
Page 270 CHAPTER 9 8354/8404 E. Lever Position Setting a. Adjustment of Position Control Lever The position control lever can be adjusted with a little load applied to the elevating arm. 1. Loosen the position control shaft (3), and lever tight- ening bolt (4).
Page 271 www.mymowerparts.com HYDRAULIC SYSTEM F. Sensitivity Control of Control Valve (MLS) 1. Apply the elevating arm with load of 500 kg (1100 lbs) and move control lever upward to be the center. This time, the MLS valve is positioned at neutral. 2.
Page 272 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 273: Chapter 10 Electric System
www.mymowerparts.com CHAPTER 10 ELECTRIC SYSTEM K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 274 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
Page 275: Electronic Instrumentation
www.mymowerparts.com ELECTRICAL SYSTEM 1. ELECTRONIC INSTRUMENTATION 615WA01B (1) Tachometer (8) Battery Charge Warning Lamp (2) Temperature Gauge (9) Grow Plug Indicator (3) Fuel Gauge (10) Hydraulic Filter Warning Lamp (4) PTO On Indicator (11) Upward Indicator (5) Engine Coolant Low Level Warning lamp (12) Parking Brake Indicator (6) Differential Lock Operation lamp (13) 4WD Lamp...
Page 276: Indicators And Warning Lights
CHAPTER 10 8354/8404 1.2 INDICATORS AND WARNING LIGHTS A. POWER-TAKE-OFF OPERATION LAMP (4) Light will illuminate when the PTO selection switch is located at Auto or Manual mode. Before you start the engine, be sure that the PTO se- lection switch is located at the Neutral position.
Page 277 www.mymowerparts.com ELECTRICAL SYSTEM F. PRE-HEAT CONTROL OPERATION LAMP When the key switch is in the “ON” position, light will illuminate. When the whether is cold, remain the key switch in the “ON” position before starting for a while or until the lamp goes out.
Page 278: Trouble Shooting
CHAPTER 10 8354/8404 2. TROUBLE SHOOTING Symptom Provable Causes Solution All electrical equipment • Battery discharged or defective Recharge or replace does not operate • Battery positive or negative cable disconnected or Repair or replace improperly connected • Fusible link blown...
Page 279 www.mymowerparts.com ELECTRICAL SYSTEM Symptom Provable Causes Solution Brake light does not light • Fuse blown Replace • Bulb blown Replace • Wiring harness disconnected or improperly Repair or replace connected Coolant level lamp does • Brake switch defective Replace not light when cooling •...
Page 280: Servicing Specifications
CHAPTER 10 8354/8404 3. SERVICING SPECIFICATIONS Item Capacity (factory spec.) Feature Battery Rated voltage capacity 80AH Start motor Rated voltage Rated power 2.0kw Alternator Rated voltage Regulator built - in type Rated current Indicator bulb Rated voltage Rated power 3.4W...
Page 281: Mechanism
www.mymowerparts.com ELECTRICAL SYSTEM 4. MECHANISM 4.1 STARTING SYSTEM A. CIRCUiT DIAGRAM FOR STARTING SYSTEM 615WA04B (1) Main fuse (8) Neutral (2) Start Relay (9) Auto (3) Start motor (10) Manual (4) Key s/w (11) PTO control s/w (5) Safety s/w (12) Micro s/w (6) PTO safety relay (7) PTO fuse...
Page 282: Operation Of Start Motor
CHAPTER 10 8354/8404 B. OPERATION OF START MOTOR a. Starter The magnet-switch type starter is composed of two main sections. The first section converts battery current into mechanical rotation to turn the engine crankshaft. It is composed of the field coil, armature, brush, commutator, pinion, overrunning clutch, etc.
Page 283 www.mymowerparts.com ELECTRICAL SYSTEM (C) When key switch is on: When the key switch is turned on, a current flows from the battery through the pull-in coil in the magnet switch section to the holding coil, energizing the plunger to pull it in.
Page 284: Charging System
CHAPTER 10 8354/8404 b. Glow plus Glow plugs are used for each pre-combustion chamber of the cylinder head to make starting easier. The glow plugs are quick-heating type, which make starting easier with short pre-heating time. 615WA10A (1) Housing...
Page 285 www.mymowerparts.com ELECTRICAL SYSTEM B. CIRCUIT DIAGRAM FOR ALTERNATOR UNIT 615WA12A C. OPERATION OF CHARGING SYSTEM · The charging system supplies electric power for various electrical devices and also charges the battery while the engine runs. · The alternator generates AC (alternating current) and the regulator converts AC into DC (direct current). It also controls the output voltage for charging current to the battery.
Page 286: Preheating System
CHAPTER 10 8354/8404 4.3 PREHEATING SYSTEM A. CIRCUIT DIAGRAM FOR PREHEATING SYSTEM 615WA13B (1) Alternator (5) Glow plug indicator (2) Key s/w (6) Glow plug (3) Preheating Controller (7) Glow Relay (4) Coolant temp. sensor PARTS SPECIFICATION (1) Capacity of the preheating relay : DC12V 70A (2) Capacity of the preheating controller : DC12V B.
Page 287: Fuse
www.mymowerparts.com ELECTRICAL SYSTEM 4.4 FUSE A. FUSE BOX DIAGRAM Classifi- Cable Connec- Appli- Remark cation standard tion cable terminal fuse AVS3. O R AVS2. O W AVS3. O RL AVS2. O WR AVS0. 85 YR AVS3. O RW 7,13,15, 6WAY 36,66,77 TERMINAL AVS0.
Page 288: Gauge And Sensors
CHAPTER 10 8354/8404 4.5 GAUGE AND SENSORS A. OIL PRESSURE SWITCH The oil pressure switch is installed on the cylinder block and leads to the oil passage of the lubricating oil. When the oil pressure falls below the specified value, the con- tacts of the oil pressure switch closes to turn on the warning lamp.
Page 289: Main Circuit Diagram
ELECTRIC SYSTEM 5. MAIN CIRCUIT DIAGRAM 615WA18A D615-W02 May-2003 10-17...

This manual is also suitable for:

8404

Cub Cadet 8354 Service Manual

Chapter 1 General Information

Chapter 2 Engine System

Chapter 3 Clutch

Chapter 4 Transmission

Chapter 5 Rear Axle

Chapter 6 Brake

Chapter 7 Front Axle

Chapter 8 Steering System

Chapter 9 Hydraulic System

Chapter 10 Electric System

Quick Links

Troubleshooting

Related Manuals for Cub Cadet 8354

Summary of Contents for Cub Cadet 8354