Shibaura CM214 Workshop Manual
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Shibaura CM214 Workshop Manual

Shibaura cm214 tractor
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Summary of Contents for Shibaura CM214

  • Page 2 This manual describes the structure, functions, maintenance and service of model CM214 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 2) Specific gravity of electrolyte Chapter 1 GENERAL ············································· 3 and charging condition ··································· 57 1-1 External Views ······················································ 4 8. Engine Stop Solenoid ·········································· 58 1-2 Specifications & Performance ································ 5 9. Fusible Link ························································ 58 1-3 Precautions Before Servicing ································· 6 10.

  • Page 4: Chapter 1 General

    Chapter 1. GENERAL...

  • Page 5: External Views

    1-1 External Views 001V...

  • Page 6: Specifications & Performance

    1-2 Specifications & Performances Model CM214 Model S773 Type Water-Cooled 4-Cycle Vertical Diesel Engine Number of Cylinders Total Stroke Volume 1005 cc Maximum Output 16.0 kW (22 PS)/2700 rpm Compression Ratio 23 : 1 Fuel Diesel Fuel Oil Starting Method...

  • Page 7: Precautions Before Servicing

    1-3 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 8: Metric Bolt Torque Specifications

    METRIC BOLT TORQUE SPECIFICATIONS Coarse Thread Fine Thread Bolt Size Grade No. Kiro-gram Newton- Kiro-gram Pitch (mm) Newton Meters Pitch (mm) Meters Meters Meters 4T, 4.8 4.9-6.9 0.5-0.6 7T, 8T, 8.8 8.3-11.3 0.85-1.15 - - - - - - - - - - - - - - - 10T, 11T 11.7-15.7...

  • Page 10: Chapter 2 Engine

    Chapter 2. ENGINE...

  • Page 11: Engine Removal

    2-1 Engine Removal 1) If necessary, remove bolts and nuts ➀ and the bonnet. 100V 2) Remove the muffler ➀ from the engine. 3) Disconnect the fuel return hose ➁ from the fuel return pipe. 4) Disconnect the wiring from the air cleaner clogging sensor ➂.

  • Page 12: Disassembly, Inspections And Reassembly

    2-2 Disassembly, Inspection and Reassembly 1. DISASSEMBLY 104V Order Disassembly Parts Name Alternator Starting motor Oil filter Relief valve Oil level gauge · Gauge guide Engine stop solenoid · Seal washer Injection pipe Return pipe Injection pump NOTE: 1. Remove the injection pipes and engine stop solenoid before remove the injection pump. 2.
  • Page 13 105V Order Disassembly Parts Name Injection nozzle · gasket Oil transfer pipe · Eye bolt · Seal washer Connector · Glow plug Thermo-sensor Oil pressure switch Head cover · O-ring Rocker arm assembly NOTE: Draw out the roll pin (A) from the No. 1 rocker arm bracket, and remove the rocker arm shaft.
  • Page 14 106V Order Disassembly Pats Name Cooling fan · V-belt · Fan holder · Fan pulley Water pump assembly · Thermostat · Gasket Crankshaft pulley Covers Timing gear case assembly · Gasket NOTE: Remove the engine stop solenoid and injection pump assembly at first. Idle gear ·...
  • Page 15 107V Order Disassembly 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 16: Engine Main Parts

    2. DISASSEMBLY AND INSPECTION 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 17: Cylinder Head Assembly

    2) Cylinder head ass’y Disassembly (1) Using a valve spring replacer, compress the valve spring to remove the valve cotter, retainer, spring and valve. (2) Remove the valve guide seal. 1. Valve guide seal 4. Valve 2. Spring 5. Valve cotter 3.
  • Page 18 ➃ Replace the valve if the clearance between the stem and guide exceeds the service limit. Clearance between valve stem and valve guide (mm) Intake valve Exhaust valve Standard Standard Service assembling Service limit assembling limit value value More than 0.045 –...
  • Page 19 ➃ Coat the valve seat surface with compound and lap the contact surface turning the valve. ➄ Check that the valve contact surface is within the standard value and the contact position is even. ➅ When the cylinder head is replaced with new one, adjust the seat contact width and seat recess to the specified values with a seat cutter before lapping.

  • Page 20: Cylinder Block

    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 ➀...

  • Page 21: Piston And Piston Ring

    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. Piston ring Piston pin Inspection 123V (1)Piston ➀ Check the piston for crack, streak and burnout on the outside surface and replace if remarkable.
  • Page 22 (2) Piston ring ➀ Replace worn out or damaged piston ring, if any. ➁ 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 23: Connecting Rod

    5) Connecting rod Torsion and parallelism of connecting rod (mm) Inspection Standard Repair value assembling value (1) Check for torsion, parallelism and damage. Torsion (per 100 mm) Less than 0.08 More than 0.2 Measure the torsion and parallelism using a Parallelism (per 100 mm) Less than 0.05 More than 0.15...

  • Page 24: Of Bearing Holder

    Reassembly (piston and connecting rod) (1) Heat the piston to about 100°C with a piston heater or the like and install it aligning the SHIBAURA mark in the piston and match mark at Ⓐ of the connecting rod. (2) Care should be taken to the figure match mark at Ⓐ...
  • Page 25 Reassembly (bearing holder, center bearing, thrust washer) (1) Install the metal with oil groove to the upper bearing holder and the metal without oil groove to the lower bearing holder (2) Install the aluminum bearing holder to the flywheel side with the stepped part facing the front and the bearing holder with identification cutting mark at the center.

  • Page 26: Crankshaft Bearing (Bush)

    8) Crankshaft bearing (bush) Inspection (1) Check the bearing (bush) and replace if peeling, melting, uneven wear, improper contact, or other damage is notice. 133V (2) Measure the oil clearance of the bearing (bush) and crankshaft journal using a cylinder gauge and micrometer.

  • Page 27: Crankshaft

    9) Crankshaft Inspection (1) To measure run-out of the crankshaft, support the crankshaft using a V block as shown in the right figure, apply a dial gauge to the crankshaft center journal, read the indication on the dial gauge rotating the shaft one turn gently.

  • Page 28: Flywheel And Ring Gear

    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: Oil Flow

    13) Oil flow 142V...

  • Page 30: Oil Pump

    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. 143V 1.

  • Page 31: Water Pump Assembly And Thermostat

    16) Water pump assembly and thermostat Disassembly (1) Remove the set plate gasket. (2) Remove the thermostat spring. 1. Water pump ass’y 2. Gasket 3. Set plate 4. Thermostat 5. Spring 6. 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.

  • Page 32: Radiator

    17) Radiator Specifications and structure Structure (1) The radiator is provided with the plate fin having superior anti-vibration characteristics. (2) The radiator cap is of the pressure type (sealing type) for higher cooling efficiency. When the cooling water is heated to high temperature (high pressure), the pressure valve is pushed and opened to release excessive pressure from the overflow pipe (shown by white arrow mark).

  • Page 33: Fuel Filter

    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 34: Injection Pump

    20) Injection pump Specification Engine Model Part Code No. Manufacturer and Injection Pump Type S773 131017710 NIPPON DENSO 094500 – 7410 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 35 Disassembly and inspection (1) Place the nozzle holder (body) in a vice and disassemble turning the nozzle nut. NOTE: Take care not to allow the needle valve to drop when removing the nozzle. (2) Wash the nozzle and needle valve and check for seizure and sticking of the nozzle and fuel leakage on the seat surface.

  • Page 36: Air Cleaner

    22) Air Cleaner Structure and functions (1) The air cleaner is connected to the cylinder with the air cleaner hose. (2) The air cleaner is of the cyclone type incorporating filter element and removes dust from the intake air. 154V Inspection and replacement (1) Take out the element every 100 –...

  • 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 NOTE: Apply the liquid gasket to around the M 10 screw holes for rear plate. Rear plate tightening torque: 46 – 54 N·m {4.7 – 5.5 kgf·m} 5. Fly wheel Align the hole to the roll pin on the crankshaft. 157V Fly wheel tightening torque 69 –...
  • Page 39 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. Oil pan tightening torque 10 – 12.7 N·m {1.0 – 1.3 kgf·m} 160V 9.
  • Page 40 NOTE: 1. Coat the rotor and vane both sides with grease before installing them. 2. Never turn the crankshaft until the timing gear case is installed. 3. Turn the oil pump cover clockwise and counterclockwise, fix the hole at the center of the spring pin inserting hole moving distance, and then install the gear case.
  • Page 41 15. Injection pump assembly ➀ 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. ➁ Tighten the injection pump with bolts and nut. Injection pump tightening torque 5 –...
  • Page 42 17 Engine stop solenoid Tighten the engine stop solenoid lightly with pliers. 18 Tappet Coat the oil to tappets and install. 19 Cylinder head ➀ Position each of the pistons at top dead center and, using a dial indicator, determine the distance each piston top to the face of the block.
  • Page 43 Oil pipe Eye bolt tightening torque 10 – 13 N·m {1.0 – 1.3 kgf·m} 171V 21 Push rod Rocker arm ass’y Install the push rod and rocker arm ass’y Rocker arm ass’y tightening torque 20 – 25 N·m {2.0 – 2.5 kgf·m} 172V 22 Valve clearance adjustment Untighten the nut of the intake and exhaust valves...
  • Page 44 24 Water pump ass’y Radiator hose Water pump ass’y Radiator hose (upper) Radiator hose (lower) 174V 25 Glow plug Connector Model Glow plug tightening torque S773 15 – 20 N·m {1.5 – 2.0 kgf·m} 26 Oil pressure switch Oil pressure switch tightening torque 15 –...
  • Page 45 30 V belt Fan pulley Cooling fan ➀ Install the fan pulley and cooling fan and then V belt. ➁ Adjust the belt tension with the alternator so that it is deflected 5~10 mm at the middle point between the crankshaft pulley and alternator pulley when depressed by a finger (about 5 kg) and tighten.

  • Page 46: Electrical Units

    2-3 Electrical Units 1. ALTERNATOR 2) Structure 1) Specifications and performance Part code No. 185046400 Type GP9165 Clockwise Rotating direction (viewed from pulley end) Working rpm 1300 – 5000 rpm Charging performance 20 A – 21 A at 12 V, 4500 rpm Charging start speed Less than 1300 rpm Regulator combined...

  • Page 47: Regulator

    Inspection Rotate the bearing manually to confirm that it rotates without noise. Assembling Reassemble the alternator in the reverse of order of its disassembly, paying attention on the following precautions. (1) When installing the bearing, place the bearing housing side of the coil plate on the flat plate. Then, press the bearing from rear side of the coil plate using a rod of φ31 diameter.

  • Page 48: Trouble Shooting

    TEST CONDITION NORMAL READING ABNORMAL READING REMARKS • No-load voltage and current test. (1) Less than DC 14 V and more than 28 (1) More than DC 15 V (1) Faulty regulator. • Engine speed – 2500 rpm. and more than 28 A. (2) Charging current is 0.5~28 A at the •...
  • Page 49 CONDITION CAUSE REMEDY No charging Is the flywheel (alternator) rotating? 1. The magnet damaged. 2. Some object seized. Replace the alternator assembly. 3. The bearing defective. 4. The flywheel damaged. Is the alternator generating? 1. Broken the stater coil. 1. Replace the alternator assembly. 2.

  • Page 50: Precaution Upon Handling

    4) Precaution Upon Handling (1) As large current flows through the regulator generating heat, the regulator must be positioned to the specified place. (2) Never remove the battery wiring during machine operation. If removed, trouble of the safety monitor, etc. is resulted.

  • Page 51: Disassembly, Inspection And Reassembly

    3) Disassembly, inspection and reassembly Disassembly (1) Remove the nut ➀ and connecting lead ➁ which connects the magnetic switch and the yoke. (2) Remove two thru bolts ➂, which tighten the yoke ➃ to the housing ➄, from the end frame ➅. (3) Remove two screws (end frame-to-brush holder) ➆...
  • Page 52 Inspection (1) Armature ➀ Check continuity between the commutator and shaft (or core) with a circuit tester. Replace the armature if continuity is indicated. ➁ Check the coil for short circuit with a growler tester and replace if it is short-circuited. ➂...
  • Page 53 (3) Brush and brush holder ➀ Roughness on the brush face If the face is rough, correct it by wrapping the commutator with a sand paper (No. 300). ➁ Replace the brush if the length is below the service limit. Brush length (mm) Standard length...

  • Page 54: Troubleshooting

    Inspection (6) Magnetic switch NOTE: 1. Do not continue the following tests for more than 5 seconds. 2. Perform the test with 1/2 of the rated voltage. ➀ Check of pull-in coil Check that the pinion gear comes out when the (-) terminal of the battery is connected to the magnet switch body and C terminal and then the (+) terminal of the battery to the 50 terminal.
  • Page 55 (2) Pinion is engaged, motor rotates, but the engine does not crank. Trouble Case Remedy Faulty clutch Replace Starting motor Damaged reduction gear Replace (3) Pinion is engaged with the ring gear but starting motor does not run. Trouble Case Remedy Disconnection or breakage of the wire connecting the battery and magnetic switch or improper grounding .

  • Page 56: Iqs System

    4. IQS SYSTEM 1) Summary The IQS system comprises the indicator lamp and glow plug. When the key switch is at the HEAT or START position, power is supplied to the glow plug to heat it quickly. 2) Circuit diagram 192V 3) Inspection of each part (1) Glow plug Y701RS...

  • Page 57: Thermometer And Thermosensor

    (2) Controller Intall the wire as shown in the right figure and turn ON the switch S1. It is normal if the indicator lamp goes out about 4.5 seconds after the switch is turned 193V 5. THERMOMETER AND THERMOSENSOR 1) Specifications (thermosensor) and structure Part code No.

  • Page 58: Oil Pressure Switch

    (1) Thermometer ➀ Remove the meter ass’y. ➁ Connect the (-) (negative) wire of the battery to the No. 1 terminal of the connector. Connect the (+) (positive) wire of the battery to the No. 4 terminal of the connector. ➂...

  • Page 59: Engine Stop Solenoid

    8. ENGINE STOP SOLENOID (1) The solenoid is provided with suction and holding terminal. Connect the positive side of the battery with a terminal, connect the negative side to the main body and inspect. (2) At this time, it is normal if the plunger is sucked and held to the main body.

  • Page 60: Trouble Shooting

    2-4 Trouble Shooting Condition Cause Remedy Defective key switch Connect or correct contact points propely. 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 61 Condition Cause Remedy Improper color of Too much engine oil. Check and adjust the quantity. engine exhaust Too low viscosity of engine oil. Check and change. (white or blue) Improper injection timing. Too late. Correct. Improper fuel. Check and change. Improper engine Excessive fuel injection.

  • Page 62: Engine Maintenance Standards Table

    2-5 Engine Maintenance Standard Table S773 * Unit for values without unit in the column of inspection item is mm. Standard Service Standard Unit Part Inspection Items Repair Value Remarks Dimension Assembling Value Limit Cylinder compression pressure More than 29.4 Engine speed 24.5 {25} MPa {kgf/cm...
  • Page 63 Standard Standard Service Unit Part Inspection Items Repair Value Remarks Dimension Assembling Value Limit Torsion of large end and small end holes Less than 0.08 More than 0.2 (per 100 mm) Parallelism of large end and small end holes Less than 0.05 More than 0.15 (per 100 mm) Longitudinal play of connecting rod and crank pin...
  • Page 64 Standard Standard Service Unit Part Inspection Items Repair Value Remarks Dimension Assembling Value Limit Valve clearance When cold (both intake and exhaust) Spring force (when intalling length is compressed to 30.4 Free height 33.5 Valve spring 201V Opening angle before TDC 13°...
  • Page 65 Standard Standard Service Unit Part Inspection Item Repair Vlue Remarks Dimensions Asembling Vlue Limit NIPPON Type (Nozzle) 093400-2840 (ND-DNOSD189) DENSO 11.76 11.27 – 12.25 Injection pressure MPa {kgf/cm {120} {115 – 125} Injection angle 4° Nozzle and holder tightening torque Install 78.4 –...

  • Page 66: Chapter 3 Tractor Main Body

    Chapter 3 TRACTOR MAIN BODY...
  • Page 67 NOTES: Precautions before start 1) Wash each part sufficiently and remove dust, liquid packing, gasket, etc. 2) Store bolts and O-rings in order not to be confused at the time of reassembly since their sizes vary depending on positions of use. 3) Handle gears carefully not to damage and store carefully so that they are not reassembled in incorrect direction.

  • Page 68: Front Axle, Transmission And Brake

    3-1 Front Axle, Transmission and Brake 1. SECTIONAL VIEWS 401V 402V...

  • Page 69: Transmission And Hst Unit

    2. FRONT AXLE, TRANSMISSION AND HST UNIT 1) Removal 1. ROPS Remove the ROPS from the main frame. 2. Seat assembly 403V ➀ Disconnect the seat switch wire at the connector. ➁ Remove the seat assembly and seat support as a set. 404V 3.
  • Page 70 4. Fender ➀ Remove the grips from the parking brake lever and four wheel drive select lever. ➁ Remove the fender. 406V 5. Piping ➀ Disconnect the piping from charge pump and top of the HST unit. 407V 6. HST neutral siwtch ➀...
  • Page 71 8. Brake rod ➀ Remove the sprit pin and flat head pin, and disconnect the brake rods at the brake lever. 410V 9. Lift arm ➀ Remove the bolt and pin, and disconnect the lift arm and hydraulic lift cylinder. ➁...
  • Page 72 12. V-Belts ➀ Remove the V-belts for front PTO and side PTO as follows: · Remove the bearing holder attaching bolts for input shaft. · Untighten the tension U-nut for side PTO. · Turn the bearing holder for make the gap and remove the two V-belts from the input shaft pulley for side PTO.

  • Page 73: Installation

    ➂ Remove the front axle and transmission assembly as follows: · Remove each two bolts for tightening frame and front wheel shaft housing at the L.H. and R.H. · Remove the four bolts from rear of front axle and transmission assembly. ·...

  • Page 74: Transmission And Front Axle Assembly

    3) Transmission and Front Axle Assembly (1) Disassembly 1. Drive shaft Drive out the drive shaft (input shaft), pulleys and bearings as a set to rearward. 420V 2. HST unit Remove the HST unit from the transmission housing as follows: ➀...
  • Page 75 4. Wheel shaft assemblies Remove the wheel shaft assemblies as follows: ➀ Remove the L.H. wheel shaft assembly from transmission housing at first. NOTE: 1. Take care the differential assembly will be removed and fall down from in the housing. 2.
  • Page 76 7. Drive shaft Remove the drive shaft and two bearings as a set. 8. Counter shaft Remove the countershaft and two bearings as a set. 9. Seal cover Remove the seal cover for inspect the ring gear back lash. 425V 10.
  • Page 77 (2) Assembly and Adjustment Reassembly generally follows disassembly procedure in reverse. During assembly observe the following: Four Wheel drive shifter fork assembly 1. Install the two way clutch assembly with align the pin in the transmission cover and notch of two way clutch assembly.
  • Page 78 4. 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 kilograms of constant pull to rotate the pinion assembly. Tighten the lock nut and crimp it at the ditch of the pinion shaft.

  • Page 79: Differential Assembly

    4) Differential Assembly (1) Disassembly 1. If installed, remove the bearings ➀. 2. Remove the bolts ➁, and separate the ring gear ➂ from the differential housing ➃. 3. Remove the thrust washer ➄ and differential gear ➅. 4. Remove the pin ➆ from in the differential housing ➃.
  • Page 80 Adjust the shims to obtain the correct backlash. Ring Gear Backlash Standard 0.1 – 0.2 mm Service limit 0.4 mm Rotate the pinion gear and check the gear tooth pattern. Adjust the differential and pinion shims to obtain the correct tooth pattern. See “Ring gear and pinion gear pattern specification and adjustment”.

  • Page 81: Front Wheel Shaft

    5) Front Wheel Shaft (1) Disassembly 1. Remove the snap ring (1) from the wheel shaft. 2. Drive out the wheel shaft (2). 3. Remove the bolts, and take out the bearing carrier (3), brake discs (4), stator (5), plate (6) and balls from in the wheel shaft housing (7).

  • Page 82: Hst Unit

    6) HST Unit For removal and installation of the HST unit only, follows the step 1 to 7 of the “2. Removal and installation of front axle and transmission, and HST unit” in Chapter 3-1 and refer to as follows: 1.
  • Page 83 5. Remove the swash plate (4), bush (17), guide assembly (51) as a set from the housing (1). 6. Remove the thrust bearing (13), bush (16), slide metal (18), bearing (54) and pin (53) from the housing (1). 7. Remove the thrust bearing (13) for motor from the housing (1). 8.
  • Page 84 (3) Reassembly Reference – Figure 440 V Caution before reassemble ★ 1. Wash each parts by washing solvent and blow with compressed air. 2. Keep each parts free from dust deposit, indentations or faults. 3. Replace seals with new one. 4.
  • Page 85 NOTE: Thrust bearing’s reference mark is installed against the swash plate. Install the swash plate assembly as follows: · The ball of guide assembly is inserted to the hole of housing while align the guide assembly and ditch of roller bearing supporter. 3.
  • Page 86 (4) Troubleshooting Replace the HST main body, if defective, as an ass’y as a rule. Condition Possible cause Remedy 1. Output shaft fails to rotate when 1. Improper operation of HST pump Check the trunnion shaft movement the HST pedal is set at forward or or motor.
  • Page 87 (5) HST Exploded Assembly Viw 440V...
  • Page 88 (6) Adjustment HST speed control rod adjustment Adjust the HST speed control rod length to 510 mm. Neutral position adjustment 1. Jack up the front and rear wheels off of the ground and place jack stands under the axles. Make sure all four wheels are clear of the ground and the commercial mower is properly supported. 2.
  • Page 89 HST pedal stopper adjustment 1. HST pedal stopper length adjust to 25 mm for forward pedal, an 30 mm for reverse pedal. 442V (7) Pressure Check High pressure relief check 1. Jack up the front and rear wheels off of the ground and place jack stands under the axles.
  • Page 90 Low pressure relief valve 1. Untighten the hose band, and disconnect the oil hose to the cylinder bottom of the hydraulic cylinder at the oil filter side. 445V 2. To check the low pressure relief valve, connect the 0–3 MPa {0–30 kgf/cm } pressure gauge to the oil pipe and secure with hose band.

  • Page 91: V-Belt

    7) V-Belt (1) Inspection Inspect the V-belts, if find the wear or some damaged replace the V-belts and adjust the belt tension. (2) Removal ➀ Disconnect the wiring from the seat switch. ➁ Remove the seat and seat support. ➂ Remove the cover from the fender. ➃...
  • Page 92 ⑪ Remove the cover for the side PTO. ⑫ Untighten the U-nut for side PTO. ⑬ Remove the two V-belts for side PTO. (3) Installation 451V Reassembly of the V-belts generally follows the disassembly procedure in reverse order. (4) Adjustment ➀...

  • Page 94: Rear Axle Assembly

    3-2 Rear Axle Assembly 1) Removal 1. Oil hose Disconnect the oil hoses from the power steering cylinder. 2. Rear axle assembly a. Pull up and hold the engine by hoist. b. Remove the bolts ➀ for fixing the front bearing holder ➁...
  • Page 95 11. Remove the idler mission case ➀ with differential shaft ➁ from the wheel shaft housing ➃. 12. Remove the differential shaft ➁. 13. Remove the snap ring ➅, bearing ➄ and idler pinion ➂ from the idler mission case ➀. 14.

  • Page 96: Installation

    21. If necessary, remove the oil seal and bush from the front bearing holder. 22. If necessary, remove the bearing from the rear bearing holder. 461V 3) Installation Reinstall the rear axle assembly generally follows the disassembly procedure in reverse.

  • Page 97: Power Steering System

    3-3 Power Steering System ★ Caution: 1. Never disassemble the Power steering control valve unit during the claim warranty term. If it is disassembled, claim is not accepted. 2. If disassembly is unavoidably required, the power steering control valve unit should be handled vary carefully since it is finished precisely.

  • Page 98: Installation

    8. Remove the bolts ➀ and plate ➁ from steering control valve unit ➂. 9. Remove the bolts ➃ and steering control valve unit ➂ from the steering column ➄. 3) Installation Reinstall generally follows disassembly procedure in reverse and observe the following: 1.
  • Page 99 7 Remove the housing (2) from the vice and put it shaft center to horizontally on the clean cloth. 8 rotate the spool (4) and sleeve (3) assembly until the pin (8) to horizontally. Push and slide out the spool and sleeve assembly by thumbs from the inner spline side ,and remove them from the housing (2).
  • Page 100 (2) Assembly NOTE: 1. Inspect the spool and sleeve for evidence of sticking, scuff marks, and any other damage before reassembly. If found defective, replace the control valve assembly. 2. Wash the material parts by clean solvent and air dry. Never use the cloth or paper for prevent the trouble by waste threads.
  • Page 101 5. Insert the spool (4) in the sleeve (3) and align the spring’s ditch. 6. Install two flat springs (7) in the spring’s ditch end. 7. Install the centering springs (6) between flat springs at the one time. Install the spring retaining ring (9) on the centering springs.
  • Page 102 16. Install the O-ring (22) on the end cap (23), and install them on the gerotor while aligning the bolt holes. 17. Apply the oil to the thread of all screw (29), and install the screws and tighten to 4.9 N·m {0.5 kgf·m} at first, and tightening order ➀...

  • Page 103: Hydraulic Control Valve

    3-4 Hydraulic Control Valve 1) Removal Remove the control valve assembly as follows: 1. Remove the right front wheel and set the safety stand under the tractor. 2. Remove the grips from accelerator lever, PTO control lever and hydraulic control lever. 3.

  • Page 104: Disassembly

    3) Disassembly Reference – Figure 474V Repair of the hydraulic control valve is limited to seal replacement only. 1. Remove the bolts (1) and pull the cap (3) and spool (2) with plate (11) out as an assembly. 2. Place the control end of the spool in a vise and remove the plate (11) and snap ring (4).

  • Page 105: Lift Linkages

    3-5 Lift Linkages 1) Removal a. Remove the split pins (1), washers (2) and pins (3). b. Remove the L.H. and R.H. lift arms (4). c. Remove the bolt (5) and pin (6) from the bracket (7). d. Remove the bolts (8) and bracket (9) from the transmission housing. e.

  • Page 106: Electric Units And Accessories

    3-6 Electric Units and Accessories 1. Location 477V 1. PTO safety switch 7. Key switch assembly 13. Engine oil pressure switch 2. HST Neutral switch 8. Fuel pump 14. Regulator 3. Brake switch 9. Air cleaner clogging warning switch 15. Glow timer 4.

  • Page 107: Safety Start And Stop System

    2. Safety Start and Stop System 1) Safety Start System Engine can be started when the three switches (HST switch, PTO switch and brake switch) are “ON” position, and then engine start relay and safety relay are energized. (1) Safety Start Circuit Safety start circuit is consists safety start relay and three switches.

  • Page 108: Safety Stop System

    2) Safety Stop System The engine is automatically stopped for safety with the driver is unseated. (1) Safety Stop Circuit The safety relay and fuel cut-off solenoid are in series, and seat switch and three switches are parallel circuit. Engine can be stopped when driver is unseated with one of three switches (PTO, HST and BRAKE switches) are “OFF”...

  • Page 109: Adjustment

    3) Adjustment (1) PTO Switch Install the PTO switch and adjust the plunger no contact to PTO lever plate when PTO lever moves to 1/3 of the travel, and tighten to lock nut. 480V (2) HST Switch Adjust the HST switch position after HST neutral position adjustment.

  • Page 110: Inspection

    4) Inspection (1) Engine start relay and safety relay. To test a relay, disconnect it from the circuit. Connect the battery, switch, relay and ohmmeter as illustration. · The switch is “OFF” position, the ohmmeter reading no continuity. · The switch is “ON” position, the ohmmeter reading continuity.
  • Page 111 (4) Fuel Sensor Use an ohmmeter to test the fuel gauge sensor. Disconnect the wiring from the sensor and connect the ohmmeter leads to the sensor terminals. · When the float at “F” position, the ohmmeter reading of 3±2 ohms is normal. ·...
  • Page 112 (7) Fuel Shut-off Solenoid 1. With the solenoid de-energized, measure the protrusion distance “A” of the plunger as shown at right. · In the shut-off position, the plunger protrusion distance should measure 25.5 mm – 26.5 mm. 2. Connect a jumper wire from the solenoid terminal to the battery positive (+) terminal.
  • Page 113 (9) Engine Coolant Temperature Sensor The sensor is located at the left side cylinder head. This sensor regulates a variable resistance to ground, which translates into the movement of the temperature gauge. (10) Engine Oil Pressure Sensor The engine oil pressure switch is located on the cylinder head.

  • Page 114: Wiring

    3. Wiring...
  • Page 115 493V...

  • Page 116: Maintenance Standards Table

    3-7 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 Backlash of each gear 0.04 – 0.2 Differential pinion thrust washer thickness 1.1 –...
  • Page 117 Standard Standard Repair Service Unit Part Inspection Item Assembling Remarks Dimensions Value Limit Value Relief valve working pressure MPa {kgf/cm 6.37 {65} Steering box High-pressure relief set pressure 17.64 {180} MPa {kgf/cm Charge circuit relief set pressure 0.49 {5} MPa {kgf/cm 44.1 –...

  • Page 118: Chapter 4

    Chapter 4. MOWER...

  • Page 119: Mower (Models Fm48 And Fm 60Cj)

    4-1 Mower (Models FM48 and FM 60CJ) 1. Gear Box Unit Removal (1) Remove the joint cover ➀, sprit pin ➁, nut ➂ and bolt ➃. (2) Remove the universal joint ➄. 900V (3) Unhook the hungers ➅ and remove the nuts ➆ and belt covers ➇.

  • Page 120: Adjustment

    2. Adjustment Adjust the V-belt tension as follows: · Install the V-belt on the pulleys, spring, tension rod and tension nut. · Tighten the tension nut until the V-belt deflection is 12 mm by push the V-belt of two driven pulleys center at 25.5 N {2.6 kgf}.

  • Page 121: Gear Box Unit Installation

    2) Assembly Reassemble the gear box assembly generally follows the disassembly procedure in reverse order and observe as follows: · If removed oil seals, replace the oil seal with new one. · Adjust the bevel gear back lash to 0.08 – 0.2 mm by shims.

  • Page 122: Adjustment

    5. Adjustment Adjust the V-belt tension as follows: · Install the V-belt on the pulleys, spring tension rod and tension nut. · Tighten the tension nut until the V-belt deflection is 12 mm by push the V-belt of two driven pulleys center at 25.5 N {2.6 kgf}.
  • Page 123 2) Assembly Reassemble the bearing case generally follows the disassembly procedure in reverse order and refer to as follows: (1) Tighten the bolt and nut as follows: · On model FM48 ➀ Bolts (M10×25 coarse thread) for bearing case: 29.4 N·m {3.0 kgf·m} ➁...

  • Page 124: Blade

    7. Blade 1) Inspection (1) Before removing the blades, check the clearance between the blade tips as shown in figure. Replace the blades if the clearance exceeds the specified wear limits. Blade tip clearance Standard 1.61 mm Wear limit 10.0 mm 914V (2) Remove the blades and inspect the blades for straightness.

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