Cub Cadet 8404 User Manual

FORM NUMBER 769-00902

88335544//88440044 SSEERRVVIICCEE M

MAANNUUAALL

MTD Products, LLC Product Training and Education Department

CONTENTS

CHAPTER 1 GENERAL INFORMATION..........................................................................................1-1

1. TRACTOR VIEW............................................................................................................................................... 1-3

2. TIGHTENING T ORQUE FOR STANDARD BOLTS AND NUTS ................................................................. 1-4

2.1 TIGHTENING TORQUE.......................................................................................................................... 1-4

3. SPECIFICATIONS............................................................................................................................................ 1-6

4. IDENTIFICATION ............................................................................................................................................. 1-8

4.1 ENGINE NUMBER................................................................................................................................... 1-8

4.2 CHASSIS NUMBER OF THE TRACTOR(CHASSIS NUMBER OF THE MACHINE)....................... 1-8

5. CAUTION BEFORE REPAIR .......................................................................................................................... 1-9

5.1 BEFORE REP AIR OR INSPECTION..................................................................................................... 1-9

5.2 ASSEMBLY AND DISASSEMBLY ........................................................................................................... 1-9

5.3 PARTS TO BE REPLACED..................................................................................................................... 1-9

5.4 PARTS ....................................................................................................................................................... 1-9

5.5 ASBESTOS PARTS................................................................................................................................ 1-10

5.6 ELECTRICAL SYSTEM ......................................................................................................................... 1-10

5.7 TUBES AND RUBBERS ........................................................................................................................ 1-11

5.8 LUBRICANT ............................................................................................................................................ 1-11

6. REGULAR CHECK LIST............................................................................................................................... 1-12

7. OIL & WATER SUPPL Y LIST........................................................................................................................ 1-13

CHAPTER 2 ENGINE SYSTEM.........................................................................................................2-1

1. GENERAL......................................................................................................................................................... 2-3

1.1 APPEARANCE.......................................................................................................................................... 2-3

1.2 SPECIFICATIONS .................................................................................................................................... 2-4

1.3 PERFORMANCE CURVE ....................................................................................................................... 2-5

1.4 DIMENSIONS ........................................................................................................................................... 2-6

1.5 GENERAL WARNING.............................................................................................................................. 2-6

2. STRUCTURE AND FUNCTION ..................................................................................................................... 2-7

2.1 BODY ......................................................................................................................................................... 2-7

2.2 LUBRICATING SYSTEM........................................................................................................................ 2-11

2.3 COOLING SYSTEM................................................................................................................................ 2-13

2.4 FUEL SYSTEM ....................................................................................................................................... 2-15

3. DISASSEMBLING AND SERVICING ...........................................................................................................2-24

3.1 TROUBLESHOOTING...........................................................................................................................2-24

3.2 SERVICING SPECIFICATIONS............................................................................................................ 2-27

3.3 CHECKING, DISASSEMBLING AND SERVICING ............................................................................ 2-33

CHAPTER 3 CLUTCH .........................................................................................................................3-1

1. DISASSEMBLY AND ASSEMBLY.................................................................................................................... 3-3

1.1 DISASSEMBLY OF PANEL FRAME........................................................................................................ 3-3

1.2 DISASSEMBLY OF FENDER AND STEPLADDER ASSEMBLY ......................................................... 3-6

2. CLUTCH............................................................................................................................................................ 3-8

2.1 CHARACTERISTICS ............................................................................................................................... 3-8

2.2 LINK STRUCTURE AND CONTROL..................................................................................................... 3-9

2.3 TROUBLESHOOTING........................................................................................................................... 3-10

2.4 SPECIFICATION .................................................................................................................................... 3-11

2.5 TIGHTENING TORQUE ........................................................................................................................ 3-11

2.6 DISASSEMBLY, MAINTENANCE .........................................................................................................3-12

CHAPTER 4 TRANSMISSION ...........................................................................................................4-1

1. STRUCTURE ................................................................................................................................................... 4-3

2. POWER TRANSMISSION ............................................................................................................................... 4-4

2.1 MAIN TRANSMISSION............................................................................................................................. 4-4

2.2 SHUTTLE.................................................................................................................................................. 4-7

2.3 HI-LO SHIFT ............................................................................................................................................. 4-8

2.4 MID PTO .................................................................................................................................................... 4-9

2.5 REAR PTO ................................................................................................................................................ 4-9

2.6 CREEPER SPEED (IF APPLICABLE )................................................................................................. 4-10

2.7 FRONT WHEEL DRIVE......................................................................................................................... 4-10

3. TRANSMISSION SHIFT LINK STRUCTURE ... .... ...................................................................................... 4-11

3.1 MAIN SHIFT.......................................................................................................................................... 4-11

3.2 SHUTTLE SHIFT .................................................................................................................................4-11

3.3 HI-LO SHIFT......................................................................................................................................... 4-12

3.4 PTO SHIFT ...........................................................................................................................................4-12

3.5 CREEPER SPEED ..............................................................................................................................4-12

3.6 MID PTO SHIFT ...................................................................................................................................4-13

3.7 FRONT WHEEL DRIVE SHIFT .......................................................................................................... 4-13

4. PTO CLUTCH................................................................................................................................................. 4-14

4.1 CHARACTERISTICS........................................................................................................................... 4-14

4.2 HYDRAULIC CIRCUIT........................................................................................................................4-14

4.3 OIL FLOW ............................................................................................................................................. 4-15

5. DIFFERENTIAL GEAR ..................................................................................................................................4-16

5.1 STRUCTURE ....................................................................................................................................... 4-16

5.2 OPERATION ......................................................................................................................................... 4-17

6. TROUBLESHOOTING ................................................................................................................................... 4-19

7. MAINTENANCE SPECIFICATION................................................................................................................4-20

8. TIGHTENING TORQUE ................................................................................................................................4-21

9. CLUTCH HOUSING ......................................................................................................................................4-22

9.1 TRANSMISSION OIL DRAINING ........................................................................................................ 4-23

9.2 CLUTCH HOUSING GROUP DISASSEMBLY ................................................................................. 4-23

10.CLUTCH HOUSING DISASSEMBLY..................................................................................................

10.1 FIRST ST AGE (DISCONNECTION OF MAIN TRANSMISSION COVER)..................................... 4-28

10.2 SECOND STAGE (DISCONNECTION OF PROPULSION SHAFT CASE)................................... 4-29

............. 4-28

10.3 THIRD STAGE (DISASSEMBLY OF 25 GEAR SHAFT AND PROPULSION SHAFT 1)...........................4-30

10.4 FOUR TH STAGE (DISASSEMBLY OF BEARING COVER ASSEMBLY) .......................................... 4-30

10.5 FIFTH STAGE (DISCONNECTION OF TRANSMISSION FORK).....................................................4-31

10.6 SIXTH STAGE (DISASSEMBLY OF 22 GEAR SHAFT)...................................................................... 4-32

10.7 SEVENTH STAGE (DISASSEMBLY OF MAIN TRANSMISSION COUNTER SHAFT) ...................4-33

10.8 MAINTENANCE ......................................................................................................................................4-35

11.INTERMEDIATE CASE .................................................................................................................................. 4-37

11.1 DISASSEMBLY, ASSEMBLY.................................................................................................................. 4-38

11.2 MAINTENANCE ......................................................................................................................................4-43

12.TRANSMISSION CASE ................................................................................................................................. 4-46

12.1 DISASSEMBL Y , ASSEMBL Y.................................................................................................................. 4-46

12.2 MAINTENANCE ......................................................................................................................................4-56

CHAPTER 5 REAR AXLE ...................................................................................................................5-1

1. STRUCTURE ................................................................................................................................................... 5-3

2. TIGHTENING TORQUE .................................................................................................................................. 5-4

3. SERVICE SPECIFICA TION ............................................................................................................................ 5-5

4. DISASSEMBL Y , ASSEMBLY ........................................................................................................................... 5-6

4.1 DISCONNECTION OF REAR AXLE GROUP ....................................................................................... 5-6

4.2 DISASSEMBLY OF REAR AXLE ............................................................................................................. 5-8

5. MAINTENANCE ................................................................................................................................................ 5-9

5.1 BEARING CHECK ................................................................................................................................... 5-9

5.2 GEAR CHECK.......................................................................................................................................... 5-9

5.3 CLEARANCE CHECK OF PLANET AR Y GEAR AND PLANETARY GEAR SHAFT........................... 5-9

5.4 CHECK THRUST COLLAR FOR WORN.............................................................................................. 5-9

CHAPTER 6 BRAKE ...........................................................................................................................6-1

1. STRUCTURE ................................................................................................................................................... 6-3

2. OPERATION...................................................................................................................................................... 6-4

3. TROUBLESHOOTING ..................................................................................................................................... 6-5

4. MAINTENANCE SPECIFICATION.................................................................................................................. 6-6

5. TIGHTENING TORQUE .................................................................................................................................. 6-6

6. BRAKE PEDAL................................................................................................................................................. 6-7

6.1 DISASSEMBLY, MAINTENANCE ........................................................................................................... 6-7

6.2 MAINTENANCE ........................................................................................................................................ 6-8

7. BRAKE CASE ................................................................................................................................................... 6-9

7.1 DISASSEMBLY AND ASSEMBL Y............................................................................................................ 6-9

7.2 OPERATION CHECK OF BRAKE CAM LEVER ................................................................................. 6-12

CHAPTER 7 FRONT AXLE.................................................................................................................7-1

1. STRUCTURE ................................................................................................................................................... 7-3

2. WHEEL ALIGNMENT....................................................................................................................................... 7-4

3. TROUBLESHOOTING ..................................................................................................................................... 7-5

4. MAINTENANCE SPECIFICATION.................................................................................................................. 7-6

5. TIGHTENING TORQUE .................................................................................................................................. 7-7

6. DISASSEMBLY, MAINTENANCE ................................................................................................................... 7-8

6.1 STRUCTURE............................................................................................................................................ 7-8

7. DISCONNECTION OF FRONT AXLE GROUP ...........................................................................................7-10

7.1 DISASSEMBLY , ASSEMBL Y.................................................................................................................. 7-10

8. DISASSEMBL Y OF FRONT AXLE ................................................................................................................7-12

8.1 FIRST STAGE (DISCONNECTION OF FRONT AXLE CASE AND BEVEL GEAR CASE) ................................. 7-12

8.2 SECOND STAGE (DISASSEMBLY OF FRONT AXLE) ...................................................................... 7-12

8.3 THIRD STAGE (DISASSEMBLY OF FRONT AXLE CASE)................................................................7-13

8.4 FOURTH STAGE (DISASSEMBLY OF FRONT AXLE SUPPORT)................................................... 7-14

8.5 FIFTH STAGE (DISASSEMBLY OF FRONT AXLE SUPPORT)......................................................... 7-15

8.6 SIXTH STAGE (DISASSEMBLY OF BEVEL PINION SHAFT) ........................................................... 7-16

8.7 SEVENTH STAGE (DISASSEMBLY OF DIFFERENTIAL GEAR) ..................................................... 7-17

9. MAINTENANCE .............................................................................................................................................. 7-18

9.1 CLEARANCE CHECK BETWEEN CENTER PIN, FRONT AXLE SUPPORT BOSS AND

FRONT AND REAL BRACKETS .............................................................................................................. 7-18

9.2 CHECK FOR BACKLASH AND TOOTH CONTACTED IN FRONT AXLE CASE............................ 7-18

9.3 CHECK FOR BEVEL GEAR BACKLASH AND TOOTH CONTACTED IN BEVEL GEAR CASE ..7-19

9.4 CHECK FOR SHIM BETWEEN AXLE CASE SUPPORT AND FRONT AXLE CASE ............................... 7-19

9.5 CHECK FOR BACKLASH AND TOOTH CONT ACTED BETWEEN BEVEL PINION SHAFT

AND SPIRAL BEVEL GEAR.................................................................................................................. 7-20

9.6 CLEARANCE CHECK BETWEEN DIFFERENTIAL PINION SHAFT AND

DIFFERENTIAL PINION........................................................................................................................ 7-21

9.7 CLEARANCE CHECK BETWEEN FRONT DIFFERENTIAL CASE, DIFFERENTIAL CASE COVER

AND DIFFERENTIAL SIDE GEAR....................................................................................................... 7-21

9.8 CHECK FOR BACKLASH AND TOOTH CONTACTED BETWEEN DIFFERENTIAL PINION AND

DIFFERENTIAL SIDE GEAR ............................................................................................................... 7-22

CHAPTER 8 STEERING SYSTEM....................................................................................................8-1

1. CHARACTERISTICS ....................................................................................................................................... 8-3

2. HYDRAULIC CIRCUIT OF POWER STEERING SYSTEM......................................................................... 8-4

3. GEAR PUMP..................................................................................................................................................... 8-5

3.1 PUMP CHARACTERISTICS ................................................................................................................... 8-5

3.2 MAJOR SPECIFICATION......................................................................................................................... 8-5

3.3 STRUCTURE OF GEAR PUMP.............................................................................................................. 8-5

3.4 OPERATION.............................................................................................................................................. 8-6

4. POWER STEERING UNIT.............................................................................................................................. 8-7

4.1 MAJOR SPEC. .......................................................................................................................................... 8-7

4.2 STRUCTURE AND OPERATION ........................................................................................................... 8-7

5. STEERING CYLINDER................................................................................................................................... 8-8

5.1 STRUCTURE............................................................................................................................................ 8-8

5.2 MAJOR SPECIFICATION......................................................................................................................... 8-8

6. OIL FLOW ......................................................................................................................................................... 8-9

6.1 IN NEUTRAL........................................................................................................................................... 8-9

6.2 TURNING TO THE RIGHT.................................................................................................................... 8-9

6.3 TURNING TO THE LEFT..................................................................................................................... 8-10

6.4 MANUAL STEERING............................................................................................................................ 8-10

7. TROUBLESHOOTING ................................................................................................................................... 8-11

8. DISASSEMBLY, MAINTENANCE ................................................................................................................. 8-12

8.1 GEAR PUMP ......................................................................................................................................... 8-12

8.2 POWER STEERING UNIT...................................................................................................................8-14

8.3 STEERING CYLINDER ....................................................................................................................... 8-21

CHAPTER 9 HYDRAULIC SYSTEM.................................................................................................9-1

1. HYDRAULIC CIRCUIT DIAGRAM.................................................................................................................. 9-3

2. STRUCTURE ................................................................................................................................................... 9-4

3. HYDRAULIC CIRCUIT DIAGRAM OF 3-POINT HYDRAULIC SYSTEM............................................................ 9-5

4. HYDRAULIC PUMP ......................................................................................................................................... 9-6

4.1 STRUCTURE OF HYDRAULIC PUMP .................................................................................................. 9-6

4.2 OPERATION.............................................................................................................................................. 9-6

5. OI L FILTER ....................................................................................................................................................... 9-7

5.1 STRUCTURE OF OIL FILTER ................................................................................................................ 9-7

5.2 FUNCTION AND OPERATION................................................................................................................ 9-7

6. CONTROL VALVE (MLS V AL VE)..................................................................................................................... 9-8

6.1 STRUCTURE............................................................................................................................................ 9-8

6.2 CIRCUIT DIAGRAM .................................................................................................................................9-8

6.3 OPERATION PRINCIPLE........................................................................................................................ 9-9

7. RELIEF VALVE (HYDRAULIC BLOCK) .......................................................................................................9-12

8. HYDRAULIC CYLINDER .............................................................................................................................. 9-13

9. STRUCTURE AND OPERATION .................................................................................................................. 9-14

9.1 STRUCTURE .......................................................................................................................................... 9-14

9.2 OPERATION............................................................................................................................................ 9-14

10.OUTSIDE HYDRAULIC EXTRACTION ....................................................................................................... 9-18

10.1 HYDRAULIC BLOCK ............................................................................................................................. 9-18

10.2 ACTING VALVE .......................................................................................................................................9-19

10.3 QUICK COUPLER ................................................................................................................................. 9-19

1 1.TOP LINK BRACKET DEVICE ..................................................................................................................... 9-20

11.1 STRUCTURE.......................................................................................................................................... 9-20

11.2 OPERATION............................................................................................................................................ 9-20

12.TROUBLESHOOTING...................................................................................................................................9-21

13.MAINTENANCE SPECIFICATION................................................................................................................9-22

13.1 3-POINT SYSTEM HYDRAULIC PUMP ..............................................................................................9-22

13.2 RELIEF VALVE .......................................................................................................................................9-22

13.3 LINK CONTROL..................................................................................................................................... 9-22

13.4 HYDRAULIC CYLINDER ......................................................................................................................9-23

14.TIGHTENING TORQUE ................................................................................................................................ 9-24

15.DISASSEMBL Y , ASSEMBL Y ......................................................................................................................... 9-25

15.1 GEAR PUMP...........................................................................................................................................9-25

15.2 MAINTENANCE ......................................................................................................................................9-27

15.3 RELIEF VALVE ....................................................................................................................................... 9-27

15.4 HYDRAULIC CYLINDER ......................................................................................................................9-28

15.5 CHECK AND ADJUSTMENT................................................................................................................. 9-34

CHAPTER 10 ELECTRIC SYSTEM ............................................................................................... 10-1

1. ELECTRONIC INSTRUMENTATION........................................................................................................... 10-3

1.1 INSTRUMENT GAUGE..........................................................................................................................10-3

1.2 INDICA TORS AND WARNING LIGHTS...............................................................................................10-4

2. TROUBLE SHOOTING..................................................................................................................................10-6

3. SERVICING SPECIFICATIONS ................................................................................................................... 10-8

4. MECHANISM...................................................................................................................................................10-9

4.1 STARTING SYSTEM .............................................................................................................................. 10-9

4.2 CHARGING SYSTEM.......................................................................................................................... 10-12

4.3 PREHEATING SYSTEM...................................................................................................................... 10-14

4.4 FUSE .................................................................................................................................................... 10-15

4.5 GAUGE AND SENSORS .................................................................................................................... 10-16

5. MAIN CIRCUIT DIAGRAM .......................................................................................................................... 10-17

CHAPTER 1

GENERAL INFORMATION

1. TRACTOR VIEW

GENERAL INFORMA TION

D615-W02 May-2003

615W101A

1-3

CHAPTER 1 8354/8404

2. TIGHTENING TORQUE FOR STANDARD BOLTS AND NUTS

2.1 TIGHTENING TORQUE

Screws, bolts and nuts whose tightening torques are not specified in this workshop manual should be tightened
according to the table below.

A . TIGHTENING TORQUE FOR ST ANDARD BOLTS AND NUTS

Grade No grade 4T 7T 9T

Unit

Nominal
Diameter

M 6

(6 mm, 0.24 in.)

M 8

(8 mm, 0.31 in.)

M 10

(10 mm, 0.39 in.)

M 12

(12 mm, 0.47 in.)

M 14

(14 mm, 0.55 in.)

M 16

(16 mm, 0.63 in.)

M 18

(18 mm, 0.71 in.)

M 20

(20 mm, 0.79 in.)

N·m

7.85
~

9.30

17.7
~

20.5

39.2
~

45.0

62.8
~

72.5

108

~

125
167

~

191
245

~

284
334

~

392

Kgf·m

47 9

lbf·ft

9.1
~

10.5

21.7
~

25.3

44.9
~

52.1

76.0
~

86.8

123

~

144
192

~

224
254

~

297
362

~

420

0.80
~

0.95

1.8
~

2.1

4.0
~

4.6

6.4
~

7.4

11.0
~

12.8

17.0
~

19.5

25.0
~

29.0

34.0
~

40.0

lbf·ft

5.79
~

6.87

13.0
~

15.2

29.0
~

33.2

46.3
~

53.5

79.6
~

92.5

123

~

141
181

~

210
246

~

289

N·m

9.80
~

11.2

23.6
~

27.4

48.1
~

55.8

77.5
~

90.1

124

~

147
196

~

225
275

~

318
368

~

431

Kgf·m

1.00
~

1.15

2.4
~

2.8

4.9
~

5.7

7.9
~

9.2

12.6
~

15.0

20.0
~

23.0

28.0
~

32.5

37.5
~

44.0

lbf·ft

7.24
~

8.32

17.4
~

20.2

35.5
~

41.2

57.2
~

66.5

91.2
~

108
145

~

166
203

~

235
272

~

318

N·m

12.3
~

14.2

29.4
~

34.3

60.8
~

70.5

103

~

117
167

~

196
260

~

303
343

~

401
490

~

568

Kgf·m

1.25
~

1.45

3.0
~

3.5

6.2
~

7.2

10.5
~

12.0

17.0
~

20.2

26.5
~

31.0

35.0
~

41.0

50.0
~

58.0

* The figures on the table above are indicated the top of screw of bolt.

1-4

D615-W02 May-2003

B. TIGHTENING TORQUE FOR STUDS

GENERAL INFORMA TION

M8
M10
M12

11.7 ~ 15.7 N·m

24.5 ~ 31.4 N·m

34.3 ~ 49.0 N·m

1.2 ~ 1.6 kgf·m

2.5 ~ 3.2 kgf·m

3.4 ~ 5.0 kgf·m

C. TIGHTENING TORQUE FOR HIGH PRESSURE HOSE UNION NUTS

Hose Size
(Inside Diameter: Inches)

Screw Size (PF)
Tightening (N·m)
Torque (kgf·m)

(lbf·ft)

1/8″ 3/16″ 1/4″ 5/16″ 3/8″ 1/2″ 5/8″, 3/4″ 1″
1/8″

9.8
1

7.2

1/4″

24.5

2.5

18.0

1/4″

24.5

2.5

18.0

3/8″

49.0
5

36.1

3/8″

49.0
5

36.1

8.6 ~ 11.5 lbf·ft

18.0 ~ 23.1 lbf·ft

25.3 ~ 36.1 lbf·ft

1/2″

58.8
6

43.3

3/4″

117.7
12

86.8

1″

137.3
14

101.2

D615-W02 May-2003

1-5

CHAPTER 1 8354/8404

3. SPECIFICATIONS

Maximum PTO power
Engine GROSS power

Engine

Capacities

Dimensions
(with std.

Tires)

Traveling
system

Model
Type
Number of cylinders

Bore and stroke

Total displacement
Rated revolution
Injection timing
Injection order
Compression ratio
Lubricating system
Cooling system
Alternator
Weight (Dry)
Fuel tank
Engine crankcase
Engine coolant
Transmission case
Front axle case
Overall length (without 3p)
Overall length (with 3p)
Overall width (minimum tread)
Overall height (Top of ROPS)
Overall height

(Top of steering wheel)
Wheelbase

Ground clearance

Tread Front

Tire size
(Std. tires)

Clutch
Steering

Model

Rear

Front
Rear

8354

28.3 HP

33.5 HP
3A165D

Indirect injection, vertical, water-cooled, 4-cycle diesel

3

87 × 92.4 mm

(3.425 × 3.637 in.)

1,647

2,700 rpm

18° before T.D.C.

1-2-3

22 : 1

Forced lubrication by trochoidal pump

Pressurized radiator, Forced circulation with water pump

12 V , 50 AMPS

179 kg

40 (10.6 U.S.gal.)

5.8

(1.5 U.S.gal.)
(1.9 U.S.gal.)

7.0
44

(11.6 U.S.gal.)

(2.0 U.S.gal.)

7.5
3,357 mm (132.2 in.)
3,468 mm (136.5 in.)
1,440 mm (56.7 in.)
2,445 mm (96.5 in.)

1,530 mm

(60.2 9n.)

1,668 mm (65.7 in.)

239 mm (9.4 in.)

1,235mm (48.4 in.)

1,166 mm

(45.9 in.)

1,077 ~ 1,387 mm

(42.4 ~ 54.6 in.)

7-16

12.4-24
Dry single stage

Hydrostatic steering system

8404

33.4 HP

40.4 HP
4A200

4

83 × 92.4 mm

(3.268 × 3.637 in.)

1,999

1-3-4-2

205 kg

7.0

(1.9 U.S.gal.)
(2.4 U.S.gal.)

8.9

3,365 mm (132.5 in.)
3,550 mm (139.8 in.)
1,505 mm (59.3 in.)
2,465 mm ( 97.0 in.)

1,545 mm

(60.8 in.)
1,780 mm (70 in.)
257 mm (10.1 in.)

1,235 mm (48.4 in.)

1,158 mm

(45.6 in.)

1,158 ~ 1,467 mm

(45.6 ~ 57.8 in.)

8-16

13.6-24

1-6

D615-W02 May-2003

GENERAL INFORMA TION

Traveling
system

Hydraulic
system

PTO

Model 8354

Transmission

Brake Traveling

Parking
Differential
Hydraulic lift control system

Pump
capacity

Three point hitch
Maximum lifting capacity
(the end of lower ling)
No. of Remote control valve

ports(Option)
PTO shaft
Revolution

(indepen­dent PTO)

Main pump

Power steering

pump

MID PTO

Rear PTO

1,650 kg (3,638 lb)

2,000 (2,542 rpm)

540 (2,451 rpm)

8404

Synchronized shuttle and transmission

8 forward and 8 reverse speeds

(CR: 16 forward and 16 reverse speeds)

Wet disc type

Connected with the traveling brake

Bevel gear

Position, Draft and Mixed control

29.7 /min (7.8 U.S.gal.)

/min (4.7 U.S.gal.)

17.8
SAE Category l

1,550 kg (3,417 lb)

2 or 4

SAE 1-3/8, 6 splines

2 or 4

2,000 (2,542 rpm)

540 (2,451 rpm)

Min. turning radius (without brake)

Traction system
Weight (with ROPS)
Traveling speed

(at 2700 engine speed
with Std. tires)

Forward (creeper)

Reverse (creeper)

3,100 mm
(112.7 in.)

Swing Draw-Bar

1,515 kg

1.6 (0.21) ~ 23.2 km/h

0.99 (0.13) ~ 14.41 mph

1.55 (0.20) ~ 21.4 km/h

0.96 (0.12) ~ 13.30 mph

3,125 mm

(123 in.)

1,665 kg

1.7 (0.21) ~ 23.4 km/h

1.06 (0.13) ~ 14.54 mph

1.56 (0.20) ~ 21.6 km/h

0.97 (0.12) ~ 13.42 mph

D615-W02 May-2003

1-7

CHAPTER 1 8354/8404

4. IDENTIFICATION

4.1 ENGINE NUMBER

The engine serial number is stamped on the left side
of the cylinder block as shown in the figure. Engine
serial number provides important information.

4.2 CHASSIS NUMBER OF THE
TRACTOR (CHASSIS NUMBER OF
THE MACHINE)

615W102A

(1) Engine Serial Number

The chassis serial number of the tractor is stamped
on the left side of the front axle frame as shown in the
figure.

615W103A

(1) Manufacture Plate
(2) Transmission Serial Number

1-8

D615-W02 May-2003

5. CAUTION BEFORE REP AIR

C C

GENERAL INFORMA TION

5.1 BEFORE REPAIR OR INSPECTION

1. In case of repair or inspection, locate the tractor
on the flat ground and pull the parking brake on.

2. Except for the items to be checked while the en­gine is running, be sure to stop the engine prior to
the work.

3. When washing parts, use parts washing solvent
for industrial use (avoid using gasoline so to pre­vent environmental pollution). For the hydraulic
parts, apply designated hydraulic oil in washing.

4. When disassembling and assembling of the hy­draulic apparatus, pay special attention not to al­low dust or foreign substance to be attached or
intermixed.

5.2 ASSEMBLY AND DISASSEMBLY

To check a failure, try to find out its underlying cause. If
assembly or disassembly is needed, perform the work
in regular sequence as specified in this repair manual.

7. Finish assembly within 20 minutes after applying
sealant, after that, wait approx. 30 minutes later
before filling with oil.

5.3 PARTS TO BE REPLACED

615W105A

The following parts should be replaced with new ones
when removed.

(1) Oil Seal
(2) Gasket
(3) Lock Nut
(4) Split Pin
(5) O-Ring

615W104A

1. Disassembled parts shall be arranged orderly.

2. Sort out the parts to be replaced from the ones to
be reused.

3. Be sure to use standard bolts and nuts that are
designated.

4. When assembling snap rings or spring pin types,
take care of assembling direction.

5. Split pin shall be spread surely not to escape when
installed.

6. When using sealant (such as gasket bond) on the
assembled surfaces, apply it evenly and consis­tently in a height of 3 ~ 5 mm (0.12 ~ 0.2 in.) on the
contact surface after removing the old bond and
cleaning the sealing surface with solvent. Apply
sealant on the center of the contact surface for the
space between the bolt holes of the contact
surface, and on the more inner side than the bolt
hole for the bolt area.

D615-W02 May-2003

5.4 PARTS

615W106A

When replacing parts, use only genuine Cub Cadet parts.

1-9

CHAPTER 1 8354/8404

5.5 ASBESTOS PARTS

Since dust out of asbestos fibrous parts is extremely
dangerous to your health, be sure to clean such parts
carefully, do not use compressed air.

5.6 ELECTRICAL SYSTEM

1. Check electrical wiring every year for any damage
or short circuit at the connections. In addition, have
your dealer inspection the electric system regularly.

2. Do not modify or reorganize the wiring of the elec­tric field parts.

3. When disconnecting the battery cable, disconnect
negative cable first, reinstall the positive cable first
when reinstalling.

Disconnect battery negative terminal

• Be sure to turn the starting key OFF
when connecting or disconnecting the
cable.

CAUTION

615W108A

5. When connecting the connector, insert it until it
snaps.

615W107A

4. Remove the connector by pulling the plastic
section, not the wiring.

615W109A

6. Be sure not to drop sensors and relays which are
fragile.

7. When replacing a broken fuse with a new one, be
sure to use the fuse of capacity as specified.

1-10

D615-W02 May-2003

5.7 TUBES AND RUBBERS 5.8 LUBRICANT

GENERAL INFORMA TION

615W112 A615W11 1 A

Be cautious of oil or other petroleum products on the
hoses and rubber parts, this may cause damage.

When assembling and fixing, apply designated lubri­cant where specified in accordance with this repair
manual.

D615-W02 May-2003

1-11

CHAPTER 1 8354/8404

6. REGULAR CHECK LIST

Check Items

Engine oil change
Engine oil filter cartridge change
Transmission oil change
Hydraulic oil filter change
Front axle oil change
Applying grease
Clutch pedal deflection
Brake pedal deflection
Fan belt tension
Fuel filter element change
Air cleaner element change
Battery electrolyte
Oil pressure fuel pipe’s inlet screw

if loosened
Radiator hose’s inlet bands if

loosened
Fuel pipe change
Radiator hose change

Hydraulic pipe joint change
Steering hose change
Toe-in
Deflection adjustment in front and

rear of the front axle
Direction control section
Bolt, nuts and pins of each part
Battery positive code adjustment &

change
Bleeding water in clutch housing
Check injection nozzle*

Indicated Hours By Hour Meter

The first
Periodically

Since

Purchased

80070060050045040035030025020015010050

1500hr

1yr 2yr

* Maintenance intervals in basis on the EPA instructions.

1-12

D615-W02 May-2003

7. OIL & WATER SUPPLY LIST

GENERAL INFORMA TION

Supply Items

Fuel

Coolant

Engine Oil

Transmission Oil
Front Axle Section

Hydraulic control lever
shaft section

Applying
Grease

3 point link section
Brake pedal link section
Bracket section in front

and rear of the front axle
Clutch release hub

3A165D
4A200B
3A165D
4A200B

Capacity

(42.3 U.S.gal.)

40

(1.85 U.S.gal.)

7.0

8.9

(2.35 U.S.gal.)
(1.45 U.S.gal.)

5.5

7.0

(1.85 U.S.gal.)

44

(11.6 U.S.gal.)

(2.0 U.S.gal.)

7.8
Small quantity

Until grease exits

Supply when removed

Recommended Spec.

No. 2 - D diesel fuel
No. 1 - D diesel fuel if temperature

is below - 10 °C (14 °F)

Fresh clean water with antifreeze

SAE 15 W - 40

Universal tractor/transmission
hydraulic oil
SAE multi - purpose type grease

D615-W02 May-2003

1-13

CHAPTER 2

ENGINE SYSTEM

1. GENERAL

1.1 APPEARANCE

ENGINE SYSTEM

The DAEDONG A series engines are vertical, water­cooled, 4-cycle, three or four cylinders diesel engines,
they concentrate DAEDONG’s foremost technologies.

With swirl combustion chamber, bosch K type fuel in­jection pump, well-balanced designs, they feature
greater power, low fuel consumption, less vibration and
noise, and low emission.

615W201A

D615-W02 May-2003

2-3

CHAPTER 2 8354/8404

1.2 SPECIFICATIONS

Model

Type

Number of cylinder
Bore and stroke

Total Displacement

Combustion
Chamber
Gross power

Maximum idling speed
Minimum idling speed
Order of firing
Direction of rotation

Injection pump
Injection pressure

Injection timing
(Before T.D.C)
Compression Ratio
Fuel
Lubricant
Dimensions
(length x width x height)
Dry weight

3A165D

Vertical, water-cooled,

4-cycle diesel engine

3

87 x 92.4 mm

3.43 x 3.64 in.
1,647 cc

100.5 in

3

Spherical type

33.5/2,700 HP/rpm

30.0/2,700 kW/rpm
2,900 rpm

850 ~ 900 rpm

1 - 2 - 3

Counterclockwise

(viewed from flywheel side)

Bosch K TYPE mini pump

140 ~ 150 kgf/cm²

13.73 ~ 14.71 MPa

1,991 ~ 2,133 psi

18 °

22 : 1

Diesel fuel

Engine oil SAE 15W-40

722.3 x 488.1 x 729.9 mm

28.4 x 19.2 x 28.7 in.
179 kg

395 lbs.

4A200B

Vertical, water-cooled,

4-cycle diesel engine

4

83 x 92.4 mm

3.27 x 3.64 in.
1,999 cc

122.0 in

3

Spherical type

40.4/2,700 HP/rpm

36.2/2,700 kW/rpm
2,900 rpm

850 ~ 900 rpm

1 - 3 - 4 - 2

Counterclockwise

(viewed from flywheel side)

Bosch K TYPE mini pump

140 ~ 150 kgf/cm²

13.73 ~ 14.71 MPa

1,991 ~ 2,134 psi

18 °

22 : 1

Diesel fuel

Engine oil SAE 15W-40

817.3 x 488.1 x 735.8 mm

32.2 x 19.2 x 29.0 in.
183 kg

403 lbs.

* NOTE: Change of parts are not subject to advance notice.

2-4

D615-W02 May-2003

1.3 PERFORMANCE CURVE

ENGINE SYSTEM

615W204A615W203A

D615-W02 May-2003

2-5

CHAPTER 2 8354/8404

1.4 DIMENSIONS

615W206A

3A165D (mm)

(in.)

4A200B (mm)

(in.)

A

602.3

23.71

697.3

27.45

B

722.3

28.44

817.3

32.18

C

280.0

11.02

280.0

11.02

D

400.0

15.75

400.0

15.75

1.5. GENERAL WARNING

• When disassembling, arrange each part on a clean
place. Do not mix them up. Replace bolts and nuts
where they were.

• When servicing electrical parts or connecting instru­ments to electrical equipment, first disconnect the
battery negative terminal.

• Replace gaskets or O-rings with new ones when
reassembling, and apply grease on a O-ring and
the oil seal when reassembling.

• When exchanging parts, use Cub Cadet parts to
maintain engine performance and safety.

• To prevent oil and water leakage, apply non-drying
adhesive to the gaskets according to this manual
before reassembling.

• When hoisting up the engine, use the hook pro­vided on the cylinder head.

• When reinstalling the engine, use the hook provided
on the cylinder head.

• When installing external cir-clips or internal cir-clips,
direct corner end to the non-loosening direction.

E

488.1

19.22

488.1

19.22

F

251.6

9.91

251.6

9.91

G

729.9

28.74

735.8

28.97

H

259.7

10.00

259.7

10.22

I

240.0

9.45

240.0

9.45

J

315.0

12.40

321.0

12.64

K

95.0

3.74

92.0

3.62

2-6

D615-W02 May-2003

2. STRUCTURE AND FUNCTION

2.1 BODY

A . CYLINDER HEAD

The cylinder head is made of special alloy cast iron
which can resist high temperature and pressure
caused by combustion. The inlet and exhaust ports are
arranged cross-flow type to get high combustion effi­ciency by protecting the suction air from being heated
and expanded by heated exhaust air.

The DAEDONG vortex type combustion chamber is de­signed for high combustion efficiency and reducing fuel
consumption. The glow plug assures easier than ever
engine starts even at -15 °C (5 °F).

(1) Combustion Chamber
(2) Inlet Port
(3) Exhaust Port
(4) Injection Nozzle
(5) Glow Plug
(6) Cylinder Head

ENGINE SYSTEM

615W207A

B. CYLINDER BLOCK

The engine has a high durability tunnel-type cylinder
block. Furthermore, liner less type, allows effective cool­ing, less distortion, and greater wear-resistance using
special material. The noise is reduced to a minimum
because each cylinder has its chamber.

D615-W02 May-2003

615W208A

615W209A

2-7

CHAPTER 2 8354/8404

C. CRANKSHAFT

The crankshaft is made of forged steel and the journals,
the crankpins and the bearing surface for the oil seal
are induction-hardened to increase wear resistance.
Each crankshaft journal is supported by the main bear­ing case (3) having a bearing inside. The front bearing­crankshaft bearing (2) is a solid type bushing and rear
and intermediate bearings are a split type. The
crankshaft, crankshaft bearings have oil holes for lu­bricant flow.

D. PISTON AND PISTON RINGS

The piston is made of an aluminum alloy which is tem­perature and pressure resistant. Three rings are in­stalled in the grooves of the piston. The top ring (1) is a
keystone type, which can withstand heavy loads, and
the barrel face on the ring fits well to the cylinder wall.
The second ring (2) is an undercut type, which pre­vents the oil from being carried up. The oil ring (3) has
chambered contact faces and an expander ring, which
increase the pressure of the oil ring against the cylin­der wall to scrape the oil. The top ring is plated with
hard chrome to increase wear resistance (The ring of
4A200T engine is made of a special steel).

615W210A

(1) Crankshaft (4) Crankshaft Bearing 2
(2) Crankshaft Bearing 1 (5) Thrust Bearing
(3) Main Bearing Case

E. CONNECTING ROD

The connecting rod (2), which converts the reciprocat­ing motion of the pistons caused by the fuel combus­tion into the rotating motion of the crankshaft, is made
of hard forged steel. The connecting rod has bearings
at both ends. The small end has a solid type bearing
(small end bushing (2)) and the big end has a split
type bearing (crankpin bearing (3)).

615W211A

(1) Top Ring (3) Oil Ring
(2) Second Ring

615W212A

(1) Small End Bushing (3) Crankpin Bearing
(2) Connecting Rod

2-8

D615-W02 May-2003

F. CAMSHAFT

The camshaft (3) is made of forged steel and its jour­nal and cams are hardened to increase wear
resistance. The cams on the camshaft open and close
the inlet and exhaust valves with the push rods and
rocker arms. The journals and their bearings are force­lubricated.

G. FUEL CAMSHAFT

This fuel camshaft is made of forged steel and its cams
are hardened and tempered to increase wear
resistance. The cams on the fuel camshaft (1) drive
the injection pump and the fuel transfer pump. The
governor balls are installed on the fuel camshaft to
control the engine speed.

ENGINE SYSTEM

615W213A

(1) Cam Gear (3) Camshaft
(2) Camshaft Stopper

H. ROCKER ARM ASSEMBL Y

The rocker arm assembly includes the rocker arms (1)
and an adjusting screw (3), which is at the end of rocker
arm and rests on the push rod, rocker arm brackets (4)
and rocker arm shaft (5). The rocker arms are activated
by the reciprocating motion of the push rods and open
or close the inlet and exhaust valves. The rocker arm
and other parts are lubricated through the drilled holes
of the brackets and the rocker arm shaft.

615W214A

(1) Fuel Camshaft (2) Injection Pump Gear

615W215A

(1) Rocker Arm (4) Rocker Arm Bracket
(2) Lock Nut (5) Rocker Arm Shaft
(3) Adjusting Screw

D615-W02 May-2003

2-9

CHAPTER 2 8354/8404

I. INLET AND EXHAUST V AL VES

The valve and its guide of the inlet are different from
those for the exhaust. Other parts, such as the spring,
spring retainers, valve spring collets, valve stem seals
are the same for both the inlet and the exhaust. All
contact or sliding surfaces are hardened to increase
wear resistance.

J. TIMING GEARS

The crankshaft drives the oil pump and the idle gear
engaged fuel camshaft and camshaft. The timings for
opening and closing the valves is extremely important
to achieve effective air inlet and sufficient gas exhaust.
The appropriate timing can be obtained by aligning the
mark on the crankshaft gear (6) with one the idle gear
(5), idle gear with camshaft gear, idle gear with injec­tion pump gear, when assembling.

615W216A

(1) Valve Spring Collet (4) Valve Stem Seal
(2) Valve Spring Retainer (5) Exhaust Valve
(3) Valve Spring (6) Inlet Valve

K. FLYWHEEL

The flywheel is installed on the rear end of the
crankshaft. Its inertia keeps the flywheel turning at a
constant speed, while the crankshaft tends to speed
up during the power stroke and to slow down during
other stokes. The flywheel has a ring gear (1), which
mesh with the drive pinion of the starter. The flywheel
has also marks “TC” and “FI” on its outer rim. The mark
TC shows the piston’s top dead center and the mark FI
shows the fuel injection timing, when they are aligned
with the mark of window on the clutch housing.

615W217A

(1) Injection Pump Gear (5) Idle Gear
(2) Fuel Camshaft (6) Crankshaft Gear
(3) Camshaft Gear (7) Crankshaft
(4) Camshaft

615W218A

(1) Ring Gear (3) Crankshaft
(2) Flywheel

2-10

D615-W02 May-2003

2.2 LUBRICATING SYSTEM

A . FLOW OF LUBRICATING OIL

The lubricating oil is forced to each journal through the
oil passages of the cylinder block, cylinder head and
shafts. The oil, splashed by the crankshaft or thrown
off from the bearings, lubricates other engine parts
such as the push rods (11), tappets (12), camshaft
(14), and crankshaft (15).

ENGINE SYSTEM

B. OIL PUMP

The oil pump is a gear type. Whose rotors have tro­choid lobes. The inner rotor (3) has 4 lobes and the
outer rotor (4) has 5 lobes, and they are eccentrically
engaged with each other. The inner rotor, which is driven
by the crankshaft through the gears, rotates the outer
rotor in the same direction, varying the space between
the lobes.

While the rotors rotate from (A) to (B), the space lead­ing to the inlet port increases, which causes the oil to
flow through the inlet port.

When the rotors rotate to (C), the port to which the space
leads is changed from inlet to outlet.

At (D), the space decreases and oil is discharged
through the outlet port.

615W219A

(1) Piston (9) Rocker Arm Shaft
(2) Idle Gear (10) Rocker Arm
(3) Oil Pump (11) Push Rod
(4) Relief Valve (12) Tappet
(5) Strainer (13) Oil Pressure Switch
(6) Oil Filter Element (14) Camshaft
(7) Bypass Valve (15) Crankshaft
(8) Oil Pan

615W220A

(1) Inlet (3) Inner Rotor
(2) Outlet (4) Outer Rotor

D615-W02 May-2003

2-11

CHAPTER 2 8354/8404

C. OIL FIL TER AND RELIEF V ALVE

The lubricating oil force-fed by the pump is filtered by
the filter cartridge, passing through the filter element
from the outside to the inside. When the filter element
accumulates dirt and the pressure difference between
the inside and the outside rises more than 98 kPa
(1.0 kgf/cm², 14 psi), the bypass valve (1) opens to
allow the oil to flow from the inlet line to outlet line,
bypassing the filter element. The relief valve ball (4) in
the inlet line allows oil to prevent damage to the lubri­cating system, when the oil pressure rises more than
441 kPa (4.5 kgf/cm², 64 psi).

615W221A

(1) Bypass Valve
(2) Bypass Adjusting Spring
(3) Filter Element
(4) Relief Valve Ball
(5) Relief Adjusting Spring

(a) To Idle Gear, Camshaft and Rocker Arm
(b) From Oil Pump

(c) To Crankshaft Journal Crankpin

(d) Drain of Relief Valve

D. OIL PRESSURE SWITCH

The oil pressure switch is installed on the cylinder
block and leads to the oil passage of the lubricating
oil. When the oil pressure falls below the specified
value, the contacts of the oil pressure switch closes to
turn on the warning lamp (1).

615W222A

(A) At Lower Oil Pressure

(49 kPa (0.5 kgf/cm², 7 psi) or less)

(B) At Proper Oil Pressure

(1) Warning Lamp (6) Rubber Washer
(2 ) Battery (7 ) Oil Pressure
(3) Contact Movable (8) Cylinder Block
(4) Contact Cup (9 ) Pressure
(5) Diaphragm

2-12

D615-W02 May-2003

2.3 COOLING SYSTEM

A. FLOW OF COOLING WATER

The cooling system consists of a radiator (5), a cen­trifugal water pump (7), a cooling fan (6) and a thermo­stat (2). The water is cooled as it flows through the
radiator core, and the fan behind the radiator pulls the
cooling air through the radiator core. The water pump
receives water from the radiator or from the cylinder
head and forces it into cylinder block. The thermostat
open or closes according to the water temperature.
When the water temperature is high, the thermostat
opens to allow the water to flow from the cylinder block
to the radiator. When the water temperature is low, the
thermostat closes and the flow stays within the block.
The opening temperature of the thermostat is approx.
71 °C (160 °F).

ENGINE SYSTEM

615W223A

(1) Water Return Pipe
(2) Thermostat
(3) Cylinder Head Water Jacket
(4) Cylinder Block Water Jacket
(5) Radiator
(6) Cooling Fan
(7) Water Pump

B. WA TER PUMP

The water pump is driven with the fan drive pulley, which
is on the water pump shaft and driven by the crankshaft
with a belt. The water pump sucks the cooled water,
forces into the cylinder block and draws out the hot
water to the radiator repeatedly. The mechanical seal
(3) prevents the water from entering the bearing (1).

615W224A

(a) From the Thermostat
(b) To the Cylinder Block

(c) From the Radiator

D615-W02 May-2003

(1) Bearing (3) Mechanical Seal
(2) Pump Body (4) Pump Impeller

2-13

CHAPTER 2 8354/8404

C. THERMOSTAT

The thermostat is wax pellet type, which controls the
flow of the cooling water to the radiator to keep the
proper temperature. The case has a seat (1) and the
pellet has a valve (2). The spindle attached to the case
is inserted into the synthetic rubber in the pellet. The
pellet is charged with wax.

(A)At Low Temperature (Lower than 71 °C (160 °F)).
The valve (2) is seated by the spring (7) and the cool-

ing water circulates in the engine through the water
return pipe but does not enter the radiator.

(B)At High Temperature (Higher than 71 °C (160 °F)).
As the water temperature rises, the wax in the pellet (3)

turns liquid and expands, repelling the spindle.
The pellet lowers and the valve (2) opens to send the

cooling water to the radiator.

615W225A

(1) Seat (6) Wax (Solid)
(2) Valve (7) Spring
(3) Pellet (8) Leak Hole
(4) Spindle (9) Wax (Liquid)
(5) Synthetic Rubber

D. RADIATOR

The radiator core consists of water carrying tubes (2)
with fins (3) at a right angle to it. The water in the radia­tor is cooled by the air flowing through between the
tube wall and the fin.

E. RADIA TOR CAP

The pressure type cap is installed on the radiator, which
prevents the pressure difference between the inside
and the outside of the radiator from deforming the radia­tor.

(A) At High Pressure

(Higher than 88 kPa (0.9 kgf/cm², 13 psi)

When the water temperature rises and the pressure in
the radiator increases above the specified pressure,
the pressure valve (1) opens to reduce the internal
pressure.

(B) At Low Pressure.
When the water temperature falls and a vacuum is

formed in the radiator, the vacuum valve (2) opens to
allow the water to enter the radiator.

615W226A

(1) Cooling Water (3) Fin
(2) Tube

615W227A

(1) Pressure Valve (2) Vacuum Valve

2-14

D615-W02 May-2003

2.4 FUEL SYSTEM

A. FLOW OF FUEL

The fuel is fed from the fuel tank (1) through the fuel
feed pump (7) to the injection pump (3) by the fuel filter
(2). The injection pump force-feds the fuel through the
injection nozzles (5), which inject the fuel into the cylin­ders for combustion. The excessive fuel from the injec­tion pump to the injection nozzles (5), which inject the
fuel into the cylinders for combustion. The excessive
fuel from the injection pump to the injection nozzles is
collected in the fuel overflow pipes (6) and returns to
the fuel tank.

ENGINE SYSTEM

615W228A

(1) Fuel Tank (5) Injection Nozzle
(2) Fuel Filter (6) Fuel Overflow Pipe
(3) Injection Pump (7 ) Fuel Feed Pump
(4) Injection Pipe

B. FUEL FILTER

The fuel filter removes dirt and water with its fine filter
paper, which collects particles of 90 microns (0.0034 in.)
at 20 kPa (0.2 kgf/cm², 3 psi). The fuel from the fuel
feed pump is filtered by the filter element (6), while
flowing through the filter body (3) has an air vent (2) to
return the air tin the fuel to the fuel tank to prevent the
engine from stopping or running irregularly.

615W229A

(a) To Fuel Tank
(b) From Fuel Feed Pump

(c) To Injection Pump

(1) Cock (4) Retainer Ring
(2) Ai r Vent (5) Pot
(3) Filter Body (6) Filter Element

D615-W02 May-2003

2-15

CHAPTER 2 8354/8404

C. FUEL FEED PUMP

The diaphragm (6) is linked to the tappet (3) with the
push rod (2). The tappet is reciprocated by the eccen­tric cam on the fuel camshaft (7).

(A)Inlet Stroke
When the diaphragm is pulled down by the spring,

vacuum in the chamber (5) causes the outlet valve (4)
to close and the atmospheric pressure in the fuel tank
to force the fuel into the chamber, opening the inlet
valve (1).

(B) Discharge Stroke
When the diaphragm is pushed up by the cam, the

pressure in the chamber causes the inlet valve to close
and forces out the fuel, opening the outlet valve.

615W230A

(a) From Fuel Tank
(b) To Fuel Filter

(1) Inlet Valve (5) Chamber
(2) Push Rod (6) Diaphragm
(3) Tappet (7) Fuel Camshaft
(4) Outlet Valve

D. FUEL INJECTION PUMP

The injection pump is Bosch K type mini injection
pump. It features a compact and light weight design.

615W240A

(a) To Injection Nozzle
(b) From Fuel Filter

(1) Delivery Valve Holder (5) Plunger
(2) Delivery Valve Spring (6) Control Rack
(3) Delivery Valve (7) Plunger Spring
(4) Cylinder (8) Tappet

2-16

D615-W02 May-2003

a. Pump Element

The pump element (1) consists of a plunger (3) and
cylinder (2), their sliding surfaces are precision ma­chined to maintain fuel tightness. The plunger (3) fits
in the control sleeve (5) at the driving surface (7). The
sleeve is engaged with the control rack, which rotate
the plunger in the cylinder to control the amount of fuel
delivery.

ENGINE SYSTEM

615W241A

b. Operation of Pump Element

(A)Before Delivery
As the taper lowers, the plunger (2) lowers and fuel is

drawn into the delivery chamber (1) through the feed
hole (4) from the fuel chamber (5).

(B) Beginning of Delivery
When the plunger is pushed up by the cam and the

head of the plunger closes the feed hole (4), the pres­sure in the delivery chamber (1) rises to push the deliv­ery valve (3) open.

(C)Delivery
While the plunger (2) is rising, delivery of fuel continues.
(D) End of Delivery
When the plunger rises further and the control groove

(6) on its periphery meets the feed hole, the fuel re­turns to the fuel chamber (5) from the delivery chamber
(1) through the control groove (6) and the feed hole (4).

(1) Pump Element (5) Control Sleeve
(2) Cylinder (6) Control Groove
(3) Plunger (7) Driving Surface
(4) Feed Hole

D615-W02 May-2003

615W242A

(1) Delivery Chamber (4) Feed Hole
(2) Plunger (5) Fuel Chamber
(3) Delivery V alve (6) Control Groove

2-17

CHAPTER 2 8354/8404

c. Amount of Fuel Delivery

(A)No Fuel Delivery
At the engine stop position of the control rack (3), the

lengthwise slot (1) on the plunger (2) aligns with the
feed hole (5). The delivery chamber (4) is led to the
feed hole during the entire stroke of the plunger. The
pressure in the delivery chamber does not build up
and no fuel is forced to the injection nozzle.

(B)Fuel Delivery
The plunger is rotated by the control rack and the feed

hole is not aligned with the lengthwise slot. When the
plunger is pushed up, the feed hole is closed by the
plunger. The pressure in the delivery chamber builds
up and forces the fuel to the injection nozzle until the
control groove (6) meets the feed hole. The amount of
the fuel to be forced into the nozzle corresponds to
distance A.

615W243A

d. Delivery Valve

The delivery valve prevents the fuel in the injection pipe
from flowing back into the delivery chamber and the
fuel in the injection nozzle from dribbling after injection.

(1) Slot (4) Delivery Chamber
(2) Plunger (5) Feed Hole
(3) Control Rack (6) Control Groove

2-18

615W244A

(1) Valve Spring (4) Fuel Chamber
(2) Valve (5) V alve Face
(3) Valve Seal (6) Relief Plunger

D615-W02 May-2003

E. FUEL INJECTION NOZZLE

The nozzle is a throttle-type one. It features low fuel
consumption and works well with DAEDONG combus­tion chamber. The nozzle valve opening pressure is
about 13.7 to 14.7 MPa (140 to 150 kgf/cm², 1991 to
2134 psi), the pressure overcomes the counterforce of
nozzle valve spring, and push the valve up instantly, the
fuel is then injected in a proper quantity into the swirl­ing air in the combustion chamber for combustion. Ad­dition or reduction of adjusting can adjust the opening
pressure. A washer of 0.1 mm corresponds to 980 kPa
(10 kgf/cm², 142 psi) change in opening pressure. The
heat seal is employed to improve the durability and
reliability of the nozzle.

ENGINE SYSTEM

615W245A

F. GOVERNOR AND IDLE COMPENSA TING

a. Disassembled View

The governor serves to keep engine speed constant by
automatically adjusting the amount of fuel supplied to
the engine according to changes in the load. The en­gine employs an all-speed governor which controls
centrifugal force of the steel ball (13) weight, produced
by rotation of the fuel camshaft (9), and tension of the
governor spring 1 (2) and 2 (3) are balanced.

(1) Nozzle Holder Ass’y (6) Nozzle Body
(2) Adjusting Washer (7) Needle Valve
(3) Nozzle Spring ( 8) Heat Seal
(4) Push Rod (9) Packing
(5) Retaining Nut

615W246A

(1) Start Spring (8) Governor Lever
(2) Governor Spring 1 (9) Fuel Camshaft
(3) Governor Spring 2 (10) Governor Ball Case
(4) Fork Lever 1 (11) Steel Ball
(5) Fork Lever 2 (12) Governor Sleeve
(6) Fork Lever Shaft (13) Steel Ball
(7) Fork Lever Holder

D615-W02 May-2003

2-19

CHAPTER 2 8354/8404

b. Operation of Governor

1) At start

The steel ball (13) has no centrifugal force. As the fork
lever 1 (4) is pulled by the start spring (1), the control
rack (14) moves to the maximum injection position. At
start, the sufficient injection of the fuel enables easy
starting.

615W247A

2) At idling

At the idling position of the speed control lever (15), the
governor spring 1 (2) is free and the governor spring 2
(3) does only act slightly. The governor sleeve (12) is
pushed leftward by a centrifugal force of steel ball (13).
Therefore, the fork lever 1 (4) and control rack (14) are
moved to the left by the governor sleeve (12) and then
the idling adjusting spring (16) is compressed by the
control rack (14). As a result, the control rack is kept at
a position here a centrifugal force of steel ball (13) and
forces start spring (1), governor spring 2 (3) and idling
limit spring are balanced, providing stable idling.

IMPORTANT:

• The idling speed has been factory-set. The idling
adjusting screw (20) and spring (16) should not be
disassembled and readjusted.

17

16

4

3

(1) Start Spring
(2) Governor Spring 1
(3) Governor Spring 2

(4) Fork Lever 1
(12) Governor Sleeve
(13) Steel Ball
(14) Control Rack
(15) Speed Control Lever
(16) Idle Adjusting Spring
(17) Idle Adjusting Screw

14

15

2

1

12

13

615W248A

2-20

D615-W02 May-2003

3) At high speed running with overload

When an overload is applied to the engine running at a
high speed, the centrifugal force of steel ball (13) be­comes small as the engine speed is dropped, and fork
lever 2 (5) is pulled to the right by the governor spring 1
(2) and 2 (3), increasing fuel injection. Though, fork
lever 2 becomes ineffective in increasing fuel injection
when it is stopped by the adjusting bolt (17). After that,
when the force of torque spring (18) becomes greater
than the centrifugal force of the steel ball, fork lever 1
(4) moves rightward to increase fuel injection, causing
the engine to run continuously at a high torque.

4) To stop engine

When the stop lever (19) is moved to the STOP position,
fork lever 1 (4) is moved leftward and the control rack
(14) is moved to the non-injection position, stopping
the engine.

ENGINE SYSTEM

615W249A

(2) Governor Spring 1 (13) Steel Ball
(3) Governor Spring 2 (17) Adjusting Bolt
(4) Fork Lever 1 (18) Torque Spring
(5) Fork Lever 2

D615-W02 May-2003

615W250A

(4) Fork Lever 1 (19) Stop Lever

(14) Control Rack

2-21

CHAPTER 2 8354/8404

A . FLOW OF INT AKE AIR AND EXHAUST GAS

(a) Intake Air
(b) Exhaust Gas

(1) Intake Manifold
(2) Air Cleaner
(3) Cylinder Head
(4) Muffler
(5) Exhaust Manifold

B. AIR CLEANER

The air cleaner is dry-cyclone type and easy to maintain.
The air from the inlet port (2) circulates along the fin (3)
and around the air cleaner element (4) and the heavier
dust is carried to the evacuator (6), to the dust exhaust
port. The fine dust in the air is filtered with the air cleaner
element (4), and the filtered air flows to the outlet port
(1).

615W251A

C. MUFFLER

The exhaust noises are absorbed, while the gases are
passed through a series of holes on the inner tube
and glass wool of the muffler.

615W252A

(a) Inlet Air

(b) To Intake Manifold

(c) Heavier Dust

(1) Outlet Port (4) Air Cleaner Element

(2) Inlet Port (5) Body

(3) Fi n (6) Evacuator

615W253A

2-22

D615-W02 May-2003

3. DISASSEMBLING AND SERVICING

3.1 TROUBLESHOOTING

ENGINE SYSTEM

Symptom Probable Cause

Engine Does Not Start

(Starter Does Not Run)

Engine Revolution is Not Smooth

• Not fuel

• Air in the fuel system

• Water in the fuel system

• Fuel pipe clogged

• Fuel filter clogged

• Excessively high viscosity of fuel
or engine oil at low temperature

• Fuel with low cetane number

• Fuel leak due to loose injection
pipe retaining nut

• Incorrect injection timing

• Fuel camshaft worn

• Injection nozzle clogged

• Injection pump malfunctioning

• Fuel transfer pump
malfunctioning

• Seizure of transfer pump
malfunctioning piston, cylinder
bore or bearing

• Compression leak from cylinder

• Improper valve seating, valve
spring broken, valve seized

• Improper valve timing

• Piston ring and bore worn

• Excessive valve clearance

• Battery discharged

• Starter malfunction

• Starter switch malfunction

• Wiring disconnected

• Fuel filter clogged or dirty

• Air cleaner clogged

• Fuel leak due to loose injection
pipe retaining nut

• Injection pump malfunctioning

• Incorrect nozzle opening
pressure

• Nozzle stuck or clogged

• Fuel over flow pipe clogged

• Governor malfunctioning

Solution

Replenish fuel
Vent air
Change fuel and repair or flush

fuel system
Clean
Clean or replace
Use the specified fuel or engine

oil
Use the specified fuel
Tighten nut

Adjust
Replace
Clean or replace
Repair or replace
Repair or replace

Repair or replace

Replace head gasket, tighten
cylinder head screws, glow plug
and nozzle holder

Repair or replace

Correct or replace timing gear
Repair or replace
Adjust
Charge
Repair or replace
Repair or replace
Connect
Clean or replace
Clean or replace
Tighten nut

Repair or replace
Adjust

Repair or replace
Clean
Repair

D615-W02 May-2003

2-23

CHAPTER 2 8354/8404

Symptom Probable Cause Solution

Either White or Blue Exhaust
Gas is Observed

Either Black or Dark Gray
Exhaust Gas is Observed

Insufficient Output

Excessive Lubrication Oil
Consumption

Fuel Mixed into
Lubricating Oil

Water Mixed Into Lubricating oil

Low Oil Pressure

• Excessive engine oil

• Piston ring and bore worn or
piston ring stuck

• Incorrect injection timing

• Insufficient compression

• Over heated

• Low grade fuel used

• Fuel filter clogged

• Air cleaner clogged

• Incorrect injection timing

• Engine’s moving parts seem to
be seizing

• Uneven fuel injection

• Insufficient nozzle injection

• Compression leak

• Piston ring’s gap facing the
same direction

• Oil ring worn or stuck

• Piston ring groove worn

• Valve stem and guide worn

• Crankshaft bearings, and crank
pin bearings worn

• Injection pump plunger worn

• Fuel transfer pump broken

• Head gasket defective

• Cylinder block or cylinder head
cracked

• Engine oil insufficient

• Oil strainer closed

• Oil filter cartridge clogged

• Relief valve stuck with dirt

• Relief valve spring weak or
broken

• Excessive oil clearance of
crankshaft bearings

• Excessive oil clearance of crank
pin bearings

• Excessive oil clearance of rocker
arm bushings

• Oil passage closed

• Improper type of oil

• Oil pump defective

Reduce to the specified level
Repair or replace

Adjust
Adjust top clearance
Lessen the load
Use the specified fuel
Clean or replace
Clean or replace
Adjust
Repair or replace

Repair or replace the injection
pump

Repair or replace the nozzle
Replace head gasket, tighten

cylinder head screws and nuts,
glow plug and nozzle holder

Shift ring gap direction

Replace
Replace the piston
Replace
Replace

Replace pump element or pump
Replace
Replace
Replace

Replenish
Clean
Replace
Clean
Replace

Replace

Replace

Replace

Clean
Use the specified type of oil
Repair or replace

2-24

D615-W02 May-2003

Symptom Probable Cause Solution

High Oil Pressure

Engine Overheating

Battery Quickly Discharge

• Improper type of oil

• Relief valve defective

• Engine oil insufficient

• Fan belt broken or tensioned
improperly

• Cooling water insufficient

• Radiator net and radiator fin
clogged with dirt

• Inside of radiator corroded

• Cooling water flow route
corroded

• Radiator cap defective

• Water pipe damaged

• Thermostat defective

• Water pump defective

• Mechanical seal defective

• Overload running

• Head gasket defective

• Incorrect injection timing

• Unsuitable fuel used

• Battery electrolyte insufficient

• Fan belt slips

• Wiring disconnected

• Regulator defective

• Alternator defective

• Battery defective

ENGINE SYSTEM

Use the specified type of oil
Replace
Replenish
Replace or adjust

Replenish
Clean

Clean or replace
Clean or replace

Replace
Replace
Replace
Replace
Replace
Lesson the load
Replace
Adjust
Use the specified fuel
Replenish distilled water and

charge
Adjust belt tension or replace
Connect
Replace
Replace
Replace

D615-W02 May-2003

2-25

CHAPTER 2 8354/8404

3.2 SERVICING SPECIFICATIONS

A. ENGINE BODY

a. Cylinder Head

Item Factory Specification Allowable Limit

Cylinder Head Surface Flatness

Top Clearance

Cylinder Head Gasket Thickness Free

Tightened

Compression Pressure
(When cranking with starting motor)

* Variance of compression pressure among cylinders should be 10% or less.

0.75 ~ 0.9 mm

0.0295 ~ 0.0354 in.

1.3 ~ 1.5 mm

0.0512 ~ 0.0591 in.

1.15 ~ 1.25 mm

0.0453 ~ 0.0492 in.

3.24 ~ 3.73 MPa
33 ~ 38 kgf/cm

469 ~ 540 psi

2

0.05 mm / 100 mm

0.002 in. / 3.94 in.

-

-

-

2.55 MPa

26 kgf/cm

370 psi

2

b. Valves

Item

Valve Clearance (Cold) IN.

EX.

V alve Seat Angle IN.

EX.

V alve Face Angle IN.

EX.

Valve Recessing

Clearance Between Valve Stem and Valve
Guide
V alve Stem O.D

V alve Stem I.D

c. Valve Timing

Item Factory Specification Allowable Limit

Inlet V alve Open

Close

Exhaust V alve Open

Close

Factory Specification

0.25 mm 0.0098 in.

0.30 mm 0.0118 in.

1.047 rad. 60°

0.785 rad. 45°

1.047 rad. 60°

0.785 rad. 45°

0.2 ~ 0.5 mm

0.0079 ~ 0.0197 in.

0.040 ~ 0.070 mm

0.00157 ~ 0.00276 in.

7.960 ~ 7.975 mm

0.31339 ~ 0.31398 in.

8.015 ~ 8.030 mm

0.31555 ~ 0.31614 in.

0.140rad 8° before T.D.C

0.611rad 35° after B.D.C

0.785rad 45° before B.D.C

0.140rad 8° after T.D.C

Allowable Limit

0.8 mm

0.0315 in.

0.10 mm

0.0039 in.

-

-

-

-

2-26

D615-W02 May-2003

d. Cylinder Bore

Item Factory Specification Allowable Limit

Cylinder bore inner
diameter

3A165D

4A200B

e. Valve Spring

Item Factory Specification Allowable Limit

Free length

Assembling load / assembling length

Squareness

f. Rocker Arm

Item Factory Specification Allowable Limit

Rocker arm shaft O.D

Rocker arm bushing I.D

87.000 ~ 87.022 mm

3.4252 ~ 3.4261 in.

83.000 ~ 83.022 mm

3.2677 ~ 3.2690 in.

41.7 ~ 42.2 mm

1.6417 ~ 1.6614 in.

12.0 kgf / 35.15 mm

26.46 lbs / 1.3839 in.

-

18.955 ~ 18.980 mm

0.74600 ~ 0.74724 in.

19.0 ~ 19.035 mm

0.74803 ~ 0.74941 in.

ENGINE SYSTEM

0.15 mm

0.0059 in.

41.2 mm

1.6220 in.

10.2 kgf / 35.15 mm

22.49 lbs / 1.3839 in.

1.0 mm

0.0394 in.

-

-

g. Tappet

Item Factory Specification Allowable Limit

Clearance between tappet and guide

Tappet O.D

Tappet guide I.D

h. Camshaft

Item Factory Specification Allowable Limit

Camshaft alignment

Cam height IN.

EX.

Clearance between camshaft

Camshaft journal O.D

Camshaft counter bore I.D

0.020 ~ 0.062 mm

0.00079 ~ 0.00244 in.

23.959 ~ 23.980 mm

0.94327 ~ 0.94410 in.

24.000 ~ 24.021 mm

0.94488 ~ 0.94571 in.

0.01 mm

0.0004 in.

33.59 mm

1.3224 in.

33.69 mm

1.3264 in.

0.050 ~ 0.091 mm

0.00197 ~ 0.00358 in.

39.934 ~ 39.950 mm

1.57221 ~ 1.57284 in.

40.000 ~ 40.025 mm

1.57480 ~ 1.57579 in.

0.07 mm

0.0028 in.

-

-

0.05 mm

0.0020 in.

33.54 mm

1.3205 in.

33.64 mm

1.3244 in.

0.15 mm

0.0059 in.

39.88 mm

1.5701 in.

-

D615-W02 May-2003

2-27

CHAPTER 2 8354/8404

I. Timing Gear

Item Factory Specification Allowable Limit

Timing gear backlash

Idle gear side clearance

Clearance between Idle gear shaft and idle

gear bushing

Idle gear shaft O.D

Idle gear bushing I.D

j. Piston Ring

Item Factory Specification Allowable Limit

Piston pin-bore I.D

Clearance between Oil ring and ring groove

Oil ring groove width

Oil ring width

Clearance between 2nd ring and ring groove

2nd ring groove width

2nd ring width

Top ring, oil ring end gap

2nd ring end gap

0.04 ~ 0.11 mm

0.0016 ~ 0.0043 in.

0.20 ~ 0.51 mm

0.0079 ~ 0.0201 in.

0.025 ~ 0.066 mm

0.00098 ~ 0.00260 in.

37.959 ~ 37.975 mm

1.49445 ~ 1.49508 in.

38.000 ~ 38.025 mm

1.49606 ~ 1.49705 in.

25.000 ~ 25.006 mm

0.98425 ~ 0.98448 in.

0.020 ~ 0.060 mm

0.00079 ~ 0.00236 in.

3.010 ~ 3.030 mm

0.11850 ~ 0.11929 in.

2.97 ~ 2.99 mm

0.11693 ~ 0.11772 in.

0.04 ~ 0.08 mm

0.00157 ~ 0.00315 in.

2.03 ~ 2.05 mm

0.07992 ~ 0.08070 in.

1.97 ~ 1.99 mm

0.07756 ~ 0.07834 in.

0.25 ~ 0.40 mm

0.0098 ~ 0.01570 in.

0.55 ~ 0.70 mm

0.0217 ~ 0.0276 in.

0.15 mm

0.0059 in.

0.9 mm

0.035 in.

0.1 mm

0.0039 in.

-

-

25.03 mm

0.9854 in.

0.15 mm

0.0059 in.

-

-

0.15 mm

0.0059 in.

-

-

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

k. Connecting Rod

Item Factory Specification Allowable Limit

Connecting rod misalignment

Clearance between Piston and small end

bushing
Piston pin O.D

Small end bushing I.D

2-28

-

0.014 ~ 0.038 mm

0.00055 ~ 0.00150 in.

25.002 ~ 25.011 mm

0.98433 ~ 0.98469 in.

25.025 ~ 25.040 mm

0.98524 ~ 0.98583 in.

0.05 mm

0.0020 in.

0.15 mm

0.0059 in.

-

-

D615-W02 May-2003

l. Crankshaft

Item Factory Specification Allowable Limit

Crankshaft Misalignment

Clearance between Crankshaft and crank-

shaft bearing 1

Crankshaft O.D

Crankshaft bearing 1 I.D

Clearance between Crankshaft and crank-

shaft bearing 2

Crankshaft O.D

Crankshaft bearing 1 I.D

Clearance between Crank pin and crank pin

bearing
Crank pin O.D

Crank pin bearing I.D

Crankshaft side clearance

-

0.040 ~ 0.118 mm

0.00157 ~ 0.00465 in.

51.921 ~ 51.940 mm

2.04414 ~ 2.04489 in.

51.980 ~ 52.039 mm

2.04646 ~ 2.04878 in.

0.040 ~ 0.104 mm

0.00157 ~ 0.00409 in.

51.921 ~ 51.940 mm

2.04414 ~ 2.04488 in.

51.980 ~ 52.025 mm

2.04646 ~ 2.04823 in.

0.025 ~ 0.087 mm

0.00098 ~ 0.00343 in.

46.959 ~ 46.975 mm

1.84876 ~ 1.84947 in.

47.000 ~ 47.046 mm

1.85040 ~ 1.85221 in.

0.15 ~ 0.31 mm

0.0059 ~ 0.0122 in.

ENGINE SYSTEM

0.08 mm

0.0031 in.

0.20 mm

0.0079 in.

-

-

0.20 mm

0.0079 in.

-

-

0.20 mm

0.0079 in.

-

-

0.5 mm

0.020 in.

B. LUBRICATING SYSTEM

a. Oil Pump

Item Factory Specification Allowable Limit

Engine oil pressure
(oil temp. 85 ~ 95 °C,
185 ~ 203 °F)

Clearance between inner rotor and outer rotor

Radial clearance between outer rotor and pump

End clearance between inner rotor and cover

At idle speed

At rated speed

more than 49.0 kPa

0.5 kgf/cm

2

7.11 psi

245 ~ 441 kPa

2.5 ~ 4.5 kgf/cm

2

35.6 ~ 64.0 psi

0.10 ~ 0.16 mm

0.0039 ~ 0.0063 in.

0.11 ~ 0.19 mm

0.0043 ~ 0.0078 in.

0.105 ~ 0.150 mm

0.00413 ~ 0.00591 in.

-

245 kPa

2.5 kgf/cm

35.6 psi

0.2 mm

0.0079 in.

0.25 mm

0.0098 in.

0.2 mm

0.00787 in.

2

D615-W02 May-2003

2-29

CHAPTER 2 8354/8404

C. COOLING SYSTEM

a. Thermostat

Valve opening temperature at beginning
Opened completely (height 8 mm 0.315 in.)

b. Radiator

Radiator tightness

Radiator cap tightness

Fan belt tension
[deflection at 98 N (10 kgf, 22 lbs) of force]

D. FUEL SYSTEM

a. Inject Pump

Injection timing (BTDC)

b. Injection Nozzle

Fuel injection pressure

Fuel tightness of nozzle valve seat

69.5 ~ 72.5 °C (157.1 ~ 162.5 °F)
85 °C (185 °F)

No leak at 137 kPa, 1.4 kgf/cm

10 seconds or more for pressure

falling from 88 ~ 59 kPa

from 0.9 ~ 0.6 kgf/cm

from 13 ~ 9 psi

7 ~ 9 mm

0.28 ~ 0.35 in.

18°

13.73 ~ 14.715 MPa
140 ~ 150 kgf/cm

2

1,991 ~ 2,134 psi

No fuel leak for 5 sec.

at pressure

12.74 MPa

130 kgf/cm

2

1,849 psi

2

, 20 psi

2

NOTE:

• Injection Sequence Four Cylinders: 1 → 3 → 4 → 2
Three Cylinders: 1 → 2 → 3
(The cylinder number is given in order from the
gear case end.)

2-30

D615-W02 May-2003

E. TIGHTENING TORQUES

ENGINE SYSTEM

Item

Cylinder head screws
Head cover nuts
* Bearing case screw 1
* Bearing case screw 2
* Flywheel screw
* Connecting rod screws
Rocker arm bracket studs
Drain plug
Glow plugs
Oil switch
Nozzle locating screws
Injection pipe nuts

Size x Pitch

M11 x 1.25

M10 x 1.25

M9 x 1.25
M10 x 1.25
M12 x 1.25

M8 x1.0
M10 x 1.25
M12 x 1.25
M10 x 1.25

PT1/8
M20 x 1. 5
M12 x 1. 5

NOTE:

• For *marked screw, bolts and nuts on the table,
apply engine oil to their threads and seats before
tightening.

• The letter “M” in Size x Pitch means that the screw,
bolt or nut dimension stands for metric. The size is
the nominal outside diameter in mm of the threads.
The pitch is the nominal distance in mm between
two threads.

N•m

103.0 ~ 107.9

8.8 ~ 10.8

46.1 ~ 51.0

68.6 ~ 73.6

98.1 ~ 107.9

46.1 ~ 51.0

48.1 ~ 55.9

32.4 ~ 37.3

19.6 ~ 24.5

14.7 ~ 19.6

49.1 ~ 68.7

24.5 ~ 34.3

kgf•m

10.5 ~ 11.0

0.9 ~ 1.1

4.7 ~ 5.2

7.0 ~ 7.5

10.0 ~ 11.0

4.5 ~ 5.0

4.9 ~ 5.7

3.3 ~ 3.8

2.0 ~ 2.5

1.5 ~ 2.0

5.0 ~ 7.0

2.5 ~ 3.5

lbf·ft

75.9 ~ 79.6

6.5 ~ 8.0

34.0 ~ 37.6

50.6 ~ 54.2

72.3 ~ 79.6

34.0 ~ 37.6

35.4 ~ 41.2

23.9 ~ 37.3

14.5 ~ 18.1

10.8 ~ 14.5

36.2 ~ 50.6

18.1 ~ 25.3

D615-W02 May-2003

2-31

3.3 CHECKING, DISASSEMBLING AND SERVICING

A . ENGINE DISASSEMBLED VIEW

ENGINE SYSTEM

(1) Cylinder Block
(2) Oil Pressure Switch
(3) Oil Pump
(4) Oil Pan
(5) Oil Strainer
(6) Oil Gauge

D615-W02 May-2003

(7) Cylinder Head
(8) Head Bolt
(9) Gear case

(10) Oil Filter

(11) Main bearing Case

Cover

(12) Bearing Case Bolt 1
(13) Main Bearing Case
(14) Bearing Case Bolt 2
(15) Rocker Arm
(16) Inlet, Exhaust V alve
(17) Cylinder Hear Cover

(18) Push Rod
(19) Tappet
(20) Camshaft
(21) Camshaft Gear
(22) Idle Gear
(23) Piston

(24) Connecting Rod
(25) Crankshaft
(26) Flywheel
(27) Flywheel Housing
(28) Starter
(29) Injection Pipe

(30) Glow Plug
(31) Nozzle
(32) Fuel Injection Pump
(33) Fuel Feed Pump
(34) Fuel Camshaft
(35) Fuel Camshaft Gear

(36) Engine Stop Solenoid
(37) Speed Control Plate
(38) Fork Lever (Governor)
(39) Impeller
(40) Thermostat
(41) Alternator

(42) Fan Drive Pulley
(43) Cooling Fan
(44) Radiator
(45) Reserve Tank Ass’y
(46) Inlet Manifold
(47) Muffler

615WA18A

(48) Exhaust Manifold
(49) Air Cleaner

2-33

B. EXTERNAL COMPONENTS

a. Checking and Adjusting

1) Fan belt

Measure the deflection, depressing the belt halfway
between the fan drive pulley and the alternator pulley at
98 N (10 kgf, 22 lbs) of force.

If the deflection is not between the factory specifications,
loosen the bolts and nuts, and relocate the alternator
to adjust.

If the belt is damaged or worn (see figure), replace the
belt.

ENGINE SYSTEM

Belt tension
(deflection)

Factory spec 7 ~ 9 mm

0.28 ~ 0.35 in.

b. Disassembly and Assembly

1) Engine body

Drain the oil and the water, if disassemble the engine
body.

1. Remove the muffler and exhaust manifold (7).

2. Remove the starter (9) and the oil pressure switch
(8).

3. Pull out the oil gauge (6).

4. Remove the alternator (5) and the fan belt (1).

5. Remove the hour meter unit (2).

6. Loosen the oil filter (3) with a filter wrench and re­move it and the oil filter flange (4).

(When reassembling)
Apply liquid gasket (three bond 1,215 or equivalent) on

the thread of the oil pressure switch (8).
Apply liquid gasket to the both sides of the hour meter

gasket.
Apply oil to the O-ring and tighten the oil filter not with

wrench but by hand.
Adjust the fan belt tension (See fan belt).

615W258A

615W259A

(1) Fan Belt (6 ) Oil Gauge
(2) Hour Meter Unit (7) Exhaust Manifold
(3) Oil Filter (8) Oil Pressure Switch
(4) Oil Filter Flange (9) Starter
(5) Alternator

* This figure does not show Hour meter Unit (2) cov-

ered with the cooling fan.

Tightening
torque

D615-W02 May-2003

Oil pressure

switch

14.7 ~ 19.6 N·m

1.5 ~ 2.0 kgf·m

10.8 ~ 14.4 lbf·ft

2-35

CHAPTER 2 8354/8404

2) Solenoid

1. Disconnect the stop lever 1 (5) from the engine stop
lever (2).

2. Remove the screw (3) and (4).

3. Remove the solenoid (7) with its support.

(When reassembling)

• Loosen the solenoid mounting screws.

• Install the support and complete the linkage be­tween the solenoid (7) and the engine stop lever
(2).

• Pushing the solenoid (7) plunger to the bottom, pull
the stop lever 2 (6) until the engine stop lever (2) is
turned to the end, then tighten the screws.

3) Intake manifold and fuel pipes

1. Disconnect the fuel pipe (3).

2. Loosen the injection pipe fitting with two wrenches
and remove the injection pipes (2).

3. Remove the intake manifold (1) and the fuel feed
pump (4).

615W260A

(1) Screw (5) Stop Lever 1
(2) Engine Stop Lever (6 ) Stop Lever 2
(3) Screw (7) Solenoid
(4) Screw

IMPORTANT:

• Tighten or loosen injection pipe fittings using the
one-hand two-wrench squeeze method.

• Cap the nozzle hole to prevent entrance of foreign
materials.

Tightening
torque

Injection pipe

nut 19 mm

(0.75 in.)

cross flats

24.5 ~ 34.3 N·m

2.5 ~ 3.5 kgf·m

18.0 ~ 25.3 lbf·ft

615W261A

(1) Intake Manifold (3) Fuel Pipe
(2) Injection Pipe (4) Fuel Feed Pump

2-36

D615-W03 May-2003

C. ENGINE BODY

a. Checking and Adjusting

1) Compression pressure

1. Run the engine until warmed up.

2. Stop the engine and remove the air cleaner, the

muffler and all nozzle holders.

3. Connect a compression tester to the nozzle holder

hole.

4. Pull the stop lever to cut the fuel and run the engine

with the starter at 250 ~ 350 rpm for 5 ~ 10 seconds.

5. Measure the maximum pressure while running, sev-

eral times.

6. If the pressure does not reach the allowable limit,

apply a small amount of oil to the cylinder wall
through the nozzle holder hole and check the pres­sure again.

7. If the pressure raises after oil is apply, check the

cylinder wall and piston ring.

8. If the pressure is still low, check the top clearance,

valve clearance and cylinder head.

ENGINE SYSTEM

615W262A

Compression
pressure

Factory spec.

3.24 ~ 3.73 MPa
33 ~ 38 kgf/cm

2

469 ~ 540 psi

Allowable limit

2.55 MPa

26 kgf/cm

2

370 psi

Difference

Allowable limit

10 %
between two
cylinders

NOTE:

• Check the compression pressure with the specified
valve clearance for proper air in taking.

D615-W02 May-2003

2-37

CHAPTER 2 8354/8404

2) Valve clearance

1. Remove the cylinder head cover and the timing win­dow cover on the flywheel housing and all glow
plugs.

2. Turn the flywheel and align the 1 TC or 1.4 TC mark
mark with the timing mark of window on the flywheel
housing to position the 1st cylinder valves at the top
head center during compression.

3. Measure the clearance at the valves marked with
in the table below with a feeler gauge.

4. If the clearance is not within the factory
specifications, turn the adjusting screw to adjust.

5. Turn the flywheel just one turn to position the 1st
cylinder valves at the top head center during overlap.

6. Measure the clearance at the valves marked with
in the table below with a feeler gauge.

7. If the cleara

615W263A

V alve
clearance

Factory spec.

In. : 0.25 mm 0.0098 in.
Ex. : 0.30 mm 0.0118 in.

(3A165D)

Cylinder NO.
Valve

1

IN EX.2IN. EX.3IN. EX.

Checking

(4A200B)

Cylinder NO.
Valve

1

IN. EX.2IN. EX.3IN. EX.4IN. EX.

Checking

b. Disassembling and Assembling
(A) Cylinder head cover, glow plugs and fuel

overflow pipes.

1. Remove the injection pipes and over flow pipe.

2. Remove the glow plugs.

3. Remove the injection nozzles and gaskets, heat
seals.

4. Remove the cylinder head cover.

615W264A

(When reassembling)

• Check that the cylinder head cover gasket is not
defective.

• Tighten the cylinder head cover cap nuts in several
steps.

2-38

615W265A

(1) Injection Nozzle (3) Heat Seal
(2) Gasket

D615-W03 May-2003

(B) Heat seal removal procedure

1. Drive screw driver lightly into the heat seal hole.

2. Turn screw driver three or four times each way.

3. While turning the screw driver, slowly pull the heat

seal put together with the injection nozzle gasket. If
the heat seal drops, repeat the above procedure.

4. Heat seal and injection nozzle gasket must be

changed when the injection nozzle is removed for
cleaning or for service.

NOTE:

• Use a philips screw driver that has a diameter

which is bigger than the heat seal hole 1/4 in.

φ

(approx.

6mm).

(C) Rocker arm assembly

1. Loosen the nuts in several steps and the specified

sequence shown in the figure and remove them.

2. Remove the rocker arm assembly and the push rod.

ENGINE SYSTEM

615W267A

(1) Philips Screw Driver (2) Nozzle
(3) Injection Nozzle Gasket (4) Heat Seal

(When reassembling)

• Rest the end of push rod at the indent of tappet and

install the rocker arm assembly.

• Tighten the nuts in several steps and in the speci-

fied sequence to the specified torque. As shown in
the figure.

• Adjust the valve clearance after assembling the

rocker arm assembly.

IMPORTANT:

• When assembling the rocker arm assembly, locate

the groove of rocker arm shaft on stud bolt.

Tightening
torque

Stud, nut

48.1 ~ 55.9 N·m

4.9 ~ 5.7 kgf·m

35.3 ~ 41.2 lbf·ft

615W268A

615W269A

(1) Rocker Arm Shaft (3) Rocker Arm Bracket
(2) Rocker Arm (4) Screw

D615-W02 May-2003

2-39

CHAPTER 2 8354/8404

(D) Cylinder head

1. Remove the screw in the specified sequence shown
in the figure and remove the cylinder head (1) and
head gasket.

2. Remove the water flange (2).

3. Take out the tappets from the cylinder block.

NOTE:

• Mark the cylinder number to the tappets to prevent
interchanging.

(When reassembling)

• Apply liquid gasket (Three bond 1215 or equivalent)
on the both sides of water flange gasket.

• Replace the head gasket with new one and place
on the cylinder block, be careful of its direction and
side.

• When using the head gasket shim, assemble the
shim first on the cylinder head.

• Before installing the tappets apply engine oil around
them.

615W270A

(1) Cylinder Head (2) Water Flange

IMPORTANT:

• Apply oil to the thread of screws and tighten in sev­eral steps and the specified sequence shown in the
figure to the specified torque.

• Check the torque after 30 minutes operation of the
assembled engine, and adjust valve clearance.

Tightening
torque

Cylinder

head

screws

103.0 ~ 107.9 N·m

10.5 ~ 11.0 kgf·m

75.9 ~ 79.6 lbf·ft

(E) Valve

1. Compress the valve spring with a replaces and re­move the collect (2).

2. Remove the retainer (3), valve spring (4), valve stem
seal (5) and the valve (1).

IMPORTANT:

• Do not interchange valves and valve parts.

• Mark the cylinder number on the valve and the parts

to prevent interchanging.

(When reassembling)

• Apply oil to the stem of valve and install in the cylin­der head.

• Lubricate the valve and the parts after reassem­bling.

615W271A

615W272A

(1) Valve (4) V alve Spring
(2) Collect (5) Valve Stem Seal
(3) Retainer

2-40

D615-W02 May-2003

1) Timing Gears and Camshafts
(A) Injection pump

1. Remove the injection pump cover (3) with the en-

gine stop lever (2).

2. Remove the injection pump.

(When reassembling)

• Apply liquid gasket to the both sides of injection

pump cover gasket and install it.

• Install the injection pump so that its control rack pin

(4) engages with the groove (5) of fork lever 1 (1).

• Install the injection pump cover with the arm of en-

gine stop lever (2) at the right of the arm of fork lever
1 (1).

(B) Governor spring and Speed control plate

1. Disconnect the governor spring 1 (1) and 2 (2) from

the governor lever (4).

2. Remove the speed control plate.

3. Remove the governor spring.

ENGINE SYSTEM

615W273A

(1) Fork Lever 1 (4 ) Control Rack Pin
(2) Engine Stop Lever (5 ) Groove
(3) Injection Pump Cover (6) Shim

(When reassembling)

• Be careful not to drop the governor springs 1, 2 into

the gear case.

• Fix the governor springs (1), (2) to the fork lever 2

(3) and pull the springs, hook on to the governor
lever (4).

• Apply a liquid gasket both side of speed control plate

gasket.

615W275A

615W274A

(1) Governor Spring 1 (3) Fork Lever 2
(2) Governor Spring 2 (4) Governor Lever

D615-W02 May-2003

2-41

CHAPTER 2 8354/8404

(C) Start spring

1. Remove the start spring (1) from the fork lever 1 (2).

(When reassembling)

• Be careful not to drop the start spring into the gear
case.

• Hook the start spring so that the longer hook is on
the fork lever side.

(D) Fan drive pulley

1. Install the stopper to the flywheel so that the crank­shaft may not turn.

2. Flatten the metal lock and loosen the crankshaft
nut (2).

3. Remove the fan drive fan drive pulley (1).

615W276A

(1) Start Spring (2) Fork Lever 1

Tightening
torque

Crankshaft

nut

137.3 ~ 156.9 N·m

14.0 ~ 16.0 kgf·m

101.3 ~ 115.7 lbf·ft

(E) Gear case

1. Remove the gear case.

(When reassembling)

• Stick the O-ring (1) to the gear case with thin grease
to prevent from coming off during reassembling.

• Apply grease to the crankshaft oil seal lip on the
gear case and take care not to damage it when
installing.

• Apply liquid gasket (three bond 1215 or equivalent)
to the both sides of gear case gasket.

615W277A

(1) Fan Drive Pulley (2) Crankshaft Nut

615W278A

2-42

(1) O-Ring

D615-W02 May-2003

(F)Water pump and relief valve

1. Remove the water pump body (1).

2. Remove the relief valve cover (2) and take out the

ball, spring and seat.

(When reassembling)

• Install the relief valve cover (2) with its mark up.

ENGINE SYSTEM

Tightening
torque

Relief valve

cover screw

32.4 ~ 36.3 N·m

3.3 ~ 3.7 kgf·m

23.9 ~ 26.8 lbf·ft

(G) Idle gear and crank gear

1. Remove the crankshaft collar (6), O-ring (5), oil

slinger (4) and crank gear collar (3) in the order.

2. Remove the idle gear (1).

3. Remove the crankshaft gear (2) with a special use

puller set.

(When reassembling)

• Heat the crankshaft gear to approx. 80 °C (176 °F)

and insert the crankshaft.

• Apply oil to the O-ring (5).

615W279A

(1) Water Pump Body (2) Relief Valve Cover

615W280A

IMPORTANT:

• Install the idle gear, aligning the alignment marks

referring to the figure.

615W281A

(1) Idle Gear (6) Crankshaft Collar
(2) Crankshaft Gear ( 7) Oil Pump Gear
(3) Crank Gear Collar (8) Injection Pump Gear
(4) Oil Slinger (9 ) Cam Gear
(5) O-Ring

D615-W02 May-2003

2-43

CHAPTER 2 8354/8404

(H)Camshaft

1. Align the holes on the cam gear (2) with the crews
to loosen them through the holes with a T handle
wrench.

2. Draw out the camshaft (1).

3. Remove the cam gear (2).

(When reassembling)

• Heat the cam gear to approx. 80 °C (176 °F) and
insert the camshaft (1).

(I) Fuel camshaft

1. Remove the fuel camshaft stopper.

2. Loosing the fork lever holder screws, remove the
fuel camshaft (4) with fork lever holder (5), fork lever
1 (1) and 2 (2).

3. Remove the Injection pump gear (3).

615W282A

(1) Camshaft (2) Cam Gear

(When reassembling)

• Heat the injection pump gear to approx. 80 °C
(176 °F) and insert the camshaft (4).

2) Connecting rod and piston

(A)Oil pan and oil filter

1. Remove the oil pan.

2. Remove the oil strainer (1).

(When reassembling)

• Be sure to install the O-ring (2) between the oil
strainer and the cylinder block.

615W283A

(1) Fork Lever 1 (4 ) Camshaft
(2) Fork Lever 2 (5 ) Fork Lever Holder
(3) Injection Pump Gear

2-44

615W284A

(1) Oil Strainer (2) O-Ring

D615-W02 May-2003

(B) Piston and connecting rod

1. Remove the screws and the connecting rod cap.

2. Push out the rod and piston assembly.

(When reassembling)

• Apply oil to the crankpin bearing, cylinder wall and

connecting rod cap screw.

• Insert the connecting rod and piston assembly with

the mark on the rod facing the injection pump, us­ing a piston ring compressor.

IMPORTANT:

• Mark the cylinder number on the piston and con-

necting rod to prevent interchanging.

• Carefully insert the piston and ring assembly in the

cylinder, compressing the rings not to damage the
chrome-plate on the piston rings.

• If the connecting rod cap screws can not be screwed

to the end by hand, replace the screw.

ENGINE SYSTEM

615W286A615W285A

(1) Piston Pin
(2) Piston
(3) Piston Pin Snap Ring
(4) Top Ring
(5) Second Ring
(6) Oil ring
(7) Connecting Rod

615W287A

D615-W02 May-2003

2-45

CHAPTER 2 8354/8404

(C) Piston ring and piston pin

1. Remove the piston rings with a piston ring replac­ing tool.

2. Remove the piston pin.

(When reassembling)

• Clean all the parts before assembling.

• Heat the piston in approx. 80 °C (176 °F) of oil for 10
~ 15 minutes, when inserting the piston pin into the
piston.

• Install the piston and connecting rod with the mark
FW on the piston to the flywheel and the mark on
connecting rod to the injection pump.

• Install the piston rings with their manufacture’s
mark to the top of piston.

• Install the expander in the oil ring with its gap oppo­site to the gap of oil ring.

• Install the top ring with its gap at 1.57 rad (90 °)
from the piston pin to the exhaust port.

• Install the second ring and oil ring with their gap at
every 2.09 rad (120 °).

615W288A

3) Crankshaft

(A)Flywheel

1. Install the stopper to the flywheel and loosen the
screw.

2. Remove the flywheel stopper and the flywheel.

(When reassembling)

• Clean the end of crankshaft and the mating surface
of the flywheel.

• Apply oil to flywheel screws.

• Fit the flywheel hole to crankshaft hole and tighten
the flywheel bolts to specified torque.

NOTE:

• Screw longer screws to the flywheel to carry It if
needed.

615W289A

(7) Connecting Rod (11) Expander Joint
(8) Connecting Rod Cap (12) Oil Ring Gap
(9) Casting Mark (13) Manufacturer’s Mark

(10) Marks

615W290A

Tightening
torque

2-46

Flywheel

screw

98.1 ~ 107.9 N·m

10.0 ~ 11.0 kgf·m

72.3 ~ 79.6 lbf·ft

D615-W02 May-2003

(B) Bearing case cover
Loosen the screw first inside and next outside, and lift

the cover (1) by screwing two screws gradually and
evenly, referring to the photo.

(When reassembling)

• Apply grease to the oil seal lip and take care that it

is not rolled when installing.

ENGINE SYSTEM

Tightening
torque

Bearing

case

cover screw

23.5 ~ 27.5 N·m

2.4 ~ 2.8 kgf·m

17.4 ~ 20.3 lbf·ft

(C)Crankshaft

1. Remove the bearing case screw 2.

2. Pull out the crankshaft, taking care not to damage

the crankshaft bearing 1.

(When reassembling)

• Apply oil to the bearing case screw 2.

• Clean the oil passage of the crankshaft with com-

pressed air.

Tightening
torque

Bearing

case

screw 2

68.7 ~ 73.6 N·m

7.0 ~ 7.5 kgf·m

50.6 ~ 54.2 lbf·ft

(D) Main bearing case

1. Remove the bearing case screws 1 (4) and remove

the main bearing case 1, 2, 3 (1).

2. Remove the thrust bearing from the flywheel end

bearing case.

615W291A

(1) Bearing Case Cover

615W292A

D615-W02 May-2003

615W293A

(1) Main Bearing Case 1, 2, 3
(2) Thrust Bearings
(3) Main Bearing Case Assembly 1
(4) Bearing Case Screw 1
(5) Crankshaft Bearing 2

2-47

CHAPTER 2 8354/8404

IMPORTANT:

• Mark the location line to the bearing case, to pre­vent interchanging.

(When reassembling)

• Clean the parts and the oil passage of the bearing
case.

• Apply oil to the journal, bearing inserts and the bear­ing case screws.

• Place the thrust bearings on the bearing case with
their oil groove outside.

• Install the main bearing case with the mark “FLY
WHEEL” toward the flywheel.

Tightening
torque

c. Servicing

1) Cylinder head and valve

(A) Cylinder head surface flatness

1. Thoroughly clean the cylinder head surface.

2. Place a straight edge on the cylinder head and
measure the clearance with a feeler gage as shown
in the figure.

3. If the measurement exceeds the allowable limit,
replace the cylinder head.

Bearing

case

screw 1

46.1 ~ 51.0 N·m

4.7 ~ 5.2 kgf·m

34.0 ~ 37.6 lbf·ft

615W294A

(6) Bearing Case

IMPORTANT:

• Do not place the straight edge on the combustion
chamber.

Flatness

Allowable

limit

0.05 mm

0.0019 in.

(B) Cylinder head surface flaw

1. Prepare an air spray red check.

2. Clean the cylinder head surface with the detergent
(B).

3. Spray the cylinder head surface with the red perme­ative liquid (A).

4. Wash away the red permeative liquid on the cylin­der head surface with the detergent (B) after ten
minutes.

5. Spray the cylinder head surface with the white de­veloper (C).

6. If any flaw is found such as a red mark, replace the
cylinder head.

615W295A

615W296A

(A) Red Permeative Liquid

(B) Detergent

(C) White Developer

2-48

D615-W02 May-2003

(C) Valve stem clearance

1. Remove the carbon from the valve guide.

2. Measure the valve stem O.D. with an outside

micrometer.

3. Measure the valve guide I.D. of cylinder head, and

calculate the clearance.

4. If the measurement exceeds the allowable limit,

replace the valve guide of the valve.

ENGINE SYSTEM

Valve stem
clearance

Valve guide
bore I.D.

Valve stem
O.D.

Factory

spec.

Allowable

limit

Factory

spec.

Factory

spec.

0.040 ~ 0.070 mm

0.00157 ~ 0.00276 in.

0.1 mm

0.004 in.

8.015 ~ 8.030 mm

0.31555 ~ 0.31614 in.

7.960 ~ 7.975 mm

0.31339 ~ 0.31398 in.

(D)Valve recessing

1. Clean the cylinder head, the valve face and the seat.

2. Insert the valve in the guide.

3. Measure the valve recessing with a depth gauge.

4. If the recessing exceeds the allowable limit, replace

the valve and check the valve seating.

Valve
recessing

Factory

spec.

Allowance

0.2 ~ 0.5 mm

0.0078 ~ 0.0197 in.

0.8 mm

0.0315 in.

615W297A

12 13111078210 65439

(E)Valve seat

1. Coat the valve face lightly with red lead and put the

valve on its seat to check the contact.

2. If the valve does not seat all the way around the

valve seat or the valve contact is less than 70%,
correct the valve seating as follows.

3. Apply compound on the valve face evenly.

4. Put the valve on its seat hold it with the valve flapper.

5. Turn and lap the valve back and forth on the valve

seat to lap.

6. Remove the compound and clean the valve and the

seat.

7. Apply oil on the valve face and finish to complete

fitting.

8. Repeat lapping until the valve seats correctly.

615W298A

615W299A

D615-W02 May-2003

2-49

CHAPTER 2 8354/8404

(F) Valve spring

1. Measure the free length of the spring with venire
calipers.

2. Place the spring on a spring compression tester and
compress to the specified length, and get the tension.

3. If the measurement is less than the allowable limit,
replace the valve spring.

Tension

Factory

spec.

117 N / 35.15 mm

12.0 kgf / 35.15 mm

26.5 lbs / 1.3839 in.

Allowable

limit

100 N / 35.15 mm

10.2 kgf / 35.15 mm

22.5 lbs / 1.3839 in.

Free
length

Factory

spec.

Allowable

limit

41.7 ~ 42.2 mm

1.6417 ~ 1.6614 in.

41.2 mm

1.622 in.

(G)Valve spring squareness (Tilt)

1. Place the spring on the surface plate and a square
at its side.

2. Measure the maximum distance A (See figure), ro­tating spring.

3. If the measurement exceeds the allowable limit re­place.

Valve spring
square ness

Allowable

limit

1.0 mm

0.039 in.

615W2A0A

(H) Rocker arm bushing and shaft clearance

1. Measure the rocker arm I.D. with an inside micrometer.

2. Measure the rocker arm shaft O.D. with an outside
micrometer.

3. If the clearance exceeds the allowable limit, replace
the rocker arm.

4. If the clearance still exceeds the allowable limit after
replacing the rocker arm replace the rocker arm shaft.

Clearance

Rocker arm
shaft O.D.

Rocker
arm I.D.

Factory

spec.

Allowable

limit

Factory

spec.

Factory

spec.

0.020 ~ 0.070 mm

0.00079 ~ 0.00276 in.

0.15 mm

0.0059 in.

18.955 ~ 18.980 mm

0.74626 ~ 0.74724 in.

19.000 ~ 19.025 mm

0.74803 ~ 0.74902 in.

2-50

9

10

11

D615-W02 May-2003

615W2A1A

615W2A2A

2) Timing gears and camshafts

(A) Timing gear backlash

1. Set a dial indicator (lever type) with its tip on the

gear tooth.

2. Move the gear to measure the backlash, holding its

mating gear.

3. If the backlash exceeds the allowable limit, check

the oil clearance of the shafts and the gear.

4. If the oil clearance is improper, replace the gear.

ENGINE SYSTEM

Clearance

Factory

spec.

Allowable

limit

0.04 ~ 0.11 mm

0.0016 ~ 0.004 in.

0.15 mm

0.0059 in.

(B) Idle gear side clearance

1. Pull the idle gear collar 2 (1) and push the idle gear

(2) to each end.

2. Measure the clearance A between the idle gear and

the idle gear collar 2 with a feeler gauge.

3. If the clearance exceeds the allowable limit, replace

the idle gear collar 1 (3).

Side
clearance

Factory

spec.

Allowable

limit

0.20 ~ 0.51 mm

0.0079 ~ 0.0201 in.

0.9 mm

0.035 in.

615W2A3A

615W2A4A

(C) Cam gear side clearance

1. Pull the cam gear (2) with the camshaft (1) to its

end.

2. Measure the clearance A between the cam gear (2)

and the camshaft stopper (3).

3. If the clearance exceeds the allowable limit, replace

the camshaft stopper (3).

Side
clearance

Factory

spec.

Allowable

limit

0.07 ~ 0.22 mm

0.0028 ~ 0.0087 in.

0.3 mm

0.0118 in.

D615-W02 May-2003

(1) Idle Gear Collar 2 (3 ) Idle Gear Collar 1
(2) Idle Gear

615W2A5A

(1) Camshaft (3) Camshaft Stopper
(2) Cam Gear

2-51

CHAPTER 2 8354/8404

A

(D) Injection pump gear side clearance

1. Pull the fuel camshaft and pull the injection pump
gear (1) to each end.

2. Measure the clearance A between the injection pump
gear (1) and the snap ring (2) on the fuel camshaft.

3. If the clearance exceeds the allowable limit, check
the gear, the bearing and the key.

Side
clearance

Factory

spec.

Allowable

limit

0.15 ~ 0.57 mm

0.0059 ~ 0.0224 in.

0.9 mm

0.035 in.

(E) Idle gear oil clearance

1. Measure the idle gear shaft O.D. with an outside
micrometer.

2. Measure the idle gear bushings I.D. with an inside
micrometer.

3. If the clearance exceeds the allowable limit, replace
the bushing.

Oil
clearance

Shaft
O.D.

Bushing
I.D.

Factory

spec.

Allowable

limit

Factory

spec.

Factory

spec.

0.025 ~ 0.066 mm

0.00098 ~ 0.00259 in.

0.1 mm

0.004 in.

37.959 ~ 37.975 mm

1.4944 ~ 1.4950 in.

38.000 ~ 38.025 mm

1.4961 ~ 1.4970 in.

615W2A6A

(1) Injection Pump Gear (2) Snap Ring

615W2A7A

(F) Replacing idle gear bushings

1. Press out the bushings using an idle gear bushing
replacing tool.

2. Clean the bushings and the bore, and apply oil to
them.

3. Press in the bushing using the replacing tool.

615W2A8A

2-52

D615-W02 May-2003

(G)Camshaft oil clearance

1. Measure the I.D. of the camshaft bore on the crank-

case with an inside micrometer.

2. Measure the O.D. of the camshaft journal with an

outside micrometer.

3. If the clearance exceeds the allowable limit, replace

the shaft.

ENGINE SYSTEM

Oil
clearance

Journal
O.D.

Bore
I.D.

Factory

spec.

Allowable

limit

Factory

spec.

Factory

spec.

0.050 ~ 0.091mm

0.00197 ~ 0.00358 in.

0.15 mm

0.0059 in.

39.934 ~ 39.950 mm

1.57221 ~ 1.57284 in.

40.000 ~ 40.025 mm

1.57480 ~ 1.57579 in.

(H)Camshaft alignment

1. Support the camshaft with V blocks on the surface

plate at both end journals and set a dial indicator
with its tip on the intermediate journal.

2. Rotate the camshaft in the V block and get the ec-

centricity (half of the measurement).

3. If the eccentricity exceeds the allowable limit, re-

place the camshaft.

Eccentricity

Allowable

limit

0.05 mm

0.002 in.

615W2A9A

(I) Cam height

1. Measure the height of the camshaft lobes at their

largest. O.D. with an outside micrometer.

2. If the measurement is less than the allowable limit,

replace the camshaft.

Cam
height

3A165
4A200

(IN.)

(EX.)

Specification

Allowable

limit

Specification

Allowable

limit

33.59 mm

1.322 in.

33.54 mm

1.320 in.

33.69 mm

1.326 in.

33.64 mm

1.324 in.

615W2B0A

615W2B1A

D615-W02 May-2003

2-53

CHAPTER 2 8354/8404

3) Connecting rod and piston

(A) Piston pin bore

1. Measure the I.D. of piston pin bore in piston (length­wise and widthwise of the piston) with a cylinder
gauge.

2. If the measurement exceeds the allowable limit, re­place the piston.

Piston Pin
bore I.D.

Factory

spec.

Allowable

limit

25.000 ~ 25.006 mm

0.9843 ~ 0.9845 in.

25.03 mm

0.9854 in.

(B) Piston pin and brushing clearance

1. Measure the piston pin O.D. with an outside
micrometer.

2. Measure the piston pin busing I.D. with an inside
micrometer.

3. If the clearance exceeds the allowable limit with new
bushing, replace the piston pin.

Piston pin
and
bushing
clearance

Piston pin
O.D.

Bushing I.
D.

Factory

spec.

Allowable

limit

Factory

spec.

Factory

spec.

0.014 ~ 0.038 mm

0.00055 ~ 0.00150 in.

0.15 mm

0.0059 in.

25.002 ~ 25.011 mm

0.98433 ~ 0.98469 in.

25.025 ~ 25.040 mm

0.98524 ~ 0.98583 in.

615W2B2A

9

10

11

615W2B3A

(C)Replacing piston pin bushing

1. Press out the bushing, using a piston pin bushing
replacing tool.

2. Clean the new bushing and the bore and apply oil
to them.

3. Press in the bushing, using the replacing tool.

IMPORTANT:

• Align the oil holes of the connecting rod and the
bushing.

2-54

615W2B4A

D615-W02 May-2003

(D) Piston ring end gap

1. Push down the ring into the cylinder to the lower

limit of ring travel in the assembled engine with a
piston.

2. Measure the ring gap with a feeler gauge.

3. If the gap exceed the allowable limit, replace the

piston ring.

ENGINE SYSTEM

Piston
ring
end
gap

2nd
ring

Top

ring,

oil ring

Factory

spec.

Allowable

limit

Factory

spec.

Allowable

limit

0.55 ~ 0.70 mm

0.0217 ~ 0.0276 in.

1.25 mm

0.0492 in.

0.25 ~ 0.40 mm

0.0098 ~ 0.0157 in.

1.25 mm

0.0492 in.

(E) Piston ring clearance

1. Clean the ring and the ring grooves, and install each

ring in its groove.

2. Measure the clearance between the ring and the

groove with a feeler gauge.

3. If the clearance exceeds the allowable limit, replace

the piston ring.

4. If the clearance still exceeds the allowable limit with

the new ring, replace the piston.

Piston
ring
clear­ance

2nd
ring

Oil ring

Factory

spec.

Allowable

limit

Factory

spec.

Allowable

limit

0.04 ~ 0.08 mm

0.00157 ~ 0.00314 in.

0.15 mm

0.0059 in.

0.02 ~ 0.06 mm

0.00079 ~ 0.00236 in.

0.15 mm

0.0059 in.

615W2B5A

615W2B6A

D615-W02 May-2003

2-55

CHAPTER 2 8354/8404

(F) Connecting rod alignment

1. Remove the connecting rod bearing and install the
bearing cap.

2. Install the piston pin in the connecting rod.

3. Install the connecting rod on the connecting rod
alignment tool.

4. Put a gauge over the piston pin and move it against
the face plate.

5. If the gauge does not fit squarely against the face
plate, measure the space between the pin of the
gauge and the face plate.

6. If the measurement exceeds the allowable limit,
replace the connecting rod.

615W2B7A

Space between
gauge pin and
face plate

Allowable

limit

0.05 mm (0.0020 in.)
at 100 mm (3.94 in.)

of gauge pin span

4) Crankshaft

(A) Flywheel deflection and crankshaft end play

1. Set a dial indicator with its tip on the rear friction
face of the flywheel near the edge.

2. Turn the flywheel and measure the deflection or the
uneven wear.

3. If the measurement exceeds the allowable limit,
remove the flywheel and check the mating faces of
the crankshaft and flywheel.

4. If scored of worn excessively, regrind or replace the
flywheel.

5. Move the crankshaft with flywheel back and forth to
each end and measure the end play.

6. If the play exceeds the allowable limit, replace the
side bearing.

Deflection

End play

Allowable

limit

Factory

spec.

Allowable

limit

0.05 mm

0.0020 in.

0.15 ~ 0.31 mm

0.0059 ~ 0.0122 in.

0.5 mm

0.020 in.

615W2B8A

2-56

D615-W02 May-2003

(B) Crankshaft alignment

1. Support the crankshaft with V blocks on the surface

plate at its front and rear journals and set a dial
indicator with its tip on the intermediate journal.

2. Rotate the crankshaft in the V blocks and get the

misalignment (half of the measurement).

3. If the misalignment exceeds the allowable limit,

replace the crankshaft.

ENGINE SYSTEM

Misalignment

Allowable

limit

0.08 mm

0.0031 in.

(C) Crankshaft journal and bearing 1 oil clearance

1. Measure the I.D. of the crankshaft bearing 1 with an

inside micrometer.

2. Measure the O.D. of the crankshaft journal with an

outside micrometer.

3. If the clearance exceeds the allowable limit, replace

the bearing referring to Replacing Crankshaft Bear­ing 1.

Oil
clearance

Journal
O.D.

Bearing 1
I.D.

Factory

spec.

Allowable

limit

Allowable

limit

Allowable

limit

0.040 ~ 0.118 mm

0.00157 ~ 0.00465 in.

0.20 mm

0.0079 in.

51.921 ~ 51.940 mm

2.04413 ~ 2.04488 in.

51.980 ~ 52.039 mm

2.04646 ~ 20.4878 in.

615W2B9A

9

10

11

615W2C0A

(D)Replacing crankshaft bearing 1

1. Press out the crankshaft bearing 1 replacing tool.

2. Clean a new crankshaft bearing 1 and bore, and

apply engine oil to them.

3. Press fit a new bearing 1 using a inserting tool,

taking due care to see that the seam of bearing 1
faces the exhaust manifold side.

D615-W02 May-2003

615W2C1A

(1) Seam

2-57

CHAPTER 2 8354/8404

(E) Crankshaft journal and bearing 2 oil clearance

1. Put plastic gauge lengthwise in the center of the
journal.

2. Install the bearing cap and tighten the screw to the
specified torque once, and remove the cap again.

3. Measure the amount of the flattening with the scale
and get the oil clearance.

4. If the clearance exceeds the allowable limit, replace
replace the bearing.

Oil
clearance

Journal
O.D.

Bearing 2
I.D.

(F) Crank pin and connecting rod bearing 2 oil clear-

ance

1. Put a strip of Plastigage lengthwise in the center of
the crank pin.

2. Install the connecting rod and tighten the screws to
the specified torque once, and remove the cap again.

3. Measure the amount of the flattening with the scale
and get the oil clearance.

4. If the clearance exceeds the allowable limit, replace
the bearing.

Factory

spec.

Allowable

limit

Allowable

limit

Factory

spec

0.040 ~ 0.104 mm

0.00157 ~ 0.00409 in.

0.20 mm

0.0079 in.

51.921 ~ 51.940 mm

2.04413 ~ 2.04488 in.

51.980 ~ 52.025 mm

2.04646 ~ 2.04823 in.

Oil
clearance

Journal
O.D.

Bearing 1
I.D.

Factory

spec.

Allowable

limit

Factory

spec.

Factory

spec.

0.025 ~ 0.087 mm

0.00098 ~ 0.00343 in.

0.20 mm

0.0079 in.

46.959 ~ 46.975 mm

1.84878 ~ 1.84941 in.

47.000 ~ 47.046 mm

1.85040 ~ 1.85221 in.

615W2C2A

2-58

D615-W02 May-2003

5) Cylinder bore

(A) Cylinder bore diameter

1. Measure the cylinder liner I.D. at sit positions shown

in the figure to find the maximum wear.

ENGINE SYSTEM

4A200B

3A165D

83.000 ~ 83.022 mm

3.2677 ~ 3.269 in.

87.000 ~ 87.022 mm

3.425 ~ 3.4261 in.

615W2C3A

615W2C4A

(A) Axial Direction
(B) Transverse Direction

1,2,3 Measuring Points

D615-W02 May-2003

2-59

CHAPTER 2 8354/8404

D. LUBRICA TING SYSTEM

a. Checking

(A) Engine oil pressure

1. Remove the oil pressure switch and install adap­tors and pressure tester.

2. Start the engine and run it until it is warmed up, and
measure the oil pressure both at idling and rated
speed.

3. If the oil pressure is less than the allowable limit,
check the amount of oil, oil filter, oil pump relief
valve, oil passages and oil clearance.

Engine
oil pres-

sure

(Reference)

Tightening
torque

(B)Oil filter and relief valve

1. Drain the engine oil and remove the oil filter to check it.

2. Check the relief valve for dirt, and the seat (2) and
ball (1) for damage.

3. If damaged, replace.

4. Check the free length of spring (3).

5. If it is less than the allowable limit, replace it.

At idle

speed

At rated

speed

pressure

Factory

Factory

Allowable

Oil

switch

spec.

spec.

limit

more than 49 kPa

0.5 kgf/cm²

7.11 psi

294 ~ 441 kPa

2.5 ~ 4.5 kgf/cm²

35.6 ~ 64.0 psi
245 kPa

2.5 kgf/cm²

35.6 psi

14.7 ~ 19.6 N·m

1.5 ~ 2.0 kgf·m

10.8 ~ 14.5 lbf·ft

615W2C5A

Spring free
length

Factory

spec

Allowable

limit

35 mm

1.38 in.
30 mm

1.18 in.

NOTE:

• Install the relief valve cover with the mark up.
Tightening

torque

Relief

cover

32.4 ~ 36.3 N·m

3.3 ~ 3.7 kgf·m

23.9 ~ 36.8 lbf·ft

2-60

615W2C6A

(1) Relief Valve Ball (3 ) Relief Valve Spring
(2) Relief Valve Seat

D615-W02 May-2003

b. Servicing

(A) Rotor and lobe clearance of oil pump

1. Measure the clearance between the outer and in­ner rotor with a feeler gauge.

2. Measure the clearance between the outer and the
housing with a feeler gauge.

3. If the clearance exceeds the allowable limit, replace
the pump.

ENGINE SYSTEM

Outer and
inner rotor
clearance

Outer and
inner
housing
clearance

Factory

spec.

Allowable

limit

Factory

spec.

Allowable

limit

0.10 ~ 0.16 mm

0.0039 ~ 0.0063 in.

0.20 mm

0.0079 in.

0.11 ~ 0.19 mm

0.0043 ~ 0.0075 in.

0.25 mm

0.0098 in.

(B) Rotor end clearance of oil pump

1. Put a strip of plastigage on the rotor and assemble
the pump.

2. Disassemble the pump and measure the amount
of the flattening with the scale to get the clearance.

3. If the clearance exceeds the allowable limit, replace
the pump.

615W2C7A

615W2C8A

End
clearance

Factory

spec.

Allowable

limit

D615-W02 May-2003

0.105 ~ 0.150 mm

0.00423 ~ 0.00591 in.

0.20 mm

0.0079 in.

615W2C9A

2-61

CHAPTER 2 8354/8404

E. COOLING SYSTEM

a. Checking Adjusting

(A)Fan belt

1. Measure the deflection, depressing the belt half­way between the fan drive pulley and the alternator
pulley at 98 N (10 kgf, 22 lbs) of force.

2. If the deflection is not between the factory specifica­tions, loosen the bolts and nuts, and relocate the
alternator to adjust.

3. If the belt is damaged or worn (See figure), replace
the belt.

Belt
tension
(direction)

Factory

spec

at 98 N (10 kgf, 22 lbs)

7 ~ 9mm

0.28 ~ 0.35 in.

of force

(B) Radiator water tightness

1. Fill radiator with water to the specified amount and
warm up the engine.

2. Set a radiator tester and raise the water pressure to
the specified pressure.

3. Check the radiator for water leaks.

4. For water leak from the pin hole, repair with a radia­tor cement, and for other leaks, replace the radiator.

Radiator
water
tightness

Factory

spec

No leaks at 137 kPa

(1.4 kgf/cm², 20 psi)

(C)Radiator cap tightness

1. Set a radiator tester on the radiator cap.

2. Apply 88 kPa (0.9 kgf/cm², 13 psi) of pressure and
measure the pressure for 10 seconds.

3. If the pressure falls below 59 kPa (0.6 kgf/cm², 9 psi),
replace the radiator cap.

615W2D0A

643W2D1A

615W2D1A

Radiator
cap
tightness

2-62

Factory

spec

More than 10 seconds

for pressure fall

from 88 ~ 59 kPa

(0.9 ~ 0.6 kgf/cm², 13 ~ 9 psi)

615W2D2A

D615-W02 May-2003

b. Disassembling and Assembling

(A)Thermostat

1. Remove the thermostat cover (2).

2. Take out the thermostat (1).

(When reassembling)

• Apply liquid gasket (Three Bond 1215 or equivalent)

to the gasket.

(B) Water pump

1. Remove the fan and fan pulley.

2. Remove the water pump body from the gear case

cover.

3. Remove the water pump flange (1).

4. Remove the impeller and water pump shaft (3).

5. Remove the impeller from the water pump shaft.

6. Remove the mechanical seal (5).

ENGINE SYSTEM

615W2D3A

(1) Thermostat ( 2) Thermostat Cover

(When reassembling)

• Replace the mechanical seal (5) with new one.

c. Servicing

(A) Thermostat valve opening temperature

1. Suspend the thermostat in the water by a string with

its end inserted between the valve and seat.

2. Heating the water gradually, read the temperatures

when the valve open and leave the string and when
the valve opens approx. 8 mm (0.315 in.)

3. If the measurements are not within the factory speci-

fications, replace the thermostat.

Opening
temperature

Factory

spec.

71 ± 1.5 °C

(160 ± 3 °F)

at beginning

Lower than 85 °C (185 °F)

At 8 mm (0.315 in.)

Of opening

615W2D4A

(1) Water Pump Flange (4) Water Pump Body
(2) Water Pump Bearing (5) Mechanical Seal
(3) Water Pump Shaft (6) Impeller

615W2D5A

D615-W02 May-2003

2-63

CHAPTER 2 8354/8404

F. FUEL SYSTEM

a. Checking and Adjusting

1) Injection pump

(A) Injection term (Injection timing)

1. Remove the injection pipes.

2. Set the speed control lever to the maximum fuel
discharge position.

3. Turn the flywheel counterclockwise (facing the
flywheel) until the fuel flow through to the hole of the
delivery valve holder (1).

4. Turn the flywheel further and stop turning when the
fuel stop to flow, to check the injection timing.

5. If the Fl mark does not align with the mark of the
window on flywheel housing, add or remove the
shim (2) to adjust.

615W2D6A

(1) Delivery Valve Holder (2) Shim

Injection
timing

3A165D, 4A200B,

0.31 rad, 18 °
before T.D.C

NOTE:

• Apply liquid gasket (There Bond 1215 or equivalent)
to the shim, when reassembling.

(Reference)

• The timing advances by removing 0.15 mm
(0.006 in) of shim and retards by adding one, approx

0.26 rad (1.5 °) of crank angle.

• Approx 3.6 mm (0.142 in.) of turn at the outer rim of
the flywheel equals 0.26 rad (1.5 °) of crank angle.

(B)Delivery valve fuel tightness

1. Remove the injection pipes, glow plugs and the in­let manifold, and install the pressure tester.

2. With the speed control lever at the fuel injection
position, turn the crankshaft counterclockwise (fac­ing the flywheel) until the pressure builds up to the
fuel injection pressure.

3. Release the pressure in the delivery chamber by
moving down the plunger to bottom dead center
(turn the crankshaft clockwise approx. 1.57 rad
(90 °) from the FI timing).

4. If the pressure drop for 5 seconds exceeds the al­lowable limit, replace the delivery valve or pump
assembly.

5. If the pressure does not built up, replace the pump
element with new one and test again.

615W2D7A

Fuel
Injection
pressure

Pressure
drop

2-64

Factory

spec.

Allowable

limit

14.71 MPa

150 kgf/cm²

2134 psi

0.98 MPa

10 kgf/cm²

142 psi

D615-W02 May-2003

b. Injection nozzle

• Never contact with spraying diesel fuel
under pressure, pressure, which can
have sufficient force to penetrate the

CAUTION

skin, causing serious personal injury.

• Be sure nobody is in direction of the
spray.

(A) Fuel injection pressure

1. Set the injection nozzle to the nozzle tester.

2. Measure the injection pressure.

3. If the measurement is not within the factory specifi­cations, adjust with the adjustment washer (1) in­side the nozzle holder.

(Reference)

• Pressure variation with 0.1 mm (0.004 in.) difference
of adjusting washer thickness is approx. 10 kgf/cm².

ENGINE SYSTEM

Fuel
injection
pressure

Factory

spec.

13.73 ~ 14.71 MPa
140 ~ 150 kgf/cm²

1991 ~ 2134 psi

(B) Fuel tightness of needle valve seat tightness

1. Set the injection nozzle to the nozzle tester.

2. Apply a pressure 130 kgf/cm² (12.75 MPa, 1849 psi).
After keeping the nozzle under this pressure for 10
seconds. Check to see if fuel leaks from the nozzle.

3. If the fuel should leak, replace the nozzle.

615W2D8A

(1) Adjustment Washer

615W2D9A

D615-W02 May-2003

2-65

CHAPTER 2 8354/8404

c. Disassembling and Assembling

1) Injection pump

IMPORTANT:

• If replacing the pump element, the amount of fuel
injection should be adjusted on specified bench.

615W2E0A

(1) Pump Body (5) Delivery Valve
(2) Control Rack (6) Tappet Roller
(3) Delivery Valve Holder (7) Cylinder
(4) Delivery Valve Spring (8) Plunger

2) Injection nozzle

(A) Nozzle holder

1. Secure the nozzle retaining nut (7) with a vise.

2. Remove the nozzle holder (1), and take out parts
inside.

(When reassembling)

• Assemble the nozzle in clean fuel oil.

• Install the push rod (4), nothing its direction.

615W2E1A

(1) Nozzle Holder (5) Distance Piece
(2) Adjusting Washer (6) Nozzle
(3) Nozzle Spring ( 7) Nozzle Nut
(4) Push Rod

2-66

D615-W02 May-2003

CHAPTER 3

CLUTCH

1. DISASSEMBLY AND ASSEMBL Y

1.1 DISASSEMBLY OF PANEL FRAME

A . FIRST ST AGE

CLUTCH

(1) Side Cover (Left, Right)
(2) Bonnet

1. Disassemble side cover (1), bonnet (2), front grill assembly (3) and cover-low (4).

D615-W02 May-2003

(3) Front Grill Assembly
(4) Cover-Low (Left, Right)

615W301A

3-3

CHAPTER 3 8354/8404

B. SECOND STAGE

615W302A 615W303A 615W304A

(1) Steering Hose Assembly T
(2) Steering Hose Assembly P
(3) Steering Hose Assembly L
(4) Steering Hose Assembly R
(5) Frame Cover
(6) Parallel Pin

1. Disassemble power steering unit connection hoses
(1), (2), (3) and (4).

2. Remove frame cover (5) in left bottom of frame as­sembly and then parallel pin (6) for connecting
shuttle lever.

3. Disconnect accelerator cable (7) and indicator
cable (8).

4. Disconnect panel wiring harness assembly (9) and
fender wiring harness assembly (10).

5. Disconnect clutch rod (11).

(7) Accelerator Cable
(8) Indicator Cable
(9) Panel Wiring Harness Assembly

(10) Fender Wiring Harness Assembly

(11) Clutch Rod

3-4

615W305A

D615-W02 May-2003

C. THIRD STAGE

1. Disengage attaching bolt (2) of frame assembly (1).

2. Disassembly frame assembly.

(When reassembling)

• When connecting with power steering unit hoses

(1), (2), (3) and (4) make sure hose color and con­necting port to be assembled properly.

CLUTCH

615W306A

(1) Frame Assembly
(2) Bolt

Connecting Port

T
P
R

L

Steering hose assembly T (Green)
Steering hose assembly P (Red)
Steering hose assembly R (White)
Steering hose assembly L (Yellow)

Hose Type

• When connecting power steering unit hose, see the
specified torque.

Hose connecting nut
tightening torque

46.6 ~ 58.9 N·m

4.8 ~ 5.2 kgf·m

18.1 ~ 21.7 lbf·ft

615W307A

(1) Steering Hose Assembly T
(2) Steering Hose Assembly P
(3) Steering Hose Assembly R
(4) Steering Hose Assembly L

D615-W02 May-2003

3-5

CHAPTER 3 8354/8404

1.2 DISASSEMBLY OF FENDER AND STEPLADDER ASSEMBLY

A . FIRST ST AGE

(1) ROPS
(2) Seat Assembly
(3) Main Shift Knob
(4) Knob (Range Lever)
(5) Knob (Position Control Lever)
(6) Knob (External Hydraulic Lever)
(7) Knob (Front Wheel Lever)
(8) Transmission Shift Lever Guide
(9) Hydraulic Lever Guide

3-6

615W308A

(10) Seat Lower Assembly

(11) Differential Clamping Rod
(12) Spring
(13) Rear Light
(14) Work Light
(15) Stepladder Assembly
(16) Bolt
(17) Bolt

D615-W02 May-2003

CLUTCH

1. Disconnect ROPS (1).

2. Disconnect seat assembly (2).

3. Disconnect knobs (3), (4), (5), (6) and (7) of each
transmission shift lever.

4. Disconnect transmission shift lever guide (8) and
hydraulic lever guide (9).

5. Disconnect differential clamping rod (11) and the
spring (12) from lower seat assembly (10).

6. Disconnect the wiring connector from rear fender
light (13) and work light (14).

7. Loosen locking bolts (16) and (17) from the step­ladder assembly (15) and seat lower assembly (10).

B. SECOND STAGE

1. Disassembly fender and stepladder assembly in a
whole.

(When reassembling)

Sect.

Stepladder assembly
and seat lower
assembly locking nut

ROPS locking bolt, nut

Spec.

M16

M14

M12

Tightening Torque

196 ~ 225 N·m

20.0 ~ 23.0 kgf·m
145 ~ 166 lbf·ft

166.7 ~ 196.1 N·m

17.0 ~ 20.0 kgf·m
123 ~ 144 lbf·ft

77.5 ~ 90.2 N·m

7.9 ~ 9.2 kgf·m

57.1 ~ 66.5 lbf·ft

D615-W02 May-2003

615W309A

3-7

CHAPTER 3 8354/8404

2. CLUTCH

2.1 CHARACTERISTICS

615W310A

(1) Clutch Disc Assembly
(2) Clutch Cover Assembly
(3) Release Bearing
(4) Clutch Release Hub

• Independent PTO method clutch are adapted enable to control the power of Running and the PTO system
independently.

• Running Clutch: Is a dry single plate clutch. Depress clutch pedal to disconnect power of running system.

• PTO Clutch: Is a wet multi plate clutch. Control the PTO switch to connect and disconnect power of the PTO.

(5) Clutch Release Fork
(6) Propulsion Shaft Case
(7) Main Clutch Lever

3-8

D615-W02 May-2003

2.2 LINK STRUCTURE AND CONTROL

• If working clutch pedal, clutch rod (2) is pulled in the

direction of arrow and release hub (5) moves to the
direction of arrow through release fork (4).

• Release bearing (6) of release hub pushes dia-

phragm spring (8) of clutch cover assembly (7), re­leases clutch disc (10) between clutch pressure
plate (9) and flywheel (11), and then disconnects
power from engine.

CLUTCH

(1) Clutch Pedal
(2) Clutch Rod
(3) Main Clutch Lever
(4) Clutch Release Fork
(5) Clutch Release Hub
(6) Release Bearing
(7) Clutch Cover Assembly
(8) Diaphragm Spring

(9) Pressure Plate
(10) Clutch Disc
(11) Flywheel

615W320A

D615-W02 May-2003

3-9

CHAPTER 3 8354/8404

2.3 TROUBLESHOOTING

Trouble

Clutch trailed

Clutch slip

Bumping noise

Crashing noise

Crashing noise

Vibration

Probable Cause

• Clutch pedal play excessive

• Clutch disk dirty due to clutch disc
assembly

• Clutch fork broken

• Clutch disc or pressure plate distorted

• Diaphragm spring of Pressure Plate
worn or broken

• Clutch pedal play too small

• Clutch disc worn excessively

• Grease or oil on clutch disc

• Clutch disc or pressure plate distorted

• Diaphragm spring weaken or broken

• Grease or oil on clutch disc

• Clutch disc or pressure plate bent

• Clutch disc boss worn or dusty

• Gear shaft bent

• Pressure plate or flywheel cracked or
scratched

• Clutch disc spline boss or gear shaft
spline worn

• Diaphragm spring not operating
constantly or broken

• Clutch disc spline boss worn

• Thrust ball bearing worn or sticking

• Thrust ball bearing sticking or dry

• Clutch disc worn excessively

• Gear shaft bent

• Clutch disc rivet worn or broken

• Clutch parts broken

Remedy Remark

Adjust

Clean

Replace
Replace

Replay pressure

Plate assembly

Adjust
Replace
Replace
Replace

Replace pressure

Plate assembly

Replace
Replace

Replace or clean

Replace
Replace

Replace

Replace
Replace

Replace
Replace

Replace or lubricate

Replace
Replace

Replace
Replace

3-10

D615-W02 May-2003

2.4 SPECIFICATION

CLUTCH

Item

Clutch pedal

Stopper bolt setting length

Clearance between safety switch
and clutch pedal

Depth from disc to the top of rivet

Play of clutch disc O.D.

Pressure plate

Diaphragm spring

2.5 TIGHTENING TORQUE

Item

Clutch pedal

Stopper bolt setting length

Clearance between safety switch
and clutch pedal

Depth from disc to the top of rivet

Play of clutch disc O.D.

Pressure plate

Diaphragm spring

Play

Height

Gap

Depth

Displacement

Flatness

Difference

Play

Height

Gap

Depth

Displacement

Flatness

Difference

Reference

30 ~ 40 mm

1.18 ~ 1.57 in.
27 ~ 29 mm

1.06 ~ 1.14 in.

3 ~ 4 mm

0.12 ~ 0.16 in.

-

-

-

-

Reference

30 ~ 40 mm

1.18 ~ 1.57 in.
27 ~ 29 mm

1.06 ~ 1.14 in.

3 ~ 4 mm

0.12 ~ 0.16 in.

-

-

-

-

Allowable Limit

-

-

-

0.3 mm

0.012 in.

2.0 mm

0.079 in.

0.2 mm

0.008 in.

0.5 mm

0.020 in.

Allowable Limit

-

-

-

0.3 mm

0.012 in.

2.0 mm

0.079 in.

0.2 mm

0.008 in.

0.5 mm

0.020 in.

D615-W02 May-2003

3-11

CHAPTER 3 8354/8404

2.6 DISASSEMBLY, MAINTENANCE

A . CLUTCH PEDAL CHECK AND ADJUST-

MENT

a. First Stage (Clutch Pedal Play Adjustment)

1. Press clutch pedal (1) by hand and measure play
(A) at the end of pedal.

2. If measurement exceeds the specified, loosen lock
nut (3) of clutch rod (2), re-adjust the length of clutch
rod, set pedal play and then tighten with lock nut.

Sect

Play of clutch pedal (A)

Specified

30 ~ 40 mm

1.18 ~ 0.57 in.

b. Second Stage (Adjustment of Clutch Pedal

Stopper Bolt)

1. When working clutch pedal when clutch is
disconnected, avoid bolt setting to prevent exces­sive force to clutch.

2. If setting (A) of stopper bolt exceeds the specified,
loosen lock nut (2), readjust the length, and then
set with lock nut.

Sect

Stopper bolt setting
length (A)

Specified

27 ~ 29 mm

1.06 ~ 1.14 in.

615W321A

(1) Clutch Pedal (2) Clutch Rod

(3) Lock Nut

615W322A

(1) Stopper Bolt (2 ) Lock Nut

c. Third Stage (Adjustment of Safety Switch)

1. Measure clearance (A) of safety switch (1) and clutch
pedal (2).

2. If the measured value exceeds the specified, loosen
safety switch lock nut (3).

Readjust and then lock not to be loosen.

Sect

Clearance of safety switch
and clutch pedal (A)

• Without working of clutch pedal, start

motor should not be prerated.

Specified
3 ~ 4 mm

0.12 ~ 0.16 in.

CAUTION

3-12

615W323A

(1) Safety Switch (2) Clutch Pedal
(3) Lock Nut

D615-W02 May-2003