Cub Cadet 8454 Service Manual

Cub Cadet 8454 Service Manual

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MTD Products, LLC Product Training and Education Department
FORM NUMBER 769-00903
K&T Saw Shop 606-678-9623 or 606-561-4983

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Summary of Contents for Cub Cadet 8454

  • Page 1 www.mymowerparts.com MTD Products, LLC Product Training and Education Department FORM NUMBER 769-00903 K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 2 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 3: Table Of Contents

    www.mymowerparts.com CONTENTS CHAPTER 1. GENERAL INFORMATION ..................1-1 1. TRACTOR VIEW ............................... 1-3 2. TIGHTENING TORQUE FOR STANDARD BOLTS AND NUTS ..............1-4 2.1 TIGHTENING TORQUE ........................1-4 3. SPECIFICATIONS ............................1-6 4. IDENTIFICATIONS ............................1-8 4.1 ENGINE NUMBER ..........................1-8 4.2 SERIAL NUMBER OF THE TRACTOR ....................
  • Page 4 www.mymowerparts.com CHAPTER 3. CLUTCH ........................3-1 1. TROUBLE SHOOTING............................ 3-3 2. SPECIFICATIONS,TIGHTENING TORQUES AND SPECIAL TOOLS ............3-4 2.1 SPECIFICATIONS ..........................3-4 2.2 TIGHTENING TORQUES ........................3-4 2.3 SPECIAL TOOLS ........................... 3-4 3. STRUCTURE AND OPERATION ........................3-5 3.1 FEATURES ............................. 3-5 3.2 STRUCTURE ............................
  • Page 5 www.mymowerparts.com 3.3 POWER TRAIN ............................4-9 3.3.1 TRANSMISSION ......................... 4-9 3.3.2 SHUTTLE SHIFT SECTION ....................4-10 3.3.3 MAIN SHIFT ..........................4-11 3.3.4 AUXILIARY SHIFT ........................4-12 3.3.5 FRONT WHEEL DRIVE ......................4-12 3.3.6 PTO SHIFT ..........................4-13 3.4 OPERATION ............................4-14 3.4.1 FEATURES ..........................
  • Page 6 www.mymowerparts.com CHAPTER 6. HYDRAULIC SYSTEMS ..................... 6-1 1. HYDRAULIC LIFT SYSTEM ..........................6-3 1.1 TROUBLE SHOOTING ......................... 6-5 1.2 SPECIFICATIONS ..........................6-6 1.3 STRUCTURE AND OPERATION ......................6-9 1.4 PREPARATION STAGE FOR DISASSEMBLING AND ASSEMBLING ........... 6-25 1.5 DISMANTLE AND ASSEMBLING ....................... 6-27 PTO CLUTCH VALVE SYSTEM ........................
  • Page 7 www.mymowerparts.com 5.3 SEPARATING REAR FENDERS AND PLATFORM ASSEMBLY ............. 7-11 5.4 DISASSEMBLING REAR AXLE CASE ....................7-14 5.5 DISASSEMBLING BRAKE CASE ...................... 7-15 6. ADJUSTMENT OF THE BRAKE ........................7-16 7. SERVICING ..............................7-17 CHAPTER 8 ELECTRIC SYSTEM ....................8-1 1.
  • Page 8 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 9: Chapter 1. General Information

    www.mymowerparts.com CHAPTER 1 GENERAL INFORMATION K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 10 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 11: Tractor View

    www.mymowerparts.com GENERAL INFORMATION 1. TRACTOR VIEW 569W101A D569-W02 May-2003 K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 12: Tightening Torque For Standard Bolts And Nuts

    CHAPTER 1 8454 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 STANDARD BOLTS AND NUTS...
  • Page 13 www.mymowerparts.com GENERAL INFORMATION B. TIGHTENING TORQUE FOR STUDS 11.7 to 15.7 N·m 1.2 to 1.6 kgf·m 8.6 to 11.5 lbf·ft 24.5 to 31.4 N·m 2.5 to 3.2 kgf·m 18.0 to 23.1 lbf·ft 34.3 to 49.0 N·m 3.4 to 5.0 kgf·m 25.3 to 36.1 lbf·ft C.
  • Page 14: Specifications

    CHAPTER 1 8454 3. SPECIFICATION MODEL 8454 Maximum PTO power 38 HP 45 HP Engine GROSS power 4A220 Engine Model Indirect injection, vertical, water-cooled, Type 4cycle diesel Number of cylinders 87 x 92.4 (3.425 x 3.638in.) Bore and stroke...
  • Page 15 www.mymowerparts.com 3. SPECIFICATION CON'T Drive system Tire size (Std. Tires) Front 9.5 - 16.6 Rear 14.9 - 24.8 Clutch Dry single disc Steering Hydrostatic steering system Synchronized shuttle Transmission 12 forward and 12 reverse speeds Brake Travel Wet disc type Parking Connected with the traveling brake Differential...
  • Page 16: Identifications

    CHAPTER 1 8454 4. IDENTIFICATION 4.1 ENGINE NUMBER Engine number is engraved in the left side of the cylin- der block as shown in the figure.Engine number fills the important role of providing it’s record. 569W103A (1) Engine Serial Number 4.2 SERIAL NUMBER OF THE...
  • Page 17: Caution Before Repair

    Apply When replacing part only genuine Cub Cadet parts. 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.
  • Page 18: Asbestos Parts

    CHAPTER 1 8454 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.
  • Page 19: Tubes And Rubbers

    www.mymowerparts.com GENERAL INFORMATION 5.7 TUBES AND RUBBERS 5.8 LUBRICANT 569W111A 569W112A Be cautious of oil or other petroleum products on the When assembling and fixing, apply designated lubri- hoses and rubber parts, this may cause damage. cant where specified in accordance with this repair manual.
  • Page 20: Regular Check List

    CHAPTER 1 8454 6. REGULAR CHECK LIST the first periodically Since Indicated Hours By Hour Meter Purchased Check Items 1500hr 1 y r 2 y r Engine oil change Engine oil filter cartridge change Transmission oil change Hydraulic oil filter change...
  • Page 21: Oil & Water Supply List

    www.mymowerparts.com GENERAL INFORMATION 7. OIL & WATER SUPPLY LIST Supply Items Capacity Recommended Spec. Fuel (42.3 U.S.gal.) No. 2 - D diesel fuel No. 1 - D diesel fuel if temperature is below - 10 °C (14 °F) Coolant (2.4 U.S.gal.) Fresh clean water with antifreeze Engine oil (1.8 U.S.gal.)
  • Page 22 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 23: Chapter 2. Engine

    www.mymowerparts.com CHAPTER 2 ENGINE K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 24 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 25: General

    www.mymowerparts.com ENGINE 1. GENERAL 1.1 APPEARANCE 569W201A The DAEDONG A series engines are vertical, water- cooled, 4-cycle, three or four cylinders diesel engines, they concentrate DAEDONG’s foremost technologies. With swirl combustion chamber, bosch K type fuel in- jection pump, well-balanced designs, they feature greater power, low fuel consumption, less vibration and noise, and low emission.
  • Page 26: Specifications

    CHAPTER 2 8454 1.2 SPECIFICATIONS MODEL 4A220 4A200T Type Vertical, water-cooled, Vertical, water-cooled, 4-cycle diesel engine 4-cycle diesel engine (Turbo) Number of cylinder Bore and stroke mm (in.) 87.0 x 92.4 (3.43 x 3.64) 83.0 x 92.4 (3.27 x 3.64) Total displacement cc (in 2,197(134.1 )
  • Page 27: Performance Curve

    www.mymowerparts.com ENGINE 1.3 PERFORMANCE CURVE 569W204A 569W203A D569-W02 May-2003 K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 28: Dimensions

    CHAPTER 2 8454 1.4 DIMENSIONS 569W205A Sample/td Spec. mm (in.) φ 400 (15.75) 4A220 697.3 (27.45) 817.3 (32.18) 280 (11.02) 502.6 (19.79) 262.5 (10.33) φ 400 (15.75) 4A200T 697.3 (27.45) 817.3 (32.18) 280 (11.02) 519 (20.43) 282.4 (11.12) φ 321 (12.64) 4A220 736 (28.98)
  • Page 29: Structure And Function

    www.mymowerparts.com ENGINE 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 intake 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.
  • Page 30 CHAPTER 2 8454 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 bear- ing case (3) having a bearing inside.
  • Page 31 www.mymowerparts.com ENGINE F. CAMSHAFT The camshaft (3) is made of forged steel and it’s jour- nals and cams are hardened to increase wear resistance. The cams on the camshaft open and close the intake and exhaust valves with the push rods and rocker arms.
  • Page 32 CHAPTER 2 8454 I. INTAKE AND EXHAUST VALVES The valve and its guide of the intake are different from those for the exhaust. Other parts, such as the spring, spring retainers, valve spring collets, valve stem seals are the same for both the intake and the exhaust. All contact or sliding surfaces are hardened to increase wear resistance.
  • Page 33: Lubricating System

    www.mymowerparts.com ENGINE 2.2 LUBRICATING SYSTEM A. FLOW OF LUBRICATING OIL The lubricating oil is forced to each journal through the oil passages of the cylinder block, cylinder head and shafts. The oil, splashed by the crankshaft or thrown off from the bearings, lubricates other engine parts such as the push rods (11), tappets (12), piston pins and timing gears.
  • Page 34 CHAPTER 2 8454 C. OIL FILTER AND RELIEF VALVE The lubricating oil force-fed by the pump is filtered by the filter cartridge, passing through the filter element from the outside to the inside. When the filter element accumulates dirt and the pressure difference between the inside and the outside rises more than 98 kPa (1.0 kgf/cm...
  • Page 35: Cooling System

    www.mymowerparts.com ENGINE 2.3 COOLING SYSTEM A. FLOW OF COOLING WATER The cooling system consists of a radiator (5), a cen- trifugal water pump (7), a cooling fan (6) and a thermo- stat (2). The water is cooled as it flows through the radiator core, and the fan behind the radiator pulls the cooling air through the radiator core.
  • Page 36 CHAPTER 2 8454 C. THERMOSTAT The thermostat is wax pellet type, which controls the flow of the cooling water to the radiator to keep the proper temperature. The case has a seat (1) and the pellet has a valve (2). The spindle attached to the case is inserted into the synthetic rubber in the pellet.
  • Page 37: Fuel System

    www.mymowerparts.com ENGINE 2.4 FUEL SYSTEM A. FLOW OF FUEL The fuel is fed from the fuel tank (1) through the fuel feed pump (7) to the injection pump (3) thru the fuel filter (2). The injection pump force-feds the fuel through the injection nozzles (5), which inject the fuel into the cylinders for combustion.
  • Page 38 CHAPTER 2 8454 C. FUEL FEED PUMP The diaphragm (6) is linked to the tappet (3) with a push rod (2). The tappet is reciprocated by the eccen- tric cam on the fuel camshaft (7). (A) Inlet stroke When the diaphragm is pulled down by the spring,...
  • Page 39 www.mymowerparts.com ENGINE a . Pump Element The pump element (1) consists of a plunger (3) and cylinder (2), their sliding surfaces are precision ma- chined to maintain fuel tightness. The plunger (3) fits in the control sleeve (5) at the driving surface (7). The sleeve is engaged with the control rack, which rotate the plunger in the cylinder to control the amount of fuel delivery.
  • Page 40 CHAPTER 2 8454 c. Amount of Fuel Delivery (A) No fuel delivery At the engine stop position of the control rack (3), the lengthwise slot (1) on the plunger (2) aligns with the feed hole (5). The delivery chamber (4) is led to the feed hole during the entire stroke of the plunger.
  • Page 41 www.mymowerparts.com ENGINE E. FUEL INJECTION NOZZLE The nozzle is a throttle-type. It features low fuel con- sumption and works well with DAEDONG combustion chamber. The nozzle valve opening pressure is about 13.7 to 14.7 MPa (140 to 150 kgf/cm , 1,991 to 2,134 psi), the pressure overcomes the counterforce of nozzle valve spring, and push the valve up instantly, the fuel is then injected in a proper quantity into the swirling air in...
  • Page 42 CHAPTER 2 8454 b. Operation of Governor a) At start The steel balls (13) have no centrifugal force. As the fork lever 1 (4) is pulled by the start spring (1), the control rack (14) moves to the maximum injection posi- tion.
  • Page 43 www.mymowerparts.com ENGINE c) At High Speed Running with a Load When a load is applied to an engine running at high speed, the engine speed drops and the centrifugal force of steel ball (13) becomes less, the fork lever 2 (5) is pulled forward by the governor spring 1 (2) and 2 (3), this increases the amount of fuel injected.
  • Page 44: Intake And Exhaust System

    CHAPTER 2 8454 2.5 INTAKE AND EXHAUST SYSTEM A. FLOW OF INTAKE AIR AND EXHAUST GAS (a) Intake Air (b) Exhaust Gas (1) Intake Manifold (2) Air Cleaner (3) Cylinder Head (4) Muffler (5) Exhaust Manifold 569W241A B. AIR CLEANER The air cleaner is dry-cyclone type and easy to maintain.
  • Page 45 ENGINE D. TURBOCHARGER (8454) The mechanism of turbocharger is the use of exhaust gas energy which rotates turbine and the power is transmitted to air compressor by a shaft. So it is pos- sible to supply more fuel to a cylinders and this will increase the power.
  • Page 46: Disassembling And Servicing

    CHAPTER 2 8454 3. DISASSEMBLING AND SERVICING 3.1 TROUBLESHOOTING Symptom Probable Cause Solution Engine Does Not Start • Not fuel Replenish fuel • Air in the fuel system Vent air • Water in the fuel system Change fuel and repair or flush fuel system •...
  • Page 47 www.mymowerparts.com ENGINE Symptom Probable Cause Solution Either White or Blue Exhaust • Excessive engine oil Reduce to the specified level Gas is Observed • Piston ring and bore worn or Repair or replace piston ring stuck • Incorrect injection timing Adjust •...
  • Page 48 CHAPTER 2 8454 Symptom Probable Cause Solution High Oil Pressure • Improper type of oil Use the specified type of oil • Relief valve defective Replace Engine Overheating • Engine oil insufficient Replenish • Fan belt broken or tensioned...
  • Page 49: Servicing Specifications

    www.mymowerparts.com ENGINE 3.2 SERVICING SPECIFICATIONS A. ENGINE BODY a . Cylinder Head Item Factory Specification Allowable Limit Cylinder Head Surface Flatness 0.05 mm / 100 mm 0.002 in. / 3.94 in. Top Clearance 0.75 ~ 0.9 mm 0.0295 ~ 0.0354 in. Cylinder Head Gasket Thickness Free 1.3 ~ 1.5 mm...
  • Page 50 CHAPTER 2 8454 d. Cylinder Bore Item Factory Specification Allowable Limit Cylinder bore inner 4A220 87.000 ~ 87.022 mm diameter 3.4252 ~ 3.4261 in. 0.15 mm 4A200T 83.000 ~ 83.022 mm 0.0059 in. 3.2677 ~ 3.2690 in. e . Valve Spring...
  • Page 51 www.mymowerparts.com ENGINE I. Timing Gear Item Factory Specification Allowable Limit Timing gear backlash 0.04 ~ 0.11 mm 0.15 mm 0.0016 ~ 0.0043 in. 0.0059 in. Idle gear side clearance 0.20 ~ 0.51 mm 0.9 mm 0.0079 ~ 0.0201 in. 0.035 in. Clearance between Idle gear shaft and idle 0.025 ~ 0.066 mm...
  • Page 52 CHAPTER 2 8454 l. Crankshaft Item Factory Specification Allowable Limit Crankshaft Misalignment 0.08 mm 0.0031 in. Clearance between Crankshaft and crank- 0.20 mm 0.040 ~ 0.118 mm shaft bearing 1 0.0079 in. 0.00157 ~ 0.00465 in. Crankshaft O.D 51.921 ~ 51.940 mm 2.04414 ~ 2.04489 in.
  • Page 53 www.mymowerparts.com ENGINE C. COOLING SYSTEM a . Thermostat Valve opening temperature at beginning 69.5 ~ 72.5 °C (157.1 ~ 162.5 °F) Opened completely (height 8 mm 0.315 in.) 85 °C (185 °F) b. Radiator Radiator tightness No leak at 137 kPa, 1.4 kgf/cm , 20 psi 10 seconds or more for pressure falling from 88 ~ 59 kPa...
  • Page 54 CHAPTER 2 8454 E. TIGHTENING TORQUES Item Size x Pitch N•m kgf•m lbf·ft Cylinder head screws M11 x 1.25 103.0 ~ 107.9 10.5 ~ 11.0 75.9 ~ 79.6 Head cover nuts M10 x 1.25 8.8 ~ 10.8 0.9 ~ 1.1 6.5 ~ 8.0...
  • Page 55: Checking, Disassembling And Servicing

    ENGINE 3.3 CHECKING, DISASSEMBLING AND SERVICING A. ENGINE DISASSEMBLED VIEW 615WA18A (1) Cylinder Block (7) Cylinder Head (12) Bearing Case Bolt 1 (18) Push Rod (24) Connecting Rod (30) Glow Plug (36) Engine Stop Solenoid (42) Fan Drive Pulley (48) Exhaust Manifold (2) Oil Pressure Switch (8) Head Bolt (13) Main Bearing Case...
  • Page 57 www.mymowerparts.com ENGINE B. EXTERNAL COMPONENTS a . Checking and Adjusting 1) Fan belt Measure the deflection, depressing the belt halfway between the fan drive pulley and the alternator pulley at 98 N (10 kgf, 22 lbs) of force. If the deflection is not between the factory specifications, loosen the bolts and nuts, and relocate the alternator to adjust.
  • Page 58 CHAPTER 2 8454 2) Solenoid 1. Disconnect the stop lever 1 (5) from the engine stop lever (2). 2. Remove the screw (3) and (4). 3. Remove the solenoid (7) with its support. (When reassembling) • Loosen the solenoid mounting screws.
  • Page 59 www.mymowerparts.com ENGINE C. ENGINE BODY a . Checking and Adjusting 1) Compression pressure 1. Run the engine until warmed up. 2. Stop the engine and remove the air cleaner, the muffler and all nozzle holders. 3. Connect a compression tester to the nozzle holder hole.
  • Page 60 CHAPTER 2 8454 2) Valve clearance 1. Remove the cylinder head cover and the timing win- dow cover on the flywheel housing and all glow plugs. 2. Turn the flywheel and align the 1 TC or 1.4 TC mark...
  • Page 61 www.mymowerparts.com ENGINE 2) Heat seal removal procedure 1. Drive screw driver lightly into the heat seal hole. 2. Turn screw driver three or four times each way. 3. While turning the screw driver, slowly pull the heat seal put together with the injection nozzle gasket. If the heat seal drops, repeat the above procedure.
  • Page 62 CHAPTER 2 8454 4) Cylinder head 1. Remove the screw in the specified sequence shown in the figure and remove the cylinder head (1) and head gasket. 2. Remove the water flange (2). 3. Take out the tappets from the cylinder block.
  • Page 63 www.mymowerparts.com ENGINE c. Timing Gears and Camshafts 1) Injection pump 1. Remove the injection pump cover (3) with the en- gine stop lever (2). 2. Remove the injection pump. (When reassembling) • Apply liquid gasket to the both sides of injection pump cover gasket and install it.
  • Page 64 CHAPTER 2 8454 3) Start spring 1. Remove the start spring (1) from the fork lever 1 (2). (When reassembling) • Be careful not to drop the start spring into the gear case. • Hook the start spring so that the longer hook is on the fork lever side.
  • Page 65 www.mymowerparts.com ENGINE 6) Water pump and relief valve 1. Remove the water pump body (1). 2. Remove the relief valve cover (2) and take out the ball, spring and seat. (When reassembling) • Install the relief valve cover (2) with its mark up. Tightening Relief valve 32.4 ~ 36.3 N·m...
  • Page 66 CHAPTER 2 8454 8) Camshaft 1. Align the holes on the cam gear (2) with the crews to loosen them through the holes with a T handle wrench. 2. Draw out the camshaft (1). 3. Remove the cam gear (2).
  • Page 67 www.mymowerparts.com ENGINE (B) Piston and connecting rod 1. Remove the screws and the connecting rod cap. 2. Push out the rod and piston assembly. (When reassembling) • Apply oil to the crankpin bearing, cylinder wall and connecting rod cap screw. •...
  • Page 68 CHAPTER 2 8454 • Install the piston and connecting rod with the mark FW on the piston to the flywheel and the mark on the connecting rod to the injection pump. • Install the piston rings with their manufacture’s mark to the top of the piston.
  • Page 69 www.mymowerparts.com ENGINE (B) Bearing case cover Loosen the screw first inside and next outside, and lift the cover (1) by screwing two screws gradually and evenly, referring to the photo. (When reassembling) • Apply grease to the oil seal lip and take care that it is not rolled when installing.
  • Page 70 CHAPTER 2 8454 IMPORTANT: • Mark a location line (6) to the bearing case, to pre- vent interchanging. (When reassembling) • Clean the parts and the oil passage of the bearing case. • Apply oil to the journal, bearing inserts and the bear- ing case screws.
  • Page 71 www.mymowerparts.com ENGINE (C) Valve stem clearance 1. Remove the carbon from the valve guide. 2. Measure the valve stem O.D. with an outside micrometer. 3. Measure the valve guide I.D. of cylinder head, and calculate the clearance. 4. If the measurement exceeds the allowable limit, replace the valve guide of the valve.
  • Page 72 CHAPTER 2 8454 (F) Valve spring 1. Measure the free length of the spring with venire calipers. 2. Place the spring on a spring compression tester and compress to the specified length, and get the tension. 3. If the measurement is less than the allowable limit, replace the valve spring.
  • Page 73 www.mymowerparts.com ENGINE b. Timing Gears and Camshafts (A) Timing gear backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear. 3. If the backlash exceeds the allowable limit, check the oil clearance of the shafts and the gear.
  • Page 74 CHAPTER 2 8454 (D) Injection pump gear side clearance 1. Pull the fuel camshaft and pull the injection pump gear (1) to each end. 2. Measure the clearance (A) between the injection pump gear (1) and the snap ring (2) on the fuel camshaft.
  • Page 75 www.mymowerparts.com ENGINE (G) Camshaft oil clearance 1. Measure the I.D. of the camshaft bore on the crank- case with an inside micrometer. 2. Measure the O.D. of the camshaft journal with an outside micrometer. 3. If the clearance exceeds the allowable limit, replace the shaft.
  • Page 76 CHAPTER 2 8454 c. Connecting Rod and Piston (A) Piston pin bore 1. Measure the I.D. of the piston pin bore in piston (lengthwise and widthwise of the piston) with a cyl- inder gauge. 2. If the measurement exceeds the allowable limit, replace the piston.
  • Page 77 www.mymowerparts.com ENGINE (D) Piston ring end gap 1. Push the ring into the cylinder to the lower limit of the ring travel in the assembled engine with a piston. 2. Measure the ring gap with a feeler gauge. 3. If the gap exceeds the allowable limit, replace the piston ring.
  • Page 78 CHAPTER 2 8454 (F) Connecting rod alignment 1. Remove the connecting rod bearing and install the bearing cap. 2. Install the piston pin in the connecting rod. 3. Install the connecting rod on the connecting rod alignment tool. 4. Put a gauge over the piston pin and move it against the face plate.
  • Page 79 www.mymowerparts.com ENGINE (B) Crankshaft alignment 1. Support the crankshaft with V blocks on the surface plate at its front and rear journals and set a dial indicator with its tip on the intermediate journal. 2. Rotate the crankshaft in the V blocks and get the misalignment (half of the measurement).
  • Page 80 CHAPTER 2 8454 (E) Crankshaft Journal and Bearing 2 Oil Clearance 1. Put plastic gauge lengthwise in the center of the journal. 2. Install the bearing cap and tighten the screw to the specified torque once, and remove the cap again.
  • Page 81 www.mymowerparts.com ENGINE e . Cylinder Bore (A) Cylinder bore diameter 1. Measure the cylinder liner I.D. at sit positions shown in the figure to find the maximum wear. 4A200T 83.000 ~ 83.022 mm 3.2677 ~ 3.269 in. 4A220 87.000 ~ 87.022 mm 3.4252 ~ 3.4261 in.
  • Page 82 CHAPTER 2 8454 E. LUBRICATING SYSTEM a . Checking (A) Engine oil pressure 1. Remove the oil pressure switch and install adap- tors and pressure tester. 2. Start the engine and run it until it is warmed up, and measure the oil pressure both at idling and rated speed.
  • Page 83 www.mymowerparts.com ENGINE b. Servicing (A) Rotor and lobe clearance of oil pump 1. Measure the clearance between the outer and in- ner rotor with a feeler gauge. 2. Measure the clearance between the outer and the housing with a feeler gauge. 3.
  • Page 84 CHAPTER 2 8454 F. COOLING SYSTEM a . Checking Adjusting (A) Fan belt 1. Measure the deflection, by depressing the belt half- way between the fan drive pulley and the alternator pulley at 98 N (10 kgf, 22 lbs) of force.
  • Page 85 www.mymowerparts.com ENGINE b. Disassembling and Assembling (A) Thermostat 1. Remove the thermostat cover (2). 2. Take out the thermostat (1). (When reassembling) • Apply liquid gasket (Three Bond 1215 or equivalent) to the gasket. 569W2C3A (1) Thermostat (2) Thermostat Cover (B) Water pump 1.
  • Page 86 CHAPTER 2 8454 G. FUEL SYSTEM a . Checking and Adjusting 1) Injection pump (A) Injection term (Injection timing) 1. Remove the injection pipes. 2. Set the speed control lever to the maximum fuel discharge position. 3. Turn the flywheel counterclockwise (facing the flywheel) until the fuel flows through the hole of the delivery valve holder (1).
  • Page 87 www.mymowerparts.com ENGINE (B) Delivery valve fuel tightness 1. Remove the injection pipes, glow plugs and the in- let manifold, and install a pressure tester. 2. With the speed control lever at the fuel injection po- sition, turn the crankshaft counterclockwise (facing the flywheel) until the pressure builds up to the fuel injection pressure.
  • Page 88 CHAPTER 2 8454 (B) Fuel tightness of needle valve seat tightness 1. Set the injection nozzle to the nozzle tester. 2. Apply a pressure 130 kgf/cm (12.75 mPa, 1,849 psi). After keeping the nozzle under this pressure for 10 seconds.
  • Page 89 www.mymowerparts.com ENGINE 2) Injection nozzle Nozzle Holder 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1), and take out the parts inside. (When reassembling) • Assemble the nozzle in clean fuel oil. • Install the push rod (4), nothing its direction.
  • Page 90 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 91: Chapter 3. Clutch

    www.mymowerparts.com CHAPTER 3 CLUTCH K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 92 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 93: Troubleshooting

    www.mymowerparts.com CLUTCH 1. TROUBLESHOOTING Symptom Provable Causes Solution Clutch slip • Clutch pedal play too small Adjust • Clutch disc facing worn Replace • Grease or oil on clutch disc facing Clean or replace • Distortion or damaged in clutch pressure plate Correct or replace and flywheel •...
  • Page 94: Specifications,Tightening Torques And Special Tools

    CHAPTER 3 8454 2. SPECIFICATIONS, TIGHTENING TORQUES AND SPECIAL TOOLS 2.1 SPECIFICATIONS Item Factory Specifications Allowable Limit Clutch pedal Free Play 20 ~ 30 mm 0.79 ~ 1.18 in. Safety switch Clearance 2 ~ 5 mm 0.079 ~ 0.197 in.
  • Page 95: Structure And Operation

    www.mymowerparts.com CLUTCH 3. STRUCTURE AND OPERATION The clutch is located between the engine and the trans- mission and is operated by stepping on the clutch pedal. When the clutch pedal is depressed, the clutch is disengaged and when it is released, the clutch is engaged and power from the engine is transmitted to the transmission.
  • Page 96: Operation

    CHAPTER 3 8454 3.3 OPERATION CLUTCH “ENGAGED” When the clutch pedal is not depressed, the clutch re- lease bearing (3) and the fingers of diaphragm spring (4) are not connected to each other. Accordingly, the pressure plate (6) is tightly pressed against the flywheel (8) by the diaphragm spring (4).
  • Page 97: Preparation Stage For Disassembling And Assembling

    www.mymowerparts.com CLUTCH 4. PREPARATION STAGE FOR DISASSEMBLING AND ASSEMBLING 4.1 SEPARATING PANEL FRAME ASSEMBLY PREPARATION 1 1. Removing the following parts. • Bonnet • Side Cover (RH, LH) • Side Skirt (RH, LH) • Battery Negative Code 569W303A (1) Side Cover (RH, LH) (4) Side Skirt (RH, LH) (2) Bonnet (5) Battery Negative Code...
  • Page 98 CHAPTER 3 8454 HYDRAULIC HOSES 1. Disconnect the main delivery hose (1), return hose (2), right turning delivery hose (3) and left turning delivery hose (4). (When reassembling) • In assembling the turning delivery hoses to the steering controller, connect the delivery hose with identification mark (type) “A”...
  • Page 99: Separating Engine And Clutch Housing Case

    www.mymowerparts.com CLUTCH 4.2 SEPARATING ENGINE AND CLUTCH HOUSING CASE PROPELLER SHAFT 1. Slide the propeller shaft covers (4), (5) after remov- ing to bolt (9). 2. Tap out the spring pin (10), and then slide the cou- pling (2) the front. (When reassembling) •...
  • Page 100: Disassembly

    CHAPTER 3 8454 SEPARATION THE ENGINE FROM CLUTCH HOUSING 1. Place the jack under the clutch housing case. 2. Hoist the engine by the nylon lift strap at the tank support. 3. Remove the engine mounting screws, and then pull the engine to the front.
  • Page 101: Adjustment Of Pedals

    www.mymowerparts.com CLUTCH 5. ADJUSTMENT OF PEDAL 5.1 DEFLECTION OF CLUTCH PEDAL A. Measure deflection of pedal by pushing clutch pedal (1) with hand. B. If the measurement is out of the factory spec, re- move lock nut (2) on clutch wire and adjust the length.
  • Page 102: Inspection And Repair

    CHAPTER 3 8454 6. INSPECTION AND REPAIR 6.1 WEAR AND DAMAGE ON CLUTCH DISC A. Measure the depth from clutch disc facing surface (1) to rivet (2). B. If the measurement is out of the allowable limit, replace it.
  • Page 103: Flatness Of Clutch Pressure Plate, Damages

    www.mymowerparts.com CLUTCH 6.3 FLATNESS OF CLUTCH PRESSURE PLATE, DAMAGES A. Measure several clearances with a space gauge along with a feeler gauge placed on the surface of the clutch pressure plate. B. If the measurement is out of the allowable limit, replace clutch cover assembly.
  • Page 104: Clearance Between Clutch Pedal Shaft And Clutch Pedal Bushing

    CHAPTER 3 8454 6.6 CLEARANCE BETWEEN CLUTCH PEDAL SHAFT AND CLUTCH PEDAL BUSHING A. Measure the outer diameter of clutch pedal shaft. B. Obtain the clearance by measuring the inner diam- eter of clutch pedal bushing. C. If the measurement is out of the allowable limit, replace it.
  • Page 105: Chapter 4. Transmission System

    www.mymowerparts.com CHAPTER 4 TRANSMISSION SYSTEM K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 106 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 107: Troubleshooting

    www.mymowerparts.com TRANSMISSION SYSTEM 1. TROUBLESHOOTING 1.1 TROUBLESHOOTING FOR SHUTTLE SHIFT IN OPERATION ERROR Symptom Provable Causes Solution Noise when the shuttle 1. Excessive deflection in the shuttle synchro Replace is shifted assembly (SPEC: 78.2) 2. Chamfering section damaged in the forward gear Replace (29 gear) and the reverse gear (24 gear) Gear is disconnected...
  • Page 108: Troubleshooting For Auxiliary And Creep Shifts In Operation Error

    CHAPTER 4 8454 1.3 TROUBLESHOOTING FOR AUXILIARY AND CREEP SHIFTS IN OPERATION ERROR Symptom Provable Causes Solution Gear shift disconnected 1. Damaged jaw at chamfering section of auxiliary Replace shift gear 2. Deficient traveling distance due to interference Correct interference with the exterior lever auxiliary shift: 10 mm, creep shift (if equipped): 10.5 mm...
  • Page 109: Troubleshooting For Front Wheel Drive In Operation Error

    www.mymowerparts.com TRANSMISSION SYSTEM 1.6 TROUBLESHOOTING FOR FRONT WHEEL DRIVE IN OPERATION ERROR Symptom Provable Causes Solution 1. Separated or unfixed φ 25 snap ring of front wheel Gear shift disconnected Assemble drive shaft 2. Deficient traveling distance due to interference with the exterior lever traveling distance: 20 mm (0.78 in.) Difficult to shift the front...
  • Page 110: Specifications

    CHAPTER 4 8454 2. SPECIFICATIONS 2.1 TIGHTENING TORQUES Middle case • Inlet bolts and nuts between middle N·m kgf·m lbf·ft case and transmission case. M12 (9T) 103.0 ~ 117.7 10.5 ~ 12.0 75.9 ~ 86.8 • 17 gear shaft lock nuts.
  • Page 111: Structure

    www.mymowerparts.com TRANSMISSION SYSTEM 3. STRUCTURE 3.1 POWER TRAIN DIAGRAM 569W401B D569-W03 June-2003 K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 112: Structure

    CHAPTER 4 8454 3.2 STRUCTURE 569W402B (1) Shuttle Shift Section (4) Clutch Pack for PTO (2) Main Gear Shift Section (5) Front Wheel Drive Shift Section (3) Hi-Low Range Shift Section (6) Creep Shift Section D569-W03 June-2003 K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 113: Power Train

    www.mymowerparts.com TRANSMISSION SYSTEM 3.3 POWER TRAIN 3.3.1TRANSMISSION 569W403A (A) Shifter (Shuttle Shift) (1) Shuttle Shaft (2) 26-26 Gear (B) Shifter (Main Shift 3-4 Stage) (3) 29-23-18-14 Gear (C) Shifter (Main Shift 1-2 Stage) (4) 17 gear Shaft (D) Shifter (Auxiliary Shift, Hi-Low) (5) 39-21 Gear (E) Shifter (Auxiliary Shift, Creep) (6) Auxiliary Shift Shaft...
  • Page 114 CHAPTER 4 8454 3.3.2SHUTTLE SHIFT SECTION 569W404A (A) Forward (B) Reverse D569-W02 May-2003 4-10 K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 115 www.mymowerparts.com TRANSMISSION SYSTEM 3.3.3MAIN SHIFT 569W405A (A) Forward (D) 2nd (B) Reverse (E) 3rd (C) 1st (F) 4th D569-W02 May-2003 4-11 K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 116 CHAPTER 4 8454 3.3.4AUXILIARY SHIFT 569W406A (A) High (B) Low (C) Creep 3.3.5FRONT WHEEL DRIVE 569W407A (A) Engaged D569-W02 May-2003 4-12 K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 117 www.mymowerparts.com TRANSMISSION SYSTEM 3.3.6PTO SHIFT 569W408A D569-W02 May-2003 4-13 K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 118: Shuttle Shift Section

    CHAPTER 4 8454 3.4 OPERATION 3.4.1FEATURES A. SHUTTLE • Synchro shuttle is applied with the features as below. 1. As for forward reverse switching over, the same stage in forward and reverse can be obtained if rais- ing slightly the shuttle lever from neutral and mov- ing forward and reverse straightly.
  • Page 119 www.mymowerparts.com TRANSMISSION SYSTEM First Stage An effort to place the main gear shift lever to the 3rd or 4th speed causes the shifter (5) and synchronizer keys (4) to move slightly. Then, the end surface of the synchronizer key (4) presses the synchronizer ring (7) against the cone- shaped portion of the gear (8).
  • Page 120: Main Shift

    CHAPTER 4 8454 Final Stage When the speed of the shifter (5) becomes the same as that of the gear (8), the force of the synchronizer ring (7) in its rotating direction is not applied to the shifter (5) and the rotation of the synchronizer ring (7) is no longer transmitted to the shifter (5).
  • Page 121: Auxiliary Shift

    www.mymowerparts.com TRANSMISSION SYSTEM C. AUXILIARY GEAR SHIFT • Composed of constant mesh with Hi/Low/Creep (option) rang shift available. 569W415A <Hi-Lo range shift section> (1) 17 Gear Shaft (5) 39-21 Gear (2) Auxiliary Gear Shifter Shaft (6) 43-21 Gear (3) Shifter (Hi/Low) (7) 39-17 Plain Gear (4) Shifter (Creep) (8) 39 Gear...
  • Page 122 CHAPTER 4 8454 E. PTO • PTO gear shift composed of constant mesh is avail- able to shift gear while PTO clutch is OFF. 569W417A <Power flow diagram> (1) PTO Clutch Shaft (4) 51 Gear (2) PTO Clutch (5) PTO Shaft...
  • Page 123: Pto Shift

    www.mymowerparts.com TRANSMISSION SYSTEM [PTO CLUTCH VALVE] A. OPERATION • In case PTO clutch switch is ON 569W419A (1) Clutch Body (8) Pressure Plate (14) Seal Ring (20) Bracket (2) Piston (9) Snap Ring (15) Spline Hub (21) Ball Bearing (3) Piston Ring (10) Clutch Disk (16) PTO Clutch Shaft (22) Snap Ring...
  • Page 124 CHAPTER 4 8454 • In case PTO clutch switch is OFF 569W420A (1) Clutch Body (8) Pressure Plate (14)Seal Ring (20) Bracket (2) Piston (9) Snap Ring (15) Spline Hub (21) Ball Bearing (3) Piston Ring (10) Clutch Disk...
  • Page 125 www.mymowerparts.com TRANSMISSION SYSTEM F. PTO SYSTEM a . Related Parts With the PTO Operation 569W421A (1) PTO Drive Shaft (2) 51 Gear (3) PTO Shaft b. Operation Principle of PTO If PTO switch is activated PTO clutch is engaged and then power from the engine is transmitted to PTO drive shaft (1) via PTO drive shaft 1.
  • Page 126: Preparation Stage For Disassembling And Assembling Transmission

    CHAPTER 4 8454 4. PREPARATION STAGE FOR DISASSEMBLING AND ASSEMBLING TRANSMISSION 4.1 DRAINING THE TRANSMISSION FLUID Draining the Transmission Fluid 1. Place oil pans underneath the transmission case. 2. Remove the drain plugs. 3. Drain the transmission fluid. 4. Reinstall the drain plugs (When refilling) •...
  • Page 127: Separating Panel Frame Assembly

    www.mymowerparts.com TRANSMISSION SYSTEM 4.2 SEPARATING PANEL FRAME ASSEMBLY Preparation 1 1. Removing the following parts. 569W424A (1) Side Cover (RH, LH) (2) Bonnet (3) Front Grille (4) Side Skirt (RH, LH) (5) Battery Negative Code Preparation 2 1. Disconnect the brake rods (4). 2.
  • Page 128 CHAPTER 4 8454 Hydraulic Pipes 1. Disconnect the main delivery hose (1), return hose (2), right turning delivery hose (3) and left turning delivery hose (4). (When reassembling) • In assembling the turning delivery hoses to the steering controller, connect the delivery hose with identification mark (tape) to the L port of the steer- ing controller.
  • Page 129: Separating Rear Fenders And Platform Assembly

    www.mymowerparts.com TRANSMISSION SYSTEM 4.3 SEPARATING REAR FENDERS AND PLATFORM ASSEMBLY Preparation 1. Remove the Rops. 2. Remove the Bolts (1) and take out the seat Assem- bly (2). 569W431A (1) Bolt (2) Seat Assembly Cover 1. Remove the bolts (1), (2) and the cover assembly (3).
  • Page 130 CHAPTER 4 8454 D. SEPARATING CLUTCH HOUSING Propeller Shaft 1. Slide the propeller shaft cover (4), (5) after remov- ing the bolt (9). 2. Tap out the spring pin (10) and then slide the cou- pling (2) to the front.
  • Page 131 www.mymowerparts.com TRANSMISSION SYSTEM Hydraulic Pipes 1. Loosen the screws (1), Bolt (2) and remove the suc- tion pipe (3). 2. Remove the pipe (4), (5), (6), (7). 569W440A (1) Screw (5) Pipe 1 (2) Bolt (6) Pipe 2 (3) Suction Pipe (7) PTO Pipe 2 (4) PTO Pipe 1 Shift Levers...
  • Page 132: Standard Table For Repair

    CHAPTER 4 8454 5. TO DISASSEMBLING AND TO ASSEMBLE 5.1 STANDARD TABLE FOR REPAIR Item Factory Spec Allowable limit 1. Clearance between thrust directions of shuttle 0 ~ 0.1 mm shaft and 17 gear shaft 0 ~ 0.0039 in.
  • Page 133 www.mymowerparts.com TRANSMISSION SYSTEM b. To Assemble 1. Assemble seal cap (11) and oil seal (12) using a jig on both sides of the clutch housing. 2. Assemble clutch lever (3) and release fork (4) after greasing the lip area of oil seal (12). 3.
  • Page 134 CHAPTER 4 8454 B. CLUTCH HOUSING AND MIDDLE CASE a. To Disassembling 1. Remove M12 bolts (3) at six places and nuts (4) at two places to loosen clutch housing (1) and middle case (2). 569W444A (1) Clutch Housing...
  • Page 135 www.mymowerparts.com TRANSMISSION SYSTEM C. MIDDLE CASE AND TRANSMISSION CASE a. To Disassembling 1. Remove bolt (3) at 4 places and nuts (4) at 4 places on assembling surfaces of middle case (1) and transmission case (2), and separate the middle case and the transmission case.
  • Page 136 CHAPTER 4 8454 D. SHUTTLE SHIFT COVER a. To Disassembling 1. Remove washer mounting bolts (12), (13) at 4 place to loosen shuttle shift cover (11). 2. Loosen snap ring (9) to draw shift arm (8) out of shift cover (11).
  • Page 137 www.mymowerparts.com TRANSMISSION SYSTEM E. MAIN SHIFT FORK a. To Disassembling 1. Remove main shift cover bolts (16) at 8 places on the middle case side to loosen main shift cover (1). 2. Loosen fork mounting spring pin (13). 3. Remove fork rod (9) to Disassembling pin (10), steel ball (8) and spring (7).
  • Page 138 CHAPTER 4 8454 F. AUXILIARY SHIFT COVER a. To Disassembling 1. Remove auxiliary shift cover bolt (11) on the middle case side to loosen auxiliary shift cover (10) in a body. 2. Disassembling the shifting arm (7) from the auxil- iary shift cover (10).
  • Page 139 www.mymowerparts.com TRANSMISSION SYSTEM G. FRONT WHEEL DRIVE LEVER a. To Disassembling 1. Loosen shifter (front wheel) (5), and Disassembling 2 shift mounting steel balls (6) and spring (7). 2. Loosen stopper mounting bolt (4) and remove stop- per (3). 3. Draw out shift arm (1) by pushing inside the middle case.
  • Page 140 CHAPTER 4 8454 H. AUXILIARY SHIFT GEAR a. To Disassembling 1. Remove middle case and transmission case. 2. Remove middle case and main shift cover. 3. Loosen with washer bolt (23) and Disassembling the auxiliary shift gear fixed on middle case and bearing case (for auxiliary shift) (22).
  • Page 141 www.mymowerparts.com TRANSMISSION SYSTEM 10. Locate fork rod (for Hi-Lo shift) (27) and shift fork (for Hi-Lo shift) (26) at right position. 11. After pushing the sub-assembled of bearing case (22) forward from the back of the middle case to be aligned with the position of parallel pin (21), knock in and fix it with four with washer bolts (23).
  • Page 142 CHAPTER 4 8454 J. REVERSE IDLE SHAFT AND IDLE GEARS a . To Disassembling 1. Remove mounting bolt (1) and seal washer (4) at the side of the middle case. 2. Remove thrust collar (5), needle bearing (6), 21 gear (7) and spacer (8) in due order with M8 x P 1.25...
  • Page 143 www.mymowerparts.com TRANSMISSION SYSTEM a . To Disassembling 1. Remove four M8 washer mounting bolts to loosen bearing cover (23). 2. Remove the caulking on 28 nut (22) to loosen the nut. 3. Slightly knock the end part of 17 gear shaft (1) backward (toward the transmission case) to re- move 17 gear shaft (1).
  • Page 144 CHAPTER 4 8454 L. SHAFT 2 569W457A (1) Snap Ring (5) O-Ring (9) Ball Bearing (12) Ball Bearing (2) Ball Bearing (6) Bearing Case (10) Oil Seal (13) Snap Ring (3) 29-23-18-14 Gear (7) Bolt (11) Snap Ring (14) Propeller Shaft 1...
  • Page 145 www.mymowerparts.com TRANSMISSION SYSTEM M . PTO DRIVE SHAFT 569W459A (1) PTO Drive Shaft (4) Snap Ring (2) Oil Seal (5) Snap Ring (3) Ball Bearing a. To Disassembling b. To Assemble 1. Separate the middle case and the transmission 1. Sub-assemble snap ring (4), 6005DD ball bearing case.
  • Page 146 CHAPTER 4 8454 N. PTO CLUTCH a. To Disassembling 1. Remove the middle case and the transmission case. 2. Remove snap ring (1) and spacer (2) fixed of the PTO clutch shaft. 3. Loosen φ 62 snap ring (3) on PTO clutch bracket (5).
  • Page 147 www.mymowerparts.com TRANSMISSION SYSTEM b. To Assemble 1. Install piston rings (3), (4) on the inner and outer sections of the piston bore, and apply grease. 2. Fix piston (2) on PTO clutch body (1). 3. Install needle bearing (13) on the inner bore and sealing (14) on the outer bore of PTO clutch body (1), and apply grease.
  • Page 148 CHAPTER 4 8454 O. PTO SHAFT a . To Disassembling 1. Loosen the bolts (1) and remove the PTO shaft as- sembly (2) ~ (13) as a unit. 2. Remove 6305 NR bearing (11) fixed on PTO shaft (9).
  • Page 149 www.mymowerparts.com TRANSMISSION SYSTEM Clearance Between Gear and Shaft 1. Measure the shaft O.D. (rubbing surface). 2. Measure the gear I.D. (rubbing surface). 3. Measure the O.D. of the two needles installed di- agonally in the needle bearing. 4. Calculate the clearance. (Clearance=Gear I.D.-{ (2 x needle O.D.)+shaft O.D.} 5.
  • Page 150 CHAPTER 4 8454 Side Clearance Between Synchronizer Ring and Gear (In Contact) 1. Press the synchronizer ring against the tapered portion of the gear, and measure the side clearance. 2. Apply thin film of red lead to the tapered portion, press the ring against it by hand, rub them together a few times, and check the contact.
  • Page 151 www.mymowerparts.com TRANSMISSION SYSTEM 5. Apply red lead lightly over several teeth at three po- sitions equally spaced on the spiral bevel gear (3). 6. Turn the spiral bevel pinion (1) while pressing a wooden piece against the periphery of the spiral bevel gear (3).
  • Page 152 CHAPTER 4 8454 Replace adjusting shim (8) with thinner one to move the bevel pinion shaft forward. And place the right side shim (5) to the left to move the bevel gear leftward. Repeat above until the proper tooth contact and back- lash are achieved.
  • Page 153 www.mymowerparts.com TRANSMISSION SYSTEM Thickness of Seal Ring 1. Measure the thickness of seal rings with an out- side micrometer. 2. If the measurement is less than the allowable limit, replace it Thickness of Factory 2.95 ~ 3.0 mm seal ring spec.
  • Page 154 CHAPTER 4 8454 P. REAR AXLE • Rear axle to transmit power shifted at the transmis- • Rear axle is driven as decelerated much by the plan- sion to the rear wheels finally is composed of brake, etary gear, while differential gear is applied to dis- differential lock and final reduction gear.
  • Page 155 www.mymowerparts.com TRANSMISSION SYSTEM A. REAR AXLE 569W484A D569-W02 May-2003 4-51 K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 156 CHAPTER 4 8454 DIFFERENTIAL GEAR • Differential gear is structured with four pin type. • Differential gear is operated by sharing out suitable revolution considering related conditions for the wheels left and right to lead turning of the tractor and traveling on curved or uneven road to be smooth.
  • Page 157 www.mymowerparts.com TRANSMISSION SYSTEM B. OPERATION OF THE REAR AXLE The final reduction system has a planetary gear system. It is compact, and is durable under heavy loads since torque loads are spread over three gears, decreasing the load on each tooth. And this system also spreads the load evenly around the circumference of the system, eliminating the sideways stress on the shafts.
  • Page 158 CHAPTER 4 8454 C. POWER FLOW OF THE REAR DIFFERENTIAL GEAR 569W489A a . Related Parts with the Rear Differential b. Operation Principle of the Rear Differential Gear Gear (1) Spiral Bevel Pinion Power is transmitted from spiral bevel pinion (1) via 39...
  • Page 159: Differential Gear

    www.mymowerparts.com TRANSMISSION SYSTEM 6. DIFFERENTIAL GEAR 6.1 STRUCTURE The differential gear assembly is a mechanism to pro- vide smooth steering. It automatically provides different optimum torques to the right and left wheels according to road resistance and braking friction at the wheels. The differential gear assembly is composed of the dif- ferential case, differential pinions, differential side gears, differential pinion shaft, spiral bevel gear, etc.
  • Page 160: Operation

    CHAPTER 4 8454 6.2 OPERATION TRAVELING STRAIGHT AHEAD <The Condition of Engaged the Diff. Lock Gear> Rotation of the spiral bevel pinion (7) is transmitted to the spiral bevel gear (2) bolted to the differential case (3). When road resistance to the right and left wheels...
  • Page 161: Locking Of The Differential Gear

    www.mymowerparts.com TRANSMISSION SYSTEM 6.3 LOCKING OF THE DIFFERENTIAL GEAR 569W493A a . Related Parts with the Operation of the b. Operation Principle of the Differential Gear Differential Gear If differential pedal (1) is pressed down, the differential (1) Differential Pedal rod connected to the pedal gets pulled forward and differential mounting fork shaft (3) gets rotated.
  • Page 162 CHAPTER 4 8454 Differential Lock When resistances to the right and left tires are different due to ground conditions or type of work, the wheel with less resistance slips and prevents the tractor from moving ahead. To compensate for this, the differential lock restricts the differential function and causes both rear axles to rotate as a unit.
  • Page 163 www.mymowerparts.com TRANSMISSION SYSTEM A. DIFFERENTIAL LOCK ASSEMBLY a . To Disassembling 1. Remove spring pin (7). 2. Take out snap pin (3) and Disassembling plane washer and pin (2). 3. Take out differential lock fork shaft (4) and remove differential lock fork (1). b.
  • Page 164 CHAPTER 4 8454 C. REAR DIFFERENTIAL GEAR GROUP 569W497A (1) Differential Gear Ass’y (10) Key (18) Differential Lock Shift (2) Spiral Bevel Gear Ass’y (11) Differential Pinion (19) Differential Bearing Case (LH) (3) Spiral Bevel Gear (12) Differential Pinion Washer...
  • Page 165 www.mymowerparts.com TRANSMISSION SYSTEM Confirmation of Reaching Up Apply minimum lightly on several thrashing faces at 3 equally divided positions in the circle circumference of the spiral bevel gear and turn the shaft of the spiral bevel pinion with a load on the spiral bevel gear, then to confirm its reaching up.
  • Page 166 CHAPTER 4 8454 E. BRAKE CASE 569W4A0A (1) Straight Pin (8) Nut (14) Nut (20) 13 Gear Shaft (2) Ball Sheet (9) Spring Washer (15) Bolt (21) Brake Case (3) Ball (10) Bolt (16) Spring Washer (22) 68 Internal Gear...
  • Page 167 www.mymowerparts.com TRANSMISSION SYSTEM F. REAL AXLE ASSEMBLY 569W4A1A (1) Bolt (7) Plate (13) Nut (18) O-Ring (2) Spring Washer (8) 13 Gear Shaft (14) Ball Bearing (19) Bearing Cover (3) Stud (9) 68 Internal Gear (15) Oil Seal (20) Bolt (4) Nut (10) Planetary Gear Support (16) Planetary Gear...
  • Page 168 CHAPTER 4 8454 Stud for assembly Tightening 196.2 ~ 225.6 N·m of the rear axle torque 20.0 ~ 23.0 kgf·m and the rim 144.7 ~ 166.3 lbf·ft Mounting bolt of 48.0 ~ 55.9 N·m the bearing cover 4.90 ~ 5.70 kgf·m of the rear axle 35.4 ~ 41.2 lbf·ft...
  • Page 169 www.mymowerparts.com TRANSMISSION SYSTEM • Differential Gear Assembly 1. Remove the differential support, nothing the num- ber of left shims. 2. Take out the differential gear assembly, nothing the number of right shims. (When reassembling) • Check the spiral bevel gear for wear or damage. If it is no longer serviceable, replace it.
  • Page 170 CHAPTER 4 8454 • Spiral Bevel Gear 1. Remove the spiral bevel gear. (When reassembling) • Check the spiral bevel gear for wear or damage. If it is no longer serviceable, replace it. Then, also re- place the spiral bevel pinion.
  • Page 171 www.mymowerparts.com TRANSMISSION SYSTEM [A] FIT Groove (1) Differential Pinion Shaft (2) Differential Pinion (3) Differential Pinion (4) Differential Pinion Washer (5) Differential Pinion Shaft 2 (6) Differential Side Gear (7) Differential Side Gear Washer (8) Differential Cover (9) Differential Case (10) Differential Lock Shifter 569W4A9A (11) Spiral bevel Gear...
  • Page 172 CHAPTER 4 8454 • Clearance Between Gear and Spline or Hub and Spline 1. Select the gear or the hub in a vise. 2. Set a dial gauge (lever type) with its finger on the spline. 3. Move the shaft (or hub) to measure the clearance.
  • Page 173 www.mymowerparts.com TRANSMISSION SYSTEM • Clearance Between Differential Case Bore (Differential Case Cover Bore) and Differen- tial Side Boss 1. Measure the bore I.D. of the differential case and differential case cover. 2. Measure the differential side gear boss O.D. and calculate the clearance.
  • Page 174 CHAPTER 4 8454 • Clearance Between Differential Pinion Shaft and Differential Pinion 1. Measure the differential pinion shaft O.D 2. Measure the differential pinion I.D and calculate the clearance. 3. If the clearance exceeds the allowable limit, replace them.
  • Page 175: Chapter 5. Front Axle

    www.mymowerparts.com CHAPTER 5 FRONT AXLE K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 176 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 177: Troubleshooting

    www.mymowerparts.com FRONT AXLE 1. TROUBLESHOOTING Symptom Provable causes Solution Reference page Front wheels - Tire pressure uneven Adjust wander to right or - Improper toe-in adjustment Adjust left (improper alignment) - Clearance between front axle case boss and Replace front axle bracket (front, rear) bushing excessive - Front axle rocking force too small Adjust - Front wheel sway excessive...
  • Page 178: Specifications

    CHAPTER 5 8454 2. SPECIFICATIONS Item Factory Specification Allowable Limit Front wheel alignment Toe-in 2 ~ 8 mm 0.08 ~ 0.32 in. Front wheel Axial sway Less than 5 mm 0.20 in. Front axle Rocking force 49.0 ~ 117.7 N 5.0 ~ 12.0 kgf...
  • Page 179 www.mymowerparts.com FRONT AXLE Item Factory Specification Allowable Limit Differential pinion to differential side Backlash 0.1 ~ 0.3 mm gear shim 0.004 ~ 0.012 in. Thickness 0.1 mm 0.0039 in. 0.1mm 0.0078 in. 0.2 mm 0.0157 in. 1.6 mm 0.0630 in. Spiral bevel pinion shaft Turning Torque 1.27 ~ 1.667 N·m...
  • Page 180: Structure

    CHAPTER 5 8454 3. STRUCTURE 3.1 OPERATION 569W501A (1) Front Axle Support (10) Front Axle Case (2) Bevel Gear (11) Front Differential Case (3) Bevel Gear Case (12) Differential Side Gear (4) Differential Shaft (13) Differential Pinion (5) 16 Bevel Gear...
  • Page 181: Front Wheel Alignment

    www.mymowerparts.com FRONT AXLE 3.2 FRONT WHEEL ALIGNMENT Front wheel alignment is a term given to mean four angle settings in three dimensions: camber, kingpin inclination, toe-in and caster angle. These angle set- tings are made for the following purposes. (1) Camber The front wheels are tilted from the vertical as viewed from the front, the wheels are farther apart at the top than at the bottom.
  • Page 182: Toe-In Adjustment

    CHAPTER 5 8454 (4) Toe-in Viewing the front wheels from above reveals that the distance between the front wheels is less at the front than at the rear. This turning in of the front wheels is called toe-in. The front wheels tend to roll outward due to the camber, but toe-in offsets this and ensures parallel rolling of the front wheels.
  • Page 183: Rocking Force Of The Front Axle, Deflection In Front & Rear Directions

    www.mymowerparts.com FRONT AXLE 2. If the difference between direction control angles left and right exceeds 1.5 °, adjust it with adjusting washer (1) in F. The direction control angle increases, if the number of adjusting washers decreases, and vice versa. •...
  • Page 184: Preparation Stage For Disassembling And Assembling

    CHAPTER 5 8454 4. PREPARATION STAGE FOR DISSEMBLING AND ASSEMBLING 4.1 SEPARATING FRONT AXLE DRAINING FRONT AXLE CASE OIL 1. Place oil pans underneath the front axle case. 2. Remove the drain plug (1) both sides and filling port plug (3) to drain the oil.
  • Page 185 www.mymowerparts.com FRONT AXLE TIE-ROD 1. Remove the tie-rod. In this case, take special care not to damage the tie-rod (1) and slotted nuts (2). (When reassembling) Tightening Slotted nut 245.2 ~ 284.5 N·m torque 25.0 ~ 29.0 kgf·m 180.8 ~ 209.8 lbf·ft Tie-rod lock nut 245.2 ~ 284.5 N·m 25.0 ~ 29.0 kgf·m...
  • Page 186: Front Axle Case And Front Axle

    CHAPTER 5 8454 5. TO DISASSEMBLING AND TO ASSEMBLE 5.1 FRONT AXLE CASE AND FRONT AXLE A. TO DISASSEMBLING 1. Remove sixteen M8 washer mounting bolts (3) on front axle case (1) and front axle cover (2) to Disas- sembling the front axle group out of front axle case (1).
  • Page 187: Bevel Gear Case And Front Axle Case

    www.mymowerparts.com FRONT AXLE 5.2 BEVEL GEAR CASE AND FRONT AXLE CASE 569W519A (1) Bolt (8) Snap Ring (13) 6011 Ball Bearing (18) Snap Ring (2) Bearing Cover (9) Shim (14) Snap Ring (19) Housing (3) Shim (10) 6208 Ball Bearing (15) Front Axle Case (20) O-Ring (4) Ball Bearing...
  • Page 188: Bevel Gear Case And Front Axle Support

    CHAPTER 5 8454 5.3 BEVEL GEAR CASE AND FRONT AXLE SUPPORT A. TO DISASSEMBLING 1. Remove four M14 bolt and two nuts (3) to separate separate bevel gear case (1) and front axle support (8). B. TO ASSEMBLE 1. Install two parallel pins (6) and two stud (5) on bevel gear case (1).
  • Page 189: Front Axle Support And Differential Gear Case

    www.mymowerparts.com FRONT AXLE 5.4 FRONT AXLE SUPPORT AND DIFFERENTIAL GEAR CASE A. TO DISASSEMBLING 1. Remove bolts (4), (6) on the assembly of front axle support (1) and differential gear case to Disassem- bling differential gear case ass’y (2) in a body. B.
  • Page 190: Front Differential Gear

    CHAPTER 5 8454 5.5 FRONT DIFFERENTIAL GEAR 569W522A (1) Front Differential Bearing Support (11) Ball Bearing (21) Parallel Pin (2) Spring Washer (12) 27 Bevel Gear (22) 8 Bevel Pinion Shaft (3) Bolt (13) UBS Bolt (23) Taper Roller Bearing...
  • Page 191 www.mymowerparts.com FRONT AXLE B. TO ASSEMBLE 1. Sub-assemble the inner rim of taper roller bearing (23) on 8 bevel pinion shaft (22). 2. Sub-assemble the outer rim of taper roller bearing (23), shim (24) and the outer rim of taper roller bear- ing (25) on differential gear case ass’y (5).
  • Page 192 CHAPTER 5 8454 9. Install shim (10), ball bearing (11), two parallel pins (6) on differential gear case (5) and tighten case cover (7) with two M12 bolts (9). 10. Sub-assemble ball bearing (4) on front differen- tial bearing support (1) and push into differential gear case ass’y (5) to tighten with five M10 bolts...
  • Page 193: Front Bracket

    www.mymowerparts.com FRONT AXLE 5.6 FRONT BRACKET A. TO DISASSEMBLING 1. Remove mounting nut (7), bolt (6) and seal washer (8). 2. Separate front bracket (2) from front axle support (1). 3. Remove two oil seals (5), DX bush (4) and adjust- ing plate (3) in front bracket (2).
  • Page 194: Rear Bracket

    CHAPTER 5 8454 5.7 REAR BRACKET A. TO DISASSEMBLING 1. Separate front axle support (1) and rear bracket ass’y (2). 2. Remove thrust collar (3), DX bushing (4) and two oil seals (5). 3. Remove O-ring (7). 4. Remove grease nipple (6).
  • Page 195: Hydraulic Lift System

    www.mymowerparts.com CHAPTER 6 HYDRAULIC SYSTEM K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 196 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 197 www.mymowerparts.com HYDRAULIC SYSTEM 1. HYDRAULIC POWER LIFT SYSTEM 569W601B D569-W03 June-2003 K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 198 Several implements can be attached at a time for their applications owing to the outlet valve of the exterior oil pressure equipped on the rear of the power lift body in 8454. D569-W02 May-2003 K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 199: Troubleshooting

    www.mymowerparts.com HYDRAULIC SYSTEM 1.1 TROUBLESHOOTING Symptom Probable Cause Solution The Rockshaft lifts jerkily. • Insufficient oil level in the tank. • Top up the level. • Pump inlet filter clogged. • Clean or replace the filter. • Infiltration of air into the pump •...
  • Page 200: Specifications

    CHAPTER 6 8454 1.2 SPECIFICATIONS A. TECHNICAL FEATURES a. Operation with drawbar pull and position control. b. Drawbar pull survey at hitch point. c. Implement lowering speed adjusted by control valve lowering regulator. d. Automatic hydraulic limit stop of angular excursion of lifting arms.
  • Page 201 www.mymowerparts.com HYDRAULIC SYSTEM D569-W03 June-2003 K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 202 CHAPTER 6 8454 D569-W03 June-2003 K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 203: Structure And Operation

    (4) Front Hydraulic Block (9) Oil Tank (Transmission Case) (5) Quick Couplers (If Equipped) The hydraulic system of the 8454 tractor is composed 3. Take out hydraulic power from the quick couplers of the main components as shown in the figure.
  • Page 204 CHAPTER 6 8454 B. HYDRAULIC CIRCUIT FOR THREE POINT HYDRAULIC SYSTEM 569W606B (1) Oil Tank (Transmission Case) (6) Front Hydraulic Block (2) Hydraulic Oil Filter Cartridge (7) Position Control Valve (3) Hydraulic Pump (8) Hydraulic Cylinder (4) Engine (9) Auxiliary Control Valve (If Equipped)
  • Page 205 www.mymowerparts.com HYDRAULIC SYSTEM C. HYDRAULIC CYLINDER VALVES a . Control Valve Control valve detects load on the implement as com- posed of such valve to control the lifting and lowering of the lift arm at a constant speed always. Since block- ing of valve oil leakage is available inside, oil lock grip- per is necessary.
  • Page 206 CHAPTER 6 8454 2. Circuit Diagram 569W609A 6-12 D569-W03 June-2003 K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 207 www.mymowerparts.com HYDRAULIC SYSTEM 3. Operation Principle Since the control valve of the hydraulic cylinder is avail- able to control oil flowing in and out of the hydraulic cylinder so to control the implement up and down at a constant speed regardless of the implement load, high work performance can be achieved without impact, along with the operation principle classified into 3 phases of neutral, delivery and discharge.
  • Page 208 CHAPTER 6 8454 569W611A (1) Control Spool (18) Annular Duct (2) Regulator Piston (19) Annular Duct (3) Check Valve (20) Hole (6) Fixed Throat (21) Hole (7) Safety Valve (22) Chamber (15) Chamber (23) Cylinder Chamber (17) Hole b. Delivery Phase...
  • Page 209 www.mymowerparts.com HYDRAULIC SYSTEM 569W612A (1) Control Spool (17) Hole (2) Regulator Piston (18) Annular Duct (4) Exhaust Valve (23) Cylinder Chamber (8) Regulator (24) Hole (15) Chamber (25) Hole (16) Exhaust Hole c. Discharge Phase During this phases the control valve supplies at the At the same time the oil contained in the cylinder cham- same time the oil coming from the pump and the oil ber (23) flows from annular duct (18) to the lowering...
  • Page 210 CHAPTER 6 8454 6-16 D569-W03 June-2003 K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 211 www.mymowerparts.com HYDRAULIC SYSTEM D. CONNECTION SYSTEM OF THE INTERNAL LEVERAGE a. Structure 569W615A (1) Lever (11) Shaft (21) Roller 2 (31) Arm (2) Needle Bearing (12) Spring Pin (22) Snap Ring (32) Nut (3) Washer (13) C a m (23) Link 3 (33) Bolt (4) Packing (14) Snap Ring...
  • Page 212 CHAPTER 6 8454 E. OPERATION Operation is Divided Into Position Control, Draft Control and Mixed Operation. a . Position Control 569W616A (1) Position Control Lever (6) Cam 1 (11) Roller 4 (2) Draft Control Lever (7) Lever (12) C a m...
  • Page 213 www.mymowerparts.com HYDRAULIC SYSTEM b. Draft Control (Fig. 632W616A,632W617A) 569W617A (1) Position Control Lever (11) Roller 4 (19) Fly Wheel (2) Draft Control Lever (12) C a m (20) Hitch Point (3) Shaft (15) Crank (21) Shaft (7) Lever (16) Shaft (22) Pin (8) Friction Shock Absorber (17) Rod...
  • Page 214 CHAPTER 6 8454 c. Combined Operation of Positioning and When roller 4 (11) meets the inclined plane of the draw- Drawbar Pull bar pull cam (12), it permits the counterclockwise rota- (Fig. 569W616A,569W617A) tion of lever (7) which by means of shock absorbers (8)
  • Page 215 www.mymowerparts.com HYDRAULIC SYSTEM F. HYDRAULIC POWER TAKE OFF If necessary, hydraulic power for implements can be taken out from front hydraulic block or using auxiliary control valves and quick couplers. • Hydraulic power for the front loader can be taken out from hydraulic block.
  • Page 216 CHAPTER 6 8454 b. Auxiliary Control Valve A double acting detent type auxiliary control valve is used, and the construction is shown in the figure right. When the auxiliary control valve operating lever is moved to the implement cylinder actuating position, the spool is moved and the oil from the pump port flows into A to B, causing the implement cylinder to operate.
  • Page 217 www.mymowerparts.com HYDRAULIC SYSTEM e . Relief Valve (Hydraulic Block) • As shown in the figure, a guide is attached at pop- pet (6) and valve chamber D.C (damping chamber) located at the bottom of the guide piston. Intake of valve enable through sliding part of guide and clear- ance of seat (5) to chamber and minimizes valve vibration as damping effect of chamber.
  • Page 218 CHAPTER 6 8454 G. TOP LINKAGE BRACKET a . Structure 569W627A (1) Top Linkage bracket (7) Bolt (12) Plate (17) Tie Rod (2) Flange (8) Lock Washer (13) Bolt (18) Spring Peaks (3) Cover (9) Bolt (14) Lock Washer...
  • Page 219: Preparation Stage For Disassembling And Assembling

    www.mymowerparts.com HYDRAULIC SYSTEM 1.4 PREPARATION STAGE FOR DISASSEMBLING AND ASSEMBLING A. DRAINING THE TRANSMISSION FLUID 1. Place oil pans underneath the transmission case. 2. Remove the drain plugs. 3. Drain the transmission fluid. 4. Reinstall the drain plugs (When refilling) •...
  • Page 220 CHAPTER 6 8454 Cover 1. Remove the bolts (1), (2) and the cover assembly (3). 569W631A (1) Bolt (3) Cover (2) Bolt C. FENDER, FLOOR SEAT AND PLATFORM ASSEMBLY 1. Remove the fender (1, 2), floor seat and platform as a unit.
  • Page 221 www.mymowerparts.com HYDRAULIC SYSTEM 1.5 DISASSEMBLING AND ASSEMBLING A. AUXILIARY CONTROL VALVES 569W635B (1) Pipe A (8) Joint Bolt 2 (15) O-Ring (16) Flange (2) Pipe B (9) Quick Coupler (12) Stud (17) Washer (5) Bracket (10) Bolt (13) Auxiliary Valve (18) Nut (6) O-Ring (11) Seal Washer...
  • Page 222 CHAPTER 6 8454 B. HYDRAULIC CYLINDER ASSEMBLY 1. Loosen the joint bolt (1). 2. Loosen and remove the hydraulic cylinder assem- bly mounting bolts ((6), (7), (8), (9)), spring wash- ers (5) and nuts (4). 3. Support the hydraulic cylinder assembly with nylon lift strap and hoist, and then take out it.
  • Page 223 www.mymowerparts.com HYDRAULIC SYSTEM D. DISTRIBUTOR VALVE (CONTROL VALVE) 1. Loosen and remove the control valve (distributor valve) mounting screws (1). 2. Take out the control valve (3). (When reassembling) • Take care not to damage the O-ring. Tightening Mounting bolt 23.6 ~ 27.4 N·m torque 2.4 ~ 2.8 kgf·m...
  • Page 224 CHAPTER 6 8454 F. BUSHINGS 1. Remove the bushings (1) and (2). (When reassembling) • Apply transmission oil to the hydraulic cylinder boss and bushings. 569W641A (1) Bushing (2) Bushing 6-30 D569-W02 May-2003 K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 225 www.mymowerparts.com HYDRAULIC SYSTEM G. CONTROL 569W642B (1) Control Valve Ass’y (10) Cover (19) O-Ring (28) Screw (37) O-Ring (2) Spacer (11) Valve (20) O-Ring (29) Nut (38) O-Ring (3) Rubber (12) Valve (21) Pin (30) Nut (39) Plug (4) Lever Ass’y (13) Spring (22) Valve Seat (31) Spring...
  • Page 226 CHAPTER 6 8454 H. DOUBLE ACTING VALVE 569W643B (1) Double Acting Valve Ass’y (9) Valve (17) Screw (24) Roller (2) Valve Body (10) Spring (18) Screw (25) Plug (3) Spool (11) Valve Sheet (19) Nut (26) O-Ring (4) O-Ring...
  • Page 227 www.mymowerparts.com HYDRAULIC SYSTEM I. TOP LINK BRACKET 569W644A (1) Top Link Bracket (7) Bolt (12) Plate (17) Tie Rod (2) Flange (8) Lock Washer (13) Bolt (18) Spring Peaks (3) Cover (9) Bolt (14) Lock Washer (19) Crank (4) Spring (10) Pin (15) Roller (20) Pin...
  • Page 228 CHAPTER 6 8454 J. CHECK AND ADJUSTMENT a . Hydraulic Cylinder Bore 1. Check the cylinder inside surface for scratches or damage. 2. Using a cylinder gauge, measure cylinder I.D. 3. If the measured exceeds the allowable limits, re- place the hydraulic cylinder block.
  • Page 229 www.mymowerparts.com HYDRAULIC SYSTEM c. Reaction Spring Assembly Reference Dimension Reaction spring Reference 50 mm assembly initial dimension 1.9685 in. length (L) 569W647A (1) Spring (3) Nut (2) Hex. Bolt d. Dimensional Setting of Position Control Bolt 1. When assembling the control valve (MLS valve) into power lift body, “A”...
  • Page 230 CHAPTER 6 8454 e . Lever Position Setting Adjustment of Position Control Lever The position control lever can be adjusted with a little load applied to the elevating arm. 1. Loosen the position control shaft (3), and lever tight- ening bolt (4).
  • Page 231 www.mymowerparts.com HYDRAULIC SYSTEM f. Sensitivity Control of Control Valve (MLS) 1. Apply the elevating arm with load of 500 kg (1100 lbs) and move control lever upward to be the center. This time, the MLS valve is positioned at neutral. 2.
  • Page 232: Pto Clutch Valve System

    CHAPTER 6 8454 2. PTO CLUTCH VALVE SYSTEM 2.1 SPECIFICATIONS AND DIAGRAM A. SPECIFICATION 8454 Solenoid valve Maximum oil flowing ( /min, gal/min) 65 (17.17) Rated oil flowing ( /min, gal/min) 7.1 (1.88) Modulating valve Relief pressure (kgf/cm , psi)
  • Page 233: Structure And Operation

    www.mymowerparts.com HYDRAULIC SYSTEM 2.2 STRUCTURE AND OPERATION A. SOLENOID VALVE a . Structure (1) Block (2) Solenoid (3) Ring (4) Plug (5) Bolt (6) O-Ring 569W651A b. Operation • In case PTO clutch switch is OFF 569W652B (1) Tank (Transmission Case) (5) Solenoid Valve (2) Filter (6) Priority...
  • Page 234 CHAPTER 6 8454 • In case PTO clutch switch is ON 569W6B9B (1) Tank (Transmission Case) (5) Solenoid Valve (2) Filter (6) Spool (3) Pump (7) Priority Valve (4) Shuttle Shift Cover The spool (6) gets moved to the left by electric current The spool (6) can be hardly operated only by the solenoid on the solenoid valve (5).
  • Page 235 www.mymowerparts.com HYDRAULIC SYSTEM B. MODULATING VALVE a . Structure 569W653A (1) Body (6) Valve Seat (11) O-Ring (15) Orifice (2) Piston (7) Cover (12) Bolt (16) Washer (3) Spring (8) Packing (13) Plug (17) Filter (4) Spring Gripper (9) Lock Nut (14) Check Valve (18) O-Ring (5) Spool...
  • Page 236 CHAPTER 6 8454 b. Operation • In case PTO clutch switch is OFF 569W654A (1) Tank (Transmission Case) (5) Solenoid Valve (9) Filter (2) Filter (6) Spool (10) Check Valve (3) Gear Pump (7) Spring (11) PTO Clutch (4) Shuttle Shift Cover...
  • Page 237 www.mymowerparts.com HYDRAULIC SYSTEM • In case PTO clutch switch is ON 569W655B Oil at Port PI comes back to Port P of the solenoid valve Oil in amount constantly regulated at the orifice of the through the valve inside returns as forced from Port B check valve through the filter compresses the inner to the valve.
  • Page 238: Assembling And Disassembling

    CHAPTER 6 8454 2.3 ASSEMBLING AND DISASSEMBLING A. SOLENOID VALVE a . To Disassembling 569W656A (1) Solenoid Ass’y (5) Spool (2) Spring (6) Plug (3) Spring (7) Wire Lead (4) Spool Spool Solenoid 1. Loosen the bolt on the cover (1) and remove the 1.
  • Page 239 www.mymowerparts.com HYDRAULIC SYSTEM C. MODULATING VALVE a . To Disassembling 1. Loosen bolt (1) to remove cover (2). 2. Take out piston (3), spring (4), spool (5) and valve sheet (6). 3. Take out check valve ass’y (8) and filter (9). •...
  • Page 240: To Check And To Repair

    CHAPTER 6 8454 2.4 TO CHECK AND TO REPAIR A. SOLENOID VALVE 1. Replace the solenoid valve ass’y if the wet-drive sFurface of the spool is worn out or damaged. 2. Perform electric conduction test on the solenoid with a tester and if not conductive, replace the solenoid valve ass’y.
  • Page 241: Power Steering System

    www.mymowerparts.com HYDRAULIC SYSTEM 3. POWER STEERING SYSTEM 3.1 TROUBLESHOOTING Symptom Probable Cause Solution - Steering wheel is 1) Orbitrol unit heavy to operate (1) Deflected center from the column. • Correct (cause if the tightening bolt with orbitrol is loosened free). (2) Abrasion due to dust on spool or •...
  • Page 242: Introduction

    CHAPTER 6 8454 3.2 INTRODUCTION 569W660A (1) Gear Pump (6) Steering Cylinder (2) Priority Valve (A) To the Transmission Case (3) Power Steering Unit (B) To the Hydraulic Block (4) Hydraulic Hose (RH) (5) Hydraulic Hose (LH) An exclusively hydraulic load reaction type of power...
  • Page 243 www.mymowerparts.com HYDRAULIC SYSTEM Oil Flow 569W661A (1) Gear Pump (5) Hydraulic Hose (LH) (9) Control Valve (2) Priority Valve (6) Steering Cylinder (10) Filter (3) Power Steering Unit (7) Hydraulic Block (11) PTO Clutch Valve (4) Hydraulic Hose (RH) (8) Power Lift Ass’y (12) Transmission Case 1.
  • Page 244: Structure And Operation

    CHAPTER 6 8454 3.3 STRUCTURE AND OPERATION A. MAIN PARTS a . Power Steering Unit The steering controller is composed of steering valve and relief valve. b. Hydraulic Pump Hydraulic pump for power steering employs a gear pump that is of efficient capacity and mechanism, and power is delivered from the cam shaft gear on the right of the engine.
  • Page 245 www.mymowerparts.com HYDRAULIC SYSTEM b. Steering Valve The steering valve is divided into valve and metering installation. The control valve is composed of housing (9), spool (2) and sleeve (5), and the metering installa- tion is composed of the trochoid pump called as GEROTOR (6).
  • Page 246 CHAPTER 6 8454 2. Metering installation oil delivered from the hydrau- lic pump to the steering cylinder passes this meter- ing installation. The metering installation composed of the trochoid pump, while absorbing oil at 3 rooms, sends out oil at different 3 rooms according to the...
  • Page 247 www.mymowerparts.com HYDRAULIC SYSTEM OIL FLOW Neutral Position When the steering wheel (2) is not being turned valve plate (3) is held in the neutral position by centering springs (4). Under this condition an oil passage is formed between port P (from pump) and port T (to trans- mission case) in the control valve and all oil from the hydraulic pump flows to port T.
  • Page 248 CHAPTER 6 8454 Left Turn The steering system operates in this same way at a left-turn as well, except that oil flows into and out of steering cylinder in the directions opposite to those at a right-turn. 569W669A P: Pump Port...
  • Page 249: Preparation Stage For Disassembling And Assembling

    www.mymowerparts.com HYDRAULIC SYSTEM 3.4 PREPARATION STAGE FOR DISASSEMBLING AND ASSEMBLING DRAINING THE TRANSMISSION FLUID Draining the Transmission Fluid 1. Place oil pans underneath the transmission case. 2. Remove the drain plugs. 3. Drain the transmission fluid. 4. Reinstall the drain plugs. (When refilling) •...
  • Page 250 CHAPTER 6 8454 Preparation 1 1. Removing the following parts. 569W672A (1) Side Cover (RH, LH) (2) Bonnet (3) Front Grille (4) Side Skirt (RH, LH) (5) Battery Negative Code Preparation 2 1. Disconnect the brake rods (4), (10).
  • Page 251 www.mymowerparts.com HYDRAULIC SYSTEM Hydraulic Pipes 1. Disconnect the main delivery hose (1), return hose (2), right turning delivery hose (3) and left turning delivery hose (4). (When reassembling) • In assembling the turning delivery hoses to the steering controller, connect the delivery hose with identification mark (tape) “A”...
  • Page 252 CHAPTER 6 8454 3.5 TO DISASSEMBLING AND TO ASSEMBLE POWER STEERING UNIT 569W679A (1) Screw (9) O-Ring (17) Retainer Ring (25) Poppet (2) End Cap (10) Rotor (18) Bearingless (26) Spring (3) O-Ring (11) Drive (19) Needle Bearing (27) Poppet...
  • Page 253 www.mymowerparts.com HYDRAULIC SYSTEM a . To Disassemble the Gerotor Parts 1. Let the port face of the tractor’s body housing vised slightly with the end cap upward. 2. Loosen 2 screws to Disassembling housing (21). • Do not tighten the vise too firmly with a steel pate or the like applied to.
  • Page 254 CHAPTER 6 8454 6. Take out spacers (5), (7) and O-ring (6) located in- side the inner spline of the rotor (10) in gerotor (4). • There is no spacer in the power steer- ing units of outlet capacities of 31 cc/ rev and 51 cc/rev.
  • Page 255 www.mymowerparts.com HYDRAULIC SYSTEM 11. Take out the spool and sleeve ass’y at the oppo- site side to the flange of the housing while push- ing the inner spline of the spool with the thumb. Be careful not to allow the circumference of the sleeve to be stuck in the inner bore of the housing this time.
  • Page 256 CHAPTER 6 8454 b . To Disassembling the Relief Valve 1. Loosen retainer screw (1) on plug (29) area of hous- ing (20) and take out retainer pin (2) and ball (3). 2. Loosen relief adjusting plug (29) with the flange face of housing (20) upward and remove O-ring (28).
  • Page 257 www.mymowerparts.com HYDRAULIC SYSTEM 3. While turning around spool (15), insert it slowly into sleeve (12), Take up the spline area to the spool to check if the spool turns lightly inside the sleeve. 569W690A (10) Sleeve (A) Positioning Marks (11) Spool (D) Spring Slot 4.
  • Page 258 CHAPTER 6 8454 6. Insert pin (13) onto the sleeve groove and insert the spool and sleeve ass’y from the gerotor side of the housing. • Check if the spool and sleeve ass’y turns lightly inside the housing. CAUTION 7.
  • Page 259 www.mymowerparts.com HYDRAULIC SYSTEM d. To Assemble the Relief Valve 1. Pick up the spring guide part with a pin set to insert poppet (25) into the flange area of the housing. 2. Insert spring (26) and damper collar (27). 3. Insert O-ring into the relief adjusting plug (29) to tighten with the housing.
  • Page 260: Hydraulic Pump

    CHAPTER 6 8454 4. HYDRAULIC PUMP 4.1 TROUBLE SHOOTING Repair item Factory spec. Measure & sequence Clearance between drive gear • Allowable limit • Install bushing on the main and main frame frame. → 0.05 mm • Fix drive shaft and idle gear.
  • Page 261: Structure And Operation

    www.mymowerparts.com HYDRAULIC SYSTEM 4.3 STRUCTURE AND OPERATION A. STRUCTURE 569W696A (1) Snap Ring (7) Sealing (13) Cover (19) Sealing (2) Bearing (8) Sealing (14) Sealing (20) Second Pump (3) Cover (Front) (9) Bushing (15) Sealing (21) Cover (Rear) (4) Sealing (10) Drive Gear Shaft (1) (16) Bushing (22) Spring Washer...
  • Page 262 CHAPTER 6 8454 B. OPERATION a. Hydraulic pump delivers constant oil flow to oper- ate the steering wheel and the hydraulic cylinder, and the hydraulic pump ass’y is composed of 2 pumps with different displacement respectively. b. Two pump applicable in the same way are as de-...
  • Page 263 www.mymowerparts.com HYDRAULIC SYSTEM 4.4 TO DISASSEMBLING AND TO ASSEMBLE A. GEAR PUMP ASSEMBLY 1. Remove hydraulic pipes (3), (4) and inlet pipes (2) installed on gear pump (1). 569W698A (1) Gear Pump (4) Hydraulic Pipe 2 (2) Inlet Pipe (5) Priority Valve (3) Hydraulic Pipe 1 2.
  • Page 264 CHAPTER 6 8454 B. GEAR PUMP 569W6A0A (1) Snap Ring (7) Sealing (13) Cover (19) O-Ring (2) Bearing (8) Sealing (14) Sealing (20) Second Pump (3) Front Cover (9) Bushing (15) Sealing (21) Cover (4) O-Ring (10) Drive Gear Shaft 1...
  • Page 265: Hydraulic Filter

    www.mymowerparts.com HYDRAULIC SYSTEM 5. HYDRAULIC FILTER 5.1 STRUCTURE AND OPERATION A. STRUCTURE 569W6A1A (1) Hydraulic Filter Hydraulic filter as of inlet filter on the inlet gear pump has permanent magnet installed on the center of the (2) Magnetic Ass’y element, and the filter mounted on the hydraulic lift is (3) Filter Bracket structured with a vacuum sensor and a thermo sensor to detect blockage.
  • Page 266 CHAPTER 6 8454 B. OPERATION a . Function It filters any particle or contaminated substance out of oil. b. Operation Principle The filtering system as of an inlet filter installed on the inlet gear pump is composed of filter bracket, magnet ass’y and element ass’y.
  • Page 267: Hydraulic Pressure Operation Principle And Trouble Shooting

    www.mymowerparts.com HYDRAULIC SYSTEM 6. HYDRAULIC PRESSURE OPERATION PRINCIPLE AND TROUBLE SHOOTING 6.1 COMPOSITION OF HYDRAULIC DEVICE & FLOW DIAGRAM OF HYDRAULIC OIL A. SCHEMATIC DIAGRAM OF HYDRAULIC DEVICE 569W6A3A (1) Gear Pump Assembly (7-2) Modulator Valve Ass’y (2) Orbitrol Unit (7-3) PTO Clutch Assembly (3) Steering Cylinder Ass’y (8) Hydraulic Block Ass’y...
  • Page 268 CHAPTER 6 8454 B. FLOW DIAGRAM OF TRANSMISSION OIL a . STEERING DEVICE & PTO CLUTCH SYSTEM Power steering Transmission Hydraulic pump 2 unit Case Hydraulic filter (7.2 cc/rev) (74 cc/rev) (Hydraulic Tank) Prior valve Solenoid valve Steering cylinder...
  • Page 269: Steering Devices

    www.mymowerparts.com HYDRAULIC SYSTEM 6.2 STEERING DEVICE A. SCHEMATIC DIAGRAM OF STEERING DEVICE 569W6A4A (1) Gear Pump Assembly [A] PTO Clutch Valve (2) Power Steering Unit [B] Lift Line (3) Steering Cylinder Ass’y [C] Flow Rate Gauge (4) Hydraulic Hose Ass’y (RH) [D] Pressure Gauge (5) Hydraulic Hose Ass’y (LH) (6) Prior Valve Assembly...
  • Page 270 CHAPTER 6 8454 D. TROUBLE SHOOTING Components Trouble Checking Remark Hydraulic pump 1. Install the flow rate gauge on the outlet of pump (refer to the sche- matic Diagram). 2. Check the discharged flow rate. First pump rated flow rate: normal if over 26.5 /min. (7.0 U.S.gal/min) Second pump rated flow rate: normal if over 15.9 /min (4.2 U.S.gal/min)
  • Page 271: Pto System

    www.mymowerparts.com HYDRAULIC SYSTEM 6.3 PTO SYSTEM A. SCHEMATIC DIAGRAM OF PTO SYSTEM 569W6A6A (1) PTO Clutch Valve (2) Orbitrol Unit (A) Steering Cylinder (1-1) Solenoid Valve Ass’y (3) Prior Valve Ass’y (B) Pressure Gauge (1-2) Modulator Valve Ass’y (4) Gear Pump Ass’y (1-3) PTO Clutch Ass’y B.
  • Page 272 CHAPTER 6 8454 D. TROUBLE SHOOTING Components Trouble Checking Remark PTO clutch does not 1. Press the push button of solenoid valve assembly to check the work. fitting of spool. 569W6A7A (Solenoid valve assembly) 2. After installing the pressure gauge on PTO hydraulic pipe, check the standard pressure value (installation position of pressure gauge: refer to schematic diagram).
  • Page 273: Hydraulic Pressure Rise & Fall Device

    www.mymowerparts.com HYDRAULIC SYSTEM 6.4 HYDRAULIC PRESSURE RISE & FALL DEVICE A. SCHEMATIC DIAGRAM OF HYDRAULIC PRESSURE RISE & FALL DEVICE 569W6A9A (1) Hydraulic Cylinder Ass’y (3) Hydraulic Pump (1-1) MLS Valve (4) Hydraulic Filter (1-2) Double Acting Valve (5) Transmission Case (2) Hydraulic Block (A) Orbital Unit (Steering Device) B.
  • Page 274 CHAPTER 6 8454 D. TROUBLE SHOOTING Components Trouble Checking Remark 1. Hydraulic block Checking of hydraulic block 1. Install the pressure gauge on coupler socket assembly to check the pressure value. - Standard pressure value : 165 kg/cm ~ 190 kg/cm (2,347 ~ 2,700 psi) (engine rotation: 2,600 rpm).
  • Page 275 www.mymowerparts.com HYDRAULIC SYSTEM Components Trouble Checking Remark 2. Double-acting How to adjust the pressure of double-acting valve valve assembly 1. Install the pressure in the coupler socket to check the standard pressure of external hydraulic pressure (Refer to schematic diagram). 2.
  • Page 276 CHAPTER 6 8454 Components Trouble Checking Remark 3. MLS valve assem- (Neutral Stage) bly (operation principle) 569W6B4A (1) Piston (3) Check Valve (2) Spool (4) Falling Valve Operation principle of MLS valve neutral stage The supply oil is exhausted to the transmission case as Spool (2)
  • Page 277 www.mymowerparts.com HYDRAULIC SYSTEM Components Trouble Checking Remark 2. Double-acting (4) Falling valve: as spool (1) is operated, the falling valve (4) falls valve assembly down by a spring to open the pipe line (C) and the oil is exhausted from the cylinder. (refer to the figure of “exhaust stage”) Operation principle of MLS valve exhaust stage The oil supplied from the pump is exhausted to the transmission...
  • Page 278 CHAPTER 6 8454 Components Trouble Checking Remark Operation principle of MLS valve supply stage Spool (1) is operated by a link to open the pipe line (A) and the oil supplied from the pump flows into the cylinder through check valve (3) while falling valve (4) closes the pipe line (C) to prevent the exhaust of oil which results in the rise of the lift arm.
  • Page 279 www.mymowerparts.com HYDRAULIC SYSTEM Components Trouble Checking Remark 4. Hydraulic cylinder How to adjust the sensitivity assembly 569W6B7A (MLS valve assembly) 1. Apply the load of 500 kg to the lift arm and move the adjusting lever up to be placed on the middle of the whole adjustment range. 2.
  • Page 280 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 281: Chapter 7. Brake

    www.mymowerparts.com CHAPTER 7 BRAKE K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 282 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 283: Troubleshooting

    www.mymowerparts.com BRAKE 1. TROUBLESHOOTING Symptom Provable Causes Solution Uneven braking force - Brake pedal play unevenly adjusted Adjust - Brake disc worn Replace - Cam Plate warped Replace Brake drags - Brake pedal play too small Adjust - Cam plate return spring weaken or broken Replace - Brake pedal return spring weaken or broken Replace...
  • Page 284: Tightening Torque

    CHAPTER 7 8454 3. TIGHTENING TORQUE Tightening torque Brake shaft 367.8 ~ 431.6 N·m 37.5 ~ 44.0 kgf·m 271.2 ~ 317.8 lbf·ft Mounting bolt of parking brake shaft 23.5 ~ 27.4 N·m 2.4 ~ 2.8 kgf·m 17.3 ~ 20.2 lbf·ft Mounting nut of brake cam lever 123.6 ~ 147.1 N·m...
  • Page 285: Structure And Operation

    www.mymowerparts.com BRAKE 4. STRUCTURE AND OPERATION 4.1 STRUCTURE 569W701A (1) Brake Case (8) Steel Ball (2) Packing (9) Steel Ball Sheet (3) Guide Pin (10) Brake Disc (4) Brake Cam (11) Plate (5) O-Ring (12) Brake Cam Lever (RH) (6) Cam Plate (RH) (13) Brake Cam Lever (LH) (7) Cam Plate (LH) D569-W02 May-2003...
  • Page 286 CHAPTER 7 8454 569W702A (1) Pedal (6) Cam Plate (2) Shaft (7) Plate (3) Brake Rod (8) Brake Disk (4) Brake Rod 3 (9) Brake Case (5) Brake Cam Lever a . Brake b. Parking Brake The parking brake is operated mechanically.
  • Page 287: Operation

    www.mymowerparts.com BRAKE 4.2 OPERATION 569W704A (1) Brake Pedal (6) Brake Cam (2) Connecting Rod (7) Cam Plate (3) Link (8) Brake Disc (4) Connecting Rod (9) Brake Plate (5) Brake Lever (10) Parking Brake Lever • If brake pedal (1) is stepped down, brake lever (5) is pulled to the direction as arrowed through con- necting rods (2), (4) and link (3), and brake cam (6) is allowed to turn cam plate (7) to let it move as...
  • Page 288: Disassembling And Assembling

    CHAPTER 7 8454 5. DISASSEMBLING AND ASSEMBLING 5.1 DRAINING THE TRANSMISSION FLUID Draining the Transmission Fluid 1. Place oil pans underneath the transmission case. 2. Remove the drain plugs. 3. Drain the transmission fluid. 4. Reinstall the drain plugs (When refilling) •...
  • Page 289: Separating Panel Frame Assembly

    www.mymowerparts.com BRAKE 5.2 SEPARATING PANEL FRAME ASSEMBLY Preparation 1 1. Removing the following parts. 569W707A (1) Side Cover (RH, LH) (4) Side Skirt (RH, LH) (2) Bonnet (5) Battery Negative Code (3) Front Grille Preparation 2 1. Disconnect the brake rods (4), (10). 2.
  • Page 290 CHAPTER 7 8454 Hydraulic Pipes 1. Disconnect the main delivery hose (1), return hose (2), right turning delivery hose (3) and left turning delivery hose (4). (When reassembling) • In assembling the turning delivery hoses to the steering controller, connect the delivery hose with identification mark (tape) “A”...
  • Page 291: Separating Rear Fenders And Platform Assembly

    www.mymowerparts.com BRAKE 5.3 SEPARATING REAR FENDERS AND PLATFORM ASSEMBLY Preparation 1. Remove the Rops. 2. Remove the Bolts (1) and take out the seat Assem- bly (2). 569W714A (1) Bolt (2) Seat Assembly Cover 1. Remove the blots (1), (2) and the cover assembly (3).
  • Page 292 CHAPTER 7 8454 D. SEPARATING CLUTCH HOUSING Propeller Shaft 1. Slide the propeller shaft cover, (4), (5), after remov- ing the screws (9). 2. Tap out the spring pin (10) and then slide the cou- pling (2) to the front.
  • Page 293 www.mymowerparts.com BRAKE Separating the Engine from Clutch Housing 1. Place the jack under the clutch housing case. 2. Hoist the engine by the nylon lift strap at the tank support. 3. Remove the engine mounting screws, and then pull the engine to the front. (When reassembling) •...
  • Page 294: Disassembling Rear Axle Case

    CHAPTER 7 8454 5.4 DISASSEMBLING REAR AXLE CASE Rear Axle Case 1. Support the transmission case with nylon lift strap and hoist. 2. Loosen and remove the rear axle case mounting screws (1), spring washer (3) and nuts (2).
  • Page 295: Disassembling Brake Case

    www.mymowerparts.com BRAKE 5.5 DISASSEMBLING BRAKE CASE Brake Case 1. Loosen and remove the nut (1), spring washer (2), plain washer (3), brake can lever (4), bolt (5) and spring washer (6). 2. Separate the brake case (7), tapping the brake case lightly.
  • Page 296: Adjustment Of The Brake

    CHAPTER 7 8454 6. ADJUSTMENT OF THE BRAKE 569W727A (1) Brake Pedal (5) Brake Rod (2) Brake Rod (6) Brake Cam Lever (3) Parking Brake Lever (7) Stop Switch (4) Brake Lever (8) Nut Brake Pedal Free Play Adjustment of the Brake Stop Switch 1.
  • Page 297: Servicing

    www.mymowerparts.com BRAKE 7. SERVICING Brake Can Lever Movement 1. Move the brake cam lever by hand to check the movement. 2. If the movement is heavy, refine the brake cam with sandpaper. 569W728A Cam Plate Flatness 1. Place the cam plate on the surface plate. 2.
  • Page 298 CHAPTER 7 8454 Brake Disc Wear 1. Measure the brake disc thickness with venire calipers. 2. If the thickness is less than the allowable limit, re- place it. Brake disc Factory 4.6 ~ 4.8 mm thickness spec. 0.181 ~ 0.189 in.
  • Page 299: Chapter 8 Electric System

    www.mymowerparts.com CHAPTER 8 ELECTRIC SYSTEM K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 300 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 301: Electronic Instrumentation

    www.mymowerparts.com ELECTRICAL SYSTEM 1. ELECTRONIC INSTRUMENTATION 569W801B (1) Tachometer (8) Battery Charge Warning Lamp (2) Temperature Gauge (9) Grow Plug Indicator (3) Fuel Gauge (10) Hydraulic Filter Warning Lamp (4) PTO On Indicator (11) Upward Indicator (5) Engine Coolant Low Level Warning lamp (12) Parking Brake Indicator (6) Differential Lock Operation lamp (13) 4WD Lamp...
  • Page 302: Indicators And Warning Lights

    CHAPTER 8 8454 1.2 INDICATORS AND WARNING LIGHTS A. POWER-TAKE-OFF OPERATION LAMP (4) Light will illuminate when the PTO selection switch is located at Auto or Manual mode. Before you start the engine, be sure that the PTO se- lection switch is located at the Neutral position.
  • Page 303 www.mymowerparts.com ELECTRICAL SYSTEM F. PRE-HEAT CONTROL OPERATION LAMP When the key switch is in the “ON” position, light will illuminate. When the whether is cold, remain the key switch in the “ON” position before starting for a while or until the lamp goes out.
  • Page 304 CHAPTER 8 8454 2. TROUBLE SHOOTING Symptom Provable Causes Solution All electrical equipment • Battery discharged or defective Recharge or replace does not operate • Battery positive or negative cable disconnected or Repair or replace improperly connected • Fusible link blown...
  • Page 305 www.mymowerparts.com ELECTRICAL SYSTEM Symptom Provable Causes Solution Brake light does not light • Fuse blown Replace • Bulb blown Replace • Wiring harness disconnected or improperly Repair or replace connected Coolant level lamp does • Brake switch defective Replace not light when cooling •...
  • Page 306: Servicing Specifications

    CHAPTER 8 8454 3. SERVICING SPECIFICATIONS Item Capacity (factory spec.) Feature Battery Rated voltage capacity 80AH Start motor Rated voltage Rated power 2.0kw Alternator Rated voltage Regulator built - in type Rated current Indicator bulb Rated voltage Rated power 3.4W...
  • Page 307: Mechanism

    www.mymowerparts.com ELECTRICAL SYSTEM 4. MECHANISM 4.1 STARTING SYSTEM A. CIRCUIT DIAGRAM FOR STARTING SYSTEM 569W804B (1) Main fuse (8) Neutral (2) Start Relay (9) Auto (3) Start motor (10) Manual (4) Key s/w (11) PTO control s/w (5) Safety s/w (12) Micro s/w (6) PTO safety relay (13) PTO Lamp Switch...
  • Page 308 CHAPTER 8 8454 B. OPERATION OF START MOTOR a. Starter The magnet-switch type starter is composed of two main sections. The first section converts battery current into mechanical rotation to turn the engine crankshaft. It is composed of the field coil, armature, brush, commutator, pinion, overrunning clutch, etc.
  • Page 309 www.mymowerparts.com ELECTRICAL SYSTEM (C) When key switch is on: When the key switch is turned on, a current flows from the battery through the pull-in coil in the magnet switch section to the holding coil, energizing the plunger to pull it in.
  • Page 310: Charging System

    CHAPTER 8 8454 b. Glow plugs Glow plugs are used for each pre-combustion chamber of the cylinder head to make starting easier. The glow plugs are quick-heating type, which make starting easier with short pre-heating time. 569W810A (1) Housing...
  • Page 311 www.mymowerparts.com ELECTRICAL SYSTEM B. CIRCUIT DIAGRAM FOR ALTERNATOR UNIT 569W812A C. OPERATION OF CHARGING SYSTEM · The charging system supplies electric power for various electrical devices and also charges the battery while the engine runs. · The alternator generates AC (alternating current) and the regulator converts AC into DC (direct current). It also controls the output voltage for charging current to the battery.
  • Page 312: Preheating System

    CHAPTER 8 8454 4.3 PREHEATING SYSTEM A. CIRCUIT DIAGRAM FOR PREHEATING SYSTEM 569W813A (1) Alternator (5) Glow plug indicator (6) Glow plug (2) Key s/w (3) Preheating Controller (7) Glow Relay (4) Coolant temp. sensor PARTS SPECIFICATION (1) Capacity of the preheating relay : DC12V 70A (2) Capacity of the preheating controller : DC12V B.
  • Page 313: Fuse

    www.mymowerparts.com ELECTRICAL SYSTEM 4.4 FUSE A. FUSE BOX DIAGRAM Classifi- Cable Connec- Appli- Remark cation standard tion cable terminal fuse AVS3. O R AVS2. O W AVS3. O RL AVS2. O WR AVS0. 85 YR AVS3. O RW 7,13,15, 6WAY 36,66,77 TERMINAL AVS0.
  • Page 314: Gauge And Sensors

    CHAPTER 8 8454 4.5 GAUGE AND SENSORS A. OIL PRESSURE SWITCH The oil pressure switch is installed on the cylinder block and leads to the oil passage of the lubricating oil. When the oil pressure falls below the specified value, the con- tacts of the oil pressure switch closes to turn on the warning lamp.
  • Page 315: Chapter 9. Cabin System

    www.mymowerparts.com CHAPTER 9 CABIN SYSTEM K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 316 www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983...
  • Page 317: Disassembly And Assembly

    www.mymowerparts.com CABIN SYSTEM 1. DISASSEMBLY AND ASSEMBLY 1. Loosen 6 setting bolts for chair assembly support and disconnect seat assembly in a body. 569W901A (1) Seat Assembly 2. Disengage 4 setting bolts for cabin assembly. 569W902A (1) Cabin Support (Front) (3) Bolt (2) Cabin Support (Rear) (4) Bolt 3.
  • Page 318 CHAPTER 9 8454 4. Open drain cock located in right of front axle frame, drain coolant, remove heat hose 2 pieces (7) con- nected to connecting pipe, and then remove air conditioner hose (4, 5). Remove wiring jack connected to the bottom of cabin.
  • Page 319 www.mymowerparts.com CABIN SYSTEM 7. Loosen head pin and snap pin connected to main transmission lever at left bottom of cabin and re- move main transmission lever. 569W908A (1) Lever 1, Front Drive (3) Pin, Joint (2) Lever 2, Front Drive (4) Snap Pin 8.
  • Page 320 CHAPTER 9 8454 10. Remove head pin and snap pin from Hi-Low shift lever connector and remove Hi-Low shift lever. 569W910A (1) Lever 2, Hi-Low (3) Lever, Hi-low (2) Rod, Hi-Low (4) Shaft, Lever 11. Remove head pin and snap pin and then remove hydraulic control rod.
  • Page 321 www.mymowerparts.com CABIN SYSTEM 13. Remove frame cover (1) in left of frame assembly and parallel pin connected with shuttle lever arm (3) and then disconnect shuttle lever from shuttle lever arm. 569W913A (1) Cover, Frame (3) Lever, Shuttle (2) Pin, Straight 14.
  • Page 322: Heater

    CHAPTER 9 8454 2. HEATER 2.1 STRUCTURE Item 8454 Heater Type Hot water type Radiating (kcal/h) HI: 2170 kcal/h Low:1900 kcal/h Air flow Hi: 230 m Low:130 m Power consumption Less than 65 W (DC12 V) Coolant Capacity 8.9 , 2.4 U.S.gal...
  • Page 323: Airconditioner

    www.mymowerparts.com CABIN SYSTEM 3. AIRCONDITIONER 3.1 AIR CONDITIONER A. STRUCTURE 569W916A (1) Compressor (4) Expansion Valve (2) Condenser (5) Vaporizer (3) Receiver Drier (6) Refrigerant B. PRINCIPLE OF AIRCONDITIONING The function of air-conditioning system is to cool the c. When the gas is cooled, this shall be concentrated air inside the cabin and lower the humidity to promote to the fluid.
  • Page 324 CHAPTER 9 8454 569W917A The above figure shows the circulation diagram of a Such low pressure, low temperature and injected fluid refrigerant which passes through the 5 main compo- enters into the coil of the vaporizer to absorb the heat nents of the air-conditioning system.
  • Page 325 www.mymowerparts.com CABIN SYSTEM As the drier contains a drying agent, it absorbs all hu- C. OPERATION PRINCIPLES OF SYSTEM midity in the system and the filter prohibits the external COMPONENTS particles to enter in. a . Refrigerant Ref.) The humidity of air-conditioning system is abso- lutely harmful.
  • Page 326 CHAPTER 9 8454 D. AIR-CONDITIONING COMPONENTS 569W918A (1) Aircon. Unit (5) Compressor (9) Hose 1, Aircon (12) Duct, Heater (2) Duct, Aircon. (6) R/D (10) Hose, Drain (13) Hose 1, Heater (3) Hose 3, Aircon (7) Condenser (11) Heater (14) Pipe 1, 2 (4) Hose 4, Aircon.
  • Page 327: Trouble Shooting

    www.mymowerparts.com CABIN SYSTEM F. OIL I. AIR CONDITIONER CONTROL Checking of compressor oil Air conditioner switch consists of air flow and tempera- ture control switches. Airflow control switch is oper- The oil used to lubricate the compressor shall be ated in three stages of LOW, MIDDLE and HIGH. Turn- supplemented when the components in the sys- ing temperature control switch clockwise enables to tem need to be replaced or a large amount of gas...
  • Page 328 CHAPTER 9 8454 Abnormal noise from the blower motor In case of the generation of abnormal noise from the blower motor and the poor revolution, change the blower motor with the new one. In case of generation of the abnormal noise caused by the foreign material in the blower or by the poor tightening, pay attention to work.
  • Page 329 www.mymowerparts.com CABIN SYSTEM Causes Checking Methods Action 4. The pressure of inlet of the Normal pressure Replacement compressor High pressure: 14 ~ 15 kg/cm (199 ~ 213 psi) Low pressure: 1.5 ~ 2.0 kg/cm (21 ~ 28 psi) Ambient temperature: 30 ~ 35 °C, Engine : about 1,500 rpm 4-1.
  • Page 330 CHAPTER 9 8454 4) The compressor does not revolve or hard to revolve. Causes Checking Methods Action 1. Loosening of belt The vibration of belt is large. Tension adjustment 2. Internal failure of compressor The belt is sliding. Repair/replacement 3.
  • Page 331 www.mymowerparts.com CABIN SYSTEM 2. Excess of refrigerant charging Status: Not cool Phenomena: - Pressure rising by overcharging of refrigerant - Lack of cooling of the compressor Cause: - Pressure rising by overcharging of refrigerant - Lack of cooling of the compressor Action: - Clean the compressor - Check and adjust fan belt or compressor motor...
  • Page 332 CHAPTER 9 8454 4. Poor extension valve Status: Not cool Phenomena: - The pressure of high /low pressure side is high. Cause: Poor extension valve, poor control of refrig- erant flow rate by poor assembling of the wound box.
  • Page 333 www.mymowerparts.com CABIN SYSTEM 3. The refrigerant does not circulate. Status: not cool (sometimes cool) Phenomena: - The pressure of low pressure side is negative and the pressure of high pressure side shows the pressure 5 ~ 6 kg/cm - Frost or dew forming in the receiver drier or the front/rear pipe connection section of extension valve.
  • Page 334 CHAPTER 9 8454 D. ELECTRICAL CIRCUIT a . Air Conditioner System 569W927A (1) Battery (6) Pressure Switch (2) Slow Blow Fuse (7) A/C Blower Switch (3) Main Switch (8) Ass’y Air-Conditional (4) Compressor Relay (9) Blower Motor (5) Compressor (10) Thermostat Main Switch (3) ON →...

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