Shibaura CM284 Workshop Manual
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Shibaura CM284 Workshop Manual

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CM364
WORKSHOP MANUAL

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Summary of Contents for Shibaura CM284

  • Page 1 FRONT MOWER CM284 CM364 WORKSHOP MANUAL...
  • Page 2 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.

  • Page 3: Table Of Contents

    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.

  • Page 4: Chapter 1. General

    Chapter 1. GENERAL...

  • Page 5: Specifications & Performances

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

  • Page 6: Precautions Before Servicing

    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.
  • Page 7 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.

  • Page 8: Chapter 2. Engine

    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...

  • Page 9: Engine Removal

    2-1 Engine Removal 1) If necessary, remove bolts and nuts and the bonnet. 2) Remove the muffler and stay from the engine. 3) Disconnect the wiring from the air cleaner clogging sensor. 4) Disconnect the wiring from the water temperature sensor and water temperature switch.

  • Page 10: Disassembly, Inspection And Reassembly

    2-2 Disassembly, Inspection and Reassembly 1. Disassembly 005X Order Disassemble Parts Name Alternator Starting motor Oil filter Relief valve Oil level gauge · Gauge guide Engine stop solenoid · Seal washer Injection pipe Injection pump NOTE: 1. Remove the injection pipes and engine stop solenoid before remove the injection pump. 2.
  • Page 11 006X Order Disassemble Parts Name Return pipe Injection nozzle · Gasket Oil transfer pipe · Eye bolt · Seal washer Connector · Glow plug Oil pressure switch Thermostat case · Gasket Head cover · O-Ring · Intake manifold · Spacer Rocker arm assembly ·...
  • Page 12 007X Order Disassemble Pats Name V-belt · Cooling fan · Fan holder · Fan pulley Water pump assembly · Gasket Crankshaft pulley Hydraulic oil pump, Cover, Drain cock. Timing gear case assembly · Gasket NOTE: Remove the engine stop solenoid and injection pump assembly at first. Idle gear ·...
  • Page 13 008X Order Disassemble Parts Name Oil pan · Gasket · Suction filter · Suction pipe Fly wheel Rear plate Oil seal Piston and connecting rod assembly NOTE: 1. Before extracting piston, remove the carbon deposit from the TDC in the cylinder. 2.

  • Page 14: Of Engine Main Parts

    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.
  • Page 15 (2) Clearance between rocker arm and rocker arm shaft Measure the rocker arm bore. 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...
  • Page 16 (2) Intake and exhaust valves and valve guide Check the head and stem of each valve and replace if burnout, wear or deformation is remarkable. 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.
  • Page 17 (3) Valve seat 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. Correct the seat using a seat cutter of 15°, 45° and 75° so that the contact width is the standard assembling value.
  • Page 18 (4) Valve spring Check the valve spring visually for damage. Measure the squareness of the spring using a square on a surface plate and replace if the service limit is exceeded. Check the free length and spring force with a spring tester and replace if the service limit is exceeded.
  • Page 19 3) Cylinder block Distortion on cylinder block top surface (mm) Standard assembling value Repair value Inspection and service 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 There should be apparent scratches, rust, corrosion, etc.
  • Page 20 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 Check the piston for crack, streak and burnout on the outside surface and replace if remarkable. 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...
  • Page 21 (2) Piston ring Replace worn out or damaged piston ring, if any. 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.
  • Page 22 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...
  • Page 23 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.
  • Page 24 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 J843 peeling, melting, uneven wear, or improper contact is No2, 3 ·...
  • Page 25 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.
  • Page 26 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.
  • Page 27 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 Less than 0.03 0.06 journal, read the indication on the dial gauge rotating the shaft one turn gently.
  • Page 28 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 –...
  • Page 29 13) Oil flow 045X...
  • Page 30 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...
  • Page 31 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 Water pump ass’y Gasket Set plate 17) Radiator and reserve tank Specifications and structure Structure...
  • Page 32 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.

  • Page 33: Disassembly, Inspection And Reassembly

    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.
  • Page 34 21) Nozzle and holder Specifications Model J843 (CM284) N843L (CM364) Model J843 (CM284) N843 (CM364) Part code No. Needle valve dia. 131406440 131406360 φ4 Pintle dia. φ1 Ass’y No. 105148 – 1210 105148 - 1170 11.76 MPa 14.7 MPa Valve opening...
  • Page 35 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.
  • Page 36 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. Thermostat cover Gasket Thermostat Thermostat case 057X Specifications and inspection Thermostat Replace if the valve is opened even only slightly at normal temperature.

  • Page 37: Engine Reassembly

    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.
  • Page 38 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 –...
  • Page 39 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.
  • Page 40 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.
  • Page 41 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.
  • Page 42 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.
  • Page 43 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 131437540 N843L 3.195 – 3.932 mm 131437550 Model 131437560 Crankshaft angle J843 N843L 131437570 17º 2.320 2.854 *131437580...
  • Page 44 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.
  • Page 45 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.
  • Page 46 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.

  • Page 47: Electrical Units

    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.
  • Page 48 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.
  • Page 49 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.
  • Page 50 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...
  • Page 51 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.
  • Page 52 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...
  • Page 53 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...

  • Page 54: Starting Motor

    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.
  • Page 55 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.
  • Page 56 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).
  • Page 57 (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...
  • Page 58 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...
  • Page 59 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 voltage readings with...
  • Page 60 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.
  • Page 61 Starting Motor (For Engine Model N843L:CM364) 1) Specifications and Performance Part code No. 185086530 Pinion ejecting voltage Less than 8 Type RA (228000-5121) Terminal voltage (V) 11.5 Continuous operation (second) Unloaded Current Less than 100 Output (V-kW) 12 – 2.0 Speed (rpm) More than 4000...
  • Page 62 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...
  • Page 63 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 Check brush spring b) Armature winding ground test Brush holder insulation test c) Commutator run-out test d) Measurement of segment mica depth...
  • Page 64 ● 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.
  • Page 65 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”...
  • Page 66 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”...
  • Page 67 Diagnosis 3 Check the operation of starting switch and relay GOOD NO GOOD Repair or replace if Remove starter and necessary repair 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”...
  • Page 68 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...

  • Page 69: Glow Plug

    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...

  • Page 70: Thermometer And Thermosensor

    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 →...

  • Page 71: Buzzer Alarm Warning System

    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.

  • Page 72: Oil Pressure Switch

    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/cm 7. Battery 1) Specifications CM284 Electrolyte specific gravity Model 75D26L 1.28/When charged fully...

  • Page 73: Engine Stop Solenoid

    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.

  • Page 74: Trouble Shooting

    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.
  • Page 75 Condition Cause Remedy Too much engine oil. Check and adjust the quantity. Improper color of engine exhaust Too low viscosity of engine oil. Check and change. Improper injection timing. Too late. Correct. Improper fuel. Check and change. Excessive fuel injection. Check and adjust.

  • Page 76: Engine Maintenance Standard Table

    2-5 Engine Maintenance Standard Table 1. J843 * Unit for values without unit in the column of inspection item is mm. Standard Service Standard Part Inspection Items Repair Value Remarks Dimension Assembling Value Limit Cylinder compression pressure More than 2.94 Engine speed 2.45 {25} MPa {kgf/cm...
  • Page 77 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 Parallelism of large end and small end holes Less than More than (per 100 mm) 0.05 0.15...
  • Page 78 Standard Standard Service Part Inspection Items Repair Value Remarks Dimension Assembling Value Limit Valve clearance When cold (both intake and exhaust) Spring force (when installing length is compressed to 30.4 High 33.5 140X Opening angle before TDC 13° Intake valve Closing angle after BDC 43°...
  • Page 79 Standard Standard Service Part Inspection Item Repair Vlue Remarks Dimensions Assembling Vlue Limit Type (Nozzle) 105007 - 1170 (NP-DN4PDN117) BOSCH 12.25 – 13.23 Injection pressure MPa {kgf/cm {125 – 135} Injection angle 4° Nozzle and holder tightening torque 58.8 – 68.6 N·m {kgf·m} {6 –...
  • Page 80 2. N843L * Unit for values without unit in the column of inspection item is mm. Standard Service Standard Part Inspection Items Repair Value Remarks Dimension Assembling Value Limit Cylinder compression pressure More than 2.94 Engine speed 2.45 {25} MPa {kgf/cm {30} at 200 rpm Cylinder head tightening torque...
  • Page 81 Standard Standard Repair Service Part Inspection Items Assembling Remarks Dimension Value Limit Value Torsion of large end and small end holes Less than (per 100 mm) 0.08 Parallelism of large end and small end holes Less than 0.15 (per 100 mm) 0.05 Longitudinal play of connecting rod and crank pin 0.1 –...
  • Page 82 Standard Standard Service Part Inspection Items Repair Value Remarks Dimension Assembling Value Limit Valve clearance When cold (both intake and exhaust) Spring force (when installing length is compressed to 30.4 Free height 33.5 Less than 144X Opening angle before TDC 13°...
  • Page 83 Standard Standard Service Part Inspection Item Repair Vlue Remarks Dimensions Assembling Vlue Limit Type (Nozzle) 105007 - 1170 (NP-DN4PDN117) BOSCH 15.20 – 16.18 Injection pressure MPa {kgf/cm {155 – 165} Injection angle 4° Nozzle and holder tightening torque 58.8 – 68.6 N·m {kgf·m} {6 –...

  • Page 84: Chapter 3. Transmission And Brake

    Chapter 3. TRANSMISSION AND BRAKE...

  • Page 85: Description And Operation

    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 Transmission 5. Fixed Gears Gearbox (2-Speed) 6. Pinion Drive Gear Differential 7. Rear Wheel Drive Assembly Output Shaft and Input Gear Cluster...
  • Page 86 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.
  • Page 87 4) Power Flow (Range gear) 304X 305X...
  • Page 88 5) Power Flow (PTO) 306X 307X...

  • Page 89: Transmission Unit

    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.
  • Page 90 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.
  • Page 91 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.
  • Page 92 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.
  • Page 93 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.

  • Page 94: Front Transmission Unit

    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.
  • Page 95 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.
  • Page 96 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.
  • Page 97 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.
  • Page 98 (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.
  • Page 99 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.
  • Page 100 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. 342X 9. Apply the grease to the 18 mm inside diameter of bearing race ①, and ball bearings ②, and install them on the PTO clutch drive shaft.
  • Page 101 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.

  • Page 102: Rear Transmission Unit

    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.
  • Page 103 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.
  • Page 104 (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.
  • Page 105 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.

  • Page 106: Pto Clutch Unit

    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.
  • Page 107 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.
  • Page 108 ● 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.

  • Page 109: Front Wheel Shaft And Brake Unit

    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.
  • Page 110 (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...

  • Page 111: Two Way Clutch Unit

    6) Two Way Clutch Unit (3) Assembly Reference – Figure 368X (SENSITRACK DISASSEMBLY) 1. Install thrust washer ⑩, driven cam ⑨, compression (1) Disassembly spring ⑧, and center cam ⑦, in the one-way clutch Reference – Figure 368X assembly housing ⑪. 2.

  • Page 112: Differential Gear Unit

    7) Differential Gear Unit (2) Inspection (1) Disassembly 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.
  • Page 113 (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.
  • Page 114 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.
  • Page 115 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...
  • Page 116 (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.

  • Page 118: Chapter 4. Hst System

    Chapter 4. HST SYSTEM...

  • Page 119: Oil Flow

    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.
  • Page 120 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”.
  • Page 121 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”.

  • Page 122: Hst Unit Removal

    2. HST UNIT REMOVAL 403X Suction Filter 7. HPL Supply Line 13. Cooler Return Line Hydraulic Pump 8. Charge Pump Suction Line 14. HST Return to Sump Foot Control Pedal 9. Hyd. Pump Supply Line 15. Power Steering Control Valve Oil Cooler 10.
  • Page 123 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.
  • Page 124 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.

  • Page 125: Precautions Before Disassembly

    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.

  • Page 126: Inspection

    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.

  • Page 127: Reassembly

    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.
  • Page 128 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.

  • Page 129: Adjustment

    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.
  • Page 130 (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"...
  • Page 131 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.
  • Page 132 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 –...

  • Page 133: Trouble Shooting And Specifications

    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.
  • Page 134 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/cm Charge Pump Pressure ··················································································...

  • Page 136: Chapter 5. Power Steering

    Chapter 5. POWER STEERING...

  • Page 137: Oil Flow

    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.
  • Page 138 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”.
  • Page 139 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”.
  • Page 140 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”.
  • Page 141 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.

  • Page 142: Control Valve Assembly

    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.
  • Page 143 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 Seal-Dust 8.
  • Page 144 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.
  • Page 145 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.

  • Page 146: Power Steering Cylinder

    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.

  • Page 147: Piping

    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.

  • Page 148: Trouble Shooting

    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.
  • Page 149 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.

  • Page 150: Chapter 6. Rear Axle Assembly

    Chapter 6. REAR AXLE ASSEMBLY...

  • Page 151: Description And Operation

    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.

  • Page 152: Rear Axle Removal

    602X Engine Two-Way Clutch 8. Drive Pinion 11. Reduction Case HST Unit Permanent FWD 9. Differential Gear 12. Tie Rod Range Slide Gear Shifter Fork Assembly 13. Wheel Shaft Drive Pinion Rear Wheel Drive Shaft 10. Drive shaft 2. REAR AXLE REMOVAL 1.

  • Page 153: Disassembly

    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.
  • Page 154 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).

  • Page 155: Inspection

    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.

  • Page 156: Assembly

    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 –...

  • Page 157: Installation

    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”...

  • Page 158: Chapter 7. Hydraulic Lift System

    Chapter 7. HYDRAULIC LIFT SYSTEM...

  • Page 159: Description And Operation

    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.

  • Page 160: Oil Flow

    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.
  • Page 161 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.
  • Page 162 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”...

  • Page 163: Overhaul

    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.
  • Page 164 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 Relief Valve Assembly Weight Transfer Valve (4) Assembly Prior to assembly coat the valve body bore and spool with clean hydraulic oil.
  • Page 165 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.
  • Page 166 (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/cm } pressure gauge to the high pressure oil hose to the cylinder.

  • Page 168: Chapter 8. Implement Drive

    Chapter 8. IMPLEMENT DRIVE...

  • Page 169: Description And Operation

    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.

  • Page 170: Power Flow

    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).
  • Page 171 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.

  • Page 172: Disengage System

    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. Shift Plate Cam PTO Lever 803X When the lift arm raised near highest position, the pin (3)

  • Page 173: Adjustment And Specification

    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.

  • Page 174: Chapter 9. Maintenance

    Chapter 9. MAINTENANCE STANDARDS TABLE...

  • Page 175: Maintenance Standards Table

    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 Slide gear-shifter fork clearance 0.2 –...
  • Page 176 Standard Standard Repair Service Unit Part Inspection Item Assembling Remarks Dimensions Value Limit Value Differential pinion – pinion shaft clearance 0.03 – 0.1 Differential pinion thrust washer thickness 1.1 – 1.2 Differential gear thrust washer thickness Differential gear/differential pinion backlash 0.2 –...

  • Page 178: Chapter 10. Electrical System

    Chapter 10. ELECTRICAL SYSTEM...

  • Page 179: Description

    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.
  • Page 180 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.
  • Page 181 1000X...

  • Page 182: And Adjustment

    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.
  • Page 183 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. ●...
  • Page 184 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. ●...
  • Page 185 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 –...
  • Page 186 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.
  • Page 187 1011X Proof meter Engine oil pressure warning lamp Engine coolant temperature gauge Charge lamp Fuel gauge Air cleaner restriction warning lamp Glow plug indicator lamp 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.
  • Page 188 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 ±...
  • Page 189 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.
  • Page 190 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”.
  • Page 191 1. Energized the coil by applying 12 volts of current across terminals A and B. 2. Connect the ohmmeter leads to terminals C and 3. There is continuity between terminals C and D if the relay is working properly. 1021X b.
  • Page 192 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.
  • Page 193 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.
  • Page 194 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.
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  • Page 208: Chapter 11. Mower

    Chapter 11. MOWER...

  • Page 209: Sectional Vier: Fm60Sd

    11-1 Sectional View : FM60SD 1101X...

  • Page 210: Specifications

    Mowing blade speed (rpm) 2899 Mowing blade end speed (m/sec.) No. of mowing blades Standard mowing blade dimensions (T × W × L, mm) 7 × 50 × 518 Gear oil (ℓ) Total weight (kg) Applicable models CM284·364 Power flow 1102X...

  • Page 211: Disassembly

    11-3 Disassembly Order Unit Disassembling procedure Belt cover Remove the right and left belt covers. 1103X 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.
  • Page 212 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.
  • Page 213 Order Unit Disassembling procedure 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.
  • Page 214 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.
  • Page 215 Order Unit Disassembling procedure 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.
  • Page 216 Order Unit Disassembling procedure 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.

  • Page 217: Reassembly And Adjustment

    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.
  • Page 218 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.
  • Page 219 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...

This manual is also suitable for:

Cm364

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