Ventrac 4520Z Service Manual
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Ventrac 4520Z Service Manual

Ventrac 4520Z Service Manual

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Service Manual
4520Z
Serial Numbers 01001–05664
09.40001Rev 00
Original Instructions (EN)

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Summary of Contents for Ventrac 4520Z

  • Page 1 Service Manual 4520Z Serial Numbers 01001–05664 09.40001Rev 00 Original Instructions (EN)
  • Page 2 Reader Comments Ventrac maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an email to techpubs@ventrac.com.
  • Page 3 Revision History Revision Date Description 4520Z 09.40001Rev 00...
  • Page 4 Operator’s and Part’s manuals are available at www.Ventrac.com under resources. Venture Products Inc.® and Ventrac reserve the right to change the product specifications or this publication without notice. DANGER This symbol indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
  • Page 5 Safety and Instructional Decals There are many safety and instruction decals affixed to the Ventrac 4520. If any decals become illegible or damaged, install a new decal. Decal part numbers are listed in the Parts Manual. Order replacement decals from an Authorized Ventrac Dealer.

  • Page 6: Table Of Contents

    Kubota Service Manuals ....................4–2 Engine Service and Repairs....................4–3 Air Cleaner System......................4–3 4520Z Removing and Installing the Air Cleaner System..........4–4 Exhaust System ....................... 4–5 4520Z Removing the Exhaust System ................4–6 4520Z Installing the Exhaust System................4–7 Fuel System ........................
  • Page 7 Removing the Fuel Pump ....................4–13 Installing the Fuel Pump....................4–14 Engine Cooling System ....................4–15 4520Z Removing the Radiator..................4–16 4520Z Installing the Radiator ..................4–17 Engine..........................4–17 Chapter 5: Hydraulic System ....................5–1 General Information......................5–2 4520 Operator’s Manual and Accessory Installation Instructions ......5–2 Towing the 4520 .......................
  • Page 8 Hydraulic Cooler Fan ......................6–49 Testing the Hydraulic Cooler Fan ................6–49 Speed Sensor ........................6–51 Testing the Speed Sensor.................... 6–52 Adjusting the Speed Sensor..................6–53 RPM Sensor ........................6–54 Testing the RPM Sensor....................6–54 Preface: Page 8 4520Z 09.40001Rev 00...
  • Page 9 Removing and Installing the Seat Mount..............7–31 Removing and Installing the Steering Wheel ............7–32 Removing and Installing the Steering Valve Cover..........7–33 Removing and Installing the Parking Brake Cover ..........7–34 Removing the Dash....................... 7–35 4520Z Preface: 09.40001Rev 00...
  • Page 10 Wiring Diagram Reference Key (Serial # 02173–05664) ........... 9–6 Wiring Diagram — Rear Harness (Serial # 02173–05664)........9–7 Wiring Diagram — Front Harness (Serial # 02173–05664) ........9–8 Wiring Diagram — Engine Harness (Serial # 02173–05664)........ 9–9 Hydraulic Schematic ......................9–10 Preface: Page 10 4520Z 09.40001Rev 00...
  • Page 11 Raising the Front of the Machine ......................1–6 Raising the Rear of the Machine ......................1–8 Ventrac equipment is tested and certified byVentrac for compliance with existing safety standards and specifications. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent on the awareness, concern, and proper training of the personnel operating, and performing maintenance of the machine.

  • Page 12: Before Operating The Machine Safety

    Before Operating the Machine Safety • Review and understand the operator’s manual before starting and operating the machine. Additional copies of the operator’s manuals are available on the Ventrac Dealer Network under resources or at www.Ventrac.com. • Never allow children to operate the machine. Never allow adults to operate the machine without proper training and instructions.

  • Page 13: While Operating The Machine Safety

    • Do not run the engine in a building without adequate ventilation. • Do not touch the engine or the muffler while the engine is running or immediately after stopping the engine. 4520Z Page 1–3 General Safety Instructions: While Operating the Machine Safety 09.40001Rev 00...

  • Page 14: Maintenance And Service Safety

    • An obstruction or blockage in a drive system or moving/rotating parts may cause a buildup of stored energy. When the obstruction or blockage is removed, the drive system or moving/rotating parts may move suddenly. Do not attempt to remove an General Safety Instructions: Maintenance and Service Page 1–4 4520Z Safety 09.40001Rev 00...
  • Page 15 • To ensure optimum performance and continued safety certification of the machine, use genuine Ventrac replacement parts and accessories. Replacement parts and accessories of other manufacturers can result in non-conformance of safety standards and can void the warranty.

  • Page 16: Jacking Instructions

    3. Park the machine on a level surface, engage the parking brake, and remove the key from the ignition. 4. Block the rear wheels using wheel chocks to prevent the machine from rolling. General Safety Instructions: Jacking Instructions Page 1–6 4520Z 09.40001Rev 00...
  • Page 17 7. Position jack stands securely under the axle assembly Note: Removing the front wheels may be required to fit jack stands under the axle assembly. 8. Lower the machine onto the jack stands and remove the jack. 4520Z Page 1–7 General Safety Instructions: Jacking Instructions 09.40001Rev 00...

  • Page 18: Raising The Rear Of The Machine

    7. Position the jack stands securely under the axle assembly Note: Removing the rear wheels may be required to fit jack stands under the axle housing. 8. Lower the machine onto the jack stands and remove the jack. General Safety Instructions: Jacking Instructions Page 1–8 4520Z 09.40001Rev 00...
  • Page 19 Standard Torque Specifications Table for Metric Class 10.9 Steel Fasteners......2–13 Standard Torque Specifications Table for Metric A2–70 or A4–70 Stainless Steel Fasteners ..............................2–14 Shop Supplies............................. 2–15 Special Tools ............................... 2–18 Venture Products Inc.® and Ventrac reserve the right to change these specifications without notice. 4520Z Page 2–1 Specifications...

  • Page 20: 4520Z Specifications

    12.2 L (13 qt) Hydraulic Oil HydroTorq XL 4.4 L (4.6 qt) (Rear trans Synthetic axle) Hydraulic Oil Cooling 50% distilled 6.6 L (7 qt) System (4520 water and 50% P,Y,Z,N) ethylene glycol antifreeze Specifications: 4520Z Specifications Page 2–2 4520Z 09.40001Rev 00...

  • Page 21: 4520Z Engine Specifications

    Gasoline (Max Engines) 10% Ethanol) Fuel System Ultra-Low 22.7 L (6 gal) 13.0053 13.0220 (Diesel Engine) Sulphur Diesel 4520Z Engine Specifications Note: Specifications and design are subject to change without notice. Manufacturer Kubota Model Number WG972–GL Type Gasoline Cylinders Displacement Engine Gross Power 23.9 kW (32hp)

  • Page 22: Torque Specifications

    Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Ventrac, either the recommended torques or a torque that is unique to the application is clearly identified and specified in this Service Manual.

  • Page 23: Fasteners With A Locking Feature

    (lever) of the torque wrench changes. When using a torque wrench with a drive-adapter wrench, multiply the listed torque recommendation by the calculated torque conversion factor (Figure 6) to 4520Z Page 2–5 Specifications: Torque Specifications 09.40001Rev 00...
  • Page 24 If the listed torque recommendation for a fastener is 103 to 127 N∙m (76 to 94 ft-lb), the proper torque when using this torque wrench with a drive-adapter wrench would be 98 to 121 N∙m (72 to 89 ft-lb). Specifications: Torque Specifications Page 2–6 4520Z 09.40001Rev 00...

  • Page 25: Standard Torque Specifications Table For Sae J429 Grade 2 Steel Fasteners

    1/4–28 6,672 1,500 5/16–24 10,676 2,400 ft-lb ft-lb 3/8–24 16,014 3,600 7/16–20 21,796 4,900 1/2–20 29,358 6,600 9/16–18 37,365 8,400 5/8–18 47,151 10,600 3/4–16 68,503 15,400 7/8–14 56,092 12,610 1–12 72,995 16,410 4520Z Page 2–7 Specifications: Torque Specifications 09.40001Rev 00...

  • Page 26: Standard Torque Specifications Table For Sae J429 Grade 5 Steel Fasteners

    1/4–28 10,230 2,300 5/16–24 16,458 3,700 ft-lb ft-lb 3/8–24 24,910 5,600 7/16–20 33,584 7,550 1/2–20 45,371 10,200 9/16–18 57,826 13,000 5/8–18 72,506 16,300 3/4–16 105,867 23,800 7/8–14 144,478 32,480 1–12 188,026 42,270 Specifications: Torque Specifications Page 2–8 4520Z 09.40001Rev 00...

  • Page 27: Standard Torque Specifications Table For Sae J429 Grade 8 Steel Fasteners

    3,250 5/16–24 23,130 5,200 ft-lb ft-lb 3/8–24 35,141 7,900 7/16–20 47,596 10,700 1/2–20 64,054 14,400 9/16–18 81,402 18,300 5/8–18 102,309 23,000 3/4–16 149,460 33,600 7/8–14 203,973 45,855 1–12 1,010 1349 265,425 59,670 4520Z Page 2–9 Specifications: Torque Specifications 09.40001Rev 00...

  • Page 28: Standard Torque Specifications Table For Astm F593 Stainless Steel Hex Cap Screw

    Clamp Load (lbs) Size in-lb in-lb 1/4–28 3,679 5/16–24 6,717 1,510 ft-lb ft-lb 3/8–24 10,160 2,284 7/16–20 13,732 3,087 1/2–20 18,500 4,159 9/16–18 23,473 5,277 5/8–18 29,603 6,655 3/4–16 29,861 6,713 7/8–14 40,795 9,171 Specifications: Torque Specifications Page 2–10 4520Z 09.40001Rev 00...
  • Page 29 Standard Torque Specifications Table for ASTM F593 Stainless Steel Hex Cap Screw (continued) Fine Thread 1–14 54,437 12,238 1 1/4–12 85,909 19,313 1 3/8–12 1,102 105,267 23,665 1 1/2–12 1,446 1,067 1,688 1,245 126,587 28,458 4520Z Page 2–11 Specifications: Torque Specifications 09.40001Rev 00...

  • Page 30: Standard Torque Specifications Table For Metric Class 8.8 Steel Fasteners

    M27 X 3 1,116 206,727 46,474 M30 X 3.5 1,135 1,513 1,116 252,254 56,709 M33 X 3.5 1,544 1,139 2,059 1,519 312,087 70,160 M36 X 4 1,985 1,464 2,647 1,952 367,512 82,620 Specifications: Torque Specifications Page 2–12 4520Z 09.40001Rev 00...

  • Page 31: Standard Torque Specifications Table For Metric Class 10.9 Steel Fasteners

    1,158 1,544 1,139 285,967 64,288 M30 X 3.5 1,570 1,158 2,093 1,544 349,132 78,448 M33 X 3.5 2,137 1,576 2,850 2,102 431,722 97,055 M36 X 4 2,746 2,025 3,661 2,700 508,391 114,291 4520Z Page 2–13 Specifications: Torque Specifications 09.40001Rev 00...
  • Page 32 M24 X 3 63,449 14,264 M27 X 3 82,688 18,589 M30 X 3.5 1,060 100,903 22,684 M33 X 3.5 1,237 1,443 1,064 127,237 28,064 M36 X 4 1,589 1,172 1,853 1,367 147,005 33,048 Specifications: Torque Specifications Page 2–14 4520Z 09.40001Rev 00...

  • Page 33: Shop Supplies

    High strength thread locking compounds may require applying heat to the fastener and the surrounding area to allow fastener removal. Follow the manufacturer recommendations for use. 4520Z Page 2–15 Specifications: Shop Supplies 09.40001Rev 00...
  • Page 34 (anaerobic). Most gasket compounds are designed to be applied to clean surfaces free of oil, chemical residue and previously used gaskets or gasket compounds. Follow the manufacturer recommendations for use. Specifications: Shop Supplies Page 2–16 4520Z 09.40001Rev 00...
  • Page 35 Do Not use an aerosol protectant on small multi-pin electrical connectors. An aerosol lubricant may also be specified. Refer to the specific service procedure for details. 4520Z Page 2–17 Specifications: Shop Supplies 09.40001Rev 00...

  • Page 36: Special Tools

    Special Tools Special tools for servicing Ventrac Commercial Products are available from your Ventrac dealer. Some of these tools are available as Ventrac parts or may also be available from a local tool supplier. Multimeter Obtain this tool locally The meter can test the electrical components and circuits for current, resistance, or voltage.
  • Page 37 The Kubota DST-I Diagnostic tool is used for engine diagnostics on the 4520N machine. Gauge Programming Tool Ventrac Part No. 72.0045 This tool allows the information cluster gauge part no. 35.0159 to be programed with the machines existing hours. The gauge programming tool is a component of the Dealer Toolkit part no.
  • Page 38 Hydraulic Pressure Gauge Ventrac Part No. 70.0097 The hydraulic pressure gauge allows technicians to check hydraulic system pressures. The hydraulic pressure gauge is a component of the Dealer Toolkit part no. 70.0121. Weather Pack Terminal Release Tool Ventrac Part No. 72.0030...
  • Page 39 Weather Pack / Metri Pack Wire Crimper Tool Ventrac Part No. 72.0027 The Weather Pack / Metri Pack wire crimper tool allows technicians to properly install Weather Pack and Metri Pack terminals. Deutsch Wire Crimper Tool Ventrac Part No. 72.0028...
  • Page 40 O-Ring Service Kit Ventrac Part No. 70.8238 The O-ring service kit contains replacement O-rings for the 4520 series machine. Part Description Number 26.0009 O-Ring, -014 for Morf-08 Viton 26.0023 O-Ring, -016 for Morf-10 Viton 26.0025 O-Ring, -012 for Morf-06 Viton 26.0035...
  • Page 41 Chapter 3 Troubleshooting Table of Contents GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems ....3–2 General Hydraulic System Problems ...................... 3–3 General Electrical System Problems....................... 3–6 General Engine Problems.......................... 3–8 4520Z Page 3–1 Troubleshooting 09.40001Rev 00...

  • Page 42: Gears - The Systematic Approach To Defining, Diagnosing And Solving Problems

    • Did the issue go away • Was the root cause of the issue correctly repaired • Are there any other new symptoms Troubleshooting: GEARS – The Systematic Approach to Page 3–2 4520Z Defining, Diagnosing and Solving Problems 09.40001Rev 00...

  • Page 43: General Hydraulic System Problems

    A faulty hydraulic cooling fan Replace the cooling fan temperature temperature sender. sender as required. A faulty hydraulic cooler fan. Replace the hydraulic cooler fan. 4520Z Page 3–3 Troubleshooting: General Hydraulic System Problems 09.40001Rev 00...
  • Page 44 The hydraulic fluid level is low. Adjust the hydraulic fluid level. The hydraulic fluid suction filter is Replace the suction filter. plugged. A faulty steering cylinder. Replace the steering cylinder. Troubleshooting: General Hydraulic System Problems Page 3–4 4520Z 09.40001Rev 00...
  • Page 45 Rotating group in the hydraulic pump or Inspect the hydraulic pumps and motors, a hydraulic motor is worn. repair or replace as needed. 4520Z Page 3–5 Troubleshooting: General Hydraulic System Problems 09.40001Rev 00...

  • Page 46: General Electrical System Problems

    Possible Cause Corrective Action A blown fuse. Replace the fuse. A faulty light. Replace the light. A faulty switch. Replace the switch. A broken wire. Locate and repair/replace the wire. Troubleshooting: General Electrical System Problems Page 3–6 4520Z 09.40001Rev 00...
  • Page 47 PTO clutch air gap is out of adjustment. Adjust the PTO clutch air gap. A damaged PTO clutch wiring harness/ Repair or replace the harness or electrical connection. connector. A faulty PTO clutch. Replace the PTO clutch. 4520Z Page 3–7 Troubleshooting: General Electrical System Problems 09.40001Rev 00...

  • Page 48: General Engine Problems

    General Engine Problems Additional engine troubleshooting information and advanced engine service procedures can be found in the engine service manual. Engine service manuals are available at https://network.ventrac.com/resources/manuals_engine. The starter will not engage. Possible Cause Corrective Action The main circuit breaker is in the O Switch the main circuit breaker to the O position.
  • Page 49 A plugged fuel filter. Inspect the fuel filter replace the fuel filter as needed. A blockage in the fuel supply hose. Inspect the fuel hoses, clean or replace the fuel hoses as needed. 4520Z Page 3–9 Troubleshooting: General Engine Problems 09.40001Rev 00...
  • Page 50 Corrective Action Engine temperature is low. Allow the engine to warm up. A faulty head gasket. Replace the head gasket as needed. There is water in the combustion Inspect engine. chamber. Troubleshooting: General Engine Problems Page 3–10 4520Z 09.40001Rev 00...
  • Page 51 Adjust the hydraulic pump tow valve. pump. A faulty hydraulic pump. Inspect and repair or replace the hydraulic pump. A faulty hydraulic motor. Inspect and repair or replace the hydraulic motor. 4520Z Page 3–11 Troubleshooting: General Engine Problems 09.40001Rev 00...
  • Page 52 Possible Cause Corrective Action The parking brake switch is out of Adjust the parking brake switch. adjustment. The neutral switch is out of adjustment. Adjust the neutral switch. Troubleshooting: General Engine Problems Page 3–12 4520Z 09.40001Rev 00...
  • Page 53 Kubota Service Manuals ........................4–2 Engine Service and Repairs........................4–3 Air Cleaner System..........................4–3 4520Z Removing and Installing the Air Cleaner System..............4–4 Exhaust System ............................4–5 4520Z Removing the Exhaust System ....................4–6 4520Z Installing the Exhaust System...................... 4–7 Fuel System ..............................

  • Page 54: General Engine Information

    Manual for additional information when servicing the machine. Kubota Service Manuals The 4520Z is powered by a Kubota WG972–GL engine. Engine service manuals are available at https://network.ventrac.com/resources/manuals_engine. Ensure that the correct engine manual is used when servicing the engine on your machine.

  • Page 55: Engine Service And Repairs

    Filter housing clamp Air inlet hose Hose clamps Air cleaner assembly Air intake hose G416501 Note: Refer to the 4520Z Operator’s Manual for maintenance procedures and service intervals for the air filters. 4520Z Page 4–3 Engine: Engine Service and Repairs 09.40001Rev 00...

  • Page 56: 4520Z Removing And Installing The Air Cleaner System

    Air Cleaner System (continued) 4520Z Removing and Installing the Air Cleaner System CAUTION The engine and air cleaner system may be hot. To avoid possible burns, allow the engine to cool before working on the engine. 1. Remove the air cleaner components as required.

  • Page 57: Exhaust System

    Exhaust System Figure 8 Exhaust Manifold Shield Muffler Brace Muffler Muffler Gasket Flywheel Cover Muffler Shield Ignition Coil Mount G419349 Note: Refer to the 4520Z Parts Manual for replacement parts. 4520Z Page 4–5 Engine: Engine Service and Repairs 09.40001Rev 00...

  • Page 58: 4520Z Removing The Exhaust System

    Exhaust System (continued) 4520Z Removing the Exhaust System CAUTION The engine and exhaust system may be hot. To avoid possible burns, allow the engine to cool before working on the engine. 1. Remove attachments from the machine. 2. Park the machine on a level surface, engage the parking brake, and remove the key from the ignition.

  • Page 59: 4520Z Installing The Exhaust System

    Exhaust System (continued) 4520Z Installing the Exhaust System 1. Position the muffler and gasket against the exhaust manifold aligning the mounting holes. 2. Loosely install the mounting bolts with washers through the manifold and into the muffler mounting flange. 3. Loosely install the washers and nuts on the mounting bolts.

  • Page 60: Fuel System

    Valve The fuel system includes a fuel tank, electric sending unit, fuel filter, and electric fuel pump. Refer to the 4520Z Operator’s Manual for service interval and maintenance information. DANGER Fuel is highly flammable: use extreme care while handling fuel.

  • Page 61: Checking The Fuel Lines And Connections

    Check the fuel lines and connections at the scheduled maintenance intervals recommended in the 4520 Operator’s Manual. Check the fuel lines for deterioration, damage, leaks, or loose connections. Replace the hoses, clamps, and fittings as necessary. 4520Z Page 4–9 Engine: Engine Service and Repairs 09.40001Rev 00...

  • Page 62: Priming The Fuel System

    1. Ensure that the fuel tank has fuel in it. 2. Turn the ignition key to the run position for approximately 30 seconds. The operator should hear the fuel pump operating. 3. Start the machine. Repeat if necessary. Engine: Engine Service and Repairs Page 4–10 4520Z 09.40001Rev 00...

  • Page 63: Removing And Installing The Fuel Tank

    5. Remove the fuel tank inner cover; refer to Removing and Installing the Fuel Tank Inner Cover, page 7–26. 6. Remove the fuel tank top cover; refer to Removing and Installing the Fuel Tank Top Cover, page 7–25. 4520Z Page 4–11 Engine: Engine Service and Repairs 09.40001Rev 00...
  • Page 64 14. Install the fuel tank inner cover. 15. Turn the fuel shut-off valve to the O position. 16. Switch the main circuit breaker to the O position, to energize the electrical system. Engine: Engine Service and Repairs Page 4–12 4520Z 09.40001Rev 00...

  • Page 65: Removing The Fuel Pump

    5. Remove the rear lower frame (tunnel) cover. 6. Disconnect the fuel pump harness connection. 7. Remove the fuel pump mounting bolts. 8. Disconnect the fuel hoses from the pump. 9. Remove the pump. 4520Z Page 4–13 Engine: Engine Service and Repairs 09.40001Rev 00...

  • Page 66: Installing The Fuel Pump

    6. Prime the fuel system; refer to Priming the Fuel System, page 4–10 and check for leaks. 7. Install the rear lower frame (tunnel) cover. Engine: Engine Service and Repairs Page 4–14 4520Z 09.40001Rev 00...

  • Page 67: Engine Cooling System

    Engine Cooling System Figure 11 Radiator Assembly Radiator Mounting Bolts Air Inlet Cover Air Box Mounting Bolt Lower Radiator Hose Upper Radiator Hose G419423 4520Z Page 4–15 Engine: Engine Service and Repairs 09.40001Rev 00...

  • Page 68: 4520Z Removing The Radiator

    Engine Cooling System (continued) 4520Z Removing the Radiator DANGER If the radiator or engine is hot, pressurized hot coolant can escape and cause burns. Do not open the radiator cap or drain the radiator when the radiator or engine is hot.

  • Page 69: 4520Z Installing The Radiator

    4–4. 4. Connect the upper and lower radiator hoses. 5. Fill the radiator with coolant; refer to the 4520Z Operator’s Manual. 6. Start the engine and check for coolant leaks. Repair any leaks as required. 7. Continue to run the engine to allow the engine to reach operating temperature.
  • Page 70 Use hoist equipment rated to lift the engine, which is approximately 72kg (159 lb). 18. Remove the engine from the machine. Engine: Engine Service and Repairs Page 4–18 4520Z 09.40001Rev 00...
  • Page 71 12. Install the radiator; refer to 4520Z Installing the Radiator, page 4–17. 13. Install the air cleaner system; refer to 4520Z Removing and Installing the Air Cleaner System, page 4–4. 14. Install the hood and grill assembly; refer to Removing and Installing the Hood, page 7–13,...
  • Page 72 3. Switch the main circuit breaker to the O position, to de-energize the electrical system. 4. Remove the radiator; refer to 4520Z Removing the Radiator, page 4–16. 5. Remove the canvas cover. 6. Loosen the pinch bolt 7. Remove the three mounting bolts from the drive shaft flange.
  • Page 73 Engine (continued) 14. Install the radiator; refer to 4520Z Installing the Radiator, page 4–17. 15. Switch the main circuit breaker to the O position, to energize the electrical system. Removing and Installing the Choke Cable Figure 12 Choke cable Clamp...
  • Page 74 (Figure 13, item 1) connection to the engine. 5. Disconnect the cable from the clamp (Figure 13, item 2), housing clamp (Figure 13, item 3), and throttle linkage clamp (Figure 13, item Engine: Engine Service and Repairs Page 4–22 4520Z 09.40001Rev 00...
  • Page 75 17. Check the throttle lever function. Ensure that the throttle lever moves smoothly, and the cable does not bind. 18. Close and secure the hood. 19. Switch the main circuit breaker to the O position, to energize the electrical system. 4520Z Page 4–23 Engine: Engine Service and Repairs 09.40001Rev 00...
  • Page 76 6. Remove the bolt and washer securing the clutch to the crankshaft. 7. Remove the clutch from the crankshaft. Engine: Engine Service and Repairs Page 4–24 4520Z 09.40001Rev 00...
  • Page 77 5. Check the clutch air gap; refer to Adjusting the PTO Electric Clutch Air Gap, page 7–4. 6. Install the grill; refer to Removing and Installing the Grill, page 7–14. 4520Z Page 4–25 Engine: Engine Service and Repairs 09.40001Rev 00...
  • Page 78 Engine: Engine Service and Repairs Page 4–26 4520Z 09.40001Rev 00...
  • Page 79 Removing the 3–Point Hitch Spool Valve..................5–35 Installing the 3–Point Hitch Spool Valve ................... 5–35 Removing the 3–Point Hitch Lift Cylinder..................5–36 Installing the 3–Point Hitch Lift Cylinder ................... 5–37 Removing and Installing the Hydraulic Fluid Reservoir ..............5–38 4520Z Page 5–1 Hydraulic System 09.40001Rev 00...

  • Page 80: General Information

    3. Turn the steering wheel left and right. 4. Cycle the primary and secondary SDLA lever forward, backward, left and right. 5. Cycle the auxiliary hydraulic controls. 6. If equipped, cycle the 3–point hitch control levers. Hydraulic System: General Information Page 5–2 4520Z 09.40001Rev 00...

  • Page 81: Remote Filtering The Hydraulic System

    This can release damaging particles into the closed-loop drive circuit causing severe damage. 4. Start the engine and set the engine speed between 2,000 and 2,500 RPM. 4520Z Page 5–3 Hydraulic System: General Information...
  • Page 82 10. Check the hoses and fittings for leaks. 11. Set the high/low shifter and the neutral assist lever to the desired position. 12. Remove the wheel chocks. Hydraulic System: General Information Page 5–4 4520Z 09.40001Rev 00...

  • Page 83: Testing The Static Implement Pressure

    Loading the hydrostatic drive system requires the machine to be tethered to an anchor point. Failure to use a proper anchor point or proper tether could result in injury or damage to equipment. 4520Z Page 5–5 Hydraulic System: General Information...

  • Page 84: Testing The Steering Valve P-Port Bypass

    You will not be able to steer the machine with the steering return hose being capped. 3. Check the static implement pressure. If the valve was bypassing, implement pressure will return and lift will function correctly. The steering valve will need to Hydraulic System: General Information Page 5–6 4520Z 09.40001Rev 00...

  • Page 85: Adjusting The Hydraulic Pump Tow Valve

    3. Remove the hydraulic pump cover; refer to Removing and Installing the Hydraulic Pump Cover, page 7–15. 4. Locate the tow valve 5. Loosen the valve a minimum of 1 turn but no more than 3 turns. 4520Z Page 5–7 Hydraulic System: General Information 09.40001Rev 00...
  • Page 86 6. Tighten the valve, torque the valve to 12 Nm (9 ft-lb). 7. After the valve is tightened, install the hydraulic pump cover. 8. Check the forward and reverse movement of the machine. Hydraulic System: General Information Page 5–8 4520Z 09.40001Rev 00...

  • Page 87: Hydraulic Hoses

    5–10. Note: If the hose has an elbow at one end, tighten the swivel nut on the elbow end before you tighten the nut on the straight end of the hose. 4520Z Page 5–9 Hydraulic System: Hydraulic Hoses 09.40001Rev 00...

  • Page 88: Installing The Hydraulic Hoses And Tubes (O-Ring Face Seal)

    Calculating the Torque Values When Using a Drive-Adapter Wrench, page 2–5 Figure 21 Mark swivel nut and fitting body Initial position Final position G212098 Hydraulic System: Hydraulic Hoses Page 5–10 4520Z 09.40001Rev 00...
  • Page 89 C. Use a wrench to tighten the nut to the correct Flats From Wrench Resistance (compare items 2 and 3 in Figure 21). 4520Z Page 5–11 Hydraulic System: Hydraulic Hoses 09.40001Rev 00...

  • Page 90: Installing The Hydraulic Fittings (Sae Straight Thread O-Ring Fittings)

    Flats From Finger Tight (FFFT) Table, page 5–15. C. If the port material is aluminum, tighten the fitting to 60% of the listed value; refer to the Fitting Installation Torque Table, page 5–15. Hydraulic System: Hydraulic Hoses Page 5–12 4520Z 09.40001Rev 00...
  • Page 91 6. If the adjustable fitting needs to align with another component, rotate the fitting counterclockwise until it is aligned to the desired position (Step 3, Figure 24). Do not rotate the adjustable fitting more than one turn counterclockwise. 4520Z Page 5–13 Hydraulic System: Hydraulic Hoses 09.40001Rev 00...
  • Page 92 Flats From Finger Tight (FFFT) Table, page 5–15. D. If the port material is aluminum, tighten the fitting to 60% of the listed FFFT value; refer to the Flats From Finger Tight (FFFT) Table, page 5–15. Hydraulic System: Hydraulic Hoses Page 5–14 4520Z 09.40001Rev 00...
  • Page 93 1.00 ± 0.25 6 (3/8 inch) 1.50 ± 0.25 8 (1/2 inch) 1.50 ± 0.25 10 (5/8 inch) 1.50 ± 0.25 12 (3/4 inch) 1.50 ± 0.25 16 (1 inch) 1.50 ± 0.25 4520Z Page 5–15 Hydraulic System: Hydraulic Hoses 09.40001Rev 00...

  • Page 94: Hydraulic Schematic

    Hydraulic Schematic The hydraulic schematic for the KN4520 machine is located in 9 Appendix A, page 9– Hydraulic System: Hydraulic Schematic Page 5–16 4520Z 09.40001Rev 00...

  • Page 95: Hydraulic Flow Diagrams

    Remote Filtering the Hydraulic System, page 5–3. WARNING Even small amounts of contamination can cause severe damage within the closed-loop circuit. 4520Z Page 5–17 Hydraulic System: Hydraulic Flow Diagrams 09.40001Rev 00...

  • Page 96: Implement Circuit

    T port. Steering input directs fluid flow from P port to L or R port, to the steering cylinder. Lift and auxiliary input directs fluid flow from P port to E port, to the spool valve. Hydraulic System: Hydraulic Flow Diagrams Page 5–18 4520Z 09.40001Rev 00...

  • Page 97: Service And Repairs

    1. Check the hydraulic fluid level in the hydraulic fluid reservoir, adjust the fluid level as required; refer to the 4520 Operator’s Manual for fluid type and quantity. 2. Lubricate O-rings and seals with clean hydraulic fluid before installing the hydraulic components. 4520Z Page 5–19 Hydraulic System: Service and Repairs 09.40001Rev 00...

  • Page 98: General Precautions For Removing And Installing Hydraulic System Components

    6. Add hydraulic oil as specified in the Operator’s Manual to the hydraulic oil tank until the oil level in the plastic site tube is within the proper range indicated by the oil level decal. Hydraulic System: Service and Repairs Page 5–20 4520Z 09.40001Rev 00...

  • Page 99: Removing The Front Hydraulic Motor

    Note: Clean the hydraulic connections before disconnecting any hydraulic hoses or fittings. 4. Label and disconnect the hydraulic hoses from the front hydraulic motor. 4520Z Page 5–21 Hydraulic System: Service and Repairs 09.40001Rev 00...

  • Page 100: Installing The Front Hydraulic Motor

    Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Relieving Pressure from the Hydraulic System, page 5–2. Hydraulic System: Service and Repairs Page 5–22 4520Z 09.40001Rev 00...

  • Page 101: Installing The Rear Hydraulic Motor

    Installing the Rear Hydraulic Motor 1. Install the hydraulic fittings into the rear hydraulic motor as required. Lubricate the new O-rings with clean hydraulic fluid; refer to Installing the Hydraulic Fittings 4520Z Page 5–23 Hydraulic System: Service and Repairs 09.40001Rev 00...

  • Page 102: Removing The Hydraulic Pump

    Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Relieving Pressure from the Hydraulic System, page 5–2. Hydraulic System: Service and Repairs Page 5–24 4520Z 09.40001Rev 00...
  • Page 103 O position. 2. Drain Hydraulic fluid from the quick couplers. 3. Remove the radiator; refer to 4520Z Removing the Radiator, page 4–16. 4. Remove the drive shaft; refer to Removing and Installing the Drive Shaft , page 4–20.

  • Page 104: Installing The Hydraulic Pump

    8. Install the drive shaft; refer to Removing and Installing the Drive Shaft , page 4– 9. Install the radiator; refer to 4520Z Installing the Radiator, page 4–17. 10. Remote filter the hydraulic system; refer to Remote Filtering the Hydraulic System, page 5–3.

  • Page 105: Removing The Sdla Spool Valve

    Installing the SDLA Spool Valve 1. Position the spool valve in the machine aligning the mounting holes, install the mounting bolts Figure 31, item 4520Z Page 5–27 Hydraulic System: Service and Repairs 09.40001Rev 00...

  • Page 106: Replacing The Sdla Spool Valve Float Detent

    3. Remove the SDLA spool valve as required; refer to Removing the SDLA Spool Valve, page 5–27. 4. Remove the two mounting bolts , pull the spool from the valve, and discard the o-ring Hydraulic System: Service and Repairs Page 5–28 4520Z 09.40001Rev 00...

  • Page 107: Removing And Installing The Hydraulic Cooler Fan

    7. Position the hydraulic cooler against the rear seat box panel aligning the mounting holes. 8. Install the four mounting bolts with washers. 4520Z Page 5–29 Hydraulic System: Service and Repairs 09.40001Rev 00...

  • Page 108: Removing And Installing The Steering Valve

    Removing and Installing the Steering Valve Cover, page 7–33. 5. Remove the hydraulic pump cover; refer to Removing and Installing the Hydraulic Pump Cover, page 7–15. Figure 34 Port identification G434381 Hydraulic System: Service and Repairs Page 5–30 4520Z 09.40001Rev 00...
  • Page 109 17. Start the machine and allow hydraulic fluid to circulate through the system. 18. Turn off the ignition and check the hydraulic fluid level, add hydraulic fluid as required. 4520Z Page 5–31 Hydraulic System: Service and Repairs 09.40001Rev 00...

  • Page 110: Removing The Steering Cylinder

    8. If the hydraulic fittings are to be removed from the steering cylinder, mark the fitting orientation, and remove the fittings from the steering cylinder and discard the O-rings from the fittings. Hydraulic System: Service and Repairs Page 5–32 4520Z 09.40001Rev 00...

  • Page 111: Installing The Steering Cylinder

    Relieving Pressure from the Hydraulic System, page 5–2. Figure 37 Mounting bolts Hydraulic hose Hydraulic fittings G444452 4520Z Page 5–33 Hydraulic System: Service and Repairs 09.40001Rev 00...

  • Page 112: Installing The Lift Cylinder

    5–10. 4. Lubricate the lift cylinder grease fittings. 5. Check the hydraulic systems for leaks and add hydraulic fluid to the system as required. 6. Install the right engine cover. Hydraulic System: Service and Repairs Page 5–34 4520Z 09.40001Rev 00...

  • Page 113: Removing The 3-Point Hitch Spool Valve

    O-rings, connect the hydraulic hoses to the fittings on the spool valve. Tighten the hose connections; refer to Installing the Hydraulic Hoses and Tubes (O-Ring Face Seal), page 5–10. 4520Z Page 5–35 Hydraulic System: Service and Repairs 09.40001Rev 00...

  • Page 114: Removing The 3-Point Hitch Lift Cylinder

    Allow the hoses to drain into an approved container. Remove and discard the O- rings from the fittings. 5. Install clean caps or plugs on the hydraulic hoses and fittings to prevent contamination. 6. Remove the front and rear cylinder mounting bolts Hydraulic System: Service and Repairs Page 5–36 4520Z 09.40001Rev 00...

  • Page 115: Installing The 3-Point Hitch Lift Cylinder

    Installing the Hydraulic Hoses and Tubes (O-Ring Face Seal), page 5–10. 4. Lubricate the lift cylinder grease fittings. 5. Check the hydraulic systems for leaks and add hydraulic fluid to the system as required. 4520Z Page 5–37 Hydraulic System: Service and Repairs 09.40001Rev 00...

  • Page 116: Removing And Installing The Hydraulic Fluid Reservoir

    8. Disconnect the supply hose from the fitting on the bottom of the reservoir. 9. Remove the reservoir from the machine. 10. To install the hydraulic fluid reservoir, position the reservoir in the machine. Hydraulic System: Service and Repairs Page 5–38 4520Z 09.40001Rev 00...
  • Page 117 14. Install the hydraulic reservoir mounting bolts. 15. Add hydraulic fluid to the reservoir. 16. Switch the main circuit breaker to the O position, to energize the electrical system. 4520Z Page 5–39 Hydraulic System: Service and Repairs 09.40001Rev 00...
  • Page 118 Hydraulic System: Service and Repairs Page 5–40 4520Z 09.40001Rev 00...
  • Page 119 Testing the Rear 12 Volt Switch......................6–38 Rear 12 Volt Momentary Switch ......................6–38 Testing the Rear 12 Volt Momentary Switch..................6–39 Parking Brake Switch..........................6–39 Testing the Parking Brake Switch......................6–40 PTO Electric Clutch ........................... 6–41 4520Z Page 6–1 Electrical System 09.40001Rev 00...
  • Page 120 Battery ................................6–65 Battery Safety ............................6–66 Cleaning the Battery and Terminals....................6–66 Charging the Battery ..........................6–67 Storing the Battery ..........................6–67 Removing the Battery ........................... 6–68 Installing the Battery..........................6–68 Electrical System: Service and Repairs Page 6–2 4520Z 09.40001Rev 00...

  • Page 121: General Information

    Kubota Engine Electrical Components When servicing or troubleshooting the engine’s electrical components use the correct engine service manual. Kubota engine service manuals and quick reference service guides are available on the Ventrac Dealer Network. 4520Z Page 6–3 Electrical System: General Information...

  • Page 122: Amperage Draw Chart

    4520K Fuel Pump 4520N General Amp Draw 4520N Fuel Pump 4520P General Amp Draw 4520P Fuel Pump 4520Y General Amp Draw 4520Y Fuel Pump 4520Z General Amp Draw 4520Z Fuel Pump Lights PTO Clutch Hydraulic Cooler Fan 4520 Options Component Description...

  • Page 123: Electrical Drawings

    Electrical Drawings The electrical schematic and wire harness drawings for the 4520 machine are in Appendix A, page 9–1. 4520Z Page 6–5 Electrical System: Electrical Drawings 09.40001Rev 00...

  • Page 124: Electrical System Quick Checks

    Electrical System Quick Checks Testing the Charging System The 4520Z uses a single 12 Volt maintenance free battery mounted under the operator’s seat. The battery is charged by a 60 Amp 12 Volt alternator mounted to the engine. 1. Park the machine on a level surface, lower any attachments to the ground, and engage the parking brake.
  • Page 125 SDLA in neutral or out of neutral**, and sit on the seat or raise your body weight from the seat. The engine should continue running or stop running as described for each test. 4520Z Page 6–7 Electrical System: Electrical System Quick Checks...
  • Page 126 Body Weight Disengages from Seat (1/2 second delay) If the power unit fails any one of the safety interlock tests, the issue must be corrected before operating the power unit. Electrical System: Electrical System Quick Checks Page 6–8 4520Z 09.40001Rev 00...

  • Page 127: Electrical Component Testing

    The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check the component/circuit for a malfunction or short. Fuse Identification, Location, and Function Front Fuse Panel Layout (Serial # 01001 — 02172) G424761 4520Z Page 6–9 Electrical System: Electrical Component Testing 09.40001Rev 00...
  • Page 128 Back-up / Horn / Directional Tractor Control Module 1 10** Diesel Stop Tractor Control Module 2 *Optional accessory **4520Y only Relays Location Function PTO Out Fuel Pump PTO In Starter Electrical System: Electrical Component Testing Page 6–10 4520Z 09.40001Rev 00...
  • Page 129 12V Front 2 Dual Hyd. Auxiliary Seat Switch, USB 25 (CB) Hydraulic Oil Cooler Fan *Optional accessory (CB) = Circuit Breaker Relays Location Function Hydraulic Oil Cooler Fan 12V Front* 4520Z Page 6–11 Electrical System: Electrical Component Testing 09.40001Rev 00...
  • Page 130 Fuses Location Fuse Circuit (Amps) Gauges / Slope Indicator Engine Run Tractor Control Module 1 Speed Sensor / Back-up / Horn / Directional Diesel Stop Tractor Control Module 2 Blank Electrical System: Electrical Component Testing Page 6–12 4520Z 09.40001Rev 00...
  • Page 131 Fuse Circuit (Amps) Fuel Pump PTO / Starter *4520Y only Relays Location Function PTO In Starter Fuel Pump PTO Out Rear Fuse Panel Layout (Serial # 02173 — 05664) G424764 4520Z Page 6–13 Electrical System: Electrical Component Testing 09.40001Rev 00...
  • Page 132 Hydraulic Oil Cooler Fan *Optional accessory Testing Fuses 1. Park the machine on a level surface, lower any attachments to the ground, engage the parking brake and remove the key from the ignition. Electrical System: Electrical Component Testing Page 6–14 4520Z 09.40001Rev 00...

  • Page 133: Relays

    The machines use a number of electrical relays. The number of terminals the relay has determines how the relay should be tested. Relays for the machine are located inside each fuse block Fuse Identification, Location, and Function, page 6–9 and TCS (if equipped). 4520Z Page 6–15 Electrical System: Electrical Component Testing 09.40001Rev 00...
  • Page 134 Engine Run 2 Interlock Change Ground to +12V Engine Stop Ground Output Engine Run 3 Interlock 1/2 sec Delay Engine Run 4 Interlock Park Brake On / Neutral Off- Lockout Glow Plug Output (4520Y Only) Electrical System: Electrical Component Testing Page 6–16 4520Z 09.40001Rev 00...
  • Page 135 86 and apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as +12 VDC is applied and removed from terminal 85. 6. Disconnect voltage from terminal 85 and multimeter lead from terminal 87. 4520Z Page 6–17 Electrical System: Electrical Component Testing 09.40001Rev 00...
  • Page 136 9 Appendix A, page 9–1. 10. Install the relay and secure the fuse block cover. 11. Switch the main circuit breaker to the O position, to energize the electrical system. Electrical System: Electrical Component Testing Page 6–18 4520Z 09.40001Rev 00...

  • Page 137: Tractor Control Module (Tcm)

    The TCM is programmed to allow the engine, the starter, or the PTO to operate only when specific input criteria are satisfied. The engine, the starter, and the PTO are controlled by outputs from the TCM. 4520Z Page 6–19 Electrical System: Tractor Control Module (TCM)

  • Page 138: Removing And Installing The Tcm

    9. Connect the wiring harness to the TCM. 10. Close and secure the hood. 11. Switch the main circuit breaker to the O position, to energize the electrical system. Electrical System: Tractor Control Module (TCM) Page 6–20 4520Z 09.40001Rev 00...

  • Page 139: Tractor Control System (Tcs)

    PTO to operate only when specific input criteria are satisfied. The engine, the starter, and the PTO are controlled by outputs from the TCS. 4520Z Page 6–21 Electrical System: Tractor Control System (TCS) 09.40001Rev 00...

  • Page 140: Removing And Installing The Tcs

    9. Connect the wiring harness to the TCS. 10. Close and secure the hood. 11. Switch the main circuit breaker to the O position, to energize the electrical system. Electrical System: Tractor Control System (TCS) Page 6–22 4520Z 09.40001Rev 00...

  • Page 141: Information Gauge Cluster

    It also contains an indicator light for the glow plugs and warning lights for low engine oil pressure, high water temperature, high hydraulic oil temperature, low voltage, and low fuel. 4520Z Page 6–23 Electrical System: Information Gauge Cluster 09.40001Rev 00...

  • Page 142: Programming The Gauge

    Exit. A timer on the gauge display will count down from 10 to 0. After the countdown is complete release the toggle switch. If the switch is released during the countdown, the save operation will be aborted. Electrical System: Information Gauge Cluster Page 6–24 4520Z 09.40001Rev 00...
  • Page 143 8. Turn the ignition key to the R position. Verify that the unlock icon is not displayed and that the hours entered are correct. 9. Disconnect the gauge programming tool. 4520Z Page 6–25 Electrical System: Information Gauge Cluster 09.40001Rev 00...

  • Page 144: Power Relay Module

    TCM. The bottom fuse provides keyed power (power from the operation of the key switch) to the front and rear fuse panels. Electrical System: Power Relay Module Page 6–26 4520Z 09.40001Rev 00...

  • Page 145: Fusible Link Harness

    Figure 50 Fusible link G424445 The 4520Z uses an 80 Amp fusible link for circuit protection. This fusible link harness connects the alternator terminal to the starter terminal. If this link should fail the charging circuit will be interrupted. Testing the Fusible Link Harness 1.

  • Page 146: Key Switch

    • OFF (STOP) position, all 12 volt power going through the key switch is off. • RUN position, 12 volt power is sent to accessories. • START position, when the key is turned to the start position the engine starter is engaged. Electrical System: Key Switch Page 6–28 4520Z 09.40001Rev 00...

  • Page 147: Testing The Key Switch

    COM B + NO B G423845 The PTO switch is located on the control panel. The switch is pulled up to engage the PTO and pushed down to disengage the PTO. 4520Z Page 6–29 Electrical System: Key Switch 09.40001Rev 00...

  • Page 148: Testing The Power Take Off (Pto) Switch

    8. Install the switch, connect the wire harness, and install the control panel after testing. 9. Switch the main circuit breaker to the O position, to energize the electrical system. Electrical System: Power Take Off (PTO) Enable Switch Page 6–30 4520Z 09.40001Rev 00...

  • Page 149: Seat Switch

    8. Replace the switch if necessary. 9. If the switch tests correctly and a circuit problem still exists, check the wire harnesses; refer to 9 Appendix A, page 9–1. 4520Z Page 6–31 Electrical System: Seat Switch 09.40001Rev 00...

  • Page 150: Headlight Switch

    The headlight switch is located on the control panel. Pushing down on the top of the switch turns on the headlights and taillights. Pushing down on the bottom of the switch turns off the headlights and taillights. Electrical System: Headlight Switch Page 6–32 4520Z 09.40001Rev 00...

  • Page 151: Testing The Headlight Switch

    Pushing down on the bottom of the switch turns on the left directional signal lights. Putting the switch in the middle position turns off the directional signal lights. 4520Z Page 6–33 Electrical System: Headlight Switch...

  • Page 152: Testing The Directional Signal Switch

    The hazard flasher switch is located on the control panel. Pushing down on the top of the switch turns on the hazard flasher lights. Pushing down on the bottom of the switch turns off the hazard flasher lights. Electrical System: Directional Signal Switch Page 6–34 4520Z 09.40001Rev 00...

  • Page 153: Testing The Hazard Flasher Switch

    The work light switch is located on the control panel. Pushing down on the top of the switch turns on the work lights. Pushing down on the bottom of the switch turns off the work lights. 4520Z Page 6–35 Electrical System: Hazard Flasher Switch...

  • Page 154: Testing The Work Light Switch

    The strobe light switch is located on the control panel. Pushing down on the top of the switch turns on the strobe light. Pushing down on the bottom of the switch turns off the strobe light. Electrical System: Work Light Switch Page 6–36 4520Z 09.40001Rev 00...

  • Page 155: Testing The Strobe Light Switch

    (toward the operator) provides power to the rear 12 volt 4 pin socket. Pushing down on the right side of the switch (away from the operator) turns off power to the 12 volt 4 pin socket. 4520Z Page 6–37 Electrical System: Strobe Light Switch...

  • Page 156: Testing The Rear 12 Volt Switch

    12 volt 4 pin socket as long as the switch is held down. Releasing the switch turns off power to the 12 volt 4 pin socket. Electrical System: Rear 12 Volt Switch Page 6–38 4520Z 09.40001Rev 00...

  • Page 157: Testing The Rear 12 Volt Momentary Switch

    When the parking brake is disengaged, the circuit is open. 4520Z Page 6–39 Electrical System: Rear 12 Volt Momentary Switch 09.40001Rev 00...

  • Page 158: Testing The Parking Brake Switch

    9 Appendix A, page 9–1 9. Connect the wire harness and close the hood. 10. Switch the main circuit breaker to the O position, to energize the electrical system. Electrical System: Parking Brake Switch Page 6–40 4520Z 09.40001Rev 00...

  • Page 159: Pto Electric Clutch

    The coil resistance should be approximately 3.0 ohms. Additionally, check that there is no continuity between either of the clutch wire connector terminals and the clutch frame. 4520Z Page 6–41 Electrical System: PTO Electric Clutch...
  • Page 160 6. If the clutch tests correctly and a circuit problem still exists, check the wire harnesses; refer to 9 Appendix A, page 9–1. 7. Connect the clutch electrical connector to the main harness. Electrical System: PTO Electric Clutch Page 6–42 4520Z 09.40001Rev 00...

  • Page 161: Warning Alarm

    9 Appendix A, page 9–1. 8. Connect the harness wires to the alarm and close the hood. 9. Switch the main circuit breaker to the O position, to energize the electrical system. 4520Z Page 6–43 Electrical System: Warning Alarm 09.40001Rev 00...

  • Page 162: Neutral Switch

    Speed, Direction, Lift, Auxiliary (SDLA) control lever is in the neutral position. The neutral switch is part of the safety interlock circuit. The machine will not start if the SDLA control lever is not in the neutral position. Electrical System: Neutral Switch Page 6–44 4520Z 09.40001Rev 00...

  • Page 163: Testing The Neutral Switch

    9 Appendix A, page 9–1. 9. Connect the wire harness and install the pump cover. 10. Switch the main circuit breaker to the O position, to energize the electrical system. 4520Z Page 6–45 Electrical System: Neutral Switch 09.40001Rev 00...

  • Page 164: Hydraulic Fluid Temperature Switches

    4. Locate the temperature switch and disconnect the wire harness. 5. Thoroughly clean the hydraulic motor around the temperature switch. 6. Remove the temperature switch from the motor and discard the O-ring. Electrical System: Hydraulic Fluid Temperature Switches Page 6–46 4520Z 09.40001Rev 00...

  • Page 165: Testing The Hydraulic Cooler Temperature Switch

    7. Remove the temperature switch from the cooler and discard the o-ring. CAUTION The hydraulic oil may be hot. Handle the oil with care to prevent personal injury or fire. 4520Z Page 6–47 Electrical System: Hydraulic Fluid Temperature Switches 09.40001Rev 00...
  • Page 166 14. Install the control panel. 15. Fill the hydraulic system to the proper level. 16. Switch the main circuit breaker to the O position, to energize the electrical system. Electrical System: Hydraulic Fluid Temperature Switches Page 6–48 4520Z 09.40001Rev 00...

  • Page 167: Hydraulic Cooler Fan

    Testing the Hydraulic Cooler Fan 1. Park the machine on a level surface, lower any attachments to the ground, engage the parking brake, and remove the key from the ignition. 4520Z Page 6–49 Electrical System: Hydraulic Cooler Fan 09.40001Rev 00...
  • Page 168 If the fan is not operational replace the fan. 5. If the fan is operational test the hydraulic cooler temperature switch; refer to Testing the Hydraulic Cooler Temperature Switch, page 6–47. Electrical System: Hydraulic Cooler Fan Page 6–50 4520Z 09.40001Rev 00...

  • Page 169: Speed Sensor

    Littlefuse 55075 Littlefuse 55505 receive a signal from the end of a gear tooth. Figure 57 Cherry GS101205 G426990 4520Z Page 6–51 Electrical System: Speed Sensor 09.40001Rev 00...

  • Page 170: Testing The Speed Sensor

    C. Use a multi meter set to DC voltage and check for approximately 12 VDC across the supply (+) pin and (-) ground pin of the machine wire harness speed sensor connector. This confirms the integrity of the circuit supply and ground wires. Electrical System: Speed Sensor Page 6–52 4520Z 09.40001Rev 00...

  • Page 171: Adjusting The Speed Sensor

    3. Adjust the sensor so that the face of the sensor is .060 in. away from the speed indicator plate. Check the clearance with a feeler gauge. 4. Tighten the mounting bolts. 4520Z Page 6–53 Electrical System: Speed Sensor 09.40001Rev 00...

  • Page 172: Rpm Sensor

    3. Remove the radiator; refer to 4520Z Removing the Radiator, page 4–16 4. Disconnect and remove the sensor from the machine. 5. Clean the sensor and inspect the sensor for any damage. Replace the sensor if the face is scratched or damaged in any way.

  • Page 173: Adjusting The Rpm Sensor

    3. Remove the radiator; refer to 4520Z Removing the Radiator, page 4–16 4. Loosen the flange nut. 5. Adjust the sensor so it is .060 in. away from the trigger plate on the drive shaft.

  • Page 174: Fuel Pump

    5. Install a temporary fuel hose from the fuel pump outlet into a 0.95 liter (1 quart) graduated cylinder. IMPORTANT When testing the fuel pump output, do not turn the key switch to the start position. Electrical System: Fuel Pump Page 6–56 4520Z 09.40001Rev 00...
  • Page 175 9 Appendix A, page 9–1. 8. Remove the temporary fuel hose. 9. Connect the fuel hoses and secure with hose clamps. 10. Prime the fuel System; Priming the Fuel System, page 4–10 4520Z Page 6–57 Electrical System: Fuel Pump 09.40001Rev 00...

  • Page 176: Fuel Level Sender

    8. Using a multimeter (ohms setting), check the resistance of the sender at the harness connector with the float in the full (up) position, and with the float in the empty (down) position. Full 20–35 ohms Empty 240–265 ohms. Move the float Electrical System: Fuel Level Sender Page 6–58 4520Z 09.40001Rev 00...
  • Page 177 9–1. 11. Carefully install sender into fuel tank and install the fuel tank main cover. 12. Switch the main circuit breaker to the O position, to energize the electrical system. 4520Z Page 6–59 Electrical System: Fuel Level Sender 09.40001Rev 00...

  • Page 178: Oil Pressure Switch

    Check the switch and the harness connector for damage or corrosion and clean or repair as necessary. 4. Connect a multimeter (ohms setting) to check the continuity of the switch: Electrical System: Oil Pressure Switch Page 6–60 4520Z 09.40001Rev 00...
  • Page 179 9 Appendix A, page 9–1. 7. After testing, connect the engine wire harness to the switch. 8. Switch the main circuit breaker to the O position, to energize the electrical system. 4520Z Page 6–61 Electrical System: Oil Pressure Switch 09.40001Rev 00...

  • Page 180: Speed Direction Lift Auxiliary (Sdla) Control Lever (Optional)

    7. Connect the wire harness, and install the control panel after testing. 8. Switch the main circuit breaker to the O position, to energize the electrical system. Electrical System: Speed Direction Lift Auxiliary (SDLA) Page 6–62 4520Z Control Lever (Optional) 09.40001Rev 00...

  • Page 181: 12 Volt Front And Rear Socket And Plug

    12 Volt Front and Rear Socket and Plug IMPORTANT This connector (4–pin socket) is designed for use with Ventrac original equipment only. This connector (4–pin socket) is rated for 20 amp maximum current draw. Engine alternator and/or battery capacity determine allowable continuous draw.
  • Page 182 Positive/Negative (Momentary Switched Reversing) * Refer to the part diagram in the attachment’s parts manual for specific wire color and terminal position for each model. Electrical System: 12 Volt Front and Rear Socket and Page 6–64 4520Z Plug 09.40001Rev 00...

  • Page 183: Battery

    Battery-electrolyte is corrosive and can burn skin and eyes and damage clothing. While working with the batteries, use extreme caution to avoid splashing or spilling the electrolyte. Always wear safety goggles and a face shield while working with batteries. 4520Z Page 6–65 Electrical System: Battery 09.40001Rev 00...

  • Page 184: Battery Safety

    (1 gallon) of water. Do not allow the soda solution to get into the battery cells. 3. Rinse the battery with clean water. 4. Clean the battery posts and battery cable terminals with a wire brush. Electrical System: Battery Page 6–66 4520Z 09.40001Rev 00...

  • Page 185: Charging The Battery

    2. Charge the battery Charging the Battery, page 6–67. 3. Store the battery on a shelf in a cool climate that will not be below freezing for an extended period of time. 4520Z Page 6–67 Electrical System: Battery 09.40001Rev 00...

  • Page 186: Removing The Battery

    To prevent possible electrical problems, install only a fully charged battery. 1. Park the machine on a level surface, lower any attachments to the ground, engage the parking brake and remove the key from the ignition. Electrical System: Battery Page 6–68 4520Z 09.40001Rev 00...
  • Page 187 7. Connect the negative battery cable to the negative battery post last. 8. Apply dielectric grease to the battery terminals to prevent corrosion. 9. Ensure that the rubber boots are placed over positive and negative cable ends and battery posts. 4520Z Page 6–69 Electrical System: Battery 09.40001Rev 00...
  • Page 188 Electrical System: Battery Page 6–70 4520Z 09.40001Rev 00...
  • Page 189 Installing the Weight Transfer Assembly ..................7–38 Removing the Parking Brake Lever....................7–39 Installing the Parking Brake Lever ..................... 7–40 Removing the Parking Brake Band ....................7–40 Installing the Parking Brake Band...................... 7–41 Removing the Parking Brake Drum ....................7–41 4520Z Page 7–1 Chassis 09.40001Rev 00...
  • Page 190 Removing the Center Pivot........................7–48 Installing the Center Pivot ........................7–49 Removing the Front Hitch Arms ......................7–50 Installing the Front Hitch Arms......................7–50 Removing the PTO Idler Pulley ......................7–51 Installing the PTO Idler Pulley......................7–51 Chassis: Battery Page 7–2 4520Z 09.40001Rev 00...

  • Page 191: General Information

    The 4520 Operator’s Manual and accessory Installation Instructions provide information regarding the operation, general maintenance, and maintenance intervals for the machine and its accessories. Refer to the Operator’s Manual and accessory Installation Instructions for additional information. 4520Z Page 7–3 Chassis: General Information 09.40001Rev 00...

  • Page 192: Adjustments

    The PTO clutch is an electric clutch that is activated by the PTO switch to engage or disengage power to belt driven attachments. The clutch also provides braking action to stop the attachment when the PTO is disengaged, or the operator presence circuit is interrupted. Chassis: Adjustments Page 7–4 4520Z 09.40001Rev 00...
  • Page 193 5. Tighten or loosen the clutch adjustment nuts as needed to achieve .5 mm (.020 in) air gap. 6. Switch the main circuit breaker to the O position, to energize the electrical system. 4520Z Page 7–5 Chassis: Adjustments 09.40001Rev 00...

  • Page 194: Adjusting The Parking Brake

    The compression spring should not cause the brake engagement tab to be lifted more than .8mm (.03 in). If the brake engagement tab movement exceeds the specified measurement, it is Chassis: Adjustments Page 7–6 4520Z 09.40001Rev 00...

  • Page 195: Adjusting Neutral

    If the machine attempts to move in either condition, adjust the neutral position. 1. Remove any attachments from the machine. 2. Park the machine on a level surface, engage the parking brake and remove the key from the ignition. 4520Z Page 7–7 Chassis: Adjustments 09.40001Rev 00...
  • Page 196 13. Engage the parking brake, shut off the engine, and remove the key from the ignition. 14. Remove the weight from the seat. 15. Install the hydraulic pump cover. 16. Remove the machine from the jack stands or supporting blocks. Chassis: Adjustments Page 7–8 4520Z 09.40001Rev 00...

  • Page 197: Adjusting The Neutral Switch

    Adjusting the Neutral Switch Figure 75 G447521 Front frame Pump arm 1. Park the machine on a level surface, lower any attachments to the ground, engage the parking brake, and remove the key from the ignition. 4520Z Page 7–9 Chassis: Adjustments 09.40001Rev 00...
  • Page 198 10. Repeat steps 8 and 9 as needed until the measurement is in the specified range. 11. Turn the ignition key to the off position and engage the parking brake. 12. Install the hydraulic pump cover. 13. Remove the wheel chocks. Chassis: Adjustments Page 7–10 4520Z 09.40001Rev 00...

  • Page 199: Service And Repairs

    7. Remove the jack stand and lower the machine to the ground. 8. Torque the wheel-lug nuts or bolts evenly to 75 Nm (55 ft-lb) in a crossing pattern. 9. Check and adjust tire pressures; refer to Operator’s Manual. 4520Z Page 7–11 Chassis: Service and Repairs 09.40001Rev 00...

  • Page 200: Removing And Installing Outer Dual Wheels

    Torque the bolt to 203 Nm (150 ft- lb). Chassis: Service and Repairs Page 7–12 4520Z 09.40001Rev 00...

  • Page 201: Removing And Installing The Hood

    8. Carefully lift the hood and install the locking flange nuts 9. Route the headlight wiring harness through the cushioned clamp connect the harness to the machine wiring harness. 10. Close the hood securely using the hood latches. 4520Z Page 7–13 Chassis: Service and Repairs 09.40001Rev 00...

  • Page 202: Removing And Installing The Grill

    Figure 79 Engine covers Mounting bolts G427425 1. Park the machine on a level surface, lower any attachments to the ground, engage the parking brake, and remove the key from the ignition. Chassis: Service and Repairs Page 7–14 4520Z 09.40001Rev 00...

  • Page 203: Removing And Installing The Hydraulic Pump Cover

    3. Remove the mounting bolts 4. Remove the hydraulic pump cover 5. To install the hydraulic pump cover, position the cover against the front frame aligning the mounting holes. 4520Z Page 7–15 Chassis: Service and Repairs 09.40001Rev 00...

  • Page 204: Removing And Installing The Right Hydraulic Pump Cover

    3. Remove the right hydraulic pump cover , by removing the mounting bolts 4. To install the right hydraulic pump cover, position the cover on the machine aligning the mounting holes. 5. Install the mounting bolts. Chassis: Service and Repairs Page 7–16 4520Z 09.40001Rev 00...

  • Page 205: Removing And Installing The Hydraulic Filter Access Cover

    4. To install the hydraulic filter access cover, position the cover on the machine aligning the mounting holes. 5. Install the mounting bolts. 6. Switch the main circuit breaker to the O position, to energize the electrical system. 4520Z Page 7–17 Chassis: Service and Repairs 09.40001Rev 00...

  • Page 206: Removing And Installing The Lower Frame Cover

    5. To install the lower frame cover, position the cover on the lower frame aligning the mounting holes. 6. Install the mounting bolts. 7. Switch the main circuit breaker to the O position, to energize the electrical system. Chassis: Service and Repairs Page 7–18 4520Z 09.40001Rev 00...

  • Page 207: Removing And Installing The Control Panel

    7. Position the control panel on the hydraulic oil cooler cover aligning the mounting holes. 8. Install the mounting bolts. 9. Switch the main circuit breaker to the O position, to energize the electrical system. 4520Z Page 7–19 Chassis: Service and Repairs 09.40001Rev 00...

  • Page 208: Removing And Installing The Hydraulic Cooler Top Cover

    7. To install the hydraulic cooler top cover, position the top cover on the machine aligning the mounting holes. 8. Loosely install all the mounting bolts and nuts. Chassis: Service and Repairs Page 7–20 4520Z 09.40001Rev 00...

  • Page 209: Removing And Installing The Hydraulic Cooler Inner Cover

    6. Locate label and disconnect the USB receptacle, rear 12–volt switch, and rear 12–volt momentary switch (if equipped) electrical connectors from the main wiring harness. 7. Remove the fuse panel mounting bolts 8. Remove the mounting bolts and nuts 4520Z Page 7–21 Chassis: Service and Repairs 09.40001Rev 00...

  • Page 210: Removing And Installing The Sdla Pivot Cover

    Flange bolt SDLA pivot cover G429942 1. Park the machine on a level surface, lower any attachments to the ground, engage the parking brake, and remove the key from the ignition. Chassis: Service and Repairs Page 7–22 4520Z 09.40001Rev 00...

  • Page 211: Removing And Installing The Right Outer Seat Box Panel

    1. Park the machine on a level surface, lower any attachments to the ground, engage the parking brake, and remove the key from the ignition. 2. Switch the main circuit breaker to the O position, to de-energize the electrical system. 4520Z Page 7–23 Chassis: Service and Repairs 09.40001Rev 00...

  • Page 212: Removing And Installing The Right Rear Seat Box Panel

    Removing and Installing the Hydraulic Cooler Top Cover, page 7–20. 4. Remove the right outer seat box panel; refer to Removing and Installing the Right Outer Seat Box Panel, page 7–23. Chassis: Service and Repairs Page 7–24 4520Z 09.40001Rev 00...

  • Page 213: Removing And Installing The Fuel Tank Top Cover

    Figure 90 Top cover Mounting bolt G430377 1. Park the machine on a level surface, lower any attachments to the ground, engage the parking brake, and remove the key from the ignition. 4520Z Page 7–25 Chassis: Service and Repairs 09.40001Rev 00...

  • Page 214: Removing And Installing The Fuel Tank Inner Cover

    4. Remove the fuel tank inner cover 5. To install the fuel tank inner cover, position the cover against the seat box frame and the fuel tank top cover aligning the mounting holes. Chassis: Service and Repairs Page 7–26 4520Z 09.40001Rev 00...

  • Page 215: Removing And Installing The Left Outer Seat Box Panel

    6. To install the left outer seat box panel, position the panel against the seat box frame aligning the mounting holes. 7. Install the mounting bolts. 8. Install the fuel tank. 9. Switch the main circuit breaker to the O position, to energize the electrical system. 4520Z Page 7–27 Chassis: Service and Repairs 09.40001Rev 00...

  • Page 216: Removing And Installing The Left Rear Seat Box Panel

    6. To install the left rear seat box panel, position the panel on the seat box frame aligning the mounting holes. 7. Install the mounting bolts. 8. Install the fuel tank. 9. Switch the main circuit breaker to the O position, to energize the electrical system. Chassis: Service and Repairs Page 7–28 4520Z 09.40001Rev 00...

  • Page 217: Removing And Installing The Roll Bar

    9. Connect any electrical connectors from work lights or strobe lights that were disconnected during the removal of the roll bar. 10. Switch the main circuit breaker to the O position, to energize the electrical system. 4520Z Page 7–29 Chassis: Service and Repairs 09.40001Rev 00...

  • Page 218: Removing And Installing The Seat

    10. Carefully tilt the seat forward and secure it with the seat prop. 11. Install the four washers and nuts on the mounting studs. 12. Connect the seat electrical connector(s). 13. Return the seat to the operating position. Chassis: Service and Repairs Page 7–30 4520Z 09.40001Rev 00...

  • Page 219: Removing And Installing The Seat Mount

    10. Install the seat as required. 11. Connect the seat electrical connector(s). 12. Return the seat to the operating position. 13. Switch the main circuit breaker to the O position, to energize the electrical system. 4520Z Page 7–31 Chassis: Service and Repairs 09.40001Rev 00...

  • Page 220: Removing And Installing The Steering Wheel

    7. Install the jam nut to secure the steering wheel in place. 8. Install the steering wheel cap. 9. Switch the main circuit breaker to the O position, to energize the electrical system. Chassis: Service and Repairs Page 7–32 4520Z 09.40001Rev 00...

  • Page 221: Removing And Installing The Steering Valve Cover

    5. To install the steering valve cover, insert the top flange of the cover in the upper cutout in the dash aligning the mounting holes. 6. Install the mounting bolt. 7. Switch the main circuit breaker to the O position, to energize the electrical system. 4520Z Page 7–33 Chassis: Service and Repairs 09.40001Rev 00...

  • Page 222: Removing And Installing The Parking Brake Cover

    5. To install the parking brake cover, position the cover over the parking brake against the dash aligning the mounting holes. 6. Install the mounting bolt and nut. 7. Switch the main circuit breaker to the O position, to energize the electrical system. Chassis: Service and Repairs Page 7–34 4520Z 09.40001Rev 00...

  • Page 223: Removing The Dash

    14. Remove the hydraulic fluid reservoir mounting bolts; refer to Removing and Installing the Hydraulic Fluid Reservoir, page 5–38. 15. Remove the dash mounting bolts 16. Lift the dash to remove it from the machine. 4520Z Page 7–35 Chassis: Service and Repairs 09.40001Rev 00...

  • Page 224: Installing The Dash

    13. Install the steering wheel; refer to Removing and Installing the Steering Wheel, page 7–32. 14. Close the hood. 15. Switch the main circuit breaker to the O position, to energize the electrical system. Chassis: Service and Repairs Page 7–36 4520Z 09.40001Rev 00...

  • Page 225: Removing The Weight Transfer Assembly

    O position. 2. Remove the air cleaner; refer to 4520Z Removing and Installing the Air Cleaner System, page 4–4. 3. Remove the left engine cover; refer to...

  • Page 226: Installing The Weight Transfer Assembly

    , the washers go on either side of the hitch inside the clevis. Secure the clevis pin in place with a cotter pin. 9. Install the left engine cover and air cleaner. Chassis: Service and Repairs Page 7–38 4520Z 09.40001Rev 00...

  • Page 227: Removing The Parking Brake Lever

    7–15. 3. Remove the parking brake cover; refer to Removing and Installing the Parking Brake Cover, page 7–34. 4. Disconnect the parking brake switch wiring harness from the main wiring harness. 4520Z Page 7–39 Chassis: Service and Repairs 09.40001Rev 00...

  • Page 228: Installing The Parking Brake Lever

    Brake band Air gap G441940 WARNING The parking brake must be disengaged as part of this procedure. Wheel chocks must be used to prevent the machine from rolling forward or backward. Chassis: Service and Repairs Page 7–40 4520Z 09.40001Rev 00...

  • Page 229: Installing The Parking Brake Band

    6. Install and adjust the speed sensor; refer to Adjusting the Speed Sensor, page 6– 7. Install the engine cover. Removing the Parking Brake Drum Figure 106 G442670 Speed indicator plate Threaded hole Bushing Bushing mounting bolt 4520Z Page 7–41 Chassis: Service and Repairs 09.40001Rev 00...

  • Page 230: Installing The Parking Brake Drum

    4. Check the brake function, adjust the parking brake as necessary; refer to Adjusting the Parking Brake, page 7–6. 5. Install and adjust the speed sensor; refer to Adjusting the Speed Sensor, page 6– 6. Install the engine cover. Chassis: Service and Repairs Page 7–42 4520Z 09.40001Rev 00...

  • Page 231: Removing The High / Low Shift Cable

    6. With the transaxle set in the low gear position, secure the clevis end onto the rear transaxle shift lever. Ensure that there is no resistance felt on the clevis pin when installing it through the clevis. If resistance is felt adjust the clevis end by turning 4520Z Page 7–43 Chassis: Service and Repairs...

  • Page 232: Removing The Rear Weight Mount

    1. Position the rear weight mount on the machine aligning the mounting holes. 2. Install the six upper mounting bolts Figure 108, item 3. Install the four lower mounting bolts Figure 108, item 4. Install the rear transaxle skid plate. Chassis: Service and Repairs Page 7–44 4520Z 09.40001Rev 00...

  • Page 233: Removing The 3-Point Hitch

    1. Position the 3–point hitch on the machine aligning the mounting holes. 2. Install the six upper mounting bolts Figure 109, item 3. Install the auxiliary coupler mounts Figure 109, item 4. Install the lift cylinder mounting bolt Figure 109, item 4520Z Page 7–45 Chassis: Service and Repairs 09.40001Rev 00...

  • Page 234: Removing The Front / Rear Connector Link

    1, Slightly raising or lowering the floor jack can remove tension from the mounting bolts. 3. Check the torque of the pinch bolts Figure 110, item 2 Torque the bolts to 20 Nm (180 in-lb). Chassis: Service and Repairs Page 7–46 4520Z 09.40001Rev 00...

  • Page 235: Removing The Connector Link Mount

    Figure 111, item 2. Apply red thread locker to the connector link mounting bolt threads. Install the connector link mounting bolt. 3. Install the forward steering cylinder mounting bolt. 4520Z Page 7–47 Chassis: Service and Repairs 09.40001Rev 00...

  • Page 236: Removing The Center Pivot

    Use hoist equipment rated to lift the machine safely. 4. Support the front of the machine using a hoist. 5. Disconnect the SDLA linkage from the hydraulic pump control arm. Chassis: Service and Repairs Page 7–48 4520Z 09.40001Rev 00...

  • Page 237: Installing The Center Pivot

    5. Install the front / rear connector link; refer to Installing the Front / Rear Connector Link, page 7–46. 6. Grease the pivot joint. 7. Install the hydraulic pump cover and lower frame cover. 4520Z Page 7–49 Chassis: Service and Repairs 09.40001Rev 00...

  • Page 238: Removing The Front Hitch Arms

    1. Position the front hitch arms on the machine aligning the mounting holes. 2. Install the hitch arm mounting bolts Figure 113, item 3 and grease the front hitch pivot points. Chassis: Service and Repairs Page 7–50 4520Z 09.40001Rev 00...

  • Page 239: Removing The Pto Idler Pulley

    Figure 114, item 4 on the machine aligning the mounting holes. 2. Install the PTO idler pulley mounting bolt Figure 114, item 3. Install the PTO drive belt Figure 114, item 4520Z Page 7–51 Chassis: Service and Repairs 09.40001Rev 00...
  • Page 240 Installing the PTO Idler Pulley (continued) 4. Install the PTO idler pulley guard Figure 114, item Chassis: Service and Repairs Page 7–52 4520Z 09.40001Rev 00...

  • Page 241: Chapter 8: Axles

    Removing and Installing Front Axle Housing Assemblies.............. 8–8 Removing and Installing Rear Axle Housing Assemblies .............. 8–9 Removing and Installing Axle Shafts....................8–10 Axle Bearing Replacement ........................8–11 Axle Seal Replacement ........................8–12 Changing Rear Transaxle Fluid......................8–12 4520Z Page 8–1 Axles 09.40001Rev 00...

  • Page 242: General Information

    The 4520 Operator’s Manual and accessory Installation Instructions provide information regarding the operation, general maintenance, and maintenance intervals for the machine and its accessories. Refer to the Operator’s Manual and accessory Installation Instructions for additional information. Axles: General Information Page 8–2 4520Z 09.40001Rev 00...

  • Page 243: Axle Assemblies

    The front and rear axle assemblies both contain the same components, two axle housings , and a transaxle . Though the axle assemblies share the same components they are installed in the machine in different orientations. 4520Z Page 8–3 Axles: Axle Assemblies 09.40001Rev 00...

  • Page 244: Service And Repairs

    2. Lift and securely support the front of machine; refer to Jacking Instructions, page 1–6. 3. Complete the following procedures before continuing. A. Remove the front wheels; refer to Removing and Installing the Wheels, page 7–11. Axles: Service and Repairs Page 8–4 4520Z 09.40001Rev 00...

  • Page 245: Installing The Front Axle Assembly

    Removing the Front Axle Assembly (continued) B. Remove the radiator; refer to 4520Z Removing the Radiator, page 4–16. C. Remove the air cleaner system; refer to 4520Z Removing and Installing the Air Cleaner System, page 4–4. D. Remove the parking brake drum; refer to...

  • Page 246: Removing The Rear Axle Assembly

    Installing the Front Axle Assembly (continued) C. Install the air cleaner system; refer to 4520Z Removing and Installing the Air Cleaner System, page 4–4. D. Install the radiator; refer to 4520Z Installing the Radiator, page 4–17. E. Install the front wheels; refer to Removing and Installing the Wheels, page 7–...
  • Page 247 5. Remove the hydraulic filter mount and hydraulic hose mount from the axle housing. 6. Disconnect the high / low shift linkage from the transaxle. 7. Remove the rear hydraulic motor mounting bolts. 4520Z Page 8–7 Axles: Service and Repairs 09.40001Rev 00...

  • Page 248: Installing The Rear Axle Assembly

    2. Park the machine on a level surface, engage the parking brake, and remove the key from the ignition. 3. Drain the fluid from the front transaxle; refer to Changing the Hydraulic Fluid, page 5–20. Axles: Service and Repairs Page 8–8 4520Z 09.40001Rev 00...

  • Page 249: Removing And Installing Rear Axle Housing Assemblies

    4. Lift and securely support the affected side of the machine and chock the wheels; refer to Jacking Instructions, page 1–6. 5. Support the transaxle with a jack or other secure method. 6. Remove the wheel; refer to Removing and Installing the Wheels, page 7–11. 4520Z Page 8–9 Axles: Service and Repairs 09.40001Rev 00...

  • Page 250: Removing And Installing Axle Shafts

    7. Remove the axle shaft from the axle housing. 8. To install the axle shaft, insert the axle shaft into the axle housing. Align the splines of the shaft to install the shaft into the transaxle. Axles: Service and Repairs Page 8–10 4520Z 09.40001Rev 00...

  • Page 251: Axle Bearing Replacement

    8. Press the axle spacer onto the axle against the bearing. 9. Install the axle shaft. 10. Install the wheel. 11. Add fluid to the rear transaxle or the hydraulic system as needed. 4520Z Page 8–11 Axles: Service and Repairs 09.40001Rev 00...

  • Page 252: Axle Seal Replacement

    11. Add fluid to the rear transaxle or the hydraulic system as needed. Changing Rear Transaxle Fluid Figure 123 G438879 Fill plug Drain plug 1. Remove any attachments from the machine. Axles: Service and Repairs Page 8–12 4520Z 09.40001Rev 00...
  • Page 253 7. Fill the rear transaxle with oil to the bottom of the oil fill hole. 8. Replace the o-ring and install the fill plug 37 Nm (27 ft-lb). 4520Z Page 8–13 Axles: Service and Repairs...
  • Page 254 Axles: Service and Repairs Page 8–14 4520Z 09.40001Rev 00...

  • Page 255: Chapter 9

    Wiring Diagram Reference Key (Serial # 02173–05664) ..............9–6 Wiring Diagram — Rear Harness (Serial # 02173–05664)............9–7 Wiring Diagram — Front Harness (Serial # 02173–05664) ............9–8 Wiring Diagram — Engine Harness (Serial # 02173–05664)............9–9 Hydraulic Schematic ..........................9–10 4520Z Page 9–1 Appendix A 09.40001Rev 00...

  • Page 256: Wiring Diagram Reference Key (Serial # 01001-02172)

    Wiring Diagram Reference Key (Serial # 01001–02172) G423891 Appendix A: Wiring Diagram Reference Key (Serial # Page 9–2 4520Z 01001–02172) 09.40001Rev 00...

  • Page 257: Wiring Diagram - Rear Harness (Serial # 01001-02172)

    Wiring Diagram — Rear Harness (Serial # 01001– 02172) G423896 4520Z Page 9–3 Appendix A: Wiring Diagram Reference Key (Serial # 01001–02172) 09.40001Rev 00...

  • Page 258: Wiring Diagram - Front Harness (Serial # 01001-02172)

    Wiring Diagram — Front Harness (Serial # 01001– 02172) G423895 Appendix A: Wiring Diagram Reference Key (Serial # Page 9–4 4520Z 01001–02172) 09.40001Rev 00...

  • Page 259: Wiring Diagram - Engine Harness (Serial # 01001-02172)

    Wiring Diagram — Engine Harness (Serial # 01001– 02172) G423894 4520Z Page 9–5 Appendix A: Wiring Diagram Reference Key (Serial # 01001–02172) 09.40001Rev 00...

  • Page 260: Wiring Diagram Reference Key (Serial # 02173-05664)

    Wiring Diagram Reference Key (Serial # 02173–05664) G423988 Appendix A: Wiring Diagram Reference Key (Serial # Page 9–6 4520Z 02173–05664) 09.40001Rev 00...

  • Page 261: Wiring Diagram - Rear Harness (Serial # 02173-05664)

    Wiring Diagram — Rear Harness (Serial # 02173– 05664) G423987 4520Z Page 9–7 Appendix A: Wiring Diagram Reference Key (Serial # 02173–05664) 09.40001Rev 00...

  • Page 262: Wiring Diagram - Front Harness (Serial # 02173-05664)

    Wiring Diagram — Front Harness (Serial # 02173– 05664) G423986 Appendix A: Wiring Diagram Reference Key (Serial # Page 9–8 4520Z 02173–05664) 09.40001Rev 00...

  • Page 263: Wiring Diagram - Engine Harness (Serial # 02173-05664)

    Wiring Diagram — Engine Harness (Serial # 02173– 05664) G423985 4520Z Page 9–9 Appendix A: Wiring Diagram Reference Key (Serial # 02173–05664) 09.40001Rev 00...

  • Page 264: Hydraulic Schematic

    Hydraulic Schematic G446694 Appendix A: Hydraulic Schematic Page 9–10 4520Z 09.40001Rev 00...
  • Page 265 Notes:...

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