Cub Cadet 8454 - Manuals

8 4. OPERATING THE PTO • Disengage the PTO, stop the engine, and waituntil all moving components have completelystopped before dismounting the tractor andconnecting, disconnecting, adjusting, cleaning,or servicing any PTO driven equipment. • Do not wear loose fitting clothing whenoperating the PTO o...

9 • Engine components become hot duringoperation and can cause a burn. Allow to cooldown before touching. • Before "jump starting" a dead battery, read andfollow all of the instructions. • Do not attempt to mount a tire on the rim. Thisshould be done by a qualified person withproper equipmen...

10 SAFETY LABELS 1. DD-T2325-50512 2. DD-T2325-50743 3. DD-T2325-50724 4. DD-T2241-50702 1 2 3 4 5 6 7

12 SECTION 1: CONTROLS AND FEATURES SWITCHES AND DASH MOUNTED CONTROLS Figure 1 A. Ignition Switch NOTE: To prevent accidental starting and/or batterydischarge, remove the key from the ignition switchwhen the tractor is not in use. The ignition switch has four positions turningclockwise as follows (...

14 To set the parking brake proceed as follows: • Lock the right and left brake pedals togetherusing the brake lock. Refer to Brake Lock inFloorboard and Fender Mounted Controls laterin this section. • Fully depress and hold the brake pedals. • Pull the brake lock lever upward and hold whilewhile re...

15 Figure 9 2. Hour meter (In Tachometer) - This meter showsthe number of hours the tractor has been oper-ated at rated engine RPM. The right-most digit(white background) indicates tenths of an hour.Monitor the hour meter to ensure all mainte-nance procedures are completed according to themaintenanc...

16 FLOOR BOARD AND FENDER MOUNTED CONTROLS Figure 11 A. Clutch Pedal When the clutch pedal is fully depressed, the tractor’sdrive clutch is disengaged. Fully and rapidly depressthe clutch pedal before shifting the main shift lever,the Hi-Lo Range lever, or the forward/reverse shiftlever. Gradually r...

17 C. Foot Throttle The foot throttle is interlocked with the hand throttle.Depressing the foot throttle increases the enginespeed. Full engine speed control can be obtainedwith the foot throttle if the hand throttle is in the fullrearward (slow) position. The foot throttle may also beused to tempor...

18 Front Wheel Drive Lever The front wheel drive lever is located in thefloorboard, below and to the left of the seat. Use the front wheel mechanism only when additionaltraction is needed to drive the tractor. For example:when operating ground engaging equipment such asa front end loader; when climb...

19 • Using Mixed Control — In draft control, when draftdecreases, the implement automatically lowers toincrease draft. However, the implement some-times lowers too much. To limit the degree theimplement can be lowered, set the position controllever at the lowest working depth desired for theimplemen...

20 SECTION 2: OPERATION ROLLOVER PROTECTIVE STRUCTURE (ROPS) This tractor is equipped with a foldable RolloverProtection Structure (ROPS) and seat belts. Whenused together they are effective in reducing injuries tothe operator in the event of an accidental tractorrollover. The safety provided by the...

21 • Tighten the fuel cap securely, and immediatelywipe up any spilled fuel. • To minimize condensation, keep the fuel tank asfull as possible without filling to capacity. It is agood practice to fill the fuel tank at the end of theday to reduce overnight condensation. • Do not allow the fuel tank t...

22 • Set the throttle lever approximately 1/4 of the wayforward (approximately 1500 RPM position). Figure 24 • Turn the ignition switch to the "ON/Preheat"position. Refer to Figure 24.NOTE: Some of the instrument panel lamps willlight momentarily to indicate they are functioning.The oil pres...

23 • Fully depress the clutch pedal and proceed asfollows: - Shift the Forward/Reverse Shift Lever to desired direction. See Figure 26. Figure 26 - Shift the Main Shift Lever to desired gear speed. See Figure 27. - Shift the Hi-Lo Range Shift Lever to desired range. See Figure 27. Figure 27 • Pull t...

26 USING THE DIFFERENTIAL LOCK Depressing the differential lock pedal engages amechanism in the transmission that locks thedifferential. This prevents the rear wheels fromrotating independently of each other and providesconstant power to both rear wheels when additionaltraction is needed. IMPORTANT:...

27 Figure 31 • After determining a desired working positionusing one, or both, controls, the stop bolts can beused to ensure the levers are returned to theirselected positions. Loosen the wing screws andslide the stop(s) against one (or both levers) andre-tighten the wing screws. Once the stop bolt ...

28 Top Link • Use holes A or B in the top link holder for the toplink when attaching non draft sensitiveimplements. See Figure 34. • Use holes B or C in the top link holder for the toplink when attaching draft sensitive implements. • Use hole A for the top link when transportingimplements. Figure 34...

29 USING REMOTE HYDRAULICS The tractor is equipped with a remote hydraulicsystem for powering hydraulically driven implementsthat are approved for usage on the tractor. WARNING: To avoid personal injury, stopthe tractor engine and relieve pressurefrom the hydraulic system beforeconnecting or disconn...

30 SECTION 3: ADJUSTMENTS ADJUSTING THE SEAT For the comfort of the operator, a single leveradjustable seat is provided to set the fore to aftposition of the seat. Adjust the seat to the mostcomfortable position that allows you to operate allcontrols and pedals. WARNING: Do not adjust the seat whent...

31 • Tighten the adjusting bolt as necessary toremove the play from the front axle, thenretighten the jam nut. • Lower the front of the tractor to the ground. ADJUSTING THE FAN BELT TENSION If the fan belt becomes loose, the engine mayoverheat and/or the battery may not charge. Checkthe belt tension...

32 To Adjust • Open the clutch access window which is locatedon the right front of the clutch housing. • Insert a 0.098 to 0.12 inch (2.5 to 3.0 mm) feelergauge between the release thrust bearing andthe release levers. Adjust the clearance byadjusting the length of the clutch rod. - Lengthen the rod...

33 To Adjust WARNING: Never operate the tractor withloose wheel assembly fasteners. Alwaystighten the fasteners to the specifiedtorque, and frequently check that theyare tight. IMPORTANT: When changing the tread width of therear wheels, you must pay attention to the direction ofthe tire’s tread desi...

34 SECTION 4: MAINTENANCE The service life and reliability of any machinedepends upon the care it is given. Proper lubricationand maintenance is a vital part of that care. Using theLubrication and Maintenance Chart as a guide, moni-tor the hourmeter on the instrument panel to ensurethe required main...

35 LUBRICATION AND MAINTENANCE CHART † First 50 hours No. Operation to be Performed Service Intervals Be fo re e ach u s e 5 0 Hour s 10 0 H o u rs 1 50 H our s 2 00 H our s 2 50 H our s 3 00 H our s 3 50 H our s 4 00 H our s 4 50 H our s 5 00 H our s 5 50 H our s 6 00 H our s 1 Y e ar 2 Y e ar s 1 ...

37 • Use No. 2 diesel fuel. Use No. 1 diesel fuel if thetemperature is below 15° F (-10°C). • The fuel tank capacity is approximately 10.6 gal.Do not overfill. Bleeding the Fuel System WARNING: Do not bleed the fuel systemwhen the engine is hot. Air must be bled from the fuel system when the fuelfil...

38 • Stop the engine before checking the fuel linehoses and clamps. • Check that the fuel line hose clamps are snuglysecuring the hoses to their respective fittings.Replace any damaged clamps. • Check the fuel hoses for wear or deterioration,and any damaged hoses should be replaceimmediately. • Afte...

39 Changing Engine Oil and Filter The engine oil and oil filter (located on the right/frontof the engine) should be changed after the first 50hours of operation, then at 100 hours and every 100hours thereafter. Refer to the LUBRICATION TABLEfor the quantity and type of oil needed. WARNING: Because t...

40 TRANSMISSION OIL AND OIL FILTER Checking the Transmission Oil Level Check the hydro transmission/hydraulic system oillevel before each use. Check the oil level only whilethe engine is stopped and the tractor is standing on alevel surface. • Locate the transmission dipstick on the rear ofthe trans...

41 • Move the drain pan beneath the filter, thenremove the filter by turning it counterclockwiseusing a filter wrench to loosen. See Figure 60. Figure 60 • Use a clean rag to clean the metal surface of thefilter base where the filter gasket makes contact. • Reinstall the drain plug in the transmissi...

42 SERVICING THE AIR CLEANER Check the air cleaner dust cup and element beforeeach use. Clean the dust out of the cup and blow offthe element weekly. Replace the element after every100 hours of operation. NOTE: The air cleaner uses a dry element, neverapply oil. • Unclip the two retainers to remove ...

44 Changing the Coolant The anti freeze and water coolant solution should bechanged every year. The cooling system capacity isapproximately 2.4 gallons. WARNING: It is dangerous to remove theradiator cap when the system is hot.Allow the system to cool beforeremoving the radiator cap. • Locate the ra...

45 • Steering cylinders. See Figure 70. Figure 70 • Brake pedal shaft (both sides). See Figure 71. Figure 71 • 3 Point top link holder (each side). See Figure 72. Figure 72 • Position lever support housing. See Figure 73. Figure 73 Periodically apply grease to both seat slides and tothe threads of t...

46 SERVICING THE BATTERY General Battery Information WARNING: • Battery posts, terminals and related accessoriescontain lead and lead compounds. Wash handsafter handling. • Battery acid must be handled with great care, ascontact with it can burn and blister the skin. It isadvisable to wear protectiv...

47 • Maintain the battery electrolyte level in each cell.Keep each cell filled to the bottom of the ring ineach vent hole. Fill with distilled water ifnecessary. See Figure 75. Figure 75 Re-charging the Battery • Remove the vent caps from the battery. Checkeach cell and fill to the bottom of the rin...

49 TRACTOR STORAGE If the tractor will not be operated for two or threemonths or longer, perform the following measuresbefore storing. • Repair or replace worn or broken parts andtighten all fasteners. • Change the engine oil and run the engine aboutfive minutes to circulate oil throughout the engin...

50 SECTION 5: TROUBLESHOOTING ENGINE TROUBLESHOOTING When Engine is Difficult To Start Cause Countermeasures Fuel is thick and doesn’t flow - Check the fuel tank and fuel filter. - Remove water, dirt and other impurities. - Check the fuel filter element for water, dirt , or other impurities, and rep...

53 BATTERY TROUBLESHOOTING Condition of Battery Cause Countermeasures Cause Starter does not function - Key is not "ON". - Battery is over-used until light becomes dim. - Defective alternator or rectifier preventing charging of the battery. - Dirty or corroded terminal contacts. - Bad brushe...

54 SECTION 6: SPECIFICATIONS Model 8454 Maximum PTO Power 38.0 PS Engine GROSS Power 45.0 HP Engine Model 4A220 Type Indirect injection, water cooled, 4-cycle diesel Number of cylinders 4 Bore and Stroke 3.425 x 3.638 Inches (87 x 92.4 mm) Total displacement 134.0 cu. in (2,197 cc) Rated revolutions...

55 SPECIFICATIONS Model 8454 PTO No. or Remote control valve ports 2 (4 optional) PTO HP 38.0 PTO shaft SAE 1-3/8 in., 6 splines Revolutions Rear PTO 540 (@ 2,451 rpm) Minimum turning radius (with brake) 112.7 in. (2,865 mm) Traction system Swing drawbar Weight (with ROPS) 3792 lbs. Approx. Speed (@...

CHAPTER 1 8454 3. SPECIFICATION MODEL 8454 Maximum PTO power 38 HP Engine GROSS power 45 HP Engine Model 4A220 Type Indirect injection, vertical, water-cooled, 4cycle diesel Number of cylinders 4 Bore and stroke 87 x 92.4 (3.425 x 3.638in.) Total displacement 2,197 Rated revolution 2,600 RPM Injecti...

GENERAL INFORMATION 1-9 D569-W02 May-2003 5. CAUTION BEFORE REPAIR 569W106A 569W107A 227W105A 5.1 BEFORE REPAIR OR INSPECTION 1. In case of repair or inspection, locate the tractor on the flat ground and pull the parking brake on. 2. Except for the items to be checked while the en- gine is running, ...

CHAPTER 1 8454 1-10 D569-W02 May-2003 569W110A 569W109A 569W108A 5.6 ELECTRICAL SYSTEM 1. Check electrical wiring every year for any damage or short circuit at the connections. In addition, haveyour dealer inspection the electric system regularly. 2. Do not modify or reorganize the wiring of the ele...

GENERAL INFORMATION 1-11 D569-W02 May-2003 569W112A 569W111A Be cautious of oil or other petroleum products on thehoses and rubber parts, this may cause damage. When assembling and fixing, apply designated lubri-cant where specified in accordance with this repairm a n u a l . 5.7 TUBES AND RUBBERS 5...

CHAPTER 1 8454 1-12 D569-W02 May-2003 6. REGULAR CHECK LIST Engine oil change Engine oil filter cartridge change Transmission oil change Hydraulic oil filter change Front axle oil change Applying grease Clutch pedal deflection Brake pedal deflection Fan belt tension Fuel filter element change Air cl...

CHAPTER 2 ENGINE www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983

ENGINE 2-5 D569-W02 May-2003 569W204A 569W203A 1.3 PERFORMANCE CURVE www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983

ENGINE 2-7 D569-W02 May-2003 569W208A 569W207A 569W206A 2. STRUCTURE AND FUNCTION 2.1 BODY A. CYLINDER HEAD The cylinder head is made of special alloy cast ironw h i c h c a n r e s i s t h i g h t e m p e r a t u r e a n d p r e s s u r ecaused by combustion. The intake and exhaust portsare arrange...

CHAPTER 2 8454 2-8 D569-W02 May-2003 569W211A 569W210A 569W209A ( 1 ) Top Ring ( 3 ) Oil Ring ( 2 ) Second Ring ( 1 ) Small End Bushing ( 3 ) Crankpin Bearing ( 2 ) Connecting Rod E. CONNECTING ROD The connecting rod (2), which converts the reciprocat-ing motion of the pistons caused by the fuel com...

CHAPTER 2 8454 2-10 D569-W02 May-2003 569W217A 569W216A 569W215A ( 1 ) Valve Spring Collet ( 4 ) Valve Stem Seal ( 2 ) Valve Spring Retainer ( 5 ) Exhaust Valve ( 3 ) Valve Spring ( 6 ) Intake Valve ( 1 ) Injection Pump Gear ( 5 ) Idle Gear ( 2 ) Fuel Camshaft ( 6 ) Crankshaft Gear ( 3 ) Camshaft Ge...

ENGINE 2-11 D569-W02 May-2003 569W219A 569W218A 2.2 LUBRICATING SYSTEM ( 1 ) Inlet ( 3 ) Inner Rotor ( 2 ) Outlet ( 4 ) Outer Rotor ( 1 ) P i s t o n ( 9 ) Rocker Arm Shaft ( 2 ) Idle Gear ( 1 0 ) Rocker Arm ( 3 ) Oil Pump (11) Push Rod ( 4 ) Relief Valve ( 1 2 ) Ta p p e t ( 5 ) Strainer ( 1 3 ) Oi...

CHAPTER 2 8454 2-16 D569-W02 May-2003 569W230A 569W229A ( a ) From Fuel Tank ( b ) To Fuel Filter ( 1 ) Inlet Valve ( 5 ) C h a m b e r ( 2 ) Push Rod ( 6 ) D i a p h r a g m ( 3 ) Ta p p e t ( 7 ) Fuel Camshaft ( 4 ) Outlet Valve ( a ) To Injection Nozzle ( b ) From Fuel Filter ( 1 ) Delivery Valve...

ENGINE 2-17 D569-W02 May-2003 569W231A 569W232A ( 1 ) Pump Element ( 5 ) Control Sleeve ( 2 ) Cylinder ( 6 ) Control Groove ( 3 ) P l u n g e r ( 7 ) Driving Surface ( 4 ) Feed Hole ( 1 ) Delivery Chamber ( 4 ) Feed Hole ( 2 ) P l u n g e r ( 5 ) Fuel Chamber ( 3 ) Delivery Valve ( 6 ) Control Groov...

ENGINE 2-19 D569-W02 May-2003 569W235A 569W236A ( 1 ) Nozzle Holder Ass’y ( 6 ) Nozzle Body ( 2 ) Adjusting Washer ( 7 ) Needle Valve ( 3 ) Nozzle Spring ( 8 ) Heat Seal ( 4 ) Push Rod ( 9 ) P a c k i n g ( 5 ) Retaining Nut ( 1 ) Start Spring ( 8 ) Governor Lever ( 2 ) Governor Spring 1 ( 9 ) Fuel ...

CHAPTER 2 8454 2-20 D569-W02 May-2003 569W238A 569W237A b. Operation of Governor a) At start The steel balls (13) have no centrifugal force. As thefork lever 1 (4) is pulled by the start spring (1), thecontrol rack (14) moves to the maximum injection posi-tion. At start, the sufficient injection of ...

ENGINE 2-21 D569-W02 May-2003 569W239A 569W240A ( 2 ) Governor Spring 1 ( 1 3 ) Steel Ball ( 3 ) Governor Spring 2 ( 1 7 ) Adjusting Bolt ( 4 ) Fork Lever 1 ( 1 8 ) Torque Spring ( 5 ) Fork Lever 2 ( 4 ) Fork Lever 1 ( 1 9 ) Stop Lever ( 1 4 ) Control Rack c) At High Speed Running with a Load When a...

CHAPTER 2 8454 2-22 D569-W02 May-2003 569W243A 569W242A 569W241A ( a ) Inlet Air ( b ) To Intake Manifold (c) Heavier Dust ( 1 ) Outlet Port ( 4 ) Air Cleaner Element ( 2 ) Inlet Port ( 5 ) Body ( 3 ) F i n ( 6 ) Evacuator 2.5 INTAKE AND EXHAUST SYSTEM C. MUFFLER The exhaust noises are absorbed, whi...

CHAPTER 2 8454 2-24 D569-W02 May-2003 3. DISASSEMBLING AND SERVICING • Not fuel • Air in the fuel system • Water in the fuel system • Fuel pipe clogged • Fuel filter clogged • Excessively high viscosity of fuel or engine oil at low temperature • Fuel with low cetane number • Fuel leak due to loose i...

ENGINE 2-27 D569-W02 May-2003 3.2 SERVICING SPECIFICATIONS A. ENGINE BODY a . C y l i n d e r H e a d 0.75 ~ 0.9 mm 0.0295 ~ 0.0354 in. 1.3 ~ 1.5 mm 0.0512 ~ 0.0591 in. 1.15 ~ 1.25 mm 0.0453 ~ 0.0492 in. 3.24 ~ 3.73 MPa 33 ~ 38 kgf/cm 2 469 ~ 540 psi 0.05 mm / 100 mm 0.002 in. / 3.94 in. - - 2.55 MP...

CHAPTER 2 8454 2-28 D569-W02 May-2003 d. Cylinder Bore Cylinder bore innerd i a m e t e r 87.000 ~ 87.022 mm 3.4252 ~ 3.4261 in. 83.000 ~ 83.022 mm 3.2677 ~ 3.2690 in. 0.15 mm 0.0059 in. 4A220 4A200T e . Va l v e S p r i n g 41.7 ~ 42.2 mm 1.6417 ~ 1.6614 in. 12.0 kgf / 35.15 mm 26.46 lbs / 1.3839 i...

ENGINE 2-29 D569-W02 May-2003 I . T i m i n g G e a r 0.04 ~ 0.11 mm 0.0016 ~ 0.0043 in. 0.20 ~ 0.51 mm 0.0079 ~ 0.0201 in. 0.025 ~ 0.066 mm 0.00098 ~ 0.00260 in. 37.959 ~ 37.975 mm 1.49445 ~ 1.49508 in. 38.000 ~ 38.025 mm 1.49606 ~ 1.49705 in. 0.15 mm 0.0059 in. 0.9 mm 0.035 in. 0.1 mm 0.0039 in. -...

CHAPTER 2 8454 2-30 D569-W02 May-2003 l . Crankshaft - 0.040 ~ 0.118 mm 0.00157 ~ 0.00465 in. 51.921 ~ 51.940 mm 2.04414 ~ 2.04489 in. 51.980 ~ 52.039 mm 2.04646 ~ 2.04878 in. 0.040 ~ 0.104 mm 0.00157 ~ 0.00409 in. 51.921 ~ 51.940 mm 2.04414 ~ 2.04488 in. 51.980 ~ 52.025 mm 2.04646 ~ 2.04823 in. 0.0...

ENGINE 2-31 D569-W02 May-2003 C. COOLING SYSTEM a . Thermostat Valve opening temperature at beginning Opened completely (height 8 mm 0.315 in.) 69.5 ~ 72.5 °C (157.1 ~ 162.5 °F) 85 °C (185 °F) b. R a d i a t o r Radiator tightness Radiator cap tightness Fan belt tension [deflection at 98 N (10 kgf, ...

CHAPTER 2 8454 2-32 D569-W02 May-2003 E. TIGHTENING TORQUES Item Cylinder head screws Head cover nuts * Bearing case screw 1 * Bearing case screw 2 * Flywheel screw * Connecting rod screws Rocker arm bracket studs Drain plug Glow plugs Oil switch Nozzle locating screws Injection pipe nuts Size x Pit...

ENGINE 2-33 D569-W02 May-2003 615WA18A 3.3 CHECKING, DISASSEMBLING AND SERVICING A. ENGINE DISASSEMBLED VIEW ( 1 ) Cylinder Block ( 2 ) Oil Pressure Switch ( 3 ) Oil Pump ( 4 ) Oil Pan ( 5 ) Oil Strainer ( 6 ) Oil Gauge ( 7 ) Cylinder Head ( 8 ) Head Bolt ( 9 ) Gear case ( 1 0 ) Oil Filter (11) Main...

ENGINE 2-35 D569-W02 May-2003 569W250A 569W249A ( 1 ) Fan Belt ( 6 ) Oil Gauge ( 2 ) Hour Meter Unit ( 7 ) Exhaust Manifold ( 3 ) Oil Filter ( 8 ) Oil Pressure Switch ( 4 ) Oil Filter Flange ( 9 ) Starter ( 5 ) Alternator B. EXTERNAL COMPONENTS a . Checking and Adjusting 1) Fan belt Measure the defl...

CHAPTER 2 8454 2-36 D569-W03 May-2003 569W251A 569W252A ( 1 ) Screw ( 5 ) Stop Lever 1 ( 2 ) Engine Stop Lever ( 6 ) Stop Lever 2 ( 3 ) Screw ( 7 ) S o l e n o i d ( 4 ) Screw ( 1 ) Intake Manifold ( 3 ) Fuel Pipe ( 2 ) Injection Pipe ( 4 ) Fuel Feed Pump 2) S o l e n o i d 1. Disconnect the stop le...

ENGINE 2-39 D569-W03 May-2003 569W259A 569W258B 569W257A (1) Philips Screw Driver (2) Nozzle (3) Injection Nozzle Gasket (4) Heat Seal ( 1 ) Rocker Arm Shaft ( 3 ) Rocker Arm Bracket ( 2 ) Rocker Arm ( 4 ) Screw 2) Heat seal removal procedure 1. Drive screw driver lightly into the heat seal hole. 2....

CHAPTER 2 8454 2-40 D569-W03 May-2003 569W262A 569W261B 569W260A 4) C y l i n d e r h e a d 1. Remove the screw in the specified sequence shown in the figure and remove the cylinder head (1) andhead gasket. 2. Remove the water flange (2). 3. Take out the tappets from the cylinder block. NOTE: • Mark...

ENGINE 2-41 D569-W02 May-2003 569W265A 569W264A 569W263A 2) Governor spring and Speed control plate 1. Disconnect the governor spring 1 (1) and 2 (2) from the governor lever (4). 2. Remove the speed control plate. 3. Remove the governor spring. ( W h e n r e a s s e m b l i n g ) • Be careful not to...

ENGINE 2-43 D569-W02 May-2003 569W271A 569W270A 569W269A 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. ( W h e n r e a s s e m b l i n g ) • Install the relief valve cover (2) with its mark up. 7) Idle g...

CHAPTER 2 8454 2-44 D569-W02 May-2003 569W272A 569W273A 569W274A d. Connecting Rod and Piston (A) Oil pan and oil filter 1. Remove the engine stand and the oil pan. 2. Remove the oil strainer (1). ( W h e n r e a s s e m b l i n g ) • B e s u r e t o i n s t a l l t h e O - r i n g ( 2 ) b e t w e e...

ENGINE 2-51 D569-W02 May-2003 569W295A 569W294A 569W293A 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, chec...

CHAPTER 2 8454 2-60 D569-W02 May-2003 569W2B6A 569W2B5A ( 1 ) Relief Valve Ball ( 3 ) Relief Valve Spring ( 2 ) Relief Valve Seat 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 un...

ENGINE 2-63 D569-W02 May-2003 569W2C3A 569W2C4A 569W2C5A ( 1 ) T h e r m o s t a t ( 2 ) Thermostat Cover ( 1 ) Water Pump Flange ( 4 ) Water Pump Body ( 2 ) Water Pump Bearing ( 5 ) Mechanical Seal ( 3 ) Water Pump Shaft ( 6 ) I m p e l l e r b. Disassembling and Assembling (A) Thermostat 1. Remove...

CHAPTER 2 8454 2-66 D569-W02 May-2003 569W2C9A ( 1 ) Pump Body ( 5 ) Delivery Valve ( 2 ) Control Rack ( 6 ) Tappet Roller ( 3 ) Delivery Valve Holder ( 7 ) Cylinder ( 4 ) Delivery Valve Spring ( 8 ) P l u n g e r c. Disassembling and Assembling 1) Injection pump I M P O R TA N T: • If replacing the...

ENGINE 2-67 D569-W02 May-2003 569W2D0A ( 1 ) Nozzle Holder ( 5 ) Distance Piece ( 2 ) Adjusting Washer ( 6 ) Nozzle ( 3 ) Nozzle Spring ( 7 ) Nozzle Nut ( 4 ) Push Rod 2) I n j e c t i o n n o z z l e N o z z l e H o l d e r 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle ho...

CHAPTER 3 CLUTCH www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983

CHAPTER 3 8454 3-4 D569-W03 June-2003 2. SPECIFICATIONS, TIGHTENING TORQUES AND SPECIAL TOOLS 2.1 SPECIFICATIONS Clutch pedal Safety switch Clutch disc spline boss to shuttleshaft Clutch disc surface to rivet Pressure plate Item Free Play C l e a r a n c e B a c k l a s h Depth F l a t n e s s 20 ~ ...

CLUTCH 3-5 D569-W02 May-2003 3. STRUCTURE AND OPERATION The clutch is located between the engine and the trans-m i s s i o n a n d i s o p e r a t e d b y s t e p p i n g o n t h e c l u t c hpedal. When the clutch pedal is depressed, the clutchis disengaged and when it is released, the clutch iseng...

CLUTCH 3-7 D569-W02 May-2003 4. PREPARATION STAGE FOR DISASSEMBLING AND ASSEMBLING 4.1 SEPARATING PANEL FRAME ASSEMBLY PREPARATION 1 1. Removing the following parts. • B o n n e t • Side Cover (RH, LH) • Side Skirt (RH, LH) • Battery Negative Code (1) Side Cover (RH, LH) (4) Side Skirt (RH, LH) (2) ...

CLUTCH 3-9 D569-W02 May-2003 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. ( W h e n r e a s s e m b l i n g ) • Apply grease to the...

CHAPTER 3 8454 3-10 D569-W02 May-2003 4.3 DISASSEMBLY A. Insert clutch center guide (1) up to the spline hub and fix it not to be come off even though clutch inletbolt (2) is removed. B. Remove clutch inlet bolts (2) and separate clutch cover assembly (4). ASSEMBLY A. Thoroughly remove worn dust att...

CLUTCH 3-11 D569-W03 June-2003 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- m o v e l o c k n u t ( 2 ) o n c l u t c h w i r e a n d a d j u s t t h elength. (1) Clut...

CHAPTER 3 8454 3-12 D569-W02 May-2003 6. INSPECTION AND REPAIR 6.1 WEAR AND DAMAGE ON CLUTCH DISC (1) D i s c (2) Rivet 6.2 CLEARANCE BETWEEN SPLINE BOSS OF THE CLUTCH DISC ANDSHUTTLE SHAFT SPLINE A. Install clutch disc (1) to shuttle shaft (2). B. Fix shuttle shaft not to shift and slightly move cl...

CLUTCH 3-13 D569-W02 May-2003 6.3 FLATNESS OF CLUTCH PRESSURE PLATE, DAMAGES A. Measure several clearances with a space gaug e along with a feeler gauge placed on the surface ofthe clutch pressure plate. B. If the measurement is out of the allowable limit , replace clutch cover assembly. C. In case ...

CHAPTER 3 8454 3-14 D569-W02 May-2003 6.6 CLEARANCE BETWEEN CLUTCH PEDAL SHAFT AND CLUTCHPEDAL 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 ...

CHAPTER 4 TRANSMISSION SYSTEM www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983

TRANSMISSION SYSTEM 4-3 D569-W02 May-2003 1. TROUBLESHOOTING 1.1 TROUBLESHOOTING FOR SHUTTLE SHIFT IN OPERATION ERROR Noise when the shuttleis shifted Gear is disconnectedwhen shifted Difficult to shift Symptom 1. Excessive deflection in the shuttle synchro assembly (SPEC: 78.2) 2. Chamfering sectio...

CHAPTER 4 8454 4-4 D569-W02 May-2003 1.3 TROUBLESHOOTING FOR AUXILIARY AND CREEP SHIFTS IN OPERATION ERROR 1.4 TROUBLESHOOTING FOR REAR DIFFERENTIAL GEAR IN OPERATION ERROR 1.5 TROUBLESHOOTING FOR REAR DIFFERENTIAL IN OPERATION ERROR Gear shift disconnected Starting gets OFF whenstarting with gear s...

TRANSMISSION SYSTEM 4-5 D569-W02 May-2003 1.6 TROUBLESHOOTING FOR FRONT WHEEL DRIVE IN OPERATION ERROR 1.7 TROUBLESHOOTING FOR PTO CLUTCH IN OPERATION ERROR 1.8 TROUBLESHOOTING FOR PTO IN OPERATION ERROR 1.9 TROUBLESHOOTING FOR PARKING BRAKE IN OPERATION ERROR Gear shift disconnected Difficult to sh...

CHAPTER 4 8454 4-6 D569-W02 May-2003 2. SPECIFICATIONS 2.1 TIGHTENING TORQUES Middle case T r a n s m i s -s i o n c a s e Rear axle/brake 75.9 ~ 86.8 57.1 ~ 66.5 94.0 ~ 130.1 17.3 ~ 20.2 57.1 ~ 66.5 35.4 ~ 41.2 17.3 ~ 20.2 35.4 ~ 41.2 57.1 ~ 66.5 35.4 ~ 41.2 91.1 ~ 108.4 91.1 ~ 108.4 57.1 ~ 66.5 57...

TRANSMISSION SYSTEM 4-7 D569-W03 June-2003 3. STRUCTURE 3.1 POWER TRAIN DIAGRAM 569W401B www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983

CHAPTER 4 8454 4-14 D569-W03 June-2003 Block-type Synchromesh Mechanism (For Main Gear Shift, Hi-Lo Range Shift Section) The hub (3) is splined to the counter shaft (9) and theshifter (5) is mounted on the synchronizer keys (4) outagainst the shifter (5). The bronze synchronizer rings(2), (7) are co...

TRANSMISSION SYSTEM 4-15 D569-W02 May-2003 First Stage An effort to place the main gear shift lever to the 3rd or4th speed causes the shifter (5) and synchronizer keys(4) to move slightly. T h e n , t h e e n d s u r f a c e o f t h e s y n c h r o n i z e r k e y ( 4 )presses the synchronizer ring ...

CHAPTER 4 8454 4-16 D569-W03 June-2003 <Main gear shift section> (1) 17 Gear Shaft (4) Shifter (1-2 Stage) (2) 26-26 Gear (5) 29-23-18-14 Gear (3) Shifter (3-4 Stage) (6) Propeller Shaft 1 B. MAIN GEAR SHIFT • Composed of full synchro mesh with key type ap-plied to the synchro. 569W414A F i n ...

CHAPTER 4 8454 4-18 D569-W02 May-2003 <PTO clutch valve> (1) PTO Clutch Shaft (6) Pressure Plate (2) Clutch Body (7) Spline Boss (3) P i s t o n (8) Brake Disc (4) Clutch Disc (9) Return Plate (5) Clutch Plate (10) Return Spring F . PTO CLUTCH SYSTEM INTRODUCTION • PTO clutch valve on the main...

CHAPTER 4 8454 4-20 D569-W02 May-2003 • In case PTO clutch switch is OFF 1. If PTO switch on the instrument board is turned OFF (neutral), the circuit returning from the priority valvevia the solenoid valve and the modulating valve toPort A of PTO clutch is disconnected. 2. Piston (2) of PTO clutch ...

TRANSMISSION SYSTEM 4-21 D569-W02 May-2003 F . PTO SYSTEM a . Related Parts With the PTO Operation (1) PTO Drive Shaft b. Operation Principle of PTO If PTO switch is activated PTO clutch is engaged andthen power from the engine is transmitted to PTO driveshaft (1) via PTO drive shaft 1. 51 gear (2) ...

CHAPTER 4 8454 4-22 D569-W02 May-2003 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 th...

TRANSMISSION SYSTEM 4-23 D569-W02 May-2003 P r e p a r a t i o n 1 1. Removing the following parts. 4.2 SEPARATING PANEL FRAME ASSEMBLY (1) Side Cover (RH, LH) (2) B o n n e t (3) Front Grille (4) Side Skirt (RH, LH) (5) Battery Negative Code 569W424A P r e p a r a t i o n 2 1. Disconnect the brake ...

TRANSMISSION SYSTEM 4-25 D569-W02 May-2003 4.3 SEPARATING REAR FENDERS AND PLATFORM ASSEMBLY P r e p a r a t i o n 1. Remove the Rops. 2. Remove the Bolts (1) and take out the seat Assem- bly (2). Cover 1. Remove the bolts (1), (2) and the cover assembly (3). Fender, Floor Seat and Platform Assembly...

CHAPTER 4 8454 4-26 D569-W02 May-2003 Hydraulic Pipes 1. Remove the brake rod (4) and delivery pipe (3). 2. Remove the delivery pipe (2). 3. Slide the rubber hose (1). ( W h e n r e a s s e m b l i n g ) • Reinstall the pipe clamps securely. Separating the Engine From Clutch Housing 1. Place the jac...

TRANSMISSION SYSTEM 4-27 D569-W02 May-2003 Shift Levers 1. Tap out the spring pins (2) of main shift rod 1 (1). ( W h e n r e a s s e m b l i n g ) • Tap in the spring pins (2) so that their split portionmay face forward. Hydraulic Pipes 1. Loosen the screws (1), Bolt (2) and remove the suc- tion pi...

CHAPTER 4 8454 4-28 D569-W02 May-2003 0 ~ 0.1 mm 0 ~ 0.0039 in. 0.1 ~ 0.2 mm 0.0039 ~ 0.0078 in. 0.2 ~ 0.4 mm 0.0078 ~ 0.0157 in. - - - 0.88 ~ 1.17 N·m 0.09 ~ 0.12 kgf·m 0.65 ~ 0.86 lbf·ft 4.9 ~ 7.85 N·m 0.5 ~ 0.8 kgf·m 3.61 ~ 5.79 lbf·ft 0.15 ~ 0.25 mm 0.006 ~ 0.0098 in. 30% min (center is 1/3 ~ 2/...

CHAPTER 4 8454 4-30 D569-W02 May-2003 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 middlecase (2). b. To Assemble 1. Remove any foreign substance cleanly out of as- sembling surfaces of clutch ...

TRANSMISSION SYSTEM 4-31 D569-W02 May-2003 Carefully tighten M12 bolts when as-s e m b l i n g M12 x 45 (four places): part C M12 stud bolts: part B Parallel pin (10 x 20 mm): part A b. To Assemble 1. Remove any foreign substance cleanly out of assem- bling surfaces of middle case (1) and transmissi...

CHAPTER 4 8454 4-34 D569-W02 May-2003 • Be sure to apply grease on O-rings be-fore fixed with shift arms. • If the packing (2) has been damaged,surely replace it with new one. CAUTION F . AUXILIARY SHIFT COVER a. To Disassembling 1. Remove auxiliary shift cover bolt (11) on the middle case side to l...

CHAPTER 4 8454 4-36 D569-W03 June-2003 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 andbearing case (for auxiliary s...

CHAPTER 4 8454 4-38 D569-W03 June-2003 K. SHAFT 1 (1) 17 Gear Shaft (2) Ball Bearing (3) Snap Ring (4) C o l l a r (5) 42 Gear (6) Inner Ring (7) Inner Ring (8) 38 Gear (9) C o l l a r (10) 33 Gear (11) Synchro Hub (12) Shifter (13) Synchronizer Spring (14) Synchronizer Ring (15) Needle Bearing (16)...

CHAPTER 4 8454 4-42 D569-W03 June-2003 To Disassembling PTO Clutch Ass’y 1. Push down pressure plate (8) with an exclusive tool and take out snap ring (9). 2. Take out clutch disc (10), clutch plate (11), spring (7), return plate (6) and brake disc (5). 3. Separate snap ring (18) from the PTO clutch...

TRANSMISSION SYSTEM 4-45 D569-W02 May-2003 Checking Contact Between Coupling andS h i f t e r 1. Check to see if there is any flaw or wear on th e spline of the coupling and shifter, and the key grooveon the coupling. 2. Engage the shifter with the coupling, and check that they slide smoothly. 3. Si...

TRANSMISSION SYSTEM 4-49 D569-W02 May-2003 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 ofseal ring Factory s p e c . Allowable limit 2.95 ~ 3.0 mm 0.116 ~ 0.118 in. 2.5 mm 0.0...

CHAPTER 4 8454 4-52 D569-W02 May-2003 DIFFERENTIAL GEAR • Differential gear is structured with four pin type. • Differential gear is operated by sharing out suitabler e v o l u t i o n c o n s i d e r i n g r e l a t e d c o n d i t i o n s f o r t h ewheels left and right to lead turning of the tra...

CHAPTER 4 8454 4-54 D569-W02 May-2003 C. POWER FLOW OF THE REAR DIFFERENTIAL GEAR a . Related Parts with the Rear Differential G e a r (1) Spiral Bevel Pinion (2) 39 Spiral Bevel Gear (3) Differential Gear Assembly (4) 13 Gear Shaft (5) Planetary Gear Assembly (6) Rear Axle (7) Differential Side Gea...

TRANSMISSION SYSTEM 4-57 D569-W02 May-2003 6.3 LOCKING OF THE DIFFERENTIAL GEAR a . Related Parts with the Operation of the D i f f e r e n t i a l G e a r (1) Differential Pedal (2) Differential Rod (3) Differential Mounting Fork Shaft (4) Differential Mounting Fork (5) Differential Mounting Shift ...

CHAPTER 4 8454 4-58 D569-W02 May-2003 Differential Lock When resistances to the right and left tires are differentdue to ground conditions or type of work, the wheelwith less resistance slips and prevents the tractor frommoving ahead. To compensate for this, the differential lock restrictsthe differ...

CHAPTER 4 8454 4-60 D569-W02 May-2003 C. REAR DIFFERENTIAL GEAR GROUP a . To Disassembling 1. Loosen four M10 bolt (25) on right side of the trans- m i s s i o n c a s e t o D i s a s s e m b l i n g d i f f e r e n t i a l b e a r -ing case (RH) (23) and shim (21). 2. Loosen four M10 bolts (22) on ...

TRANSMISSION SYSTEM 4-61 D569-W02 May-2003 D. DIFFERENTIAL GEAR ASSEMBLY a. To Disassembling 1. Loosen eight UBS bolts (14) on differential case (right) (13) to Disassembling shim (17), differential side gear22 (7) and 39 spiral bevel gear (4). 2. Disassembling parallel key (10), differential pinion...

CHAPTER 4 8454 4-64 D569-W02 May-2003 G. PLANETARY GEAR ASSEMBLY a . To Disassembling 1. Knock three spring pins (6) to be located in plan- etary gear shaft. 2. Draw planetary gear shaft (3) using a replacing tool and remove thrust collar (4), needle bearing (5) and21 planetary gear (2) (three place...

TRANSMISSION SYSTEM 4-65 D569-W02 May-2003 • Differential Case Cover and DifferentialS i d e G e a r 1. Remove the differential case cover (3). 2. Remove the differential side gear (1) and differen- tial side gear washer (2). ( W h e n r e a s s e m b l i n g ) • Apply Liquid lock (Three Bond 1372 o...

CHAPTER 4 8454 4-66 D569-W02 May-2003 (When reassembling) • Check the differential pinion (2), (3) and pinion shaft(1), (5) or excessive wear. If these parts are dam-aged or excessively worn, replace their parts theyare in mesh with, or they sliding on. • A p p l y m o l y b d e n u m d i s u l f i ...

TRANSMISSION SYSTEM 4-67 D569-W02 May-2003 • Checking Bearing 1. Hold the inner race, and push and pull the outer r a c e i n a l l d i r e c t i o n s t o c h e c k f o r w e a r a n dr o u g h n e s s . 2. Apply transmission fluid to the bearing, and hold the inner race. Then, turn the outer race ...

CHAPTER 5 FRONT AXLE www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983

FRONT AXLE 5-7 D569-W02 May-2003 3.2 FRONT WHEEL ALIGNMENT Front wheel alignment is a term given to mean fourangle settings in three dimensions: camber, kingpininclination, toe-in and caster angle. These angle set-tings are made for the following purposes. (1) Camber The front wheels are tilted from...

CHAPTER 5 8454 5-8 D569-W02 May-2003 3.3 TOE IN ADJUSTMENT ( 1 ) Apply air pressure as specified to tires. ( 2 ) Measure the front width (A) and the rear width (b) between the front wheels while straightened to ob-tain the difference (toe-in). ( 3 ) For other than specified, loosen the tightening nu...

FRONT AXLE 5-9 D569-W03 June-2003 2. If the difference between direction control angles left and right exceeds 1.5 °, adjust it with adjustingw a s h e r ( 1 ) i n F . T h e d i r e c t i o n c o n t r o l a n g l ei n c r e a s e s , i f t h e n u m b e r o f a d j u s t i n g w a s h e r sdecrease...

CHAPTER 5 8454 5-10 D569-W02 May-2003 PROPELLER SHAFT (4), (5) 1. Slide the propeller shaft cover (4), (5) after remov- ing the bolt (9). 2. Tap out the spring pin (10), and then slide th e cou- pling (2) to the front. ( W h e n r e a s s e m b l i n g ) • Apply grease to the splines of the propelle...

CHAPTER 5 8454 5-12 D569-W03 June-2003 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). 2. Remove...

FRONT AXLE 5-13 D569-W02 May-2003 5.2 BEVEL GEAR CASE AND FRONT AXLE CASE A. TO DISASSEMBLING 1. Remove six M8 washer mounting bolts to loosen bearing cover (2). 2. Remove shim (3), 6208 ball bearing (4) and 16 bevel gear (5) at the top of bevel gear case (16). 3. Remove plug (7) at the bottom of fr...

FRONT AXLE 5-15 D569-W02 May-2003 569W521A 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. TO ASSEMBLE 1. Apply liquid gasket evenly on the assembling sur- face of front...

CHAPTER 5 8454 5-16 D569-W02 May-2003 5.5 FRONT DIFFERENTIAL GEAR (1) Front Differential Bearing Support (2) Spring Washer (3) Bolt (4) Ball Bearing (5) Differential Gear Case (6) Parallel Pin (7) Case Cover (8) Spring Washer (9) Bolt (10) S h i m s A. TO DISASSEMBLING 1. Remove inlet bolt (3) on fr...

CHAPTER 6 HYDRAULIC SYSTEM www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983

HYDRAULIC SYSTEM 6-3 D569-W03 June-2003 1. HYDRAULIC POWER LIFT SYSTEM 569W601B www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983

HYDRAULIC SYSTEM 6-9 D569-W02 May-2003 1.3 STRUCTURE AND OPERATION A. STRUCTURE (1) Gear Pump (2) Orbital Unit (3) PTO Clutch Valve (4) Front Hydraulic Block (5) Quick Couplers (If Equipped) The hydraulic system of the 8454 tractor is composedof the main components as shown in the figure.This system...

CHAPTER 6 8454 6-10 D569-W03 June-2003 B. HYDRAULIC CIRCUIT FOR THREE POINT HYDRAULIC SYSTEM Hydraulic Oil Flow 1. When the engine (4) is started, the hydraulic pump (3) is rotated to draw oil from the transmission case(1) through the suction pipe. Supplied oil is filteredby the hydraulic oil filter...

HYDRAULIC SYSTEM 6-11 D569-W02 May-2003 c. Control Valve 1. Structure 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 loweringof the lift arm at a constant speed always. Since block-ing of valve oil leak...

HYDRAULIC SYSTEM 6-17 D569-W02 May-2003 569W615A D. CONNECTION SYSTEM OF THE INTERNAL LEVERAGE a. Structure b. How the Internal Leverage System Works Application is classified into three of position control,draft control and position & draft mixed control. ( 1 ) Lever ( 2 ) Needle Bearing ( 3 ) ...

HYDRAULIC SYSTEM 6-21 D569-W03 June-2003 F . HYDRAULIC POWER TAKE OFF If necessary, hydraulic power for implements can betaken out from front hydraulic block or using auxiliarycontrol valves and quick couplers. • Hydraulic power for the front loader can be takenout from hydraulic block. • On 8454tra...

CHAPTER 6 8454 6-22 D569-W03 June-2003 c. Quick Couplers Quick couplers provided with these tractors are con-nectable even under pressure with both halves or ei-ther half pressurize. To connect the male half (1) to thebody (2), slide the sleeve (5) to the rear on the body halfand insert the male hal...

CHAPTER 6 8454 6-24 D569-W02 May-2003 G. TOP LINKAGE BRACKET a . S t r u c t u r e b. How the Top Linkage Bracket Works If impact is applied on the implement, cover (3) andspring (4) absorb the impact with the top link whileconnected to the linkage by plate (12) and tie rod (17)to raise the implemen...

HYDRAULIC SYSTEM 6-25 D569-W02 May-2003 1.4 PREPARATION STAGE FOR DISASSEMBLING ANDASSEMBLING 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) • Fill up fro...

HYDRAULIC SYSTEM 6-27 D569-W03 June-2003 1.5 DISASSEMBLING AND ASSEMBLING A. AUXILIARY CONTROL VALVES (1) Pipe A (8) Joint Bolt 2 (2) Pipe B ( 9 ) Quick Coupler (5) Bracket (10) Bolt ( 6 ) O - R i n g ( 11 ) Seal Washer 569W635B (if equipped) 1. Loosen and remove the joint bolt 2 (8), hydraulic pipe...

HYDRAULIC SYSTEM 6-29 D569-W02 May-2003 D. DISTRIBUTOR VALVE (CONTROL VALVE) 1. Loosen and remove the control valve (distributor valve) mounting screws (1). 2. Take out the control valve (3). ( W h e n r e a s s e m b l i n g ) • Take care not to damage the O-ring. (1) Screw (2) Lock Washer (3) Dist...

CHAPTER 6 8454 6-32 D569-W03 June-2003 H. DOUBLE ACTING VALVE a . To Disassembling 1. Remove O-rings (7), (8). 2. Remove Roller (25) and pin (18) and then Disas- sembling bent arm (24) and ring (26). 3. Remove 2 screws, gasket (13) and cover (12) and then loosen bolt (11), and washer (10) on the cov...

CHAPTER 6 8454 6-34 D569-W02 May-2003 569W645A 569W646A J. CHECK AND ADJUSTMENT a . Hydraulic Cylinder Bore 1. Check the cylinder inside surface for scratches or d a m a g e . 2. Using a cylinder gauge, measure cylinder I.D. 3. If the measured exceeds the allowable limits, re- place the hydraulic cy...

HYDRAULIC SYSTEM 6-35 D569-W02 May-2003 569W648A 569W647A c. Reaction Spring Assembly Reference D i m e n s i o n ( 1 ) S p r i n g ( 3 ) N u t ( 2 ) Hex. Bolt d. Dimensional Setting of Position Control Bolt 1. When assembling the control valve (MLS valve) into power lift body, “A” dimension will be...

CHAPTER 6 8454 6-38 D569-W02 May-2003 2. PTO CLUTCH VALVE SYSTEM 2.1 SPECIFICATIONS AND DIAGRAM A. SPECIFICATION Solenoid valve Modulating valve Maximum oil flowing ( /min, gal/min) Rated oil flowing ( /min, gal/min) Relief pressure (kgf/cm 2 , psi) Oil flowing ( /min, gal/min) 65 (17.17) 7.1 (1.88)...

HYDRAULIC SYSTEM 6-39 D569-W03 June-2003 2.2 STRUCTURE AND OPERATION A. SOLENOID VALVE a . S t r u c t u r e (1) Block (2) S o l e n o i d (3) R i n g (4) P l u g (5) Bolt (6) O - R i n g b. O p e r a t i o n • In case PTO clutch switch is OFF Oil at Port PI (gear pump) returns from Port A to thetan...

CHAPTER 6 8454 6-44 D569-W02 May-2003 2.3 ASSEMBLING AND DISASSEMBLING A. SOLENOID VALVE a . To Disassembling (1) Solenoid Ass’y (2) S p r i n g (3) S p r i n g (4) S p o o l S p o o l 1. Loosen the bolt on the cover (1) and remove the cover. 2. Take out the spring and spool. (5) S p o o l (6) P l u...

HYDRAULIC SYSTEM 6-45 D569-W02 May-2003 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). Relief pressures e t Factory s p e c . 16 ~ 18 kgf/cm 2 T i g ...

CHAPTER 6 8454 6-46 D569-W02 May-2003 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 solenoidvalve ass...

HYDRAULIC SYSTEM 6-47 D569-W02 May-2003 3. POWER STEERING SYSTEM 3.1 TROUBLESHOOTING 1) Orbitrol unit ( 1 ) Deflected center from the column. ( 2 ) Abrasion due to dust on spool or sleeve. ( 3 ) Excessive tightening torque of bolts (7 places) on end cover. 2) P u m p ( 1 ) Incapable drive. ( 2 ) Wor...

HYDRAULIC SYSTEM 6-49 D569-W02 May-2003 Oil Flow 1. If the engine starts and the hydraulic pump turns, oil in T/M case is absorbed and delivered compul-sorily to the steering controller via the priority valve. 2. This valve protects the hydraulic circuit by govern- ing the maximum pressure (approx. ...

CHAPTER 6 8454 6-50 D569-W02 May-2003 3.3 STRUCTURE AND OPERATION B. STRUCTURE a. Power Steering Unit The steering controller for power steering is composedof steering valve and relief valve. (1) End Cap (6) GEROTOR (2) S p o o l (7) Centering Spring (3) S p a c e r (8) P i n (4) B e a r i n g (9) H...

CHAPTER 6 8454 6-52 D569-W02 May-2003 569W666A C. OPERATION a . Hydraulic Circuit for Power Steering System 1. Power steering pump (3), driven by the engine sucks oil from transmission case (1), and it to steeringcontroller (5) through the hose. 2. The oil which has entered steering controller (5) i...

HYDRAULIC SYSTEM 6-53 D569-W02 May-2003 OIL FLOW Neutral Position When the steering wheel (2) is not being turned valveplate (3) is held in the neutral position by centerings p r i n g s ( 4 ) . U n d e r t h i s c o n d i t i o n a n o i l p a s s a g e i sformed between port P (from pump) and port...

HYDRAULIC SYSTEM 6-55 D569-W02 May-2003 3.4 PREPARATION STAGE FOR DISASSEMBLING ANDASSEMBLING 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. ...

HYDRAULIC SYSTEM 6-57 D569-W02 May-2003 Hydraulic Pipes 1. Disconnect the main delivery hose (1), return hose (2), right turning delivery hose (3) and left turningdelivery hose (4). ( W h e n r e a s s e m b l i n g ) • I n a s s e m b l i n g t h e t u r n i n g d e l i v e r y h o s e s t o t h es...

CHAPTER 6 8454 6-58 D569-W02 May-2003 3.5 TO DISASSEMBLING AND TO ASSEMBLE POWER STEERING UNIT (1) Screw (9) O - R i n g (2) End Cap (10) Rotor (3) O - R i n g (11) Drive (4) Stator (12) Sleeve (5) S p a c e r (13) P i n (6) O - R i n g ( 1 4 ) Centering Spring (7) S p a c e r (15) S p o o l (8) Spa...

HYDRAULIC SYSTEM 6-59 D569-W02 May-2003 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). 3. Loosen 7 screws (1). 4. Remove end cap (2). 5. Remove O-ring (3) out of the end...

CHAPTER 6 8454 6-62 D569-W02 May-2003 c. To Assemble the Control 1. Insert the dust seal into the flange section of the h o u s i n g . 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 ...

HYDRAULIC SYSTEM 6-65 D569-W02 May-2003 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 ho...

HYDRAULIC SYSTEM 6-67 D569-W02 May-2003 4.3 STRUCTURE AND OPERATION A. STRUCTURE (1) Snap Ring (7) S e a l i n g (2) B e a r i n g (8) S e a l i n g (3) Cover (Front) (9) B u s h i n g (4) S e a l i n g (10) Drive Gear Shaft (1) (5) P i n (11) Passive Gear (1) (6) First Pump (12) C o u p l i n g (13...

HYDRAULIC SYSTEM 6-69 D569-W02 May-2003 2. Loosen and remove bolt (2), gear pump (1) and gasket. (1) Gear Pump Assembly (2) Bolt 569W699A • Be careful not to cause damages onthe gasket. If damaged, replace it witha new one. 4.4 TO DISASSEMBLING AND TO ASSEMBLE A. GEAR PUMP ASSEMBLY 1. Remove hydraul...

HYDRAULIC SYSTEM 6-71 D569-W02 May-2003 5. HYDRAULIC FILTER 5.1 STRUCTURE AND OPERATION A. STRUCTURE (1) Hydraulic Filter (2) Magnetic Ass’y (3) Filter Bracket (4) Vacuum Sensor (5) Thermostat Sensor Hydraulic filter as of inlet filter on the inlet gear pumphas permanent magnet installed on the cent...

CHAPTER 6 8454 6-72 D569-W02 May-2003 B. OPERATION a . Function It filters any particle or contaminated substance out ofoil. b . O p e r a t i o n P r i n c i p l e The filtering system as of an inlet filter installed on theinlet gear pump is composed of filter bracket, magnetass’y and element ass’y...

HYDRAULIC SYSTEM 6-73 D569-W02 May-2003 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 (1) Gear Pump Assembly (2) Orbitrol Unit (3) Steering Cylinder Ass’y (4) Hydraulic H...

CHAPTER 6 8454 6-74 D569-W02 May-2003 B. FLOW DIAGRAM OF TRANSMISSION OIL a . STEERING DEVICE & PTO CLUTCH SYSTEM b . Hydraulic pressure Lift Device T r a n s m i s s i o n C a s e (Hydraulic Tank) Hydraulic filter Hydraulic pump 2 (7.2 cc/rev) Power steering u n i t (74 cc/rev) Steering cylinde...

HYDRAULIC SYSTEM 6-79 D569-W02 May-2003 6.4 HYDRAULIC PRESSURE RISE & FALL DEVICE A. SCHEMATIC DIAGRAM OF HYDRAULIC PRESSURE RISE & FALL DEVICE (1) Hydraulic Cylinder Ass’y (1-1) MLS Valve (1-2) Double Acting Valve (2) Hydraulic Block B. PRINCIPLE OF OPERATION The hydraulic pressure rise &am...

CHAPTER 7 BRAKE www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983

BRAKE 7-5 D569-W02 May-2003 4. STRUCTURE AND OPERATION 4.1 S T R U C T U R E (1) Brake Case (2) P a c k i n g (3) Guide Pin (4) Brake Cam (5) O - R i n g (6) Cam Plate (RH) (7) Cam Plate (LH) (8) Steel Ball (9) Steel Ball Sheet (10) Brake Disc (11) Plate (12) Brake Cam Lever (RH) (13) Brake Cam Leve...

CHAPTER 7 8454 7-6 D569-W02 May-2003 b . P a r k i n g B r a k e The parking brake is operated mechanically.If the hand lever located at the lower part of the instrumentp a n e l i s p u l l e d u p w a r d w i t h b r a k e p e d a l s t e p p e dpowerfully, the parking brake lever holds the brake ...

CHAPTER 7 8454 7-8 D569-W02 May-2003 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) • Fil...

BRAKE 7-9 D569-W02 May-2003 P r e p a r a t i o n 2 1. Disconnect the brake rods (4), (10). 2. Disconnect the clutch rod (2). 3. Remove the accelerator rod (12). 4. Disconnect the foot accelerator rod (11). 5. Remove the panel frame cover (7) and disconnect the connectors (6). 6. Remove the shuttle ...

BRAKE 7-11 D569-W02 May-2003 Fender, Floor Seat and Platform Assembly 1. Remove the fender (1, 2), floor seat and platform as a unit. 569W716A Cover 1. Remove the blots (1), (2) and the cover assembly (3). (1) Bolt (3) Cover (2) Bolt 569W715A 5.3 SEPARATING REAR FENDERS AND PLATFORM ASSEMBLY P r e p...

CHAPTER 7 8454 7-14 D569-W02 May-2003 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). 3. Support the rear axle case (4) with nylon lift strap...

BRAKE 7-15 D569-W02 May-2003 It is Possible to Disassemble as Shown in theFigure Above. ( W h e n r e a s s e m b l i n g ) • Place the brake discs (9) so that the hole “A” of thesecond disc should be overlapped 70% or more. • Apply grease to the O-ring (12) and take care not todamage them. Brake Ca...

CHAPTER 7 8454 7-16 D569-W02 May-2003 6. ADJUSTMENT OF THE BRAKE B r a k e P e d a l F r e e P l a y 1. Press the center of the pedal with a force of approx. 39.2 ~ 58.8 N (4 ~ 6 kgf, 8.8 ~ 13.2 lbs), and mea-sure the free play of the brake pedal edge. 2. If the measurement is not within the factory...

CHAPTER 8 ELECTRIC SYSTEM www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983

ELECTRICAL SYSTEM 8-3 D569-W03 June-2003 1. ELECTRONIC INSTRUMENTATION 1.1 INSTRUMENT GAUGE 569W801B (1) Tachometer ( 2 ) Temperature Gauge ( 3 ) Fuel Gauge ( 4 ) PTO On Indicator ( 5 ) Engine Coolant Low Level Warning lamp ( 6 ) Differential Lock Operation lamp ( 7 ) Engine Oil Pressure Warning Lam...

CHAPTER 8 8454 8-4 D569-W02 May-2003 569W802A (1) Differential Lock Operation Pedal (A) Push A. POWER-TAKE-OFF OPERATION LAMP (4) Light will illuminate when the PTO selection switch islocated at Auto or Manual mode. Before you start the engine, be sure that the PTO se-lection switch is located at th...

CHAPTER 8 8454 8-8 D569-W03 June-2003 3. SERVICING SPECIFICATIONS Item 12V 80AH 12V 2.0kw 12V 50A 14V 3 . 4 W Capacity (factory spec.) Regulator built - in type Feature Battery Start motor Alternator Indicator bulb Rated voltage capacity Rated voltage Rated power Rated voltage Rated current Rated vo...

CHAPTER 8 8454 8-10 D569-W02 May-2003 B. OPERATION OF START MOTOR a. Starter The magnet-switch type starter is composed of two main sections. The first section converts battery current intomechanical rotation to turn the engine crankshaft. It is composed of the field coil, armature, brush, commutato...

CHAPTER 8 8454 8-12 D569-W03 June-2003 569W810A b. Glow plugs Glow plugs are used for each pre-combustion chamberof the cylinder head to make starting easier. The glowplugs are quick-heating type, which make starting easierwith short pre-heating time. (1) Housing (3) Insulating powder (2) Metal tube...

ELECTRICAL SYSTEM 8-13 D569-W02 May-2003 569W812A B. CIRCUIT DIAGRAM FOR ALTERNATOR UNIT 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...

CHAPTER 8 8454 8-14 D569-W02 May-2003 ( 1 ) Alternator ( 2 ) Key s/w ( 3 ) Preheating Controller ( 4 ) Coolant temp. sensor 569W813A 4.3 PREHEATING SYSTEM A. CIRCUIT DIAGRAM FOR PREHEATING SYSTEM ( 5 ) Glow plug indicator ( 6 ) Glow plug ( 7 ) Glow Relay PARTS SPECIFICATION (1) Capacity of the prehe...

CHAPTER 8 8454 8-16 D569-W02 May-2003 4.5 GAUGE AND SENSORS 569W815A (1) Terminal contact (2) Diaphragm A. OIL PRESSURE SWITCH The oil pressure switch is installed on the cylinder blockand leads to the oil passage of the lubricating oil. Whenthe oil pressure falls below the specified value, the con-...

CHAPTER 9 CABIN SYSTEM www.mymowerparts.com K&T Saw Shop 606-678-9623 or 606-561-4983

CABIN SYSTEM 9-3 D569-W02 May-2003 1. DISASSEMBLY AND ASSEMBLY 1. Loosen 6 setting bolts for chair assembly support and disconnect seat assembly in a body. (1) Seat Assembly 2. Disengage 4 setting bolts for cabin assembly. (1) Cabin Support (Front) (3) Bolt (2) Cabin Support (Rear) (4) Bolt 3. R e m...

CHAPTER 9 8454 9-8 D569-W02 May-2003 2. HEATER 2.1 S T R U C T U R E 2.2 DISASSEMBLY AND ASSEMBLY 1. Open drain cock in right of front axle frame and drain coolant. 2. Remove heater hose connected to connecting plate 1, 2 and heater assembly using clamp. 3. Disconnect duct hose and wiring connected ...

CABIN SYSTEM 9-11 D569-W02 May-2003 C. OPERATION PRINCIPLES OF SYSTEM COMPONENTS a . R e f r i g e r a n t In order to accomplish the intrinsic function of air-con-ditioning system, it is needed to use the suitable re-frigerant - which features relatively low temperatureboiling point and the desirab...

CHAPTER 9 8454 9-12 D569-W02 May-2003 D. AIR-CONDITIONING COMPONENTS (1) Aircon. Unit (2) Duct, Aircon. (3) Hose 3, Aircon (4) Hose 4, Aircon. I M P O R TA N T: • Do not emit the refrigerant outside the air. • Care shall be taken to handle the refrigerant to avoidthe failure. • The skin and eyes may...

CHAPTER 9 8454 9-16 D569-W02 May-2003 4) The compressor does not revolve or hard to revolve. The vibration of belt is large. The belt is sliding. Sliding when revolving Sliding when revolving Sliding caused by the contamina-tion around the magnetic clutch Te n s i o n a d j u s t m e n t R e p a i r...

CHAPTER 9 8454 9-20 D569-W02 May-2003 D. ELECTRICAL CIRCUIT a . Air Conditioner System (1) Battery (2) Slow Blow Fuse (3) Main Switch (4) Compressor Relay (5) C o m p r e s s o r The above figure shows the circuit composing the airconditioning system. The magnetic clutch of the compressor is operate...