Engine Overhaul Kama 554

/ Engine Overhaul Kama 554 #241  
In the few tractor split repair and reassemble projects I have been involved in it always helped to rotate the engine a little when you get to the point where it should drop into place, the splines may not be aligned. I have seen people destroy the pressure plates trying to force it. I have had someone on the front with a breaker bar turning the crank pulley bolt to align the splines. In a pinch I have even inched around the flywheel with a bar.

I was wondering if this was the issue as well. After splitting my tractor, I engaged the PTO and turned it by hand to get the splines to line up so the two halves would mate back up. Quick and easy.
 
/ Engine Overhaul Kama 554 #242  
I was wondering if this was the issue as well. After splitting my tractor, I engaged the PTO and turned it by hand to get the splines to line up so the two halves would mate back up. Quick and easy.

That works as well. Just have to get the splines lined upand it will drop in place.
 
/ Engine Overhaul Kama 554 #243  
Crikey! That's quite a project you've got going on Rob, and it looks like it will be better than new when done. You and Dave Krug should get together if you two haven't already. Dave's done a remarkable job redoing a JD 4300 that was beat to crap.
 
/ Engine Overhaul Kama 554 #244  
That's quite a project you've got going on Rob, and it looks like it will be better than new when done.

I agree, and I have seen Rob's excellent work close-up. I will be visiting
(again) during the World AG Expo in a few weeks. By then the Kama will
be working again and he will be into another project.
 
/ Engine Overhaul Kama 554
  • Thread Starter
#245  
Matt, you are right, Dave and I are good friends.
Like he said, he'll be staying with us while he attends the Ag Fair. In fact, so will Brian later in the week.

You guys who gave advice to turn the splines are right on the money.
Instead of turning the PTO, the other day, I was turning the crankshaft with a large socket on it. I had the decompression active so it was easy to turn. I rotated back and forth, but that was not the problem. The problem was that I didn't have the 2 halves square and parallel to each other. That's when I quit.

But I went out the next day and started over again with Loretta helping.
We split the 2 halves apart to get measurements of when engagement occurs. I also loosened the clutch pack and reset the clutch(es) with my home made "clutch alignment tool", but it was set correctly the first time already.

Then I measured both halves and determined the following.
This was so that we would now what the hold up was. My calcs told me that the PTO clutch splines touch first when the bell housing flanges are apart approx 1.650". The main clutch splines touch at approx 1.300", and finally, the pilot bearing touches at approx 1/2". Seems to me that should be the first to engage, but it's the last.

Anyway, after we got the 2 halves line up again, we tried pushing them together.
Guess what? With a little rotating of the crank while pushing together, the darn thing went together!
Hurrah!!:D I used the bolts to suck in the last .300", so I knew the pilot had seated already, and everything was already lined up.

Anyway, here are some photos of the tractor back together again.
It looks pretty sweet all cleaned up and painted.

 
/ Engine Overhaul Kama 554
  • Thread Starter
#246  
It took some time to fill all the fluids back up.
The radiator, the front power steering hydraulic reservoir, the rear hydraulic reservoir, the middle box and trans (my oil seal comes out when I remove the front drive shaft), the oil filter and engine oil, and finally the fuel filter and fuel tank. Once I finished doing that, I pumped the fuel injector hand pump to prime the system. Then, using the decompression, I cranked it over until I saw oil pressure.
I let the decompression knob go and the Kama fired right up.

I suppose you want to know the outcome, right?
Well, here it is. You can read the oil pressure in each photo. After letting it warm up a little, I took the first photo at about 1200rpm. The second one is at 2100rpm. The third one is backing down to 1600rpm, and the last one, after about 1/2+ hour of running, was at idle 800rpm. The oil pressure at idle after a good warm up was still at 55psi or so, where before it would start to drop close to 20psi.



This just goes to show you that if you try hard enough you will succeed.
Man, I'm soooo glad I had the courage to take it all apart again and do the bottom end rebuild to make it right. Loretta and I are very, very happy. All our hard work paid off.
I want to take this opportunity to thank all of you who took the time to post encouragement and advice.
Many, many thanks to all.
Rob-
 
/ Engine Overhaul Kama 554 #247  
It took some time to fill all the fluids back up.
The radiator, the front power steering hydraulic reservoir, the rear hydraulic reservoir, the middle box and trans (my oil seal comes out when I remove the front drive shaft), the oil filter and engine oil, and finally the fuel filter and fuel tank. Once I finished doing that, I pumped the fuel injector hand pump to prime the system. Then, using the decompression, I cranked it over until I saw oil pressure.
I let the decompression knob go and the Kama fired right up.

I suppose you want to know the outcome, right?
Well, here it is. You can read the oil pressure in each photo. After letting it warm up a little, I took the first photo at about 1200rpm. The second one is at 2100rpm. The third one is backing down to 1600rpm, and the last one, after about 1/2+ hour of running, was at idle 800rpm. The oil pressure at idle after a good warm up was still at 55psi or so, where before it would start to drop close to 20psi.

This just goes to show you that if you try hard enough you will succeed.
Man, I'm soooo glad I had the courage to take it all apart again and do the bottom end rebuild to make it right. Loretta and I are very, very happy. All our hard work paid off.
I want to take this opportunity to thank all of you who took the time to post encouragement and advice.
Many, many thanks to all.
Rob-

Told ya it would purr like a kitten. Congrats on a job well done!
 
/ Engine Overhaul Kama 554 #248  
Rob, sure came out nice, but then there never was any doubt. Ought to last a good long time now. So are you going to have it all muddy soon? :eek: :D ;)
 
/ Engine Overhaul Kama 554 #249  
Nice job Rob and Miss Loretta. The machine looks great too boot.

Chris
 
/ Engine Overhaul Kama 554 #250  
Congrats on a good job that is well done.
Ha, so now youse got another new tractor to break in and use hard - just like the other one.

Thanks for documenting and taking all the pictures - you have made things a lot easier for those coming behind you, with the same problems.

Well done Rob and Loretta.

Jim
 
/ Engine Overhaul Kama 554
  • Thread Starter
#251  
Thanks again guys ...
I don't know about "there was never any doubt", because truthfully, I was sweating bullets over this whole ordeal and I prayed it would come out good. Never having done this, it wasn't exactly encouraging to me.

I was soooo close to saying "screw it, I'm selling it".
But I got to thinking about all the stuff I've done with that tractor ... all the improvements and modifications I've done to it over the years. I just couldn't get rid of it. Most of the stuff I broke (other than this) was due to operator malfunction. Which I could've broken on any other brand tractor ... regardless. Crashing into a boulder and snapping off a tie rod end for example, or churning the gears forward and backwards at high speed with 2,500lbs in the bucket in 4wd stressed and eventually broke my front drive gears. All those things would have screwed up any other tractor too (IMHO), because most warn against doing so right in the owners manual.

The little annoyances of owning a Chinese tractor like things not being machined exactly right are easy to fix (but annoying nevertheless). The electrical problems, which I know nothing about are a pain too. But now, one phone call and "POOF" Larry is here to fix it in 9 minutes. So I can live with it. I figure I've saved pretty close to $100,000 (no kidding because I got quotes for several projects) in dirt work, backhoe work, road work, plowing, mowing etc. Quite an outstanding return for a tractor that I paid $10,800 bucks for. Throw in the Koyker loader with 72" bucket, an 8' Nardi Backhoe, a Howse 6' Rotary Cutter, my famous 7' Howse Boxblade and Leinbach Post hole digger, the package went all the way up to $18,500 for all of it. I had to pay $2,000 for shipping to my property, so if you count that, the total was just over 20 grand delivered to my doorstep (campsite back then). Not bad for all that I saved. How many guys can say that their tractor has paid for itself almost 5 times over in 4-1/2 years? Yeah, I've spent money on modifications, regular maintenance and repairs over 5 years, but a lot of that is normal. I do all my own maintenance and repairs (and even mods) so my expenses are way less than having to take it to the dealer for service or repairs (or mods). It just goes to show you that owning a Chinese tractor may not be for everyone. If you don't (or can't) do the work yourself, it may end up not being such a good deal after all. In my case I view it as a great deal.

I've been through just about every part on that tractor by now.
Just about everything is either OK as is, or has been modified or improved to American standards. I've always posted both the success stories and failures equally, so you guys know the good, the bad and the ugly about this tractor.:) Even though I didn't end up balancing the pistons and rods, I did make a chart of all the measurements, fits and tolerances. I also have a book for all the Napa replacement parts. This is of most value since I know I can get parts for it. This project took me to another level of tractor ownership. It's given me more confidence...that I can overcome even some of the greater problems. Certainly a lot more satisfaction.

It's been pouring here as I see it is over much of our state and others.
Even so, I think, later, I'll take Huge Kama out and hook up the FEL and maybe the backhoe. I am still in a semi-unconscious state of shock that it runs so well and smooth, with a lot of oil pressure. And at the same time, I feel exhausted, if you know what I mean.
I was also gonna go pig hunting earlier today because I saw rooting ALL OVER Murder Meadow right in front of South Camp where Brian visited me the first time and Larry and Ken stayed when they visited. But I couldn't wait to check out the forum first.
Rob-
 
/ Engine Overhaul Kama 554 #252  
Gosh Rob, you forgot to mention the priceless degrees you earned. Mechanical, Electrical, and Metallurgical. Those go well alongside that real world MBA. :D
 
/ Engine Overhaul Kama 554 #255  
WOW ! I gotta say- this thread has left me speechless! :eek: I doubt it if I have the guts to do what you did. I would've just dropped in a new motor and be done with it, but then before long I would've had same issues as before. So I gotta say- I give you more then a super A+++ for guts, A+++ for doing a job well done. I am sure its the best feeling in the world to get your tractor up and running now before then before. :D Congrats.

Maybe you can help me with my kubota if run into the same issue in the future ..:eek: Should be easier with a tiny motor compared to yours.:p
 
/ Engine Overhaul Kama 554 #256  
Rob - Thank-you for another fantastic read.

You and that Kama should be inseparable after this venture. It should make you proud to know your baby inside and out. How could you ever part with her now? :)

Now go out there and make us proud with a new project around the ranch.
 
/ Engine Overhaul Kama 554 #257  
I wore my best flannel for that picture. :D
...and it may never be the same again.
I get the onerous task of trying to get all that oil and grease out! After 'Spray & Wash'ing it, pre-soak with in-wash stain remover, using the stain cycle, and OxiPlus, the stains are out, but it still smells like oil and grease. :(
and he wasn't kidding about it being his best flannel shirt.
 
/ Engine Overhaul Kama 554 #258  
...and it may never be the same again.
I get the onerous task of trying to get all that oil and grease out! After 'Spray & Wash'ing it, pre-soak with in-wash stain remover, using the stain cycle, and OxiPlus, the stains are out, but it still smells like oil and grease. :(
and he wasn't kidding about it being his best flannel shirt.

Loretta
try soaking it in powered dish washer soap in some water for a couple of days

tom
 
/ Engine Overhaul Kama 554 #259  
...and it may never be the same again.
I get the onerous task of trying to get all that oil and grease out! After 'Spray & Wash'ing it, pre-soak with in-wash stain remover, using the stain cycle, and OxiPlus, the stains are out, but it still smells like oil and grease. :(
and he wasn't kidding about it being his best flannel shirt.

Looks like Rob has a new "shop" shirt now!:D I've got several. I wear them over my other shirts. Welding is pretty hard on them but cooler than my leathers.
 
/ Engine Overhaul Kama 554 #260  
Congrats Rob and Loretta!

I totally agree with evertone else's positive comments and of course I am selfishly thankful (AGAIN) for the outstanding documentation on how to fix our tractors. I think your posts have added at least $1000 to the practical value of my Kama.

Loretta - some Goo-Gone or one of the other citrus type degreasers might help with that smell.

I also agree with Jay - sometimes I like to crap up a newer shirt (sorry Diane) just so I'm not wearing old rags in the shop :)

Brad
 

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