Saton S-650G Operating instructions

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SATOH
TRACTOR
f
Ls-65()G
REnAIR
MANML
SATOH AGRICUTTURAL MACHINE
7
Publication No. 03
MFG. CO*LTD,

CO}ITENTS
ENGiINE SYSTEM ...-....."""""""""'t"r"""""""""""'t""""..""" A
CLUTCH SYSTEM //../..I{.|EE..L, r . ..' r, r r, . . r.,
/'..r(.hEE..k rr...rrrrrrr..r.r..rt!r. B
STEERI ilG LI I{KAGE SYSTEII
TRANsMlssl0il sysTE |l .#6rn. A..... KEo.* fr.i.r{s.......... ll
BRAKE SYSTEM...r..r.......r.........r...........................r..................rrr. E
ELECTRI0AL SYSTEM r e. r .,frn6.
DRAFT CoNTRoL.....,...........................r................................r....... H
p0UuER ASSISTED STEERIJ{G...................................................... I

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SATOH TruTOR
ENGINE SYSTEM
. PUBLICATI0il JIo.03-A
MoDEL s.65()(G
REPAIR MANUAL
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CONTENTS
THE ENGINE . GENERAL
1. Cylinder Head
2. Cylinder Block
3. Pistons and Crankshaft
4. Valve Mechanism
5. lntake and Exhaust Mechanism
6. Governor
7. Cooling System
8. Lubricating Mechanism
9. Elestrical SYstem
ETUGINE
Disassembling Order
1-1 . Removing the Engine . .
1-2. Disasembling the Engine
Checking Maintenance and Limit of Adiustment
2-1 . Cylinder Head . .
2-2. Piston and Cylinder Block
2-3. Connecting Rod
24. Crankslraft and Main Bearing Metal
2-5. Camshaft . .
2-6. Timing Chain Sprocket and Chain Adiuster
AssemblingOrder .. ..
3-1 . Assembling the Engine
3-2. Mounting the Engine
Spgcifications .. ..........
LUBRICATIOT{SYSTEM ....
1. Lubrication System - General
2. Disassembling the Oil Pump . . . .
2-1 . Removing the Oil Pump
2-2. Disasembling the Oil Pump
3. Checking, Maintenance and Limit of Adiustment
3-1 . Checking and Adjusting the Oil Pump
3-2. Oil Filter Replacement
3-3. Checking and Adjusting the Oil Pump Driven Gear Shaft
34. Adjusting the End Play of Oil Pump Driven Gear Shaft
4 tT'I?"ruili,ff': : :
1.
2.
3.
4.
3
3
3
7
15
15
18
21
23
25
26
27
27
38
38
39
39
40
40
40
40
40
41
41
42
42
42
42

5, Specif ications
51. Oil Pump Specifications
5-2. Oil F ilter Specif ications
SYSTEM ....
Cooling System - General - .
Disasembling Order . .
2-1 . Removing the Water PumP
2-2. Disassembling the Water PumP
Checking Maintenance ?nd Limit of Adiustment
31 . lnspection of Water PumP . .
3l2. Checking the Thermostat
AssemblingtheWaterPumP .... ..
Mounting thg Water Pump . . . . . . . . . .
lrstalling the Thermostat . . . . . . . . . .
Specifications .. ..
7-1 . WaterPump r. . . . . . . . . . . . .
7-2. ThgrmosEt.. ,o....o.
.42
.42
.42
.43
j
COOLING
1.
2.
3.
*4.
5.
6.
7.
FUEL SYSTEM
Fuel System - .Generct
AirCleaner o o . . .
2-1 . Rennving the Air Cleaner Element
2-2. Checking the Air Cleaner . . . .
2-3. Air Cleaner Specifications . .
Fugl Pump...,.....
31 " Removing the Fuel Pump . .
3-2. Disasembling the Fuel Pump . .
3-3. Checking the Fuel Pump
34. Assembling the Fuel Pump . .
35. lnsUlling the Fuel Pump
36. Fuel Pump Specifications . . . .
4. Fugl Filtgr . . . . . . ... . , . . . .
5. Carburetor .. ..
51 . C"onstruction . .
5-2. Disassembling the Carburetor
$3. Checking, Maintenance and Limit of
5.4. Assembling the Carburetor . .
t5. MountingtheCarburetor .... .
$6. Specif ications . .
1.
2.
43
43
43
43
4
M
4
4
45
45
45
45
45
47
47
47
47
47
47
47
47
48
48
48
49
49
49
50
50
50
54
55
55
55
I_
gOiustment

6. Governor
6-1. Governor System - General
6-2. Governor - Operation and Construction
6-3. Purpose of Governor Adjustments
&4. Maintenance
6-5. lnterlock Adjustment between C;rburetor
Spark Plug
.55
55
.56
.58
.58
.58
.59
59
59
59
59
59
59
60
61
61
61
6l
63
.63
.63
.63
.63
.63
.63
.63
.63
.64
.il
.64
.u
.64
.u
.64
.65
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and Governor
IGTTIITION SYSTEM
1. Spark Plug
1 -1 . lnspection and Adjustment of
1-2. Spark Plug Specifiiitions
Distributor
2-1 . Removing the Distributor
2-2. Disasembling the Distributor
2-3. Checking, Maintenanc€ and Limit of Adjustment
24. Asembling the Distributor
2-5. Mounting the Distributor
2-6. lgnition Timing lnspection and Adiustment
2-7 . Distributor Specifications
TOURBLESHOOTI]UG
1. The Ergine Lacks Power . .
1 -1 . Fuel C.omprssion is lnsuff icient
1-2. lgnition Timing is lncorrect
1-3. Fuel Lsrel is Low
14. Carburetor Dravw lnsufficient Amount of Air
1-5. Engine Overheats . . . .
2. Fuel Canzumption is Excessive
2-1 . Engine Oil Leaks
2-2. Oil Comes Up into the Combustion Chamber
2-3. Oil Comes Down from Valve System
Engine is Hard to Surt
3-1. Engine has Starting Difficulty : .
3-2. lgnition System is Defective
3-3. Engine
34. Carburetor
Engine is Noisy
4-1 . Piston
+2. Crankshaft
+3. ConnectingRod .... ....
U. tMiscellaneous
3.
4.
I
l

6.
5. F iring lrregularities
S1. lgnition System
*2. Air-fuel Mixture
$3. Valves . .
u. cylinderHead .. ....
lncorrest ldle Speed Adiustment . .
Gl . Carburgtor . . . . . . . .
G2. AirEnteringFuel Line .... ....
6-3.Va1vgs...........o....
il. Cylindgr Head . . . . . . . . . . . .
Engine Runs not Smoothly (when acceleratedl . . . .
7-1 . Carburgtor . o . . . . . . . . . . . . . . . .
7-2. lgnitionSystgm .. ...... ...
7 3" Ergine, . . . . . . . . . . . . . . . . . . . . . . . . .
65
65
65
65
66
66
66
66
66
66
66
66
66
66
7.

THE ENGINE - GENERAL
TllE ENGINE-GENERAL
This PB engine is a high performance, water-cooled, 4-cylinder, in-line gasoline engine, employing the overhead valve and high
cam shaft system. The cylinder bore and the piston stroke measure 2'6772 in' (68 mm) and 2'6772 in' (68 mm)'
respectively. ln this sense, the cylinder is o{ a square type, having a total displacement of 60.2 cu. in' (987 cc) and a
compr.ession ratio of 8.6 to l. The maximum output is 25 PS at 2,800 r.p.m. and the maximum torque 46'9 lt-lbl2,2$O
r.p.m. (6.5 kg-m/2,2OO r.p.m.). The description of the engine is as follows:

t
1. Cylinder Head
Being made of a light alloy, the cylinder head is light
in weight, provid ing excellent rad iation eff iciency.
The domeshaped combustion chamber is shrinkage-
fitted with ductile cast iron valve seats. The intake
and the exhaust valves are arranged opposite to each
other the cylinder head; that is, the cros-flow design
is employed for better combustion eff iciency.
2. Cylinder Block
The cylinder block is precisioncast from a light alloy
meEl by means of pressure die casting. To support
the crankshaft, f ive bearings of the deep skirt type are
employed. The cylinder liners are made of special
cast iron and replaceable. They are directly cooled
by water and sealed with two "4" rings.
3. Pistons and Crankshaft
The pistons are of a conical ellipse type manufacturd
by LO-EX. The crankslraft is made of ductile cast
iron supsior in durability and wear-resistance, and
supported by five main bearings. The main bearings
are made of an aluminum alloyed with tin, which is
also excellent in durability and wear-resistance.
4. UalYe Meclnnism
The high cam shaft design is employed, along with
five special iron bearings, for increased rigidity. This
permits high speed relolutions. The cam shaft is
driven by a Renold-made chain, wtrose tension is
adjustable by means of the chain. adjuster and
vibration dampr. To reduce the cfrain noise, the
contacting surfaces of the chain is finished with
heat-proof and wear-proof rubber.
5. lntake and Exhaust Mechanism
The exhaust manifold is made of cast iron, and the
intake manifold made of a light alloy metal. Both
manifolds ?re of independent branch Wpe. The hot
spot is heated by warmed "cooling water". ln the
intake system, a Stronberg type carburetor, having a
downdraft double-venturi is used.
6. GoYernor
The Governor is of f ly weight type and controlled by
means of all speed governor system.
-1
8. Lubricating Mechanism
Total pressure lubrication is carried out by a trochoid
gpar oil -pump, which is driven by the cam shaft drive
gear. A cartridge type oil f ilter is employed.
9. Electrical System
Electrical component is of 12-volt capacity. The
alternator is l Samp. capacity, and the starter of
1.O-kW. As the battery, the N40L Wpe is used, and
the distributor is provided with a vacuum and
centrif ugal type automatical advancer.
7. Cooling System
Cooling system is the type of forcedcirculation, and
the pressure in the radiator is 9.954 lbs/sq. in. by
which the high efficiency of heat radiation is secur-
ed. Their qystem is incorporated with the Wax type
thermostat and the water pump is of the centrifugal
type. The miterial of cooling fan is the synthetic
resin, consisting of 4 wings,

ENGINE
ENGINE
1. Disassembling 0rder
Note: Notes on Engine Dirssembly
Both engine and transmission are very heavy in weight. ln addition, they must be kept in a horizontal
position while being disassembled, and therefore, engine disassembly operations should be performed
on solid f loors.
To keep the tractor in a horizontal position, place a wooden wedge between the front extension and
the axle beam.
Be sure that necessary wrenche, such as a special tool (No. N033S SOCKET WRENCH SET), special
tool (No. BT-100 DOUBLE OFFSET BOX WRENCH SET), and (No. BT-9 OPEN-END WRENCH
SET), and other special tools including a chain block are all available on hand.
Put a rnark on each engine component part such as a piston. piston ring, valve, valrre spring, metal,
tappet, push rod. etc. in order of the cylinders, so that you will not corifuse dbout parts.
Take special care not to datnage the removed parts, and put them in order.
l-1 . Remoying the Engine
1. Bemove the negative (-) corde from the battery.
2. Remove the wires from the alternator (A) , starting
motor (B) and hed light (cl.
c
o
o
o
o
b
\
Fig. I
Remove the bonnet.
Disconnect the wires from the oil pressure switch
(A) and the water heat gauge (B) .
Fig. 2
5. Removing the radiator
Throughly drain off the cooling water from the
radiator and cylinder block. Loose the water hose
clip (A) and pull out the water hose from the
radiator. Remove the radiator mounting bolts (B) ,
(C), and fitting nut for radiator support (D), and
remove the radiator.
3.
4.
Fig. 3

ENGINE
6. Removing the tractor meter cable, throttle wire
and choke wire
Remove the governor cover {A), and disconnect
the tractor meter cable (B) , throttle wire (C) and
choke wire (D) . Remove the governor cover. *l
Fig. 4
7 . Removing the fuel pipe
Remove the fuel pipe (Al . To prevent
entering the fuel tank, cover it with a
cloth "
Fig. 6
9.
Figr' 7 end I
10. Removing the hydraulic oil pipe
a. Remove the hydraulic oil pipe clamp (A).
Removing the silencer pipe
Remove the nut (A) mountlng both exhaust
manifold and silencer pipe, and remove the silenc-
er mounting nut (B). Then remove the silencer
pipe.
dust from
clean dry
Fis. 5
8. Removing the drag link
Pu ll out the split p in from the ball socket
connecting the Pitman arm and drag link, and
remove the slotted nut (A). Remove the ball
socket by using the special tool (No. TRH-12 TIE
ROD END REMOVEBI
Fig. 9

EN GINE
Fig. l0
c. Remove the banjo bolt (Cl"
Fig. I I
d. Loosen the strainer body (D), and take it out.
Fig. t 2
e.
b. Remove the magnet plug (B), and drain off the
hydraulic oil case. When reusing the oil, put it in a
clean container while taking care not to allow dust
to enter the oil.
Remove the pump flange mounting bolt (E) from
both inlet and outlet sides. Cover the ends of the
pipe so that no dust will enter the pipe.
Removing the hydraulic pump and pump bracket.
Remove the four bolts setting the pump joint (A),
and remove the pump joint. Remove the four nuts
(B) from the pump (C). Remove the two screw
(M8 x 25l, and three bolts (MB x 45) from the
pump bracket, and remove the bracket (D).
Note: As alignment of the center line betureen
crankshaft and the hydraulic oil pump had been
correctly fixed at 0.001 181 in. (0.03 mm) during
factory assembly, do not attempt to remove the
pump unless otherwise it is definitely necsary to
work out its remowt.
Removing the flange coupling and CG-type rubber
coupling
Remove the three bolts which fasten the CG-type
rubber coupling to the crak pulley, and remove the
flange coupling and CG-type rubber coupling.
Fig. l3
11.
Fig. 14
12.

EN G INE
13. Remove the engine mounting rubber mounting nut
(A) on both right and left sides, and remove the
engine support mounting bolt (B).
Fig. 15
14. Removing the alternator and V-belt
a. Remove the bolt as shown in Fig. 16, and remo\€
the alternator strap tB) from the alternator (A)-
b. Remove the alternator mounting nut and bolt, and
remove the alternator and V-belt (C) from the
alternator bracket.
i,,' {e
Fig. 16
15. lnstall the chain block on the engine hanger (A) on
the manifold on both exhaust and inuke sides.
Do not hoist the engine, but pull the wire so that
it becomes slightly tight.
Place a garage jack under the clutch housing.
Do not iack up the tractor, Just raise the jack so
that it is just tightly locked under the tractor.
Remove the'bolts (A) , four each on both right and
left sides, and the four bolts (B) , also four each on
both sides, which mounting the chasisand clutch
housing. Remove the three screws (C) from the
re*,r plate, and pull the re:,r plate downuard.
Pull out the clrasis and front axle toward the
front.
Removing the engine mounting and alternator
bracket
Remove the mounting nut, and remove the engine
mounting (A) from the alternator bracket.
l
Fig. l7
16"
17.
Fig. t 8
18.
19.
a.

EN GI NE
Fis. l9
b. Remove the three mounting nuts, and remove the
alternator bracket (B) from the cylinder block-
Fis. fr
20. Remove the starter
starter. mounting nut, and remove the
Remove the four nuts (A) and nuts (B) (one each
on both right and left sides) , which mounting the
engine and clutch housing. Next, adjust the chain
block suspending the engine so that the stud bolt
will not be under excessive load. Then pull the
engine toward the front.
Fig. 22
1-2. Dlsasembling the Engine
1. lnstall the engine on the special tool (No. @90010
ENGINE STAND) by mears of one bolt and three
nuts then renpving the clutch unit.
Fig. 23
21 .
Fis. 2l

_l
EN GIN E
2. Draining the engine lubricants
Remove the drain plug and drain off the engine
lubricants.
Fig. 24
3- Remove the clutch, flywheel and crank pulley
a. As shown in Fig. 25, remove 6 pcs. of scrarus and
remove the clutch" Make sure that the removal
order for screws should be diagonally done.
Fig. 25
b. As shown in Fig. 26, raise up the lock washer of its
bent portion.
c. As shown in Fig. 26, install the special tool (No.
0490100 RtNG GEAR BRAKE) so that the crank-
shaft and f lywheel cannot be rotated.
d. Remove 6 pcs. of the rock bolts and remove the
flywheel (A) from the crankshaft.
Fig. fi
e. Rernove lock bolt from the crank pulley (A) at the
front of the engine.
Fig" 27
f . Remove the special tool (No. 0490100 R tNG
GEAR BRAKE).
4. Removing the air cleaner
a. Loosen two hose bands, and remove the hot air
hose (A) from the air cleaner and the carburetor.
Fig. 28
b, Loosen two wing nuts, and raise the clamp (B).
Remove the air cleaner bands (c) and remove the
air cleaner"
'*t
J

EN G INE
R emoving the d istributor
Pull the high tension wire out of each spark plug,
Pull out the vacuum advance hose (A) connected
to the distributor, as shown in Fig. 30.
Unscraru the nuts (B), and pull upward the
distributor, as shown in Fig. 31.
Fig. 3l
Removing the V-belt and idler assembly
Screw in the adjusting bolt (A) to make the V-belt
tight, and loosen the governor pulley lock nub, as
shown in Fig. 32.
Loosen the adlusting bolt and move the idler
pulley (B ) in the direction of the arrow shown in
F is 33.
Then pull down the governor operating lever (C)
to the carburetor side, and remove the V-belt (D)
from each pulley.
Unscrew two nuts and bolts, and remove the idler
assembly (E) from the governor bracket and the
timing chain cover.
Fb. 33
7. Removing the governor and governor bracket
a. Remove the lock nut which has been already
loosened according to 6-a above, and slip the
governor pulley (A) off the governor shaft. Then
remove the key (B) on the governor shaft.
b
c.
Fig. 29
Fig. fi
6.
a.
5.
ct.
b.
c.
';.
Fis. 32
Fig. 34

I
10 EN GINE
b. Remove the governor operating lever and remove
the rod assembly.
c. Remove the nuts and bolts shornrn in Fig. 35.
d. Unscrew three nuts shown in Fig. 36, and remove
the governor. Remove the governor bracket and
remove the engine bracket from the cylinder
block.
Fig.35
e. Unscrew three bolts and nuts ( D), then, the
gpvernor (A), the go\emor bnacket (B) and the
engine bracket ,(C) which have already .bem
removed aaording to 74 above, can be separated.
Fig. 37
8. Removing the cooling fan and cooling fan oom-
plete
a. Unscrew four bolts, and remove the cboting fan
(A) , fan spacer, pump pulley (B) from the cooling
fan complete.
b. Unscrew three nuts, and remove the cooling fan
complete (C) and alternator strap from the rylin-
der head.
c. Take out the thermosEt from the thermostat
casing.
'Removing the water pump
Pull the inake rnanifold water hose (A) out of the
water pump by loosening the clip.
Unscrew four nuts, and remove the alternator stay
(C) and water pump (B) from the cylinder head.
Fig. fi Fig. 39
:Fig. s6
b.
Fig. 4l

EN GIN E11
R emoving the oil f ilter
Pull out the oil level gauge.
Remove the oil f ilter from the cylinder block by
using an special tool (No. 0490130 OIL FILTER
WRENCH} (A).
Fig. 42
I 1. Removing the fuel filter
a. Unscrew the carburetor connecting bolt,
remove the f uel hose (Al connected to
carbu retor.
b. Unscrew two nuts, and remove the fuel pump
from the cylinder block. Then remove the
and
the
(B)
in-
su lator.
c. Remove the oil pressure switeh (C) and the
breather pipe (D).
Fis. 43
12. R emoving the carburetor
Unscrew two nuts, and remove the carburetor
(A). Remove the insulator (B) from the intake
manif old.
Fig. 44
13. Removing the intake manifold
Unscrew eight nuts and remove the engine hanger
(A). Then remove the intake manifold (B) from
the cyl inder head, together with the governor
cover stay and the a ir cleaner stay mounted
thereon.
Fig. 45
14" Rernoving the exhaust manifold
Unscrew eight nuts, remove the engine hanger (A) ,
and then remove the exhaust manifold (B) from
the cylinder head.
10.
a.
b.
Fig. 46

-l
12 EN GI NE
-trlE
Fig.47
15. Removing the rocker arm cover
Unscrew two bolts and remove the rocker arm
cover from the cYlinder head-
16. Removing the cylinder hed assembly
a. Unscrew ten cylinder head nuts.
b. Pull upward rocker arm asembly (A).
c. Pull upward eight push rods (B).
d. Remove the cylinder head assembly (C) from the
cylinder block.
e. Remove the cylinder had gasket.
Fis. 48
17. Pull eight tappet followers from the cylinder head
by using a proper tool such as a magnet.
>'*.g- ap
18. Removing the oil pump drive gear shaft.
a. Unscrew two nutS and remove the oil pump drive
gear cover (A).
b. Unscrew three nuts and remove the blind cover
(B).
c. Lift off the oil pump drive gear shaft (D) together
with the shim (E) and the thrust washer (C)"
Fig. fi
19. Turn the engine upside down and noW the oil pan
is upward.
20. Removing the oil pan.
Undo twenty-two nuts securing the oil pan (B) and
lift off the oil pan from the rylinder block.
21 . Unfasten the lock bolts and remove the crank*raft
Pullqr (A) from the crankshaft.
Fig. 5l
?E
,#€
Fi,. 49

EN GI ]'IE 13
22. Removing the timing chain cover
Undo nine nuts and remove the timing chain cover
(A)
Fig. 52
23. Removing the chain adjuster assembly.
a. Undo two nuts and remove the chain adjuster
assembly (A).
b. Remove the oil baffle plate (B) from the crank-
shaft.
c. Remove the key (C) from the crankshaft.
d. Undo two nuts and remove the vibration damper
assembly (D),
Fis. 53
24. Removing the timing chain.
a" Undo two nuts securing the camshaft (A)
b. Remove the camshaft & camsprocket wheel and
the timing sprocket wheel together with the timing
chain (B) from the crankshaft and the rylinder
block as shown in Fig. 54.
{-t
Fig. 54
25. Removing the front Plate.
Undo two nuts and r'emove the front plate from
the cylinder block.
Fig. 55
n. Removing the oil pump.
a. Loosen the conn€tion nuts and detach the oil
pipe (A) from the cylinder block.
b. Unscrew two nuts and remove the oil strainer (B)
from the oil pump (C).
c. Unscrew four nuts and lift up the oil pump.
)
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Di'r-
Fig. 56
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