Aufsitzmäher_Baron 4WD_Hydraulic Service Manual by Walker Vertriebs AG

Tuff Torq KXH FRONT AXLE SERVICE MANUAL

Assembly & Inspection

---- GENERAL ---

Apply grease.

Notes: - Be sure not to damage machined surface of each part. - Pay close attention to HST parts. - Be sure that slit direction in spring pins is 90º to shaft when installing. - Apply grease whenever seals and o-rings are installed - Take care not to damage lip area of oil seal.

1) Assembly of MOTOR COVER ASSY Assembly of JOINT PIPE (built-in parts) - JOINT PIPE - PACKING 19015 - RING, BACK-UP 18 1.

× 2 × 6 × 4

Install RING, BACK-UP 18 and PACKING 19015 on JOINT PIPE.

Note: - Coat PACKING with a small amount of grease.

Assembly of CONNECTING BLOCK (built-in parts) - CONNECTING BLOCK - JOINT PIPE

×1 × 2

1. Insert JOINT PIPE into CONNECTING BLOCK. Note: - Coat PIPE surface with a small amount of grease. - Be careful not to damage RING and PACKING when installin g JOINT PIPE.

Assembly of CONNECTING BLOCK to MOTOR COVER (built-in parts) - MOTOR COVER - CONNECTING BLOCK - BOLT M8 × 65 1.

× 1 × 1 × 1

Install MOTOR COVER CONNECTING BLOCK and tighten with BOLT 8 × 65.

Note: - Coat PIPE surface with a small amount of grease. Tightening Torque – 23 Nm ~ 30 N·m

Assembly of SEAL TC162607 (built-in parts) - MOTOR COVER - SEAL, TC162607 1.

× 1 × 2

Insert SEAL TC162607 into MOTOR COVER.

Note: - Coat SEAL lip with grease.

Assembly of FULCRUM (built-in parts) - FULCRUM - WASHER, 12 - NUT, 12 - PACKING, P14 - MOTOR COVER

× 1 × 1 × 1 × 2 × 1

Install two PACKING P14 on MOTOR COVER.

Apply grease

Note: - Coat PACKING with a small amount of grease. - Insert FULCRUM into MOTOR COVER.

- Install WASHER 12 and NUT 12. Note: - Tighten NUT by hand for temporary fix, because adjustment will be necessary later.

Apply grease

Assembly of CAM LEVER (built-in parts) - CAM LEVER - RING, 16 - MOTOR COVER 1.

×1 ×1 ×1

Insert CAM LEVER into MOTOR COVER through SEAL.

Note: - Coat small amount of grease around seal lip area. 2.

Fasten with RING 16.

Assembly of CONTROL ARM (built-in parts) - CONTROL ARM - CONTROL SHAFT - PIN 6.0A × 25 - RETURN SPRING 1.

× 1 × 1 × 1 × 1

Insert CONTROL SHAFT into CONTROL ARM.

Note: - Pay attention to SHAFT direction. Long end

Short en

Drive PIN into CONTROL ARM.

Note: - Be alert to orientation of slit in PIN. Slit must be 90º of SHAFT.

Assembly of CONTROL ARM and RETURN SPRING to MOTOR COVER (built-in parts) - CONTROL ARM - RETURN SPRING - MOTOR COVER 1.

× 1 × 1 × 1

Place SPRING onto CONTROL ARM.

2. Install CONTROL ARM on MOTOR COVER. Note: - Coat CONTROL SHAFT with a small amount of grease.

Spring Stopper

- Hook SPRING on MOTOR COVER with flat head screw driver and tap the CONTROL SHAFT with soft hammer. (Do not tap the squared boss!) Install SPRING onto MOTOR COVER with flat head screw drive

Contact betwee

Assembly of CONTROL LEVER (built-in parts) - CONTROL LEVER - PIN 6.0A × 32 - ADJUST PLATE - WASHER, 8 - BOLT 8 × 25 - MOTOR COVER (CONTROL SHAFT) 1.

n CONTROL ARM

× 1 × 1 × 1 × 2 × 2 × 1

and FULCRUM.

INSERT CONTROL LEVER into CONTROL SHAFT.

2. Tap PIN into CONTROL LEVER. Note: - Be alert to orientation of slit in PIN.

Installing ADJUST PLATE to CONTROL LEVER. (built-in parts) - ADJUST PLATE - BOLT, 8 × 25 - WASHER, 8 - NUT, 8

× 1 × 2 × 2 × 2

1. Assemble ADJUST PLATE with BOLTS & NUTS. Slit must be

Note: - Be careful of direction of ADJUST PLATE.

90º to SHAF

- Hand tighten BOLTS and NUTS, because adjustment will be necessary later.

Hand tighten BOLTS & NUT

2.) MOTOR KIT ASSEMBLY Assembly of CENTER CASE CMP (built-in parts) - CHECK VALVE CMP - COLLAR - CENTER CASE - STRAINER

× 1 × 1 × 1 × 1

Install COLLAR, STRAINER, and HECK VALVE CMP into CENTER CASE. Note: - Pay attention to direction of STRAINER.

Assembly of CYLINDER BLOCK ASSY CYLNDER (built-in parts) - PISTON - PISTON SPRING - SPRING RETAINER - CYLINDER BLOCK 1.

× 10 × 10 × 10 × 2

Install RETAINER, SPRING into PISTON.

2. Install the PISTON CMP into BLOCK. Note: - Apply a film of oil on PISTON surface. - Make sure that RETAINER and SPRING are placed in the PISTON during installation.

Assembly of MOTOR SHAFT (built-in parts) - MOTOR SHAFT - BEARING 6001 C3 - SPRING 12

× 2 × 2 × 2

1. Insert MOTOR SHAFT into BEARING 6001. Note: - Tap innner ring of BEARING straight ahead. (Do not tap outer ring!) 2. Fasten with RING 12 onto MOTOR SHAFT. Note: - Make sure the RING is completely seated in the groove. 7

Note direction of STRAINE

Assembly of SWASH SUPPORT R (built-in parts) - MOTOR SHAFT - SWASH SUPPORT R - RING 28 - THRUST METAL

× 1 × 1 × 1 × 2

1. Insert MOTOR SHAFT with BEARING into SWASH SUPPORT R. Note: - No need to use hammer. 2. Fasten with RING 28 onto SWASH SUPPORT R. Note: - Make sure the RING is seated completely in the groove. 3. Put METAL, THRUST on SWASH SUPPORT R. Note: - Apply grease on the back surface of the THRUST.METALS (To keep them in place.)

Apply a film of oil on PISTON surface

- Make sure THRUST METALS are seated on the pins. (Be careful, there are many chances for the METALS to slip from the pins during installation.)

Assembly of SWASH PLATE (built-in parts) - SWASH PLATE - BEARING, 51106

× 1 × 1 Tap inner rac

1. Install BEARING unit, 51106 into SWASH PLATE. Note: - Be careful of direction for each. A: PLATE (larger I.D.) … Bottom B: BALL, RETANER … Mid C: PLATE (smaller I.D.) … Top

Fasten by placin g

Fasten by seating RING in groove, completel 8

Assembly of SWASH SUPPORT R, SWASH PLATE and CYLINDER BLOCK ASSY. (built-in parts) - SWASH SUPPORT R × 1 - SWASH PLATE × 1 - CYLINDER BLOCK ASSY. × 1 1. Put SWASH PLATE on SWASH SUPPORT R. Note: - Make sure that there is no gap between METAL and SWASH SUPPORT R. Place on Coat back surface of THRUST METAL S with grease 2.

Install CYLINDER BLOCK ASSY to SWASH SUPPORT R.

Note: - Apply oil to contact surfaces of PISTONs and BEARING. - After assembly confirm that PISTONS and BEARING did not fall out of position.. Assembly of SWASH SUPPORT L (built-in parts) - MOTOR SHAFT × 1 - SWASH SUPPORT L × 1 - RING 28 × 1 × 1 - BEARING, 51106 × 1 1.

A is not th e C

B C

Insert MOTOR SHAFT with BEARING into SWASH SUPPORT L.

Note: - No need to use hammer.

C PLATE must be on to p.

Confirm that THRUST METAL S

Fasten with RING 12 onto MOTOR SHAFT.

Note: - Make sure the RING is positioned completely in the groove.

Apply oil

Apply oil.

3. Install BEARING 51106 in SWASH SUPPORT L. Note: - Be careful of direction for each. PLATE (larger I.D.) … Bottom BALL, RETANER … Mid PLATE (smaller I.D.) … Top Loose fittin

Fasten by placing

Assembly of SWASH SUPPORT L and CYLINDER BLOCK ASSY. (built-in parts) - SWASH SUPPORT - BLOCK ASSY, CYLINDER

× 1 × 1

RING completely in groove.

4. Install BLOCK ASSY CYLINDER to SWASH SUPPORT L. Note: - Apply oil around piston surface and BEARING surface.

A is not the same as C.

- Make sure no gap between PLATE and BALL RETANER. Assembly of CENTER CASE ASSY to MOTOR COVER. (built-in parts) - SWASH SUPPORT R × 1 - SWASH SUPPORT L × 1 - CENTER CASE CMP × 1 - MOTOR COVER × 1 - PIN 10 × 13 × 4 - PIN 10 × 18 × 2 - PACKING, S10 × 2 - BOLT (M8 × 90) × 4 - BOLT (M8 × 85) × 1 - BOLT (M8 × 100) × 1

“PLATE C” (without I.D. o n surface) must be located

1. Put PACKING, S10 (2 pcs.) onto MOTOR COVER. Note: - Coat PACKING with a small amount of grease to prevent it from falling out of position.

- Insert PIN 10 × 18 (2 pcs.) into CENTER CASE CMP.

Apply oil

2. Install CENTER CASE CMP to MOTOR COVER and slightly tighten with BOLT (M8 × 85) and BOLT (M8 × 100) Note: - Make sure of CENTER CASE CMP direction. - Be sure that PACKING S10 stays in the hole during installation.

L Coat surface with grease.

Grasp MOTOR COVER with vice or equivalent tool.

4. Insert PIN 10 × 13 (4 pcs.) into MOTOR COVER. Note: - Coat Pin surfaces with a small amount of grease before installing to assist in retaining them in place.

Note the directio n

BOLT (M8 × 8

Assemble SWASH SUPPORT R with CYLINDER BLOCK ASSY to MOTOR COVER.

Note: - Apply OIL to the contact surface of CYLINDER BLOCK and CENTER CASE.

Maintain some clearanc

BOLT (M8 × 10

- While aligning MOTOR SHAFT to hole in CENTER CASE take precautions not to damage contact surface.

Coat PINS with greas

- Grasp CENTER CASE CMP and SWASH SUPPORT R with both hands. - Press more after shaft end is aligned with hole in CENTER CASE.

- Slide SWASH SUPPORT R over (Locator) PIN 10 × 13 while aligning SWASH PLATE with square boss of CONTROL ARM.

Apply oi

Align PIN 10×13 on MOTOR COVER into bolt holes of SWASH SUPPORT R.

- Secure with BOLT 8 X 90 (2 pcs.) and hand tighten.. Make sure that there is no ga p between THRUST METAL and

6. Assemble SWASH SUPPORT L and CYLINDER BLOCK ASSY to MOTOR COVER. Note: - Apply oil to the contact surface of CYLINDER BLOCK and CENTER CASE.

Insert SWASH PLAT E onto square boss of CONTROL ARM.

- Grasp CENTER CASE CMP and SWASH SUPPORT L with both hands. Locator Pi

- Press more when shaft end is aligned to hole in CENTER CASE. BOLT 8 × 9

(Do not damage contacting surface during installation!)

Maintain even clearanc

Apply oil.

- Slide SWASH SUPPORT L over (Locator) PIN 10 × 13..

- Secure SWASH SUPPORT L with BOLT 8 × 90 (2 pcs.) and hand tighten..

Apply oi

7. Press SWASH SUPPORTs and CENTER CASE evenly as much as possible with both hands before tightening bolts. 8.

Tighten SWASH SUPPORT L & R and CENTER CASE CMP with BOLTs by turns in small steps.

Note: BOLT(×4) for SWASH SUPPORT L, R BOLT(×2) for CENTER CASE through CONNECTING BLOCK. TIGHTENING TORQUE - 23 ~ 30 N·m BOLT 8 × 9

Locator Pins

9. Confirm that CYLINDER BLOCKs can rotate smoothly, by hand, after tightening bolts.

Press evenly

Assembly of FRONT AXLE CASE ASSY (built-in parts) - GASKET (COVER) × 1 - MOTOR KIT × 1 - FRONT AXLE CASE × 1 - BOLT, M10 × 30 × 9 - OIL CAP, M20 × 1 - BEND, SUCTION × 1 - PACKING, P18 × 1 - PACKING, P14 × 1 - BOLT, 8 × 20 × 1 - PIN, 10 × 18 × 3

Maintain even clearanc

1. Place GASKET (COVER) on FRONT AXLE CASE. Note: - Coat small amount of grease to retain the position.

Insert PIN 10 × 18 into SWASH SUPPORT L, R and CENTER CASE CMP.

Rotate CYLINDER BLOCKs by hand to assure correct assembly.

3. Assemble MOTOR KIT to FRONT AXLE CASE. Note: - Install COVER evenly between MOTOR KIT and FRONT AXLE CASE.

GASKET (COVER)

4. Tighten with (9) BOLTs (M10 × 30). Note: - Make sure to align holes of GASKET with holes in casting before insert bolts. TIGHTENING TORQUE 44 ~ 60 N·m

Position gasket (cover) evenly.

5. Insert PACKING P18 onto OIL CAP M20 and install it in Port of FRONT AXLE CASE. Note: - Coat PACKING P18 with a small amount of grease. - OIL CAP TIGHTENING TORQUE 8 ~ 13 N·m – HAND TIGHT

6. Insert PACKING P14 into BEND, SUCTION and install it to FRONT AXLE CASE with BOLT 8 × 20. Note: - Coat PACKING P14 with a small amount of grease. - BOLT TIGHTENING TORQUE 23 ~ 30 N·m

- Finish -

---- GENERAL ---

Notes: - Make sure not to damage machined surface of each part. - Make sure that slit direction is 90 degree to shaft whenev er split pins are installed. - Apply grease to lips of oil seals and packings before installation. - Avoid damage to lip area of oil seals.

Install RING 24 completely in groov

1.) Assembly of SPINDLE ASSY 1 set for LH side, 1 set for RH side. (Built-in parts) - FRONT AXLE SHAFT ×2 - FINAL GEAR 51T ×2 - FRONT BEARING COVER ×2 - BEARING 6004 C3 ×2 - BEARING 6005 C3 ×2 - RING, 47 ×2 - RING, 24 ×2 - PACKING G140 ×2 - SEAL, TC254708 ×2 1.

Tap inner race using pipe

Fasten RING 24 onto FRONT AXLE SHAFT and nsert BEARING 6005 C3.

Note: - Make sure the RING is seated completely in groove. - Tap inner race of BEARING straight. 2.

Tap inner rac e using pipe

Insert FRONT AXLE SHAFT into FINAL GEAR 51T and BEARING 6004 C3.

Note: - Tap inner race of BEARING straight (Do not tap outer race!)

Insert SEAL TC254708 into FRONT BEARING COVER and Fasten with RING 47.

Note: - Make sure the RING is seated completely in the groove.

Place PACKING G140 on FRONT BEARING COVER.

Note: - Apply grease to PACKING before installation..

Apply grease to packing

Insert FRONT AXLE SHAFT into FRONT BEARING COVER through SEAL.

Note: - Apply a small amount of grease around lip of SEAL.. - Be careful to avoid damage to SEAL lip while installing FRONT AXLE SHAFT.

2.) Assembly of FRONT SHAFT ASSY

Tap inner race

1 set for LH side, 1 set for RH side. (Built-in parts) - GEAR 11T ×2 - BEARING 6001 C3 ×2 - SPLINE COLLAR B ×4 - JOINT SHAFT ×2 - BEARING 6002 C3 ×2 - AXLE FLANGE ×2

Insert shaft of GEAR 11T into BEARING 6002 C3 and then BEARING 6001 C3.

Note: - Tap inner race of BEARING straight. (Do not tap outer race!) 2.

Loose fittin

Insert GEAR 11T with BEARING into flange case.

Note: - Sometimes it is not easy to insert, May require re-inserting again. (Do not tap with hammer!) 3.

Insert JOINT SHAFT into SPLINE COLLAR.

Insert JOINT SHAFT with SPLINE COLLAR into shaft of GEAR 11T through flange case.

Note: - Pay attention not to come off the SPLINE COLLAR, when assembling.

3.) Assembly of FRONT GEAR BOX ASSY 1 set for LH side, 1 set for RH side.

·FRONT GEAR BOX L(R) CMP (Built-in parts) - BUSH 121511.5 - FRONT GEAR BOX L(R) - BEARING 6906 C3 - BEARING 6908 C3 - RING, 47

×2 ×2 ×2 ×2 ×2

Difference between L and R i s which side the hole is locat

Tap outer ring

Insert BEARING 6906 C3 into FRONT GEAR BOX L(R) and fasten it with RING 47.

Note: - Coat the outer surface of BEARING with oil. - Tap outer race of BEARING. (Do not tap inner riace!) - Make sure the RING 47 is completely seated in groove.

RING, 47

Seat completely in groove

Apply oil to outer 2.

Insert BEARING 6908 C3 into FRONT GEAR BOX L(R).

Note: - Coat the outer surface of BEARING with oil.

Confirm that BEARING 6908 C3 is positioned Correctly through window of bearing pocket. (arrow)

BEARING PARTS (Built-in parts) - WASHER, SEAL 6 - WASHER, SEAL 8 - SEAL, TC46641 - BOLT, 6x12 - BOLT, 8x16

Confirm BEARING position

×2 ×2 ×2 ×2 ×2

Insert SEAL TC46641 to FRONT GEAR L(R) CMP.

Install WASHER SEAL 6 and 8 to BOLT 6x12 and BOLT 8x12; and install the bolt assemblies to FRONT GEAR L(R) CMP.

Note: BOLT, 6x12: TIGHTENING TORQUE 4.9 ~ 6.9Nm BOLT, 8x16: TIGHTENING TORQUE 12.7 ~16.7Nm - Apply grease to surfaces of WASHER SEAL.

4.) Assembly of FRONT GEAR CASE ASSY 1 set for LH side, 1 set for RH side. (Built-in parts) - FRONT GEAR CASE - COLLAR, 30X38X4.5 - RING, 30 - FRONT GEAR BOX ASSY L - FRONT GEAR BOX ASSY R 1. 2.

×2 ×2 ×2 ×1 ×1

Apply grease

Insert FRONT GEAR CASE into FRONT GEAR BOX ASSY through SEAL..

Note: - Apply a small amount of grease around seal lip area. - Be careful to avoid SEAL lip from damage when FRONT GEAR CASE is installed.

Insert COLLAR 30×38×4.5 into FRONT GEAR CASE through FRONT GEAR BOX and install RING 30.

Note: - RING 30 is surely assembled into the groove of FRONT GEAR CASE.

RING,30

Seat completely in groove

5.) Assembly of FRONT SHAFT 2 ASSY 1 set for LH side, 1 set for RH side. (Built-in parts) - SHAFT FRONT 2nd ×2 - FINAL PINION GEAR 9T ×2 - GEAR 28T ×2 - BEARING 6003 C3 ×4 1. 2.

Tap inner race

Install FINAL PINION GEAR 9T and GEAR 28T into BEARING 6003

Note: - Tap innner race of BEARING straight. (Do not tap outer ring!) - Be careful not to damage of GEAR. Tap inner race

Insert FINAL PINION GEAR 9T with BEARING into FRONT GEAR BOX ASSY.

Insert SHAFT FRONT 2 into FINAL PINION GEAR 9T through FRONT GEAR BOX ASSY.

Install GEAR 28T with BEARING into SHAFT FRONT 2 in FRONT GEAR CASE ASSY.

6.) Assembly of SPINDLE ASSY and FRONT GEAR BOX ASSY 1 set for LH side, 1 set for RH side. (Built-in parts) - SPINDLE ASSY - FRONT GEAR BOX ASSY - BOLT (M8×25) 1.

×2 ×2 ×2

Align all hole

Install SPINDLE ASSY to GEAR BOX ASSY.

2. Tighten the (2) assemblies with BOLTs (M8×25). Note: - Tighten bolts diagonally. TIGHTENING TORQUE 23 ~ 30Nm

7.) Assembly of AXLE FLANGE N ASSY 1 set for LH side, 1 set for RH side. (Built-in parts) - AXLE FLANGE ×2 - PIN (8×16) ×4 - PACKING, G45 ×4 1.

Insert PIN 8X16 (2 pcs.) into AXLE FLANGE.

Place PACKING G45 (2 pcs.) to AXLE FLANGE.

Apply grease

Apply greas

Note: - Apply a small amount of grease on PACKING.

8.) Assembly of AXLE FLANGE ASSY, FRONT GEAR CASE ASSY and FRONT AXLE CASE ASSY. (Built-in parts) - AXLE FLANGE ASSY - FRONT GEAR CASE ASSY - FRONT AXLE CASE ASSY - BOLT(M8×25) - SEAL CAP 56

×2 ×2 ×1 ×16 ×2

Align spline

Install AXLE FLANGE ASSY to FRONT AXLE CASE ASSY.

Note: - Align the spline of GEAR 11T.

Locator pin

- Pay close attention that SPLINE COLLAR does not fall from shaft during assembly.

Secure the assemblies with BOLTs (M8×25).

No gap

Note: - Tighten bolts diagonally. TIGHTENING TORQUE 23 ~ 30Nm - Make sure no gap before tightening bolts.

Align GEAR 11 T with GEAR 2

Install FRONT GEAR CASE ASSY to AXLE FLANGE ASSY.

Locator hole Note: - Align GEAR 11T with GEAR 28T. - Make sure there is no gap between flanges of assembliesy before snugging bolts.

Secure the assemblies with BOLTs (M8×25).

Note: - Tighten bolts diagonally. TIGHTENING TORQUE 23 ~ 30Nm

No gap

Insert SEAL CAP into FRONT GEAR CASE.

Note: - Do not tap too hard! - Do not tap center of SEAL CAP,because of dent! - Use soft hummer!

9.) Assembly of TIE ROD 1.

Install per photograph (Parts Catalogue).

Long. Short.

- LEFT HAND SIDE

- RIGHT HAND SIDE

Lock NUT to PI

Note: - Between NUT and PIN: TIGHTENING TORQUE 3 ~ 7Nm

Lock NUT to NU

- Between NUT and NUT: TIGHTENING TORQUE 38 ~ 42Nm

10.) Assembly of STEERING ROD 1.

Install per photos & parts catalogue drawing

11.) Finishing 1.

Set AXLE straight with both spindle.

Place ADJUST PLATE on CAM LEVER without gap.

Tighten them with BOLTs (M8×25) TIGHTENING TORQUE 23 ~ 30N·m

Note: - This procedure should be after adjustment of speed ratio on vehicle. - NUT for FULCRUM: TIGHTENING TORQUE 23.3 ~ 25.7Nm

No gap

Adjust speed ratio by turning FULCRUM on the vehicle and then tighten NUT.

- Finish -