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
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