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Cub Cadet 7360SS Service Manual

Series 7000 compact tractor
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SERVICE MANUAL
SERIES 7000
COMPACT TRACTOR
Model Number
7360SS
CUB CADET • P.O. BOX 368023 • CLEVELAND, OHIO 44136-9723

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Summary of Contents for Cub Cadet 7360SS

  • Page 1 SERVICE MANUAL SERIES 7000 COMPACT TRACTOR Model Number 7360SS CUB CADET • P.O. BOX 368023 • CLEVELAND, OHIO 44136-9723...

  • Page 2: Table Of Contents

    INDEX 1. GENERAL 1. SAFETY 2. LOCATION OF ENGINE MODEL, ENGINE SERIAL NO. AND TRACTOR SERIAL NO. IDENTIFICATIONS 3. SPECIFICATION AND DATA 4. TRANSMISSION DIAGRAM 5. TIGHTENING TORQUES 6. PRECAUTIONS FOR DISASSEMBLY 7. GENERAL INFORMATION 2. ASSEMBLY REMOVAL AND REINSTALLATION 1.

  • Page 3: Table Of Contents

    5. CLUTCH 5-1 DISASSEMBLING 5-2 REASSEMBLING 5-3 ADJUSTMENT 6. TRANSMISSION 6-1 CLUTCH HOUSING DISASSEMBLING 6-2 CENTER CASE DISASSEMBLING 6-3 TRANSMISSION CASE DISASSEMBLING 6-4 CLUTCH HOUSING REASSEMBLING 6-5 CENTER CASE REASSEMBLING 6-6 TRANSMISSION CASE REASSEMBLING 6-7 CHECK AND MAINTENANCE 7. REAR AXLE 7-1 DIFFERENTIAL CASE ASSY DISASSEMBLING 7-2 REAR AXLE DISASSEMBLING 7-3 BRAKE CONTROL DISASSEMBLING...

  • Page 4: General

    I. GENERAL...

  • Page 5: Safety

    1. SAFETY...

  • Page 7: Location Of Engine Model, Engine Serial No And Tractor Serial No. Identifications

    2. LOCATION OF ENGINE MODEL, ENGINE SERIAL NO. AND TRACTOR SERIAL NO. IDENTIFICATIONS (1) ENGINE MODEL (3) TRACTOR SERIAL NO. Engine model is relieved on right side of Tractor Serial No. is punched on right side of cylinder block . Enter this model and engine transmission center case.

  • Page 8: Specification And Data

    3. SPECIFICATION AND DATA Capacities Engine oil capacity with filter change ———————————————— 4.5 liters 4.8 QTS NOTE : Oil filter capacity is 0.5 liters (0.13 US Galls) Cooling capacity ————————————————————————— 7.1 liters 7.9 QTS Transmission & Hydraulic oil———————————————————— 43 liters 45.9 QTS MFD Axle ————————————————————————————...

  • Page 9: Transmission Diagram

    4. POWER TRANSMISSION DIAGRAM...

  • Page 10: Tightening Torques

    5. TIGHTENING TORQUES...

  • Page 11: Precautions For Disassembly

    6. PRECAUTIONS FOR DISASSEMBLY Place snap ring that square side face to force Slit Shaft movement Slit Shaft movement...

  • Page 12: General Information

    7. GENERAL INFORMATION...
  • Page 13 II. ASSY REMOVAL AND REINSTALLATION...

  • Page 14: Front Axle Assy Removal And Reinstallation

    1. FRONT AXLE ASSY REMOVAL AND REINSTALLATION (2)STEERING HOSE REMOVAL 1-1 FRONT AXLE ASSY REMOVAL 1.Remove the two hoses from steering cylinder (1) 4WD SHAFT REMOVAL 1. Remove cover A 2. Remove the snap ring at joint (rear side) from the shaft groove.

  • Page 15: Front Axle Assy Reinstallation

    (4) FRONT & REAR HOLDER REMOVAL 1-2 FRONT AXLE ASSY 1. Remove mounting bolts of front holder. REINSTALLATION *Install the front axle assy with reversed procedure of removal. Use following adjustment and service standards for the reinstallation. 1. When reinstall the front axle assy to chassis, tighten the mounting bolts of the rear holder first.

  • Page 16: Engine Assy Removal And Reinstallation

    2. ENGINE ASSY REMOVAL AND REINSTALLATION 2-1 ENGINE ASSY REMOVAL (1) HARNESSES REMOVAL 1. Remove front grille, bonnet, side covers and panel cover. 2. Disconnect battery cable (Disconnect negative cable first and then disconnect positive cable.) 5. Disconnect the harnesses at oil pressure sensor, fuel cut solenoid, electric fuel feed pump and fuel gauge.
  • Page 17 (2) PANEL REMOVAL 1. Disconnect the clutch rod and brake rods (Left and right brake rods). (Lever side) 2. Disconnect the shuttle wire. 3. Disassemble the operator seat area. (Transmission side)
  • Page 18 4. Disconnect the connectors of harness B. 5. Remove the steering hoses from the flow divider and transmission case. (Flow divider) Column cover Bolt Bolts (Transmission case)
  • Page 19 (3) ENGINE REMOVAL 8. Remove the suction and pressure pipe from pump I and II. 1. Drain the coolant from radiator and drain the transmission oil. 2. Remove the 4WD Shaft. (See Page 13) 3. Remove the panel Assy. (See Page 17) 4.
  • Page 20 2-2 ENGINE REINSTALLATION *Install the engine with reversed procedure of removal Use following adjustment and service standards for the reinstallation. 1. When reinstall the engine to clutch housing, apply the liquid packing (Threebond #1208D) to the mating surface of engine rear plate and clutch housing.
  • Page 21 6. Shuttle wire installation. 8. Clutch pedal free play 1) Set the length of wire at transmission side to [0.787~1.181 in.] 5.8 in (147 mm). 9. After reinstall the harnesses and tachometer cable, clamp them not to touch the muffler, manifold and fan belt.

  • Page 22: Clutch Housing, Transmission Case, Rear Axle Case And Hydraulic Lift Case Removal And Reinstallation

    3. CLUTCH HOUSING, TRANSMISSION CASE, REAR AXLE CASE AND HYDRAULIC LIFT CASE REMOVAL AND REINSTALLATION 3-1. HOUSINGS REMOVAL 2. Remove the main shift lever linkages. 3. Lift the center case and remove it from transmission case. (1) CLUTCH HOUSING REMOVAL 1.
  • Page 23 (3) HYDRAULIC LIFT CASE REMOVAL 1. Remove the seat and seat bracket. 2. Remove the lever grip from position control lever and remove the lever guide by removing the fixing bolts. 3. Remove the top link bracket . Top link bracket (8) REAR AXLE CASE REMOVAL 1.

  • Page 24: Housing Reinstallation

    3) Remove mounting bolts of ROPS lower bracket and remove the bracket. 2. Disconnect the brake rod at brake lever on the rear axle case. 3-2. HOUSING REINSTALLATION *Reinstall the housings with reverse procedure of the removal. Use following values as adjustment and service standard for the installation.
  • Page 25 5. In case of equipping the draft control and disassembling the top link bracket, adjust the dimension of stopper bolt to 29 mm(1.14in) and lock it by jam nut. (3) Center case reinstallation 1. Apply the liquid packing (Threebond #1208D) to the mating surface of the center case and transmission case.

  • Page 26: Engine

    The trouble to be taken into account as the most 4. ENGINE valid reason for overhauling the engine is(4): in actually determining when to overhaul the 4-1. DETERMINING WHEN TO engine, it is reasonable to take this trouble into OVERHAUL THE ENGINE account in conjunction with the other ones (2) COMPRESSION PRESSURE (1)DETERMINING WHEN TO...
  • Page 27 (5)Carefully check each part or component for any sign of faulty condition during 1. Be sure to measure the compression removal or cleaning. The part will tell you pressure on all cylinder. how it acted or what was abnormal about 2.
  • Page 28 (6)PREPARATION FOR DISASSEMBLY 1. Engine oil draining Remove the drain plug from the bottom of the oil pan and allow the oil to drain. Refil capacity ——— 1.19 gal (4.5 L) Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

  • Page 29: Trouble Shooting

    4-2. TROUBLE SHOOTING Problem 1 : Fuel knock More or less knock occurs in diesel engines. This may be caused either by an excessively large delay period or by a too fast rate of fuel injection. (1)Items to be checked for ahead •...
  • Page 30 Problem 2 : Overheating (1) Items to be checked for ahead Overheating might also be caused by abnormal operating conditions. If the engine is over- heating but its cooling system is not cont- ributing to this trouble, it is necessary to check the difference between the ambient temper- ature when the engine is in normal operation (with the thermostat fully open).
  • Page 31 Problem 3 : Black exhaust smoke (1)Items to be checked for ahead • Clogged air cleaner • Poor quality fuel (2)Inspection procedure Problem 4 : Erratic idle speeds (1)Items to be checked for ahead • Maladjusted engine control • Wrong oil grade for weather conditions •...
  • Page 32 Problem 5 : Low power or loss of power (1)Items to be checked for ahead • Stuck running parts • Wrong oil grade for weather conditions • Poor quality fuel • Clogged air cleaner • Restricted exhaust line • Faulty power take-off (2)Inspection procedure...
  • Page 33 Problem 6 : Starting system troubleshooting...

  • Page 35: Disassembling

    4-3. DISASSEMBLING (1)CYLINDER HEAD DISASSEMBLY 1.Rocker cover 2.Rocker shaft assembly 3.Push rod 4.Cylinder head bolt 5.Cylinder head 6.Cylinder head gasket 7.Valve lock 8.Valve retainer 9.Valve spring 10.Valve 11.Stem seal 12.Valve cap 3.Cylinder head bolt removal 1.Rocker shaft assembly removal Loosen the cylinder head bolts in two or three (1)Remove the bolts that hold the rocker steps in the sequence shown.
  • Page 36 4.Cylinder head assembly removal 6.Valve stem seal removal Lift the cylinder head straight up with a hoist. Remove the valve stem seals with pliers. If the gasket is seized and the cylinder head Do not reuse the valve stem seals. cannot be separated from the cylinder block, tap around the thick side portion of the cylinder head with a plastic hammer.
  • Page 37 (2) TIMING GEAR•FLYWHEEL (1) Flywheel (8) Timing gear case (13) Pump camshaft gear (2) Rear plate (9) Idler gear (14) Bearing (3) Oil seal case (10) Valve camshaft gear (15) Pump camshaft (4) Tappet (11) Thrust plate (16) Oil pump (5) Speedometer driven gear (12) Valve camshaft (17) Front plate...
  • Page 38 2.Rear plate removal The rear plate is doweled in position. Pull the plate as straight as possible when removing it. 5.Speedometer driven gear removal Remove the lock plate and speedometer driven gear in that order. 3.Oil seal case removal Remove the bolts that hold the oil seal case in Unless the speedometer driven gear is position.
  • Page 39 Item Limit Standard Crankshaft gear and idler gear 0.04 to 0.12 Idler gear and (0.0016 to 0.0047) camshaft gear Idler gear and fuel injection 0.30 pump (0.0118) camshaft gear Camshaft gear 0.08 to 0.19 7.Timing gear case removal and P.T.O. gear (0.003 to 0.0075) Remove the bolts that hold the timing gear Fuel injection...
  • Page 40 Do not cause the damage to the lobes or bearing journals when removing the camshaft. 11.Fuel injection pump camshaft removal (1)Remove the stopper bolt. 14.Front plate removal Remove four bolts that hold the front plate in position. Tap the plate lightly with a plastic hammer to separate the gasket.
  • Page 41 (3) CYLINDER BLOCK, CRANKSHAFT,PISTONS AND OIL PAN DISASSEMBLY (1)Oil pan (2)Oil screen (3)Connecting rod cap (4)Connecting rod bearing (lower) Remove 5 thru 10 as an assembly (5)Connecting rod (6)Piston pin (7)No.1 ring (8)No.2 ring (9)Oil ring (10)Piston (11)Connecting rod bearing (upper) (12)Main bearing cap (13)Main bearing(lower)
  • Page 42 2.Oil screen removal 4.Connecting rod cap removal Loosen the nut that holds the screen in (1)Lay the cylinder block on its side. position and remove the screen. (2)Put identification on each connecting rod and cap combination as to its location in the engine.
  • Page 43 6.End play measurement for crankshaft 8.Crankshaft removal Set a dial indicator so that it will touch the end Remove the crankshaft. of the crankshaft and measure the end play. If the end play exceeds the limit, replace the flanged bearing in No.3 journal. Do not cause damage to the bearings.
  • Page 44 (2)Insert the push rod of the tool into the bore in the piston for the piston pin and, using an arbor press, remove the piston pin. (3)Use this Piston Pin Setting Tool to install the connecting rod to the piston.

  • Page 45: Reassembling

    4-4. REASSEMBLING (1) CYLINDER HEAD REASSEMBLING (1) Rocker cover (7) Valve Lock * Reassemble the cylinder head with reverse (2) Rocker shaft assembly (8) Valve retainer procedure of disassembling. Use the following (3) Valve push rod (9) Valve spring values as adjustment and service standard. (4) Cylinder head bolt (10) Valve (5) Cylinder head...
  • Page 46 3.Valve spring installation (3)Put new cylinder head gasket in position Install the valve spring with the white on the cylinder block, making sure the enameled end up. guide bolts are all in alignment with their respective holes in the gasket. Do not use any gasket adhesive or other substances on the top face of the cylinder block.
  • Page 47 7.Cylinder head bolt tightening (1)Remove the guide bolts and install the bolts that hold the cylinder head to the cylinder block. (2)Tighten the bolts in number sequence in two or three steps to the specified torque. 0.5 kgf•m 4 lbf•ft) Tightening torque 5 N•m] 8.Valve push rod installation...
  • Page 48 (2) TIMING GEAR•FLYWHEEL REASSEMBLING 1) Flywheel (2) Rear plate (3) Oil seal case (8) Timing gear case (13) Pump camshaft gear (4) Tappet (9) Idler gear (14) Bearing (5) Speedometer driven gear (10) Valve camshaft gear (15) Pump camshaft (6) PTO gear (11) Thrust plate (16) Oil pump (7) Crankshaft pulley...
  • Page 49 3.Engine turning (2)Put the camshaft(with gear)in position in (1)Install two bolts (M12x1.25)in the flywheel the cylinder block. bolt holes in the crankshaft. (2)Put a bar between the bolts and turn the crankshaft to bring No.1 piston to the top Do not cause damage to the lobes and center as shown in the illustration.
  • Page 50 6.Idler gear installation (2)Tighten the crankshaft pulley nut to the (1)Lubricate the idler gear with engine oil. specified torque. (2)Install the idler gear in position with its 17.5 2.5 kgf•m “3”,“2”and “11”marks in alignment Tightening torque (127 18 lbf•ft) [172 25N•m] with the “33”mark on the fuel injection pump camshaft gear, the “22”mark on the...
  • Page 51 (2)Put the rear plate in position on the cylinder block with its dowel holes in alignment with the dowels. Tighten the bolts that hold the rear plate to the specified torque. 1 kgf•m Tightening torque 7 lbf•ft) 10 N•m] 11.Tappet installation Lubricate the tappets with engine oil and put Install the starter to the rear plate before them in position in the cylinder block.
  • Page 52 (5)Have someone hold the crankshaft pulley 11.Valve clearance adjustment with a wrench to prevent the flywheel Make reference to“VALVE CLEARANCE” from rotating. (page 100) (6)Tighten the four bolts that hold the flywheel to the specified torque. 13.5 0.5 kgf•m 4 lbf•ft) Tightening torque [132 5 N•m]...
  • Page 53 (3) CYLINDER BLOCK, CRANKSHAFT,PISTONS AND OIL PAN REASSEMBLING (1)Oil pan (2)Oil screen (3)Connecting rod cap (4)Connecting rod bearing (lower) Reassemble 5 thru 10 (5)Connecting rod (6)Piston pin (7)No.1 ring (8)No.2 ring (9)Oil ring (10)Piston (11)Connecting rod bearing (upper) (12)Main bearing cap (13)Main bearing(lower) (14)Crankshaft (15)Main bearing(upper)
  • Page 54 2.Crankshaft installation (1)Clean the crankshaft with cleaning solvent and blow dry with compressed air. Install the front and bearing caps in (2)Fasten a hoist to the crankshaft and hold position so their end faces are even with the it in horizontal position. Carefully put the end faces of the cylinder block.
  • Page 55 4.Side seal installation (1)Coat the side seals with Three Bond 1212. (2)Insert the side seals between the cylinder block and the front and rear caps and push in them by hand as far as possible, with their rounded side toward the outside of the cylinder block.
  • Page 56 (5)After assembling the piston and connecting 7.Piston and connecting rod installation rod, make sure the connecting rod moves (1)Lubricate the piston and piston rings with freely. engine oil. (2)Move the piston rings on the piston so that the end gaps are apart from a direction parallel to, or transverse to, the piston pin.
  • Page 57 (4)Tighten the connecting rod cap nuts in steps to the specified torque. Do not hit the piston with a hammer to install the piston and connecting rod. This will put 3.55 0.25 kgf•m Tightening torque (25.7 2 lbf•ft) force on the piston and connecting rod and [34.8 2.5 N•m] cause damage to the piston rings and crankpin.
  • Page 58 10.Oil pan installation (2)Tighten the bolts that hold the oil pan to the cylinder block in a crisscross pattern (1)Clean the mating surfaces of the oil pan and to the specified torque. cylinder block and coat them with Three Bond 1207C.
  • Page 59 3.Water pump assembly removal (4)COOLING SYSTEM Remove the water pump assembly. DISASSEMBLY REMOVAL 1.Cooling fan removal Hold the fan by one hand remove the four bolts that hold the fan in position. Remove the fan and spacers. Keep the spacers with the for installation. 2.Thermostat case removal Remove the thermostat case assembly containing thermostat.
  • Page 60 3.Governor assembly removal (5)FUEL SYSTEM DISASSEMBLY (1)Remove the tie rod cover. REMOVAL (2)Remove the spring from the tie rod with a pliers to disconnect the tie rod from the 1.Fuel injection pipe removal fuel injection pump. Disconnect the fuel injection pipes and fuel (3)Remove the governor assembly.
  • Page 61 (6)AIR INLET AND EXHAUST SYSTEM DISASSEMBLY REMOVAL 1.Exhaust manifold removal Remove the exhaust manifold from the cylinder head. (3)Remove the fuel injection pump. Keep a record of the thickness of shims for installation. 2.Air inlet cover removal Remove the air inlet cover from the cylinder head.
  • Page 62 3.Oil pressure switch removal (7)LUBLICATION SYSTEM REMOVAL Remove the oil pressure switch with Oil Pressure Switch Socket Wrench(MD998054) 1.Oil filter removal (special tool). (1)Put a container under the oil filter to catch the oil. (2)Remove the oil filter from the cylinder block with a filter wrench.
  • Page 63 (8)ELECTRICAL SYSTEM DISASSEMBLY 1. Starter disassembly (1)magnetic switch (2)rear bracket (3)brush holder assembly (4)yoke (5)armature (6)cover (7)center bracket (8)gear (9)spring set (10)stopper ring (11)stopper (12)pinion (13)spring (14)pinion shaft (15)lever (16)front bracket (1)Magnetic switch (a)Loosen the nut that holds the connector to the M terminal of the magnetic switch and disconnect the connector from the Keep the rear bracket with washer for...
  • Page 64 Any time the pinion is removed, a new stopper ring must be installed. (4)Cover removal Remove the cover and remove the snap ring and washer. (7)Pinion shaft removal Remove the spring, lever, reduction gear and pinion shaft from the front bracket. Do not mix the sequence of spring, lever and reduction gear when the pinion shaft is (5)Center bracket removal...
  • Page 65 2. Alternator (1)through bolts (2)pulley (3)rotor (4)rear bearing (5)bearing retainer (6)front bearing (7)front bracket (8)stator core (9)brush holder (10)rectifier (11)rear bracket Disassembly procedure (3)Stator core and rectifier removal (1)Stator core separation from front bracket (a)Unsolder the leads from the rectifier and (a)Pry the stator core off the front bracket remove the stator core from the rectifier.
  • Page 66 3.Injection pump Check the injection pump for items listed in the chart below and replace it if defective. Do not attempt to make repairs by disassembling. Test item Test method Criteria Low idle speed Use a tachometer. Standard farm engine: Exhaust smoke 1)Check by quickly increasing Not too much black or gray...
  • Page 67 (3)Pinion shaft end play adjustment (9)ELECTRICAL SYSTEM The maximum permissible limit of the end REASSEMBLING play(thrust gap) for the pinion shaft is 0.5mm 1.starter (0.020 in) Follow the reverse of disassembly and use the (a)Put the pinion shaft, reduction gear washer procedure that follows.
  • Page 68 (5)Pinion clearance adjustment The pinion clearance must be 0.020 to 0.079 in. (0.5 to 2.0mm). With the pinion held in cranking position, lightly push it toward commutator end to measure free movement (clearance). If the clearance is not correct, make adjustment to it. Increase the amount of packings if the clearance is too large;...
  • Page 69 2.Alternator Follow the reverse of disassembly and use the procedure that follows. (a)The rear bearing has a groove for the snap ring. Install the snap ring in this groove, making sure its tab is in the deep portion of the groove. (b)When installing the new rear bearing, put it in position with the side that has a groove toward the slip rings of the rotor.
  • Page 70 3. Shutoff solenoid installation (f)Back off the shutoff solenoid 30•to 45• (a)Remove the tie rod cover. turn(the clearance between the control (b)Coat the threads of the stop solenoid rack and plunger will be 0.0059 to 0.0070ı in. with thread sealant(three Bond 1212). (0.15 to 0.20 mm) and tighten the nut to the specified torque.
  • Page 71 (10)COOLING SYSTEM REINSTALLATION 1.Water pump installation Put a new gasket in position on the water pump flange. Install the water pump in position on the cylinder block. 4.Thermoswitch and thermounit combination installation Coat the threads of the combination with Three Bond 1104.
  • Page 72 (11)ELECTRICAL SYSTEM REINSTALLATION 1.Glow plug installation Install the glow plug in position in the precombustion chamber and tighten in to the specified torque. 1.75 0.25 kgf•m Tightening torque (12.7 1.8 lbf•ft) [17.2 2.5 N•m] 2.Alternator installation (1)Put the alternator in position. Install the adjusting plate bolt in position to hold the alternator in position.
  • Page 73 3.Oil pressure switch installation (12)LUBLICATION SYSTEM Coat the threads of the switch with thread REINSTALLATION sealant (Three Bond 1102). Use Oil Pressure 1.Pressure relief valve installation Switch Socket Wrench(MD998054)(special Put the relief valve in position on the cylinder tool) to install the oil pressure switch. block and tighten in to the specified torque.
  • Page 74 (13)FUEL SYSTEM REINSTALLATION 1.fuel injection nozzle installation (1)Put the gasket on the nozzle. (2)Put the nozzle assembly in position in the cylinder head and tighten it to the speci- fied torque. 0.5 kgf•m Tightening torque 4 lbf•ft) 5 N•m] 4.Sliding sleeve installation Install the sliding sleeve on the sliding sleeve shaft and make sure the sleeve moves freely.
  • Page 75 6.Fuel injection line installation (1)Put the fuel leak-off line in position and connect it to the fuel injection nozzles. (2)Put the fuel injection lines in position and connect them to the fuel injection pump. Install the clamps...
  • Page 76 (b)Close the switch to make sure the pinion (13)ELECTRICAL SYSTEM shifts into cranking position properly DISASSEMBLY REMOVAL and the starter runs at speeds higher than 1.Starter is specified. If the current draw and / or 1.1Testing before disassembly removal operating speed is out of the standard, (1)Clearance between pinion and housing disassemble the starter for inspection (pinion clearance)
  • Page 77 (3)Magnetic switch (a)disconnect the connector from the M Due to the amount of current being passed terminal of the magnetic switch. through the solenoid series winding, this test (b)Connect the magnetic switch to a 12 volt must be made within 10 seconds. battery with a switch as shown in the illustration to test the pull-in coil.
  • Page 78 2.2.Precautions for removal 2.Alternator Following is a list of basic precautions that 2.1.Inspection before removal should always be observed for removal: The correct diagnosis of the charging system (1)When installing the battery, care must be requires a careful inspection with the alternator used to make sure the negative (-) termi- on the engine to determine whether or not it is nal is grounded.
  • Page 79 (2)The voltmeter reading must be zero(0) (6)Increase the engine speed. Measure the when the starter switch is in OFF position. maximum output current at the specified It must be lower than the battery voltage alternator speed when the voltmeter when the switch is in ON position(the reading is 13.5 volts.

  • Page 80: Inspection

    4-5. INSPECTION (1) CYLINDER HEAD AND VALVE MECHANISM 1.cylinder head Using a heavy accurate straight edge and a feeler gauge, check the bottom face for warpage in three positions lengthwise, two crosswise and two widthwise as shown in the illustration. If warpage exceeds the limit, reface the bottom face with a surface grinder.
  • Page 81 4.Valve push rods (2)Clearance between valve stem and valve Using V-blocks and a dial indicator, check for guide. bend. If the bend exceeds the limit, replace the The valve guide wears more rapidly at its both push rod. ends than at any other parts. Measure the bore Unit:mm(in.) in the guide for the stem at its ends with an Item...
  • Page 82 (b)Install a new guide into the cylinder head by pushing it with an arbor press from the upper side of the head until the specified height to the top of the guide is obtained. (c)Insert a new valve into the guide and make sure the valve slides in the guide freely.
  • Page 83 (b)The valve margin must be not less than the limit. If the margin seems to be less than the limit when the valve is refaced, replace the valve. (7)Valve lapping Be sure to lap the valves in the seas after refacing or replacing the valves or valve seats.
  • Page 84 (c)Wash the valve and valve seat with dry cleaning solvent. (d)Apply engine oil to the valve and lap it in the seat. (e)Check the valve face for contact. 6.Combustion jet replacement Replace the combustion jets only when they are cracked or defective. (1)To remove the jet, insert a 6mm(0.24in.) diameter round bar through the bore in the cylinder head for the glow plug and tap...
  • Page 85 (2)TIMING GEARS AND FLYWHEEL 1.Camshaft (1)Clearance between journal and bushing Measure the diameter of the journal and the bore in the bushing for the shaft to find the clearance as shown in the illustration. If the clearance exceeds the limit, replace the bushing.
  • Page 86 Unit:mm(in.) (2)Clearance between tappet and cylinder Item Standard Limit block Lobe height 35.72 34.72 Measure the diameter of the tappet and the of camshaft (1.4063) (1.3669) bore in the cylinder block for the tappet to find the clearance. If the clearance exceeds the 2.Fuel injection pump camshaft limit, replace the tappet.
  • Page 87 (a)Removal (2)Idler shaft replacement Heat the ring gear evenly with an Install a new idler shaft to the cylinder block acetylene torch. Tap the ring gear all the so that its dimension from the face of the block way around with a bar and a hammer as is 26.5 0.5 mm(1.043 0.020 in.).
  • Page 88 Unit:mm(in.) (3)CYLINDER BLOCK, CRANKSHAFT, Item Standard Limit PISTONS AND OIL PAN No.1 comp- 0.06 to 0.10 0.30(0.0118) 1.Pistons, Piston Rings and Piston Pins ression ring (0.0024 to 0.0039) (1)Diameter of piston No.2 comp- 0.05 to 0.09 0.20(0.0079) Measure the diameter of the piston at its skirt ression ring (0.0020 to 0.0035) in a direction transverse to the piston pin with...
  • Page 89 Inside diameter of gauge 2.Connecting rods +0.03 +0.0012 Standard: 78 mm(3.07 in.) Check the connecting rod for bend or twist as 0.25 mm(0.0098 in.)oversize: follows: +0.03 +0.0012 78.25 mm(3.08 in.) (a)Measure”C”and”L”If”C”exceeds0.05 mm 0.50 mm(0.0197 in.)oversize: (0.0020 in.)per 100 mm(3.94in.)of”L”straighten +0.03 +0.0012 78.50 mm(3.09...
  • Page 90 (c)To check the connecting rod fitted to the (b)Measure the diameter of the crankpin as piston for bend, put the connecting rod shown in the illustration to find the and piston on the surface plate as shown clearance between the crankpin and in the illustration, insert a round bar connecting rod bearing.
  • Page 91 a)Grind all the crankpins of one crankshaft to the same undersize. b)Finish the crankpin fillets to a radius of 2.5 mm(0.098 in.). Unit:mm(in.) Item Nominal size Standard Limit Diameter 51.985to of journal (2.05) 52.000 (standard) (2.04665to 2.04724 clearance 0.030 to (2)Clearance between journal and main between 0.077...
  • Page 92 (5)Crankshaft gear installation (a)Install the key in position on the crank- shaft. (b)Install the gear in position with its keyway in alignment with the key as shown in the illustration. (3)Runout Support the crankshaft on its front and rear journals in V-blocks or in a lathe and check runout at the center journal with a dial indica- tor as shown in the illustration.
  • Page 93 Unit:mm(in.) Piston and piston ring Bore Size Size code Standard Limit +0.03 Standard +0.0012 (3.07 +0.03 0.25(0.0098) 78.25 Standard +0.0012 oversize (3.0807 ) +0.2 +0.03 0.50(0.0197) 78.50 (+0.08) +0.0012 oversize (3.0905 Taper and 0.01(0.0004) out-of-round maximum (2)Warpage of top face Using a heavy accurate straight edge and a feeler gauge, check the top face for warpage in two positions lengthwise, two crosswise and...
  • Page 94 3.Thermoswitch(standard) (4)COOLING SYSTEM Hang the thermoswitch in the pan of oil with its 1.Water pump temperature sensing end below the surface of Check the impeller and shaft for rotation. If oil and measure the resistance while heating they do not rotate freely or have noise, replace the oil as shown in the illustration.
  • Page 95 (5)LUBRICATION SYSTEM 1.Oil pump Visually check the pump for rough rotation or 3.Pressure relief valve other defects. Replace the pump assembly if (1)Check the valve seat for contact. defective. Check the spring for damage. (2)Measure the oil pressure at which the 2.Oil pressure switch relief valve opens (the oil pressure with (1)Test for continuity between the terminal...
  • Page 96 (c)Brush holders (6)ELECTRICAL SYSTEM Test for no continuity between the positive 1.Starter brush holder and brush holder base (1)Brushes as shown in the illustration. If there is (a)Wear any continuity between them, replace Replace the brushes if they are worn the brush holder.
  • Page 97 (b)Diameter of commutator Measure the diameter of commutator. If it exceeds the limit, replace the armature. Unit: mm (in.) Item Standard Limit Diameter of 32(1.26) 31(1.22) commutator (e)Testing for grounded circuit Test the armature for grounded circuit as shown in the illustration. If there is any continuity between commutator segment and coil, the armature is grounded and should be replaced.
  • Page 98 (3)Field coils Replace the yoke assembly if - (a)There is any continuity between the brush and yoke. (b)There is no continuity between the brushes. (c)The pole piece or coil is loosen. (4)Bearings Replace the bearings if they are noisy or fail to run freely.
  • Page 99 2.Alternator (1)Diodes (a)Test the resistance between the diode and heat sink. First touch the positive (+) prod of an ohmmeter to the diode, then the negative (-) prod. If the resistance is infinite in both cases, the diode is open. If it is nearly zero in both cases, the diode is shorted.
  • Page 100 (4)Brushes (c)To install the new brushes, put them in (a)Make replacement of brushes that have position in the brush holder and solder been worn down to,or beyond, the wear the leads to the brushes. limit line. (b)To remove the brushes from the brush 3.Glow plug holder for replacement, unsolder the Test for continuity between the terminal and...

  • Page 101: Adjustment

    (3)Loosen the lock nut for the adjusting 4-6 ADJUSTMENT screw. With a feeler gauge inserted (1)VALVE CLEARANCE between the rocker arm and valve cap, adjust the valve clearance by turning the adjusting screw. Make an adjustment to the valve clearance Unit: mm(in.) when the engine is cold.
  • Page 102 (2)FUEL INJECTION TIMING 1.Preparation (1)Close the fuel filter valve. (2)Disconnect the No. 1 fuel injection pipe from the cylinder head and injection pump. (3)Remove No. 1 delivery valve holder from the injection pump. Remove the delivery valve and spring from the holder. Restore the delivery valve holder only to the (2)Slowly turn the crankshaft clockwise, injection pump.
  • Page 103 3.Adjustment (1)If the fuel injection timing is incorrect, change the thickness of shims under the fuel injection pump. An increase or decrease of the shims by 0.1 mm(0.004 in.)will vary the timing by 1. (2)Increase the thickness of the shims to retard the timing or decrease it to advance the timing.
  • Page 104 (3)IDLER R.P.M SETTING Make sure that the valve clearance and injection timing are correct and that the fuel injection nozzles have no defect. (1)Start and run the engine at low idle until the coolant temperature above 60 C (140 F). (2)To set the low idle rpm, loosen the lock nut for the idling set bolt and turn the set bolt to make the engine run at the...
  • Page 105 (4)INJECTION NOZZLE 1.Inspection An increase or decrease of washer thickness (1)Injection Pressure (valve opening pressure) by 0.1 mm (0.004 in.) will vary injection test pressure by 10 kgf/cm (142 psi)[981kPa]. (a)Install the injection nozzle on the tester. 10 kinds of washer are available in thicknesses Slowly operate the tester handle to bleed from 1.25 mm(0.0493 in.) to 1.70 mm(0.0669 (remove) air from the tester.
  • Page 106 (3)Nozzle tip washing and replacement (a)Loosen the retaining nut and remove the tip from the injection nozzle. Wash the Keep the needle valves with their respective bodies needle valve and body in clean diesel fuel. After washing, put the needle valve in the body in clean diesel fuel.
  • Page 107 (5)FAN BELT (1)Measure the deflection of the belt. Apply 10 kgf (22 lbf)[98 N] force midway between the alternator pulley and the crankshaft pulley. (2)Adjust the belt if the deflection is not correct. Loosen the adjusting bolt and move the alternator to obtain the required belt deflection.

  • Page 108: Special Tools

    4-7.SPECIAL TOOLS In addition these special tools. commercially available tools such as bearing puller , valve seat cutting tool , valve guide installing tool , valve spring compressing tool , oil filter wrench , etc . are necessary.

  • Page 109: Clutch

    5. CLUTCH 5-1 DISASSEMBLING (1) DISASSEMBLING CLUTCH ASSY 1. Remove the fixing bolts of clutch cover and remove the clutch assy from engine flywheel. *When loosen the fixing bolts, loosen them diagonally . 2. Remove cotter pin, clevis pin and release lever.
  • Page 110 5-3 ADJUSTMENT (2) REASSEMBLING CLUTCH ASSY (1) CLUTCH PEDAL ADJUSTMENT 1. Reassemble the clutch assy with reverse procedure of disassembling. Use following 1. Depress the clutch pedal by hand and values as adjustment and service standard measure the amount of pedal free play at for the assembling.
  • Page 111 2. In case that the measurement is out of the following limit, replace the clutch disk assy. (2) STOPPER ADJUSTMENT 1. Adjust the stopper length and lock the stopper Item Standard value Service limit by lock nut. Depth to rivet 0.05 ~0.075 in.

  • Page 112: Transmission

    2) Remove snap ring(2) from main shaft and 6. TRANSMISSION remove gear 22T and bearing(3). 6-1. CLUTCH HOUSING DISASSEMBLING 3) Remove snap ring(4) and remove drive (1) COVER B SUB ASSY REMOVAL shaft A. 1. Remove the fixing bolt of cover B and remove cover B sub assy.
  • Page 113 4. Disassemble PTO hydraulic clutch assy. (1) Case (9) Brake disk (2) Piston (10) Seal ring set (3) Seal ring (11) Gear set 40T (4) Disk assy (12) Seal ring (5) Ring set (13) Ring (6) Spring (14) Back plate (7) Washer (15) Belleville spring (8) Return plate...

  • Page 114: Center Case Disassembling

    6-2 CENTER CASE DISASSEMBLING (2) COVER C SUB ASSY DISASSEMBLING 1. Disassemble drive shaft (1) COVER C SUB ASSY REMOVAL 1) Remove drive shaft and remove pipe shaft. 1. Remove the fixing bolts of main shift lever 2) Remove bearing(1), gear 18T, collar(2),gear holder and remove the holder.
  • Page 115 (3) DISASSEMBLE SHUTTLE SHIFT CONTROL 1. Disconnect shuttle shift wire from link. 2. Remove link from arm and remove holder. 3. Remove stopper bolt. (4) COVER D REMOVAL Remove fixing bolts of cover and remove cover from center case (5) COVER D SUB ASSY DISASSEMBLING 1.
  • Page 116 2. Disassemble reverse shaft 1) Remove plate and remove reverse shaft Shift fork from cover D. 2) Remove snap ring , washer, gear 17T, and needle bearings from reverse shaft. Differential case assy 6-3 TRANSMISSION CASE DISASSEMBLY Pinion shaft 3. Remove fixing bolts of holder L.H. and R.H. Counter shaft and lock plates.
  • Page 117 2. Disassemble drive shaft. (2) COVER E SUB ASSY REMOVAL 1) Move snap ring(3) and remove gear 23T 1. Remove 4WD rod and remove fixing bolt of and 35T from pipe shaft.. plate. 2) Remove bearing(1), snap ring(2) from pipe 2.

  • Page 118: Clutch Housing Reassembling

    4. 4WD shaft disassembling. 6-4 CLUTCH HOUSING REASSEMBLING 1) Remove 4WD shaft and gear *Assemble the clutch housing with reverse procedure of disassembling. (1) COVER B REINSTALLATION Reinstall the cover B with reverse procedure of removal. Use following adjustment and service standards for the reassembling.

  • Page 119: Center Case Reassembling

    3. PTO hydraulic clutch reassembling 6-5. CENTER CASE REASSEMBLING For the installation of return plate, face the *Reassemble the center case with reverse stamping surface (round edge side)of the procedure of removal. plate to brake disk. (1) COVER C SUB ASSY REINSTALLATION *Reinstall the cover C sub assy with reverse procedure of removal.
  • Page 120 (2) COVER C REASSEMBLING 2) Install the sleeve to hub that the bigger chamfer side of sleeve face to spline step *Reassemble the cover C with reverse side of hub. procedure of disassembling. Use following values as adjustment and service standard for reassembling.
  • Page 121 2. Shuttle linkage. (3) COVER D REINSTALLATION Adjust the wire length. (See page 16) *Reinstall the cover D sub assy with reverse procedure of removal. (4) COVER D SUB ASSY REASSEMBLING Use following values as adjustment and *Reassemble the cover D sub assy with service standard for reassembling.

  • Page 122: Transmission Case Reassembling

    (2) COVER E SUB ASSY REASSEMBLING 6-6 TRANSMISSION CASE REASSEMBLING *Reassemble the rear differential case with *Reassemble the transmission case with reverse procedure of disassembling. Use reverse procedure of disassembling. following values as adjustment and service (1) REAR DIFFERENTIAL CASE REASSEMBLING standard for reassembling.
  • Page 123 3. Pinion Shaft 4. 4WD Shaft (3) PTO SHAFT REINSTALLATION *Reinstall the PTO shaft with reverse procedure of removal. Use following values as adjustment and service standard for reinstallation. 1) Adjust the distance between center of 1. PTO Shaft differential case and rear end of pinion gear 1) Adjust the end play at PTO shaft to teeth to [4.21 0.002in.] by shim.

  • Page 124: Check And Maintenance

    2. Check the backlash of differential ring gears. 6-6 CHECK AND MAINTENANCE Backlash ; (1) DIFFERENTIAL GEAR AND PINION SHAFT Standard value : [0.004~0.008 in.] Shift fork Service limit : [0.012 in.] Shifter groove Replace the gear if backlash is out of service limit.
  • Page 125 5. Check of Double cone Synchromesh 1) outer synchronizer ring ,inner synchronizer ring ,synchronizer corn (a) Make sure there is no damage and scratch on the tooth surface of gear and cone surface. (b) Assemble the outer ring ,innner ring and corn to the gear.
  • Page 126 6. Checking the hydraulic clutch 1) Clutch disk Measure the clutch disk thickness and check the wear of disk. In case of the depth of groove of disk is out of service limit, replace the disk. Depth of groove ; Standard value : [0.0028~0.0079 in.] Service limit : [0.0012 in.]...

  • Page 127: Rear Axle

    7. REAR AXLE 7-2. REAR AXLE DISASSEMBLING (1) REAR AXLE ASSY REMOVAL 7-1. DIFFERENTIAL CASE ASSY DISASSEMBLING (See page 23.) (1) DIFFERENTIAL CASE ASSY REMOVAL (See page 21.) (2) REAR AXLE ASSY DISASSEMBLING DIFFERENTIAL CASE ASSY 1. Remove snap ring and remove liner, bearing and gear 59T from axle shaft.

  • Page 128: Brake Control Disassembling

    (3) BRAKE ASSY REMOVAL 7-3. BRAKE CONTROL DISASSEMBLING 1. Remove fixing bolts of holder (6). (1) BRAKE (LH) DISASSEMBLING 1. Disconnect the rod (7) between brake link 2. Remove arm (3). L.H. (6) and L.H. brake arm. 3. Remove brake Assy (4-5). 2.

  • Page 129: Differential Case Assy Reassembling

    6. Disconnect the brake rod between brake link 7-4. DIFFERENTIAL CASE ASSY R.H. and R.H. brake lever. REASSEMBLING *Reassemble the differential case assy with 7. Remove snap ring and remove brake link R.H. reverse procedure of disassembling. from link shaft. (1) DIFFERENTIAL CASE ASSY REASSEMBLING 8.

  • Page 130: Rear Axle Reassembling

    7-5. REAR AXLE REASSEMBLING 1. Make sure that the snap ring is completely * Reassemble the rear axle with reverse installed in the groove. procedure of disassembling. 2. Pull the brake lever (3) for making sure that the (1) REAR AXLE REASSEMBLING brake is functioning properly.

  • Page 131: Brake Control Reassembling

    7-6. BRAKE CONTROL REASSEMBLING (2) BRAKE R.H. REASSEMBLING *Reassemble the brake control with reverse *Reassemble the brake R.H. with reverse procedure of disassembling. procedure of disassembling. Use following values for rear axle reassembling as (1) BRAKE L.H. REASSEMBLING adjustment and service standard. *Reassemble the brake L.H.
  • Page 132 7-7. CHECK AND MAINTENANCE (1) BACKLASH 1. Check the backlash at differential case assy ] and side clearance. In case that the values are out of the following standard, adjust them. Item Standard (in.) Backlash at differential case assy 0.004~0.015 Side clearance at differential case assy 0~0.004 Backlash between diff.

  • Page 133: Front Axle

    8. FRONT AXLE 8-1. FRONT AXLE REMOVAL (1) FRONT AXLE REMOVAL See page 13. (2) HOLDER ASSY DISASSEMBLING (1)REAR BRACKET (2)FRONT BRACKET (3)CENTER CASE R.H. (4)CENTER CASE L.H. (5)HOLDER (6)PINION SHAFT (7)BEARING CASE (8)SHIM (9)OIL SEAL (10)NUT 4. Remove nut (10) and remove front bracket (2). 1.
  • Page 134 (3) KNUCKLE ARM, FINAL CASE 1. Remove fixing bolts of knuckle arm and DISASSEMBLING remove knuckle arm from gear case. 2. Remove fixing bolts of cover and remove cover from gear case. 3. Remove snap ring (1) and remove bearing (2), gear 38T, liner and axle shaft from cover.
  • Page 135 1. Remove fixing bolts of king pin case assy and remove king pin case assy . 2. Remove fixing bolts of arm holder (11) and remove arm holder (11) from king pin case (1). 3. Remove fixing bolts of cover (12) and remove cover (12) from king pin case (1).

  • Page 136: Front Axle Reassembling

    8-2. FRONT AXLE REASSEMBLING *Special tool for bushing (A) and (B) *Reassemble front axle with reverse insullation. procedure of disassembling. (1) FRONT AXLE ASSEMBLY Parts number MA-19619032000 for (A) *Reassemble holder assy with reverse MA-19619031000 for (B) procedure of disassembling. 1)REAR BRACKET (2)FRONT BRACKET (3)CENTER CASE R.H.
  • Page 137 3. Tighten the nut until no play is produced but Use following values for reassembling of bracket can be turned lightly. knuckle arm and final case as adjustment and service standard. 1. Apply lithium grease to o-ring and lip of oil seal for assembling.
  • Page 138 (3) KING PIN CASE REASSEMBLING *Reassemble king pin case with reverse procedure of disassembling. Use following values for reassembling of king pin case as adjustment and service standard. 1. Apply lithium grease at o-ring and oil seal. 2. Wind seal tape to fixing bolts (15) of arm holder.
  • Page 139 (4) CENTER CASE AND DIFF. CASE REASSEMBLING *Reassemble center case and diff. case with reverse procedure of disassembling. (1)CENTER CASE R.H. (2)CENTER CASE L.H. (3)DIFFERENTIAL CASE (4)RING GEAR (5)SIDE GEAR (6)PINION (7)DIFFERENTIAL SHAFT (8)GEAR 14T (9)PINION SHAFT (10)LINER (11)LINER (12)O-RING (13)DRAIN PLUG (14)JOINT Use following value for reassembling of center...

  • Page 140: Front Axle Check And Maintenance

    4) Apply heat resistant grease sliding surface. 2. Check the backlash of bevel gears. In case that the backlash is out of standard, readjust it. 4. Diff. case installation 1) Adjust the backlash between ring gear and Item Standard value (in.) pinion shaft to [0.0098~0.0138 in.] by liner at Backlash between bevel 0.008~0.0157...
  • Page 141 (3) CLEARANCE BETWEEN KNUCKLE ARM HOLDER AND BUSHING 1. Check the clearance between knuckle arm holder and bushing. In case that the clearance is out of service standard,replace it. Item Standard value(in.) Service limit(in.) Clearance between 0.00118~ 0.0079 holder and bushing 0.00236 (4) CLEARANCE BETWEEN HOLDER AND KNUCKLE ARM...

  • Page 142: Steering

    1) Remove fixing screws of rear cover and 9. STEERING remove rear cover. 9-1. OPERATOR CONTROL AREA REMOVAL 2) Remove fixing bolts (4) and nuts (5) of plate (1) STEERING WHEEL REMOVAL (3). 3) Disconnect the wire of engine control lever and shuttle lever.

  • Page 143: Steering Unit Disassembling

    (2) STEERING WHEEL DISASSEMBLING 1. Remove steering unit fixing bolts and remove steering unit (1) from column. 2. Remove cap (9) , nut (10) and washer and remove steering wheel (8) from shaft (7). 3. Remove boot (6) with plate (3) and remove snap ring , liner (20) and shaft (7) from column (2).
  • Page 144 1. Rotary disassembling 2. Controls disassembling 1) Remove screw 28 (6 pieces), retainer screw 1) Remove retaining ring (2) from housing. 29 (1 piece) and end cap (27). 2) Remove o-ring (21) from end cap (27). 2) Turn spool (17) and sleeve (16) until pin (20) comes to horizontal.

  • Page 145: Hydraulic Cylinder Disassembling

    4) Pull out spool(17)and sleeve(16)from housing. Do not disassemble or adjust the adjust plug (Pull them out to opposite side of flange.) for relief pressure setting at dealer. 5) Remove pin (20) from spool (17) and sleeve (16) assy. 9-3 HYDRAULIC CYLINDER DISASSEMBLING (1) HYDRAULIC CYLINDER ASSY REMOVAL 1.
  • Page 146 3. Disconnect battery negative code and positive 6. Remove chassis and radiator. code. Remove battery. 7. Remove hydraulic cylinder assy. 4. Remove radiator hoses and air cleaner hose (2) HYDRAULIC CYLINDER ASSY from engine. DISASSEMBLING 1. Remove tie rod end (6) , rod (9), rod end (8) and packing case (3).

  • Page 147: Operator Control Area Reassembling

    9-4. OPERATOR CONTROL AREA REASSEMBLING *Reassemble operator control area with reverse procedure of disassembling. (1) STEERING WHEEL REINSTALLATION *Reinstall steering wheel with reverse procedure of removal. Use following values as adjustment and service standard. (1)STEERING UNIT (2)COLUMN (3)PLATE (4)BOLT (5)NUT (6)BOOT (7)SHAFT (8)STEERING WHEEL...

  • Page 148: Steering Unit Reassembling

    (2) STEERING WHEEL REASSEMBLING *Reassemble steering wheel with reverse procedure of removal. Use following values as adjustment and service standard. 1. Apply grease to spline of the shaft. 2. Adjust the end play at shaft to be less than [0.0197 in.] by liner. 3.
  • Page 149 1. Rotary reassembling 1) Install o-ring (21) to end cap (24) and tighten Put the mark (line) at spline end surface of with screws (28, 29). drive (23) to ensure the position. 2) Tightening torque of screws [15.19 lbf•ft ] Make sure of location for installation of screw (29).
  • Page 150 9) Install retaining ring to housing groove. 2) Make sure that the spool (17) can be turned Make sure that the retaining ring is smoothly. completely dropped in the groove. 3) In case that the sleeve and spool have 10) Install dust seal and X-ring seal to seal aliment mark, aline the mark.
  • Page 151 9-6. HYDRAULIC CYLINDER ASSY 1. Packing case tightening torque ; [72.33lbf•ft] REASSEMBLING (Apply the threebond #1901 to thread.) *Reassemble the hydraulic cylinder assy with reverse procedure of disassembling. In case of removing the hose, take the (1) HYDRAULIC CYLINDER ASSY following procedure for air removal REASSEMBLING *Reassemble hydraulic cylinder assy with...
  • Page 152 2. Direction of installation of dust seal and U 2. Direction of installation of dust seal and U packing is as shown in the following drawing. packing is as shown in the following drawing. 3. After tighten the packing case, calk the 3.
  • Page 153 9-7. CHECK AND MAINTENANCE (1) TOE-IN ADJUSTMENT 1. Set the tire pressure to [22.335 psi] 2. Set the front tire to straight ahead. Measure the distance between left and right tire center at front (B) and rear (A) side of tire. Toe-in = A - B = [0~0.394 in.] (2) STEERING WHEEL FREE PLAY 1.

  • Page 154: Hydraulics

    10. HYDRAULICS 10-1. MAIN HYDRAULICS DISASSEMBLING (1) HYDRAULIC PUMP DISASSEMBLING 1. Hydraulic pump removal 1) Remove suction and pressure pipes from pumps. 2) Remove fixing nuts and bolts of pumps and remove pumps. 3) Pump I is supplying hydraulics to hitch and pump II is supplying hydraulics to power steering and PTO clutch.
  • Page 155 3. Pump II disassembling 2. Control valve disassembling 1) Remove plug at unload valve and remove spring and unload valve. 2) Remove plug at poppet and remove plate and spring at spool. 3) Remove nuts at poppet and spool. Remove spool, poppet and spring.

  • Page 156: Hydraulic Lift Disassembling

    2. Lift shaft disassembling 10-2. HYDRAULIC LIFT DISASSEMBLING 1) Remove snap rings and remove lift arms (2). (1) LIFT SHAFT AND CYLINDER 2) Remove colors (6) and o-rings (5). DISASSEMBLING 3) Remove set bolt and washer at power 1. Cylinder disassembling arm (8) and remove lift shaft (1) with 1) Remove fixing bolt of pin (19) and remove pin bushing (3).
  • Page 157 (2) HYDRAULIC LINKAGE DISASSEMBLING (1)CONTROL VALVE (2)GUIDE (3)ROLLER (4)SPRING (5)POWER ARM (6)LINK (7)LINK H (8)PLATE (9)POSITION SHAFT (10)DRAFT SHAFT (11)SHAFT (12)ARM (13)LEVER B (14)LEVER A (15)LINER (16)NUT (17)LINK B (18)LINK J (19)LINK (20)LINK E 1. Control valve removal 3) Remove spring (4). 1) Remove snap ring on the pin at plate (8) and 4) Remove snap ring at position shaft (9) and disconnect the control valve (1) and link H (7).
  • Page 158 (3) POSITION CONTROL LEVER REMOVAL 1) Remove piston control lever. 2) Remove rod A. 3) Remove plate (F) (4) FLOW CONTROL VALVE DISASSEMBLING 1. Loosen lock nuts (3) and remove screw (4), plate (5), washer and spring (6) . 2. Remove sleeve (8), ball (9) and spring(10). 3.

  • Page 159: Main Hydraulics Reassembling

    10-3. MAIN HYDRAULICS REASSEMBLING *Reassemble the main hydraulics with reverse procedure of disassembling. (1) HYDRAULIC PUMPS REASSEMBLING *Reassemble pump I and II with reverse procedure of disassembling. Use following values as adjustment and service standard of reassembling. Tightening torque of pump bolts. [18.08~21.7 lbf•ft] 2.

  • Page 160: Hydraulic Lift Reassembling

    10-4. HYDRAULIC LIFT REASSEMBLING *Reassemble hydraulic lift with reverse procedure of disassembling. (1) LIFT SHAFT AND CYLINDER REASSEMBLING *Reassemble the lift shaft and cylinder with reverse procedure of disassembling. Use following values for reassembling as adjustment and service standard. 1. Cylinder reassembling 1) Apply oil at o-ring for the assembling.
  • Page 161 3) Install the bushing (9) to piston rod (10). 5) Drive in bushing at lift shaft to [0.374~0.394 Bushing should be placed with its slit in.] deep as shown in the following drawing. coming as shown in the following drawing. 6) Apply molybdenum(MoS2) to spline of lift 4) Install the bushings (3) to lift case.
  • Page 162 (2) HYDRAULIC CONTROL LINKAGE REASSEMBLING *Reassemble the hydraulic control linkage with reverse procedure of disassembling. Use following values as adjustment and service (1)CONTROL VALVE standard for reassembling. (2)GUIDE (3)ROLLER (4)SPRING (5)POWER ARM (6)LINK (7)LINK H (8)PLATE (9)POSITION SHAFT (10)DRAFT SHAFT (11)SHAFT (12)ARM (13)LEVER B...
  • Page 163 3)After adjustment of plate position , lock the 3) Aline the punch mark of lever B (13) and all three nuts (16). draft shaft (10). 2. Control linkage installation 1) O-ring installation to shafts Fit the draft shaft (10) and shaft (11) in the housing and pull it out until o-ring groove comes to out side of housing.
  • Page 164 3. Position control lever reassembling 1) Fix the handle stopper and place the position control lever to the highest position. 2) Adjust the play Fat top position of lift arm to be [0.197~0.394in.] by adjusting the rod (A) length. 4. Flow control valve reassembling 1) Adjust the height of plate (7) by shim (1 and 2) to turn the screw (4) smoothly.

  • Page 165: Hydraulic Line Checking

    10-5. HYDRAULIC LINE CHECKING 1. During the installation 1) Apply oil to o-rings and install them not to stick out. 2) Assemble the parts with care not to get contamination to the hydraulic ports. 2. Filter installation 1) Wipe the installation surface of filter base and apply the oil to the packing of filter for the installation.
  • Page 166 3. Tightening torques of hydraulic line...

  • Page 167: Hydraulic Check And Maintenance

    10-6. HYDRAULICS CHECK AND Item Standard Service MAINTENANCE value (in.) limit (in.) Clearance between 0.00236~ (1) HYDRAULIC LIFT SYSTEM CHECKING cylinder and piston 0.00386 0.00787 1. Clearance of bushing 1) Measure the outer of diameter of lift shaft and power arm pin. 2) Measure the inner diameter of bushings and calculate the clearances.
  • Page 169 11. ELECTRICS 11-1. ELECTRIC DIAGRAM 168~169...

  • Page 170: Electrical

    11-2. SPECICATIONS Electrical System Type of System ................12 Volt, Negative Ground Battery .....................12 Volt, 500 CCA Group 22F, Top Stud Terminals Alternator ..................12 Volt, 50 Ampere Output Voltage Regulator .................IC Built in Alternator Starter Motor ..............12 Volt, 2 kw with Solenoid Switch Head Lamp ......................35 Watt Flasher Lamp ......................23 Watt Rear Red Lamp ......................20 Watt...

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