Cub Cadet 8404 Manual de Serviço

88335544//88440044 SSEERRVVIICCEE MMAANNUUAALL MTD Products, LLC Product Training and Education Department www.mymowerparts.comK&

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CHAPTER 3 8354/84043-12D615-W02 May-2003615W323A615W322A615W321A2.6 DISASSEMBLY, MAINTENANCEA. CLUTCH PEDAL CHECK AND ADJUST-MENTa. First Stage (

CLUTCH3-13D615-W02 May-2003615W324A615W325AB. DISASSEMBLY, ASSEMBLYa. First Stage (Disconnection of Clutch Hous-ing and Flywheel Housing)1. Support

CHAPTER 3 8354/84043-14D615-W02 May-2003615W328A615W327A615W326AC. MAINTENANCEa. Check of Play Between Clutch Disc SplineBoss and Gear Shaft1. At

CLUTCH3-15D615-W02 May-2003615W329Ad. Check of Flywheel and Clutch PressurePlate1. Check to see if the flywheel and clutch pressureplate are faulty

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CHAPTER 4TRANSMISSIONwww.mymowerparts.comK&T Saw Shop 606-678-9623 or 606-561-4983

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TRANSMISSION4-3D615-W03 May-2003615W401AForward: 8th Stage, Reversing: 8th Stage(*:Option,Forward: 16th Stage, Reversing: 16th Stage)1. STRUCTURESec

CHAPTER 4 8354/84044-4D615-W02 May-2003615W403A2.1 MAIN TRANSMISSION• Consists of full synchro mesh and employs key type as synchro.A. Power Tran

TRANSMISSION4-5D615-W02 May-2003615W405A615W404AB. Synchro Operation1st Stage• By shifting the main transmission shift lever, shifter(3) and key (2)

GENERAL INFORMATION1-3D615-W02 May-2003615W101A1. TRACTOR VIEWwww.mymowerparts.comK&T Saw Shop 606-678-9623 or 606-561-4983

CHAPTER 4 8354/84044-6D615-W02 May-2003615W406AFinal Stage• When the rotation speed of shift (3) are equal withthat of gear (6), the rotation for

TRANSMISSION4-7D615-W02 May-2003615W407AForwardShuttle shaft (1) → Spline hub (2) → Shift (3) → 19 Gear(4) → 23 Gear (6) → 23-21 Gear shaft (5)Rever

CHAPTER 4 8354/84044-8D615-W02 May-2003615W408ALow SpeedHi-Lo shift shaft (1) → Spline boss (2) → Shift (3) → 18Gear (4) → 42 Gear (6) → Spiral b

TRANSMISSION4-9D615-W02 May-2003615W410A615W409A2.4 MID PTO• Consists of an independent PTO, which uses a gearengagement shift method and performs g

CHAPTER 4 8354/84044-10D615-W02 May-2003615W412A615W411A2.7 FRONT WHEEL DRIVE• Employs a gear engagement type and disengage/engage in a simple st

TRANSMISSION4-11D615-W02 May-2003615W414A3.1 MAIN SHIFT• The transmission shift lever (1) is located in left ofthe driver’s seat and is connected to

CHAPTER 4 8354/84044-12 D615-W02 May-2003615W417A3.5 CREEPER SPEEDModel:(IF APPLICABLE ) • Creep speed lever (1) is located at left of driver’sse

TRANSMISSION4-13D615-W02 May-2003615W418A3.6 MID PTO SHIFT• Mid PTO lever (1) is located to the right of thedriver’s seat and connected to the mid P

CHAPTER 4 8354/84044-14D615-W02 May-2003615W420A(1) Clutch Body(2) Seal Ring(3) Piston(4) Piston Ring(5) Piston Ring(6) Brake Plate(7) Return Pla

TRANSMISSION4-15D615-W02 May-2003615W423A615W422AB. With PTO Clutch OFFa. If PTO conversion switch is set to [OFF], the PTOclutch valve will operate

CHAPTER 1 8354/84041-4D615-W02 May-20032. TIGHTENING TORQUE FOR STANDARD BOLTS AND NUTS2.1 TIGHTENING TORQUEScrews, bolts and nuts whose tighteni

CHAPTER 4 8354/84044-16D615-W03 May-2003615W428B5.1 STRUCTURE• Differential gear is a 4 pin type, distributes and pro-vides suitable rpm’s automa

TRANSMISSION4-17D615-W02 May-2003615W431AB. Turning a Corner• Rotation of spiral bevel pinion (1) will be transmit-ted to spiral bevel gear (2). Whe

CHAPTER 4 8354/84044-18D615-W02 May-2003615W433A(1) Differential Locking Fork Shaft(2) Differential Locking Fork(3) Differential Locking Shift(4)

TRANSMISSION4-19D615-W02 May-2003Re-supplyReplaceReplaceReplaceReplaceReplace andreassemblyTightenAdjustAdjustReplaceReplaceMaintenanceReplaceAdjust

CHAPTER 4 8354/84044-20D615-W02 May-20030.8 mm0.031 in.0.5 mm0.02 in.80 %2.05 mm0.081 in.2.05 mm0.081 in.1.40 mm0.005 in.0.15 mm0.006 in.0.3 mm0.

TRANSMISSION4-21D615-W02 May-2003M18M8M10M12M12M12M12M12M12M6M8M8M8M10M10M12M12M12M8M10M6M8M8M10M10M8M10M12M12M12M32M10M22M10M10M10M10 (UBS)The foll

CHAPTER 4 8354/84044-22D615-W02 May-2003615W435ADISASSEMBLY, MAINTENANCE(1) 22 Gear Shaft (PTO)(2) 25 Gear Shaft(3) 23-19 Gear Shaft (PTO)(4) Cou

TRANSMISSION4-23D615-W02 May-2003615W438A615W436A9.1 TRANSMISSION OIL DRAINING1. Loosen oil drain plug in the lower of clutch housingand transmissio

CHAPTER 4 8354/84044-24D615-W02 May-2003615W439A1. Disconnect brake rod (1) from the left and right oftractor body.2. Loosen intake pipe 3 (2) an

TRANSMISSION4-25D615-W02 May-2003615W440AC. Third Stage (Disconnection of ClutchHousing and Flywheel Housing)1. Support the lower of clutch housing

GENERAL INFORMATION1-5D615-W02 May-2003B. TIGHTENING TORQUE FOR STUDSM8M10M1211.7 ~ 15.7 N·m24.5 ~ 31.4 N·m34.3 ~ 49.0 N·m1.2 ~ 1.6 kgf·m2.5 ~ 3.2 k

CHAPTER 4 8354/84044-26D615-W02 May-2003615W441A615W442AD. Fourth Stage (Transmission RodDisconnection)1. Pull out spring pin (2) of transmission

TRANSMISSION4-27D615-W02 May-2003615W444A615W443AE. Fifth Stage (Disconnection of IntermediateCase and Clutch Housing)1. Disengage the shuttle trans

CHAPTER 4 8354/84044-28D615-W02 May-2003615W446A615W445A10.1 FIRST STAGE (DISCONNECTION OFMAIN TRANSMISSION COVER)1. Disengage main transmission

TRANSMISSION4-29D615-W02 May-2003615W448A615W447A10.2 SECOND STAGE (DISCONNECTION OFPROPULSION SHAFT CASE)1. Loosen clutch release fork (1) locking

CHAPTER 4 8354/84044-30D615-W03 May-2003615W451B615W449B(1) Propulsion Shaft Cover(2) 25 Gear Shaft(3) Snap Ring(4) 26 Gear(5) Oil Seal10.3 THIRD

TRANSMISSION4-31D615-W03 May-2003615W453B615W452A10.5 FIFTH STAGE (DISCONNECTION OFTRANSMISSION FORK)(When reassembling)1. Loosen locking bolt (2),

CHAPTER 4 8354/84044-32D615-W02 May-2003615W454A(1) 25 Gear Shaft (4) Ball Bearing(2) Snap Ring (5) Collar(3) Snap Ring10.6 SIXTH STAGE (DISASSEM

TRANSMISSION4-33D615-W02 May-2003615W455A1. Loosen snap ring (1) for shaft.2. Pull out bearing (2), (3) using bearing puller.3. Disassemble thrust c

CHAPTER 4 8354/84044-34D615-W02 May-2003615W456A(1) Shaft, Counter(2) Bearing, Ball(3) Cir-clip(4) Collar, Thrust(5) Gear, 24(6) Bearing, Needle(

TRANSMISSION4-35D615-W02 May-2003615W458A615W457AC. Checking for Groove Clearance BetweenTransmission Fork and Shift Groove.1. Measure groove depth

CHAPTER 1 8354/84041-6D615-W02 May-20033. SPECIFICATIONSEngineModel28.3 HP33.5 HP3A165D387 × 92.4 mm(3.425 × 3.637 in.)1,6471-2-3179 kg5.8 (1.5

CHAPTER 4 8354/84044-36D615-W02 May-2003615W460A615W459AD. Synchro Assembly Check1. Check synchronizer key and spring for damage andreplace it if

TRANSMISSION4-37D615-W02 May-2003615W461A(1) PTO Clutch Assembly(2) 12 Gear Shaft(3) 23-21 Gear(4) 19 Gear(5) 16 Gear(6) Shuttle Shaft(7) 18 Gear11.

CHAPTER 4 8354/84044-38D615-W02 May-2003615W463A(1) Transmission Case(2) Intermediate Casea. First Stage (Disconnection of IntermediateCase and T

TRANSMISSION4-39D615-W02 May-2003615W466A615W465A615W464Ab. Second Stage (Disconnection of bearingover assembly)1. Disengage bearing cover (1) attac

CHAPTER 4 8354/84044-40D615-W02 May-2003615W469A615W468A615W467Ac. Third Stage (Disassembly of Shuttle Fork)1. Straighten cocking of lock washer

TRANSMISSION4-41D615-W02 May-2003615W472A615W471A615W470Af. How to Assemble Synchro Assembly• Put gear side (a) on inner cone (b). With center cone(

CHAPTER 4 8354/84044-42D615-W02 May-2003615W473Ab. Second Stage (Disconnection of PTO Clutch)1. Disengage snap ring (1) for hole and pull out pre

TRANSMISSION4-43D615-W02 May-2003615W459A615W458A615W457AC. Checking for clearance betweenTransmission Fork and Shift groove.1. Measure groove depth

CHAPTER 4 8354/84044-44D615-W02 May-20032. With synchronizer ring contacted with taper cone ofthe opposite gear, measure the clearance betweensyn

TRANSMISSION4-45D615-W02 May-2003615W477A615W476A615W475AF. Checking piston, pressure plate and returnplate for flatness1. Using feeler gage, measur

GENERAL INFORMATION1-7D615-W02 May-20031,650 kg (3,638 lb)2 or 42,000 (2,542 rpm)540 (2,451 rpm)3,100 mm(112.7 in.)1,515 kg1.6 (0.21) ~ 23.2 km/h0.9

CHAPTER 4 8354/84044-46D615-W03 May-2003615W478A(1) Aux. Shift Shaft(2) Spiral Bevel Pinion(3) Front Drive Shaft(4) 13 Gear Shaft(CR option)(5) I

TRANSMISSION4-47D615-W02 May-2003615W482A1. Remove the main transmission bracket (1) attach-ing bolt (2) and disconnect bracket and main trans-missi

CHAPTER 4 8354/84044-48D615-W02 May-2003615W483Ad. Fourth Stage (Disconnection of Rear AxleCase)1. Loosen bolt (1) and nut (2) and disconnect rea

TRANSMISSION4-49D615-W02 May-2003615W488A615W487AB. Disconnection of Transmission Casea. First Stage (Disconnection of PTO Shaft)1. Loosen bearing c

CHAPTER 4 8354/84044-50D615-W02 May-2003615W490A(1) MID PTO Case(2) Bolt with Washer(3) Front Wheel Drive Shaft AssemblySealing agent Three bond

TRANSMISSION4-51D615-W02 May-2003615W495A(1) Nut(2) Bearing Cover(3) Bolt(4) Bearing Case(5) Shim(6) Taper Roller Bearing Assembly1. Straighten cock

CHAPTER 4 8354/84044-52D615-W02 May-2003615W496Af. Sixth Stage (Disassembly of Spiral bevelpinion shaft)1. Pull out taper roller bearing (1) usin

TRANSMISSION4-53D615-W02 May-2003615W4A1A(1) Ball Bearing (9) Counter Shaft(2) 31 Spur Gear (10) 41 Spur Gear(3) Ball (11) Ball Bearing(4) Spring (1

CHAPTER 4 8354/84044-54D615-W02 May-2003615W4A4ASect. Spec. Tightening torqueTightening bolt M10 48.0 ~ 55.9 N·m4.9 ~ 5.7 kgf·m35.5 ~ 41.2 lbf·ft

TRANSMISSION4-55D615-W02 May-2003615W4A5A1. Disassemble taper roller bearing (1), (2) using spe-cial tool.2. Pull out differential locking shift (3)

CHAPTER 1 8354/84041-8D615-W02 May-2003615W103A615W102A4. IDENTIFICATION4.1 ENGINE NUMBERThe engine serial number is stamped on the left sideof t

CHAPTER 4 8354/84044-56D615-W02 May-2003615W4A7A615W4A6A12.2 MAINTENANCEA. Bearing Check1. With bearing inner wheel seized, pull in and outouter

TRANSMISSION4-57D615-W02 May-2003615W4A9Ae. Backlash Adjustment Method• Determine entire amount of shim (3), (4) with pre-load of left and right tap

CHAPTER 4 8354/84044-58D615-W02 May-2003615W4B2A615W4B1A615W4B0A<Good Tooth Contact>• More than 35% tooth contacted. The center is lo-cated

TRANSMISSION4-59D615-W02 May-2003615W4B5Ae. Backlash Check of Differential Pinion andDifferential Side Gear1. Set dial gauge at tooth surface of dif

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CHAPTER 5REAR AXLEwww.mymowerparts.comK&T Saw Shop 606-678-9623 or 606-561-4983

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REAR AXLE5-3D615-W02 May-2003615W501AMODEL: 8354 / 8404(1) Rear Axle Case(2) Rear Axle(3) 55 Gear (8354) / 60 Gear (8404)(4) 10 Gear Shaft(8354)/11

CHAPTER 5 8354/84045-4D615-W02 May-2003ItemRear wheel tightening boltBrake case and rear wheel caseTightening bolt, nutLock nutRear axle case cov

REAR AXLE5-5D615-W02 May-20030.5 mm0.197 in.0.3 mm0.086 in.---1.0 mm (Oil groove depth:Min. 0.3 mm)0.0394 in. (Oil groovedepth: Min. 0.0118 in.)0.1

GENERAL INFORMATION1-9D615-W02 May-2003615W105A615W106A615W104A5. CAUTION BEFORE REPAIR5.1 BEFORE REPAIR OR INSPECTION1. In case of repair or inspec

CHAPTER 5 8354/84045-6D615-W02 May-2003615W504A615W505A4.1 DISCONNECTION OF REAR AXLEGROUPA. First Stage (Disconnection of Rear Wheel)1. Support

REAR AXLE5-7D615-W02 May-2003615W513A615W514A1. Insert spring pin (1) into planetary gear shaft (2).2. When pulling out the planetary gear shaft (2)

CHAPTER 5 8354/84045-8D615-W02 May-2003615W507A4.2 DISASSEMBLY OF REAR AXLE1. Using bearing puller, pull out ball (roller) bearing(2) from the re

REAR AXLE5-9D615-W02 May-2003615W520A5.4 CHECK THRUST COLLAR FOR WORN1. Measure the thickness of thrust collar.2. If it exceeds specified limits, re

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CHAPTER 6BRAKEwww.mymowerparts.comK&T Saw Shop 606-678-9623 or 606-561-4983

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BRAKE6-3D615-W02 May-2003• For the left and right running brake, an independent mechanical wet disc brake is used and operated through brake pedalby

CHAPTER 6 8354/84046-4D615-W02 May-20032. OPERATION615W602A(1) Cam Plate (3) Brake Plate(2) Brake Disc (4) Brake Case(5) Ball (7) Brake Cam(6) Ge

BRAKE6-5D615-W02 May-2003AdjustReplaceReplaceAdjustReplaceReplaceReplaceAdjustReplaceReplaceReplaceChange• Brake pedal clearance is not constant• Br

CHAPTER 1 8354/84041-10D615-W02 May-2003615W109A615W108A615W107A5.6 ELECTRICAL SYSTEM1. Check electrical wiring every year for any damageor short

CHAPTER 6 8354/84046-6D615-W02 May-20034. MAINTENANCE SPECIFICATION---0.3 mm(0.012 in.)0.3 mm(0.012 in.)20.5 mm (0.8071 in.)4.2 mm (0.165 in.)2.1

BRAKE6-7D615-W02 May-2003615W605A6.1 DISASSEMBLY, MAINTENANCE[CHECK AND ADJUSTMENT]A. First Stage (Clearance Adjustment of BrakePedal)1. Disengage t

CHAPTER 6 8354/84046-8D615-W02 May-20036.2 MAINTENANCECheck the clearance between brake lever bush andbrake shaft1. Measure I.D. of brake lever b

BRAKE6-9D615-W02 May-2003615W608A7.1 DISASSEMBLY AND ASSEMBLYA. Disconnection of Brake Case Groupa. First Stage (Disconnection of Brake Case)(1) Bol

CHAPTER 6 8354/84046-10D615-W02 May-2003615W609A39.2 ~ 49.0 N·m4.0 ~ 5.0 kgf·m28.9 ~ 36.2 lbf·ft77.5 ~ 90.2 N·m7.9 ~ 9.2kg f·m57.1 ~ 66.5 lbf·ftM

BRAKE6-11D615-W02 May-2003615W613A615W612AModel Part name Assembly position83548404Cam plate (left)Cam plate(right)Left of transmissioncaseRight oft

CHAPTER 6 8354/84046-12D615-W02 May-2003615W615A615W616A(When reassembling)• Rounding of snap ring should be toward bearing.a. Second Stage (Disa

BRAKE6-13D615-W02 May-2003615W618A615W619AD. Wear Check of Brake Disc1. Measure the thickness of brake disc.2. If the measured value exceeds the all

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CHAPTER 7FRONT AXLEwww.mymowerparts.comK&T Saw Shop 606-678-9623 or 606-561-4983

GENERAL INFORMATION1-11D615-W02 May-2003615W112A615W111ABe cautious of oil or other petroleum products on thehoses and rubber parts, this may cause

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FRONT AXLE7-3D615-W03 May-2003615W701B1. STRUCTURE• The front axle is applied with a bevel gear type to improve work ability and extend the applicab

CHAPTER 7 8354/84047-4D615-W02 May-2003Camber not only decreases bending and warpingagainst vertical load and running resistance butalso keeps sa

FRONT AXLE7-5D615-W02 May-2003AdjustAdjustReplaceAdjustReplaceTightenAir bleedingReplaceReplaceReplaceReplaceReassemblyAdjust or replaceRefillReplac

CHAPTER 7 8354/84047-6D615-W02 May-2003-----------0.25 mm0.098 in.--0.20 mm0.0079 in.-----2 ~ 8 mm0.08 ~ 0.32 in.1.8 kgf/cm² 25.6 psi1.6 kgf/cm²

FRONT AXLE7-7D615-W02 May-2003272 ~ 31891.2 ~ 10834.4 ~ 37.691.2 ~ 108123.0 ~ 137.557.2 ~ 66.517.4 ~ 20.391.2 ~ 108.457.2 ~ 66.535.4 ~ 41.2Tie rod l

CHAPTER 7 8354/84047-8D615-W02 May-2003615W707A615W706A6.1 CHECK AND ADJUSTMENTA. First Stage (Tow-In)1. Set tire to the specified air pressure.2

FRONT AXLE7-9D615-W03 May-2003615W708A(1) Adjusting Bolt (2) NutC. Third Stage (Adjustment of Front AxleRocking Force)1. Raise the front axle and ma

CHAPTER 7 8354/84047-10D615-W02 May-2003(1) Propulsion Shaft Cover 1(2) Propulsion Shaft Cover 2(3) Bolt(4) Coupling(5) Spring Pin(6) Propulsion

FRONT AXLE7-11D615-W02 May-2003615W713A615W714AD. Fourth Stage (Disconnection of Front AxleAssembly)1. Support the lower of engine with a hydraulic

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CHAPTER 1 8354/84041-12D615-W02 May-20036. REGULAR CHECK LISTEngine oil changeEngine oil filter cartridge changeTransmission oil changeHydraulic

CHAPTER 7 8354/84047-12D615-W02 May-2003615W716A1. Loosen the attaching bolt of front axle cover (1) anddisconnect the front axle (2) and cover f

FRONT AXLE7-13D615-W02 May-2003615W717A1. Pull out snap ring (1) and disassemble plug (2).2. Pull out snap ring (3) and disassemble bevel gear(5) an

CHAPTER 7 8354/84047-14D615-W03 May-2003615W719B615W720A1. Disengage the attaching bolt (2) of bevel gear case(1) and disconnect bevel gear case

FRONT AXLE7-15D615-W02 May-2003615W722A615W721A8.5 FIFTH STAGE (DISASSEMBLY OF FRONT AXLE SUPPORT)1. Disconnect the front bracket (1) and rear brack

CHAPTER 7 8354/84047-16D615-W03 May-2003615W724A615W725ASect. Spec. Tightening torqueThe attaching bolt ofcenter pinM12 77.5 ~ 90.2 N·m7.9 ~ 9.2

FRONT AXLE7-17D615-W02 May-2003615W726A(1) Ball Bearing(2) Spiral Bevel Gear(3) Bolt(4) Differential Case Cover(5) Front Differential Case(6) Differ

CHAPTER 7 8354/84047-18D615-W02 May-2003615W727A615W728A9.1 CLEARANCE CHECK BETWEEN CENTERPIN, FRONT AXLE SUPPORT BOSS ANDFRONT AND REAL BRACKETS

FRONT AXLE7-19D615-W02 May-2003615W729A615W730A9.4 CHECK FOR SHIM BETWEEN AXLECASE SUPPORT AND FRONT AXLE CASE1. With front axle case and bevel gear

CHAPTER 7 8354/84047-20D615-W03 May-2003615W740A9.5 CHECK FOR BACKLASH AND TOOTHCONTACTED BETWEEN BEVEL PINIONSHAFT AND SPIRAL BEVEL GEARA. Backl

FRONT AXLE7-21D615-W02 May-2003615W742A615W741A1.0 mm (0.039 in.) 1.2 mm (0.047 in.)9.6 CLEARANCE CHECK BETWEENDIFFERENTIAL PINION SHAFT ANDDIFFERE

GENERAL INFORMATION1-13D615-W02 May-20037. OIL & WATER SUPPLY LISTSupply ItemsFuelCoolantEngine OilTransmission OilFront Axle SectionCapacity40

CHAPTER 7 8354/84047-22D615-W03 May-2003615W743A9.8 CHECK FOR BACKLASH AND TOOTHCONTACTED BETWEEN DIFFERENTIALPINION AND DIFFERENTIAL SIDE GEAR1.

CHAPTER 8STEERING SYSTEMwww.mymowerparts.comK&T Saw Shop 606-678-9623 or 606-561-4983

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STEERING SYSTEM8-3D615-W02 May-2003615W802A(1) Hydraulic Filter(2) Hydraulic Pump(3) Modulating Valve(4) Power Steering Unit(5) Hydraulic Block(6) A

CHAPTER 8 8354/84048-4D615-W03 May-2003RRLL615W803BHYDRAULIC OIL FLOW• When the engine is started, the hydraulic pump will be driven to pass oil

STEERING SYSTEM8-5D615-W02 May-2003615W804A3.3 STRUCTURE OF GEAR PUMP(1) Snap Ring(2) Bearing(3) Cover (Front)(4) Seal Ring(5) Pin(6) First Pump(7)

CHAPTER 8 8354/84048-6D615-W02 May-2003615W805A(1) Inflow to Pump (4) Outflow From Pump(2) Bushing (5) Pump Housing(3) Gear (6) Drive Shaft3.4 OP

STEERING SYSTEM8-7D615-W02 May-2003615W806A4.2 STRUCTURE AND OPERATION• Power steering controller consists of steering valveand relief valve.• Steer

CHAPTER 8 8354/84048-8D615-W02 May-2003615W809A5.1 STRUCTURE(1) Tube (4) Dust Seal(2) Packing (5) Rod(3) Bush[A] Rod O.D [B] Tube I.D5.2 MAJOR SP

STEERING SYSTEM8-9D615-W02 May-2003615W810A615W811A6.1 IN NEUTRALIf the steering wheel is not rotated, valve plate (3) keepsin neutral by using a ce

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CHAPTER 8 8354/84048-10D615-W02 May-2003615W812A6.3 TURNING TO THE LEFTThe steering system operates in the same direction asin rotating to the le

STEERING SYSTEM8-11D615-W02 May-20031.Power steering unit(1) Column and centermismatched.(2) Spool and sleeve dirty(3) Excessive tightening torqueof

CHAPTER 8 8354/84048-12D615-W02 May-2003615W814A1. Disassemble bolt (2).2. Detach gear pump (1).3. Detach O-ring (3)- See assembly bolt spec (M10

STEERING SYSTEM8-13D615-W02 May-2003212223615W815Ab. Disassembly of Gear Pump(1) Snap Ring(2) Bearing(3) Cover (Front)(4) Sealing(5) Pin(6) First Pu

CHAPTER 8 8354/84048-14D615-W02 May-2003615W816A615W817A• Loosen bolt (1) and disconnect power steering unit(2).(When reassembling)• When attachi

STEERING SYSTEM8-15D615-W02 May-2003615W818AB. Disassembly, Assembly of Power Steering Unit(1) Screw(2) End cap(3) O-Ring(4) Stator(5) Spacer(6) O-R

CHAPTER 8 8354/84048-16D615-W02 May-2003615W819A615W820A615W821AC. Disassembly of Power Steering Unita. Disassembly of GEROTOR1. With end cap upw

STEERING SYSTEM8-17D615-W02 May-2003615W824A615W823A615W822A7. Disassemble GEROTOR. Make sure rotor notdropped from outer ring of GEROTOR.8. Pull ou

CHAPTER 8 8354/84048-18D615-W02 May-2003615W825A615W826A615W827Ab. Disassembly of Relief Valve1. Disassemble retainer screw (1) from plug (29) of

STEERING SYSTEM8-19D615-W02 May-2003615W828A615W829A5. While raising spool and from sleeve and com-pressing the opposite end of centering spring byh

CHAPTER 2ENGINE SYSTEMwww.mymowerparts.comK&T Saw Shop 606-678-9623 or 606-561-4983

CHAPTER 8 8354/84048-20D615-W02 May-2003615W840Ab. Assembly of Relief Valve1. Insert poppet (25) into flange of housing with springguide seized u

STEERING SYSTEM8-21D615-W02 May-2003615W841A8.3 STEERING CYLINDERA. Checka. Steering Wheel Clearance• After starting engine, wait for the engine to

CHAPTER 8 8354/84048-22D615-W02 May-2003615W843A(5) Steering Cylinder Assembly(7) Support Pin(10) Spacer Barrel(When reassembling)• When attachin

STEERING SYSTEM8-23D615-W02 May-2003b. Air Bleeding in Steering Hose• After the engine has stopped, run engine at 2000 ~2200 rpm, turn steering whee

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CHAPTER 9HYDRAULIC SYSTEMwww.mymowerparts.comK&T Saw Shop 606-678-9623 or 606-561-4983

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HYDRAULIC SYSTEM9-3D615-W03 May-2003615W901B1. HYDRAULIC CIRCUIT DIAGRAMwww.mymowerparts.comK&T Saw Shop 606-678-9623 or 606-561-4983

CHAPTER 9 8354/84049-4D615-W02 May-200363056305615W903AThe hydraulic system consists of major componentsas shown in the above figure. This system

HYDRAULIC SYSTEM9-5D615-W03 May-2003615W904B(1) Oil Tank (Transmission Case)(2) Oil Filter(3) Hydraulic Pump(4) Engine(5) Relief ValveHYDRAULIC OIL

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CHAPTER 9 8354/84049-6D615-W02 May-2003212223615W906A615W905A4.1 STRUCTURE OF HYDRAULIC PUMP4.2 OPERATIONA. The hydraulic pump provides constant

HYDRAULIC SYSTEM9-7D615-W02 May-2003615W907A615W908A5.1 STRUCTURE OF OIL FILTERA. Function• Filters particle or sludge from oil.B. Operation• Oil fi

CHAPTER 9 8354/84049-8D615-W02 May-2003615W910A615W909A6.1 STRUCTURE6.2 CIRCUIT DIAGRAM6. CONTROL VALVE (MLS VALVE)www.mymowerparts.comK&T Sa

HYDRAULIC SYSTEM9-9D615-W02 May-2003615W911A6.3 OPERATION PRINCIPLE• Since the control valve of the hydraulic cylinder isavailable to control oil fl

CHAPTER 9 8354/84049-10D615-W02 May-2003615W912AB. Delivery Phase(1) Control Spool(2) Regulator Piston(3) Check Valve(6) Fixed Throat(7) Safety V

HYDRAULIC SYSTEM9-11D615-W02 May-2003615W913ADuring this phases the control valve supplies, at thesame time, the oil coming from the pump and the oi

CHAPTER 9 8354/84049-12D615-W02 May-2003615W915A615W914A• As shown in the figure, a guide is attached at pop-pet (6) and valve chamber D.C (dampi

HYDRAULIC SYSTEM9-13D615-W02 May-2003615W916A8. HYDRAULIC CYLINDERwww.mymowerparts.comK&T Saw Shop 606-678-9623 or 606-561-4983

CHAPTER 9 8354/84049-14D615-W02 May-2003615W917A9.1 STRUCTURE(1) Lever(2) Needle Bearing(3) Washer(4) Packing(5) Pin(6) Roller 3(7) Lock Screw(8)

HYDRAULIC SYSTEM9-15D615-W02 May-2003615W918A9.2 OPERATIONOperation is Divided Into Position Control, Draft Control and Mixed Operation.A. Position

ENGINE SYSTEM2-3D615-W02 May-20031. GENERAL1.1 APPEARANCE615W201AThe DAEDONG A series engines are vertical, water-cooled, 4-cycle, three or four cyl

CHAPTER 9 8354/84049-16D615-W02 May-2003615W919AB. Draft Control (Fig. 225W918A,225W919A)By positioning the control lever (1) for position contro

HYDRAULIC SYSTEM9-17D615-W02 May-2003When roller 4 (11) meets the inclined plane of the draw-bar pull cam (12), it permits the counterclockwise rota

CHAPTER 9 8354/84049-18D615-W03 May-2003615W921A615W920B10.1 HYDRAULIC BLOCKA: To implement control valve “IN” portB: From implement control valv

HYDRAULIC SYSTEM9-19D615-W03 May-2003615W922B10.2 ACTING VALVEA. Operation principleA double acting detent type auxiliary control valve isused, and

CHAPTER 9 8354/84049-20D615-W02 May-2003615W924A11.2 OPERATIONIf shock is applied to the implement, it will be absorbedby cover (3), spring (4),

HYDRAULIC SYSTEM9-21D615-W02 May-2003Hydraulic cylinder rises irregularlyHydraulic cylinder doesn’tElevating arm is positioned atSTOP and there is p

CHAPTER 9 8354/84049-22D615-W02 May-200329.7 l/m7.85 U.S.gal/min0.11 mm0.0043 in.25.0 mm0.984 in.83548404Depth of scratchClearanceLength0.09 mm0.

HYDRAULIC SYSTEM9-23D615-W02 May-200313.4 HYDRAULIC CYLINDERItem Reference Dimension Allowable LimitCylinder bore I.D.Relationship Rightbetween hyd

CHAPTER 9 8354/84049-24D615-W02 May-2003ItemHydraulic pipe joint boltHydraulic pipe attaching bolt (M10)Hydraulic block support attaching bolt (M

HYDRAULIC SYSTEM9-25D615-W02 May-2003615W925A15.1 GEAR PUMPA. Disconnection of Gear Pump Assembly1. Disassemble hydraulic pipe (3, 4) and intake pip

CHAPTER 2 8354/84042-4D615-W02 May-20031.2 SPECIFICATIONSModelTypeNumber of cylinderBore and strokeTotal DisplacementCombustionChamberGross power

CHAPTER 9 8354/84049-26D615-W02 May-2003615W927AB. Disassembly and Assembly of Gear Pump(1) Snap Ring(2) Bearing(3) Cover (Front)(4) Seal Ring(5)

HYDRAULIC SYSTEM9-27D615-W03 May-2003615W929A615W928B15.2 MAINTENANCEHousing Bore (Depth of Scratch)1. Check if scratch occurred by gear in the surf

CHAPTER 9 8354/84049-28D615-W03 May-2003615W930B1. Disengage joint bolt 2 (8) and detach the hydraulicpipe (1), (2) bracket (5), and quick couple

HYDRAULIC SYSTEM9-29D615-W02 May-2003615W933A(1) Screw (13) Flange(2) Bolt (14) Clutch Hub(3) Lock Washer (15) Spring(4) Gasket (16) Bolt(5) Support

CHAPTER 9 8354/84049-30D615-W02 May-2003615W934A(1) Bolt(2) Lock Washer(3) Control Valve Assembly(4) Power Lift Body (Hydraulic Cylinder Block)d.

HYDRAULIC SYSTEM9-31D615-W02 May-2003615W937Af. Bush1. Remove bush (1), (2)(When reassembling)• When assembling new bush, apply the boss andbush of

CHAPTER 9 8354/84049-32D615-W02 May-2003g. Disassembly, Assembly of MLS Valve615W938Aa) To Disassembling1. Loosen 3 adjusting screws (16) with a

HYDRAULIC SYSTEM9-33D615-W02 May-2003615W939Aa) Disassembly1. Before disassembling the top link holder assembly,disassemble the socket support and c

CHAPTER 9 8354/84049-34D615-W02 May-2003615W940A615W941A15.5 CHECK AND ADJUSTMENTA. Hydraulic Cylinder Bore1. Check the cylinder inside surface f

HYDRAULIC SYSTEM9-35D615-W02 May-2003615W943A615W942AC. Reaction Spring Assembly ReferenceDimension(1) Spring (3) Nut(2) Hex. BoltD. Dimensional Set

ENGINE SYSTEM2-5D615-W02 May-2003615W204A615W203A1.3 PERFORMANCE CURVEwww.mymowerparts.comK&T Saw Shop 606-678-9623 or 606-561-4983

CHAPTER 9 8354/84049-36D615-W02 May-2003615W944A(1) Position Control Lever(2) Draft Control Lever(3) Position Control Shaft(4) Hex. Bolt(5) Lifti

HYDRAULIC SYSTEM9-37D615-W02 May-2003615W945AF. Sensitivity Control of Control Valve (MLS)1. Apply the elevating arm with load of 500 kg (1100lbs)

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CHAPTER 10ELECTRIC SYSTEMwww.mymowerparts.comK&T Saw Shop 606-678-9623 or 606-561-4983

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ELECTRICAL SYSTEM10-3D615-W03 May-20031. ELECTRONIC INSTRUMENTATION1.1 INSTRUMENT GAUGE615WA01B(1) Tachometer(2) Temperature Gauge(3) Fuel Gauge(4)

CHAPTER 10 8354/840410-4D615-W02 May-2003615WA02A(1) Differential Lock Operation Pedal(A) PushA. POWER-TAKE-OFF OPERATION LAMP (4)Light will illu

ELECTRICAL SYSTEM10-5D615-W03 May-2003K. TURN SIGNAL LAMP INDICATOR (14 AND 15)Light will be flash when operating the turn signal switchto the left

CHAPTER 10 8354/840410-6D615-W02 May-2003All electrical equipmentdoes not operateFuse blown frequentlyBattery discharges toofastStarter motor doe

ELECTRICAL SYSTEM10-7D615-W02 May-2003Brake light does not lightCoolant level lamp doesnot light when coolingwater is insufficientCoolant level lamp

CHAPTER 2 8354/84042-6D615-W02 May-2003615W206A1.4 DIMENSIONS3A165D (mm)(in.)4A200B (mm)(in.)A602.323.71697.327.45B722.328.44817.332.18C280.011.0

CHAPTER 10 8354/840410-8D615-W03 May-20033. SERVICING SPECIFICATIONSItem12V80AH12V2.0kw12V50A14V3.4WCapacity (factory spec.)Regulator built - in

ELECTRICAL SYSTEM10-9D615-W03 May-2003(1) Main fuse(2) Start Relay(3) Start motor(4) Key s/w(5) Safety s/w(6) PTO safety relay(7) PTO fuse(8) Neutra

CHAPTER 10 8354/840410-10 D615-W02 May-2003B. OPERATION OF START MOTOR615WA05A615WA06Aa. StarterThe magnet-switch type starter is composed of two

ELECTRICAL SYSTEM10-11D615-W02 May-2003(C) When key switch is on:When the key switch is turned on, a current flows fromthe battery through the pull-

CHAPTER 10 8354/840410-12D615-W03 May-2003615WA10Ab. Glow plusGlow plugs are used for each pre-combustion chamberof the cylinder head to make sta

ELECTRICAL SYSTEM10-13D615-W02 May-2003615WA12AB. CIRCUIT DIAGRAM FOR ALTERNATOR UNITC. OPERATION OF CHARGING SYSTEM· The charging system supplies e

CHAPTER 10 8354/840410-14D615-W03 May-2003(1) Alternator(2) Key s/w(3) Preheating Controller(4) Coolant temp. sensor615WA13B4.3 PREHEATING SYSTEM

ELECTRICAL SYSTEM10-15D615-W03 May-20034.4 FUSEA. FUSE BOX DIAGRAM615WA14AClassifi-cationCablestandardConnec-tionterminalAppli-cablefuseRemark351113

CHAPTER 10 8354/840410-16D615-W02 May-20034.5 GAUGE AND SENSORS615WA15AB. COOLANT TEMPERATURE SENSORThe coolant temperature sensor consists of te

ELECTRIC SYSTEM10-17D615-W02 May-2003615WA18A5. MAIN CIRCUIT DIAGRAMwww.mymowerparts.comK&T Saw Shop 606-678-9623 or 606-561-4983

ENGINE SYSTEM2-7D615-W02 May-2003615W209A615W208A615W207A2. STRUCTURE AND FUNCTION2.1 BODYA. CYLINDER HEADThe cylinder head is made of special alloy

CONTENTSCHAPTER 1 GENERAL INFORMATION ...1-11. TRACTOR VIEW...

CHAPTER 2 8354/84042-8D615-W02 May-2003615W212A615W211A615W210AC. CRANKSHAFTThe crankshaft is made of forged steel and the journals,the crankpins

ENGINE SYSTEM2-9D615-W02 May-2003615W215A615W214A615W213AH. ROCKER ARM ASSEMBLYThe rocker arm assembly includes the rocker arms (1)and an adjusting

CHAPTER 2 8354/84042-10D615-W02 May-2003615W218A615W217A615W216A(1) Valve Spring Collet (4) Valve Stem Seal(2) Valve Spring Retainer (5) Exhaust

ENGINE SYSTEM2-11D615-W02 May-2003615W220A615W219A2.2 LUBRICATING SYSTEMA. FLOW OF LUBRICATING OILThe lubricating oil is forced to each journal thro

CHAPTER 2 8354/84042-12D615-W02 May-2003615W222A615W221AC. OIL FILTER AND RELIEF VALVEThe lubricating oil force-fed by the pump is filtered bythe

ENGINE SYSTEM2-13D615-W02 May-2003615W223A615W224A2.3 COOLING SYSTEMB. WATER PUMPThe water pump is driven with the fan drive pulley, whichis on the

CHAPTER 2 8354/84042-14D615-W02 May-2003615W227A615W226A615W225AD. RADIATORThe radiator core consists of water carrying tubes (2)with fins (3) at

ENGINE SYSTEM2-15D615-W02 May-2003615W229A615W228A(1) Fuel Tank (5) Injection Nozzle(2) Fuel Filter (6) Fuel Overflow Pipe(3) Injection Pump (7) Fue

CHAPTER 2 8354/84042-16D615-W02 May-2003615W240A615W230AC. FUEL FEED PUMPThe diaphragm (6) is linked to the tappet (3) with thepush rod (2). The

ENGINE SYSTEM2-17D615-W02 May-2003615W241A615W242Aa. Pump ElementThe pump element (1) consists of a plunger (3) andcylinder (2), their sliding surfa

2. CLUTCH...

CHAPTER 2 8354/84042-18D615-W02 May-2003615W244A615W243Ad. Delivery ValveThe delivery valve prevents the fuel in the injection pipefrom flowing b

ENGINE SYSTEM2-19D615-W02 May-2003615W245A615W246AE. FUEL INJECTION NOZZLEThe nozzle is a throttle-type one. It features low fuelconsumption and wor

CHAPTER 2 8354/84042-20D615-W02 May-20031311514432121617615W248A615W247A2) At idlingAt the idling position of the speed control lever (15), thego

ENGINE SYSTEM2-21D615-W02 May-2003615W249A615W250A3) At high speed running with overloadWhen an overload is applied to the engine running at ahigh s

CHAPTER 2 8354/84042-22D615-W02 May-2003615W253A615W252A615W251A(a) Inlet Air(b) To Intake Manifold(c) Heavier Dust(1) Outlet Port (4) Air Cleane

ENGINE SYSTEM2-23D615-W02 May-20033. DISASSEMBLING AND SERVICING• Not fuel• Air in the fuel system• Water in the fuel system• Fuel pipe clogged• Fue

CHAPTER 2 8354/84042-24D615-W02 May-2003• Excessive engine oil• Piston ring and bore worn orpiston ring stuck• Incorrect injection timing• Insuff

ENGINE SYSTEM2-25D615-W02 May-2003• Improper type of oil• Relief valve defective• Engine oil insufficient• Fan belt broken or tensionedimproperly• C

CHAPTER 2 8354/84042-26D615-W02 May-2003Valve Clearance (Cold) IN.EX.Valve Seat Angle IN.EX.Valve Face Angle IN.EX.Valve RecessingClearance Betwe

ENGINE SYSTEM2-27D615-W02 May-2003d. Cylinder BoreCylinder bore innerdiameter 87.000 ~ 87.022 mm3.4252 ~ 3.4261 in. 83.000 ~ 83.022 mm 3.2677 ~ 3.26

10.3 THIRD STAGE (DISASSEMBLY OF 25 GEAR SHAFT AND PROPULSION SHAFT 1) ... 4-3010.4 FOURTH STAGE (DISASSEMBLY OF BEARING COVER

CHAPTER 2 8354/84042-28D615-W02 May-2003I. Timing Gear0.04 ~ 0.11 mm0.0016 ~ 0.0043 in.0.20 ~ 0.51 mm0.0079 ~ 0.0201 in.0.025 ~ 0.066 mm0.00098 ~

ENGINE SYSTEM2-29D615-W02 May-2003l. Crankshaft-0.040 ~ 0.118 mm0.00157 ~ 0.00465 in.51.921 ~ 51.940 mm2.04414 ~ 2.04489 in.51.980 ~ 52.039 mm2.0464

CHAPTER 2 8354/84042-30D615-W02 May-2003C. COOLING SYSTEMa. ThermostatValve opening temperature at beginningOpened completely (height 8 mm 0.315

ENGINE SYSTEM2-31D615-W02 May-2003E. TIGHTENING TORQUESItemCylinder head screwsHead cover nuts* Bearing case screw 1* Bearing case screw 2* Flywheel

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ENGINE SYSTEM2-33D615-W02 May-2003615WA18A3.3 CHECKING, DISASSEMBLING AND SERVICINGA. ENGINE DISASSEMBLED VIEW(1) Cylinder Block(2) Oil Pressure Swi

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ENGINE SYSTEM2-35D615-W02 May-2003615W259A615W258A(1) Fan Belt (6) Oil Gauge(2) Hour Meter Unit (7) Exhaust Manifold(3) Oil Filter (8) Oil Pressure

CHAPTER 2 8354/84042-36D615-W03 May-2003615W260A615W261A(1) Screw (5) Stop Lever 1(2) Engine Stop Lever (6) Stop Lever 2(3) Screw (7) Solenoid(4)

ENGINE SYSTEM2-37D615-W02 May-2003615W262AC. ENGINE BODYa. Checking and Adjusting1) Compression pressure1. Run the engine until warmed up.2. Stop th

5. TIGHTENING TORQUE ...

CHAPTER 2 8354/84042-38D615-W03 May-2003615W265A615W264A615W263A(1) Injection Nozzle (3) Heat Seal(2) Gasketb. Disassembling and Assembling(A) Cy

ENGINE SYSTEM2-39D615-W02 May-2003615W269A615W268A615W267A (1) Philips Screw Driver (2) Nozzle (3) Injection Nozzle Gasket (4) Heat Seal(1) Rocker

CHAPTER 2 8354/84042-40D615-W02 May-2003615W272A615W271A615W270A(D) Cylinder head1. Remove the screw in the specified sequence shownin the figure

ENGINE SYSTEM2-41D615-W02 May-2003615W274A615W273A(B) Governor spring and Speed control plate1. Disconnect the governor spring 1 (1) and 2 (2) fromt

CHAPTER 2 8354/84042-42D615-W02 May-2003615W276A615W277A615W278A(E) Gear case1. Remove the gear case.(When reassembling)• Stick the O-ring (1) to

ENGINE SYSTEM2-43D615-W02 May-2003615W281A615W280A615W279A(F)Water pump and relief valve1. Remove the water pump body (1).2. Remove the relief valve

CHAPTER 2 8354/84042-44D615-W02 May-2003615W282A615W283A615W284A(H)Camshaft1. Align the holes on the cam gear (2) with the crewsto loosen them th

ENGINE SYSTEM2-45D615-W02 May-2003615W286A615W285A(B) Piston and connecting rod1. Remove the screws and the connecting rod cap.2. Push out the rod a

CHAPTER 2 8354/84042-46D615-W02 May-2003615W290A615W289A3) Crankshaft(A) Flywheel1. Install the stopper to the flywheel and loosen thescrew.2. Re

ENGINE SYSTEM2-47D615-W02 May-2003615W293A615W292A(C)Crankshaft1. Remove the bearing case screw 2.2. Pull out the crankshaft, taking care not to dam

6. OIL FLOW ...

CHAPTER 2 8354/84042-48D615-W02 May-2003615W296A615W295Ac. Servicing1) Cylinder head and valve(A) Cylinder head surface flatness1. Thoroughly cle

ENGINE SYSTEM2-49D615-W02 May-200312 13111078210 65439615W299A615W298A(D)Valve recessing1. Clean the cylinder head, the valve face and the seat.2. I

CHAPTER 2 8354/84042-50D615-W02 May-200311109615W2A1A615W2A2A(H)Rocker arm bushing and shaft clearance1. Measure the rocker arm I.D. with an insi

ENGINE SYSTEM2-51D615-W02 May-2003615W2A5A615W2A4A(B) Idle gear side clearance1. Pull the idle gear collar 2 (1) and push the idle gear(2) to each e

CHAPTER 2 8354/84042-52D615-W02 May-2003615W2A7A615W2A8A(E) Idle gear oil clearance1. Measure the idle gear shaft O.D. with an outsidemicrometer.

ENGINE SYSTEM2-53D615-W02 May-2003615W2B1A615W2B0A(H)Camshaft alignment1. Support the camshaft with V blocks on the surfaceplate at both end journal

CHAPTER 2 8354/84042-54D615-W02 May-200311109615W2B4A615W2B3A(B)Piston pin and brushing clearance1. Measure the piston pin O.D. with an outsidemi

ENGINE SYSTEM2-55D615-W02 May-2003615W2B6A(E) Piston ring clearance1. Clean the ring and the ring grooves, and install eachring in its groove.2. Mea

CHAPTER 2 8354/84042-56D615-W02 May-2003615W2B8A4) Crankshaft(A) Flywheel deflection and crankshaft end play1. Set a dial indicator with its tip

ENGINE SYSTEM2-57D615-W02 May-200311109615W2C1A615W2C0A(C)Crankshaft journal and bearing 1 oil clearance1. Measure the I.D. of the crankshaft bearin

14.TIGHTENING TORQUE ...9

CHAPTER 2 8354/84042-58D615-W02 May-2003615W2C2A(F) Crank pin and connecting rod bearing 2 oil clear-ance1. Put a strip of Plastigage lengthwise

ENGINE SYSTEM2-59D615-W02 May-2003615W2C3A615W2C4A5) Cylinder bore(A) Cylinder bore diameter1. Measure the cylinder liner I.D. at sit positions show

CHAPTER 2 8354/84042-60D615-W02 May-2003615W2C6A615W2C5AD. LUBRICATING SYSTEMa. Checking(A) Engine oil pressure1. Remove the oil pressure switch

ENGINE SYSTEM2-61D615-W02 May-2003615W2C7A615W2C8A615W2C9A(B) Rotor end clearance of oil pump1. Put a strip of plastigage on the rotor and assemblet

CHAPTER 2 8354/84042-62D615-W02 May-2003615W2D2A643W2D1A615W2D0AE. COOLING SYSTEMa. Checking Adjusting(A) Fan belt1. Measure the deflection, depr

ENGINE SYSTEM2-63D615-W02 May-2003615W2D3A615W2D4A615W2D5Ac. Servicing(A) Thermostat valve opening temperature1. Suspend the thermostat in the water

CHAPTER 2 8354/84042-64D615-W02 May-2003FuelInjectionpressurePressuredropFactoryspec.Allowablelimit14.71 MPa150 kgf/cm²2134 psi0.98 MPa10 kgf/cm²

ENGINE SYSTEM2-65D615-W02 May-2003615W2D8A(B) Fuel tightness of needle valve seat tightness1. Set the injection nozzle to the nozzle tester.2. Apply

CHAPTER 2 8354/84042-66D615-W02 May-2003615W2E1A2) Injection nozzle(A) Nozzle holder1. Secure the nozzle retaining nut (7) with a vise.2. Remove

CHAPTER 3CLUTCHwww.mymowerparts.comK&T Saw Shop 606-678-9623 or 606-561-4983

CHAPTER 1GENERAL INFORMATIONwww.mymowerparts.comK&T Saw Shop 606-678-9623 or 606-561-4983

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CLUTCH3-3D615-W02 May-2003615W301A1. DISASSEMBLY AND ASSEMBLY1.1 DISASSEMBLY OF PANEL FRAMEA. FIRST STAGE1. Disassemble side cover (1), bonnet (2),

CHAPTER 3 8354/84043-4D615-W02 May-20031. Disassemble power steering unit connection hoses(1), (2), (3) and (4).2. Remove frame cover (5) in left

CLUTCH3-5D615-W02 May-2003615W306A615W307AC. THIRD STAGE1. Disengage attaching bolt (2) of frame assembly (1).2. Disassembly frame assembly.(When re

CHAPTER 3 8354/84043-6D615-W02 May-2003615W308A1.2 DISASSEMBLY OF FENDER AND STEPLADDER ASSEMBLYA. FIRST STAGE(1) ROPS(2) Seat Assembly(3) Main S

CLUTCH3-7D615-W02 May-2003615W309A1. Disconnect ROPS (1).2. Disconnect seat assembly (2).3. Disconnect knobs (3), (4), (5), (6) and (7) of eacht

CHAPTER 3 8354/84043-8D615-W02 May-2003615W310A2. CLUTCH2.1 CHARACTERISTICS(1) Clutch Disc Assembly(2) Clutch Cover Assembly(3) Release Bearing(4

CLUTCH3-9D615-W02 May-2003615W320A2.2 LINK STRUCTURE AND CONTROL• If working clutch pedal, clutch rod (2) is pulled in thedirection of arrow and rel

CHAPTER 3 8354/84043-10D615-W02 May-20032.3 TROUBLESHOOTINGClutch trailedClutch slipBumping noiseCrashing noiseCrashing noiseVibrationTrouble• Cl

CLUTCH3-11D615-W02 May-20032.4 SPECIFICATIONClutch pedalStopper bolt setting lengthClearance between safety switchand clutch pedalDepth from disc to