Cub-cadet 8454 Bedienungsanleitung

88445544 SSEERRVVIICCEE MMAANNUUAALL MTD Products, LLC Product Training and Education Department FORM NUMBER 769-00903

CHAPTER 3 84543-10D569-W02 May-20034.3 DISASSEMBLYA. Insert clutch center guide (1) up to the spline huband fix it not to be come off even though

CLUTCH3-11D569-W03 June-20035. ADJUSTMENT OF PEDAL5.1 DEFLECTION OF CLUTCH PEDALA. Measure deflection of pedal by pushing clutch pedal(1) with hand.

CHAPTER 3 84543-12D569-W02 May-20036. INSPECTION AND REPAIR6.1 WEAR AND DAMAGE ON CLUTCHDISC (1) Disc (2) Rivet6.2 CLEARANCE BETWEEN SPLINEBOSS

CLUTCH3-13D569-W02 May-20036.3 FLATNESS OF CLUTCHPRESSURE PLATE, DAMAGESA. Measure several clearances with a space gaugealong with a feeler gauge pl

CHAPTER 3 84543-14D569-W02 May-20036.6 CLEARANCE BETWEEN CLUTCHPEDAL SHAFT AND CLUTCHPEDAL BUSHINGA. Measure the outer diameter of clutch pedal s

CHAPTER 4TRANSMISSION SYSTEM

TRANSMISSION SYSTEM4-3D569-W02 May-20031. TROUBLESHOOTING1.1 TROUBLESHOOTING FOR SHUTTLE SHIFT IN OPERATION ERRORNoise when the shuttleis shiftedGea

CHAPTER 4 84544-4D569-W02 May-20031.3 TROUBLESHOOTING FOR AUXILIARY AND CREEP SHIFTS IN OPERATION ERROR1.4 TROUBLESHOOTING FOR REAR DIFFERENTIAL G

TRANSMISSION SYSTEM4-5D569-W02 May-20031.6 TROUBLESHOOTING FOR FRONT WHEEL DRIVE IN OPERATION ERROR1.7 TROUBLESHOOTING FOR PTO CLUTCH IN OPERATION E

GENERAL INFORMATION1-3D569-W02 May-20031. TRACTOR VIEW569W101A

CHAPTER 4 84544-6D569-W02 May-20032. SPECIFICATIONS2.1 TIGHTENING TORQUESMiddle caseTransmis-sion caseRear axle/brake75.9 ~ 86.857.1 ~ 66.594.0 ~

TRANSMISSION SYSTEM4-7D569-W03 June-20033. STRUCTURE3.1 POWER TRAIN DIAGRAM569W401B

CHAPTER 4 84544-8D569-W03 June-20033.2 STRUCTURE (1) Shuttle Shift Section (2) Main Gear Shift Section (3) Hi-Low Range Shift Section (4) Clutch

TRANSMISSION SYSTEM4-9D569-W02 May-20033.3 POWER TRAIN3.3.1TRANSMISSION (1) Shuttle Shaft (2) 26-26 Gear (3) 29-23-18-14 Gear (4) 17 gear Shaft (5)

CHAPTER 4 84544-10D569-W02 May-20033.3.2SHUTTLE SHIFT SECTION569W404A(A) Forward (B) Reverse

TRANSMISSION SYSTEM4-11D569-W02 May-20033.3.3MAIN SHIFT569W405A(A) Forward(B) Reverse(C) 1st(D) 2nd(E) 3rd(F) 4th

CHAPTER 4 84544-12D569-W02 May-20033.3.4AUXILIARY SHIFT3.3.5FRONT WHEEL DRIVE569W406A569W407A(A) High (B) Low (C) Creep(A) Engaged

TRANSMISSION SYSTEM4-13D569-W02 May-2003569W408A3.3.6PTO SHIFT

CHAPTER 4 84544-14D569-W03 June-2003Block-type Synchromesh Mechanism(For Main Gear Shift, Hi-Lo Range Shift Section)The hub (3) is splined to the

TRANSMISSION SYSTEM4-15D569-W02 May-2003First StageAn effort to place the main gear shift lever to the 3rd or4th speed causes the shifter (5) and sy

CHAPTER 1 84541-4D569-W02 May-20032. TIGHTENING TORQUE FOR STANDARD BOLTS AND NUTS2.1 TIGHTENING TORQUEScrews, bolts and nuts whose tightening to

CHAPTER 4 84544-16D569-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 G

TRANSMISSION SYSTEM4-17D569-W03 June-2003<Hi-Lo range shift section> (1) 17 Gear Shaft (5) 39-21 Gear (2) Auxiliary Gear Shifter Shaft (6) 43

CHAPTER 4 84544-18D569-W02 May-2003<PTO clutch valve> (1) PTO Clutch Shaft (6) Pressure Plate (2) Clutch Body (7) Spline Boss (3) Piston

TRANSMISSION SYSTEM4-19D569-W02 May-2003[PTO CLUTCH VALVE]A. OPERATION• In case PTO clutch switch is ON (1) Clutch Body (8) Pressure Plate (2) Pist

CHAPTER 4 84544-20D569-W02 May-2003• In case PTO clutch switch is OFF1. If PTO switch on the instrument board is turned OFF(neutral), the circuit

TRANSMISSION SYSTEM4-21D569-W02 May-2003F. PTO SYSTEMa. Related Parts With the PTO Operation (1) PTO Drive Shaftb. Operation Principle of PTOIf PTO

CHAPTER 4 84544-22D569-W02 May-20034. PREPARATION STAGE FOR DISASSEMBLING ANDASSEMBLING TRANSMISSION4.1 DRAINING THE TRANSMISSIONFLUIDDraining th

TRANSMISSION SYSTEM4-23D569-W02 May-2003Preparation 11. Removing the following parts.4.2 SEPARATING PANEL FRAMEASSEMBLY (1) Side Cover (RH, LH) (2)

CHAPTER 4 84544-24D569-W02 May-2003Hydraulic Pipes1. Disconnect the main delivery hose (1), return hose(2), right turning delivery hose (3) and l

TRANSMISSION SYSTEM4-25D569-W02 May-20034.3 SEPARATING REAR FENDERSAND PLATFORM ASSEMBLYPreparation1. Remove the Rops.2. Remove the Bolts (1) and ta

GENERAL INFORMATION1-5D569-W02 May-2003B. TIGHTENING TORQUE FOR STUDSM8M10M1211.7 to 15.7 N·m24.5 to 31.4 N·m34.3 to 49.0 N·m1.2 to 1.6 kgf·m2.5 to

CHAPTER 4 84544-26D569-W02 May-2003Hydraulic Pipes1. Remove the brake rod (4) and delivery pipe (3).2. Remove the delivery pipe (2).3. Slide the

TRANSMISSION SYSTEM4-27D569-W02 May-2003Shift Levers1. Tap out the spring pins (2) of main shift rod 1 (1).(When reassembling)• Tap in the spring pi

CHAPTER 4 84544-28D569-W02 May-20030 ~ 0.1 mm0 ~ 0.0039 in.0.1 ~ 0.2 mm0.0039 ~ 0.0078 in.0.2 ~ 0.4 mm0.0078 ~ 0.0157 in.---0.88 ~ 1.17 N·m0.09 ~

TRANSMISSION SYSTEM4-29D569-W02 May-20034. Assemble propeller shaft case (8) while greasedenough after sub-assembled with oil seal (9) andO-ring (10

CHAPTER 4 84544-30D569-W02 May-2003B. CLUTCH HOUSING AND MIDDLE CASEa. To Disassembling1. Remove M12 bolts (3) at six places and nuts (4) attwo p

TRANSMISSION SYSTEM4-31D569-W02 May-2003Carefully tighten M12 bolts when as-semblingM12 x 45 (four places): part CM12 stud bolts: part BParallel pin

CHAPTER 4 84544-32D569-W02 May-2003D. SHUTTLE SHIFT COVERa. To Disassembling1. Remove washer mounting bolts (12), (13) at 4 placeto loosen shutt

TRANSMISSION SYSTEM4-33D569-W02 May-2003E. MAIN SHIFT FORKa. To Disassembling1. Remove main shift cover bolts (16) at 8 places onthe middle case sid

CHAPTER 4 84544-34D569-W02 May-2003• Be sure to apply grease on O-rings be-fore fixed with shift arms.• If the packing (2) has been damaged,surel

TRANSMISSION SYSTEM4-35D569-W02 May-2003G. FRONT WHEEL DRIVE LEVERa. To Disassembling1. Loosen shifter (front wheel) (5), and Disassembling2 shift m

CHAPTER 1 84543. SPECIFICATIONMODEL8454Maximum PTO power38 HPEngine GROSS power45 HPEngine Model4A220TypeIndirect injection, vertical, water-cooled,

CHAPTER 4 84544-36D569-W03 June-2003H. AUXILIARY SHIFT GEARa. To Disassembling1. Remove middle case and transmission case.2. Remove middle case a

TRANSMISSION SYSTEM4-37D569-W03 June-2003• When assembling, let the oil grooveof the thrust collar faced toward thegear.I. SHUTTLE SHAFT SECTIONa. T

CHAPTER 4 84544-38D569-W03 June-2003K. SHAFT 1 (1) 17 Gear Shaft (2) Ball Bearing (3) Snap Ring (4) Collar (5) 42 Gear (6) Inner Ring (7) Inne

TRANSMISSION SYSTEM4-39D569-W02 May-2003a. To Disassembling1. Remove four M8 washer mounting bolts to loosenbearing cover (23).2. Remove the caulkin

CHAPTER 4 84544-40D569-W03 June-2003a. To Disassembling1. Remove the middle case and the transmission caseand Disassembling snap ring (11) fixed

TRANSMISSION SYSTEM4-41D569-W02 May-2003 (1) PTO Drive Shaft (2) Oil Seal (3) Ball BearingM.PTO DRIVE SHAFTa. To Disassembling1. Separate the middl

CHAPTER 4 84544-42D569-W03 June-2003To Disassembling PTO Clutch Ass’y1. Push down pressure plate (8) with an exclusive tooland take out snap ring

TRANSMISSION SYSTEM4-43D569-W02 May-2003b. To Assemble1. Install piston rings (3), (4) on the inner and outersections of the piston bore, and apply

CHAPTER 4 84544-44D569-W02 May-2003b. To Assemble1. Sub-assemble 6305 ball bearing (12), oil seal (5),(6) on the rear case (2).2. Sub-assemble 63

TRANSMISSION SYSTEM4-45D569-W02 May-2003Checking Contact Between Coupling andShifter1. Check to see if there is any flaw or wear on thespline of the

3. SPECIFICATION CON'TDrive systemTire size (Std. Tires) Front 9.5 - 16.6 Rear 14.9 - 24.8Clutc

CHAPTER 4 84544-46D569-W02 May-2003Backlash and Tooth Contact Between SpiralBevel Gear and Spiral Bevel Pinion1. Set a dial gauge (lever type) wi

TRANSMISSION SYSTEM4-47D569-W02 May-2003More than 35 % red lead contact area on the gear toothsurface. The center of tooth contacts at 1/3 of the en

CHAPTER 4 84544-48D569-W02 May-2003Piston Return Spring Free Length1. Measure the free length of spring with venirecalipers.2. If the measurement

TRANSMISSION SYSTEM4-49D569-W02 May-2003Thickness of Seal Ring1. Measure the thickness of seal rings with an out-side micrometer.2. If the measureme

CHAPTER 4 84544-50D569-W02 May-2003P. REAR AXLE• Rear axle to transmit power shifted at the transmis-sion to the rear wheels finally is composed

TRANSMISSION SYSTEM4-51D569-W02 May-2003A. REAR AXLE569W484A

CHAPTER 4 84544-52D569-W02 May-2003DIFFERENTIAL GEAR• Differential gear is structured with four pin type.• Differential gear is operated by shari

TRANSMISSION SYSTEM4-53D569-W02 May-2003B. OPERATION OF THE REAR AXLEThe final reduction system has a planetary gear system.It is compact, and is du

CHAPTER 4 84544-54D569-W02 May-2003C. POWER FLOW OF THE REAR DIFFERENTIAL GEARa. Related Parts with the Rear DifferentialGear (1) Spiral Bevel Pi

TRANSMISSION SYSTEM4-55D569-W02 May-20036. DIFFERENTIAL GEAR6.1 STRUCTUREThe differential gear assembly is a mechanism to pro-vide smooth steering.I

CHAPTER 1 84541-8D569-W02 May-20034. IDENTIFICATION4.1 ENGINE NUMBEREngine number is engraved in the left side of the cylin-der block as shown in

CHAPTER 4 84544-56D569-W02 May-2003TURNING THE CORNER<The Condition of not Engaged the Diff. Lock Gear>The power from the engine on spiral

TRANSMISSION SYSTEM4-57D569-W02 May-20036.3 LOCKING OF THE DIFFERENTIAL GEARa. Related Parts with the Operation of theDifferential Gear (1) Differen

CHAPTER 4 84544-58D569-W02 May-2003Differential LockWhen resistances to the right and left tires are differentdue to ground conditions or type of

TRANSMISSION SYSTEM4-59D569-W03 June-2003A. DIFFERENTIAL LOCK ASSEMBLYa. To Disassembling1. Remove spring pin (7).2. Take out snap pin (3) and Disas

CHAPTER 4 84544-60D569-W02 May-2003C. REAR DIFFERENTIAL GEAR GROUPa. To Disassembling1. Loosen four M10 bolt (25) on right side of the trans-miss

TRANSMISSION SYSTEM4-61D569-W02 May-2003D. DIFFERENTIAL GEAR ASSEMBLYa. To Disassembling1. Loosen eight UBS bolts (14) on differential case (right)(

CHAPTER 4 84544-62D569-W02 May-2003E. BRAKE CASEa. To Disassembling1. Remove eight bolts (10) and four nuts (8) on bothsides of the transmission

TRANSMISSION SYSTEM4-63D569-W02 May-2003F. REAL AXLE ASSEMBLYa. To Disassembling1. Remove side bolt (1) and nut (4) of the transmis-sion case to loo

CHAPTER 4 84544-64D569-W02 May-2003G. PLANETARY GEAR ASSEMBLYa. To Disassembling1. Knock three spring pins (6) to be located in plan-etary gear s

TRANSMISSION SYSTEM4-65D569-W02 May-2003• Differential Case Cover and DifferentialSide Gear1. Remove the differential case cover (3).2. Remove the d

GENERAL INFORMATION1-9D569-W02 May-20035. CAUTION BEFORE REPAIR569W106A569W107A227W105A5.1 BEFORE REPAIR OR INSPECTION1. In case of repair or inspec

CHAPTER 4 84544-66D569-W02 May-2003 (When reassembling)• Check the differential pinion (2), (3) and pinion shaft(1), (5) or excessive wear. If th

TRANSMISSION SYSTEM4-67D569-W02 May-2003• Checking Bearing1. Hold the inner race, and push and pull the outerrace in all directions to check for wea

CHAPTER 4 84544-68D569-W02 May-2003• Clearance Between Shift Fork and ShifterGroove1. Measure the width of shift fork.2. Measure the shifter groo

TRANSMISSION SYSTEM4-69D569-W02 May-2003• Clearance Between Differential Case Bore(Differential Case Cover Bore) and Differen-tial Side Boss1. Measu

CHAPTER 4 84544-70D569-W02 May-2003• Clearance Between Differential PinionShaft and Differential Pinion1. Measure the differential pinion shaft O

CHAPTER 5FRONT AXLE

FRONT AXLE5-3D569-W02 May-20031. TROUBLESHOOTINGAdjustAdjustReplaceAdjustReplaceTightenBleedReplaceReplaceReplaceReplaceReassembleAdjust or replaceR

CHAPTER 5 84545-4D569-W03 June-2003Front wheel alignmentFront wheelFront axleFront axle case boss (front)to bracket bushingFront axle case boss (

FRONT AXLE5-5D569-W03 June-2003Differential pinion to differential sidegear shimSpiral bevel pinion shaft(Pinion shaft only)Spiral bevel pinion shaf

CHAPTER 1 84541-10D569-W02 May-2003569W110A569W109A569W108A5.6 ELECTRICAL SYSTEM1. Check electrical wiring every year for any damageor short circ

CHAPTER 5 84545-6D569-W02 May-20033. STRUCTURE3.1 OPERATION(1) Front Axle Support(2) Bevel Gear(3) Bevel Gear Case(4) Differential Shaft(5) 16 Be

FRONT AXLE5-7D569-W02 May-20033.2 FRONT WHEEL ALIGNMENTFront wheel alignment is a term given to mean fourangle settings in three dimensions: camber,

CHAPTER 5 84545-8D569-W02 May-20033.3 TOE IN ADJUSTMENT(1) Apply air pressure as specified to tires.(2) Measure the front width (A) and the rear

FRONT AXLE5-9D569-W03 June-20032. If the difference between direction control anglesleft and right exceeds 1.5 °, adjust it with adjustingwasher (1)

CHAPTER 5 84545-10D569-W02 May-2003PROPELLER SHAFT (4), (5)1. Slide the propeller shaft cover (4), (5) after remov-ing the bolt (9).2. Tap out th

FRONT AXLE5-11D569-W02 May-2003TIE-ROD1. Remove the tie-rod. In this case, take special carenot to damage the tie-rod (1) and slotted nuts (2).(When

CHAPTER 5 84545-12D569-W03 June-20035. TO DISASSEMBLING AND TO ASSEMBLE5.1 FRONT AXLE CASE AND FRONT AXLEA. TO DISASSEMBLING1. Remove sixteen M8

FRONT AXLE5-13D569-W02 May-20035.2 BEVEL GEAR CASE AND FRONT AXLE CASEA. TO DISASSEMBLING1. Remove six M8 washer mounting bolts to loosenbearing cov

CHAPTER 5 84545-14D569-W02 May-20035.3 BEVEL GEAR CASE AND FRONTAXLE SUPPORTA. TO DISASSEMBLING1. Remove four M14 bolt and two nuts (3) to separa

FRONT AXLE5-15D569-W02 May-2003569W521AA. TO DISASSEMBLING1. Remove bolts (4), (6) on the assembly of front axlesupport (1) and differential gear ca

GENERAL INFORMATION1-11D569-W02 May-2003569W112A569W111ABe cautious of oil or other petroleum products on thehoses and rubber parts, this may cause

CHAPTER 5 84545-16D569-W02 May-20035.5 FRONT DIFFERENTIAL GEAR (1) Front Differential Bearing Support (2) Spring Washer (3) Bolt (4) Ball Beari

FRONT AXLE5-17D569-W03 June-2003B. TO ASSEMBLE1. Sub-assemble the inner rim of taper roller bearing(23) on 8 bevel pinion shaft (22).2. Sub-assemble

CHAPTER 5 84545-18D569-W03 June-2003Confirmation of Reaching UpApply minimum lightly on several thrashing faces atthree equally divided positions

FRONT AXLE5-19D569-W02 May-2003569W525A5.6 FRONT BRACKETA. TO DISASSEMBLING1. Remove mounting nut (7), bolt (6) and seal washer(8).2. Separate front

CHAPTER 5 84545-20D569-W02 May-20035.7 REAR BRACKETA. TO DISASSEMBLING1. Separate front axle support (1) and rear bracketass’y (2).2. Remove thru

CHAPTER 6HYDRAULIC SYSTEM

HYDRAULIC SYSTEM6-3D569-W03 June-20031. HYDRAULIC POWER LIFT SYSTEM569W601B

CHAPTER 6 84546-4D569-W02 May-2003 (1) Control Valve (2) Double Acting ValveHydraulic lift system to raise the implement connectedto the 3 point

HYDRAULIC SYSTEM6-5D569-W02 May-20031.1 TROUBLESHOOTING• Insufficient oil level in the tank.• Pump inlet filter clogged.• Infiltration of air into t

CHAPTER 1 84541-12D569-W02 May-20036. REGULAR CHECK LISTEngine oil changeEngine oil filter cartridge changeTransmission oil changeHydraulic oil f

CHAPTER 6 84546-6D569-W02 May-20031.2 SPECIFICATIONSA. TECHNICAL FEATURESa. Operation with drawbar pull and position control.b. Drawbar pull surv

HYDRAULIC SYSTEM6-7D569-W03 June-2003

CHAPTER 6 84546-8D569-W03 June-2003

HYDRAULIC SYSTEM6-9D569-W02 May-20031.3 STRUCTURE AND OPERATIONA. STRUCTURE (1) Gear Pump (2) Orbital Unit (3) PTO Clutch Valve (4) Front Hydraulic

CHAPTER 6 84546-10D569-W03 June-2003B. HYDRAULIC CIRCUIT FOR THREE POINT HYDRAULIC SYSTEMHydraulic Oil Flow1. When the engine (4) is started, the

HYDRAULIC SYSTEM6-11D569-W02 May-2003c. Control Valve1. StructureC. HYDRAULIC CYLINDER VALVESa. Control ValveControl valve detects load on the imple

CHAPTER 6 84546-12D569-W03 June-20032. Circuit Diagram569W609A

HYDRAULIC SYSTEM6-13D569-W02 May-20033. Operation PrincipleSince the control valve of the hydraulic cylinder is avail-able to control oil flowing in

CHAPTER 6 84546-14D569-W02 May-2003b. Delivery PhaseDuring this phase the control valve supplies the oil onpressure to the cylinder and it conseq

HYDRAULIC SYSTEM6-15D569-W02 May-2003c. Discharge PhaseDuring this phases the control valve supplies at thesame time the oil coming from the pump an

GENERAL INFORMATION1-13D569-W02 May-20037. OIL & WATER SUPPLY LISTSupply ItemsFuelCoolantEngine oilTransmission oilFront axle sectionCapacity40

CHAPTER 6 84546-16D569-W03 June-2003

HYDRAULIC SYSTEM6-17D569-W02 May-2003569W615AD. CONNECTION SYSTEM OF THE INTERNAL LEVERAGEa. Structureb. How the Internal Leverage System WorksAppli

CHAPTER 6 84546-18D569-W02 May-2003569W616AE. OPERATIONOperation is Divided Into Position Control, Draft Control and Mixed Operation.a. Position

HYDRAULIC SYSTEM6-19D569-W02 May-2003569W617Ab. Draft Control (Fig. 632W616A,632W617A)By positioning the control lever (1) for position controlagain

CHAPTER 6 84546-20D569-W02 May-2003When roller 4 (11) meets the inclined plane of the draw-bar pull cam (12), it permits the counterclockwise rot

HYDRAULIC SYSTEM6-21D569-W03 June-2003F. HYDRAULIC POWER TAKE OFFIf necessary, hydraulic power for implements can betaken out from front hydraulic b

CHAPTER 6 84546-22D569-W03 June-2003c. Quick CouplersQuick couplers provided with these tractors are con-nectable even under pressure with both h

HYDRAULIC SYSTEM6-23D569-W02 May-2003569W626A569W625A• As shown in the figure, a guide is attached at pop-pet (6) and valve chamber D.C (damping cha

CHAPTER 6 84546-24D569-W02 May-2003G. TOP LINKAGE BRACKETa. Structureb. How the Top Linkage Bracket WorksIf impact is applied on the implement, c

HYDRAULIC SYSTEM6-25D569-W02 May-20031.4 PREPARATION STAGE FORDISASSEMBLING ANDASSEMBLINGA. DRAINING THE TRANSMISSION FLUID1. Place oil pans underne

CHAPTER 6 84546-26D569-W02 May-2003C. FENDER, FLOOR SEAT AND PLATFORMASSEMBLY1. Remove the fender (1, 2), floor seat and platform asa unit.Cover1

HYDRAULIC SYSTEM6-27D569-W03 June-20031.5 DISASSEMBLING ANDASSEMBLINGA. AUXILIARY CONTROL VALVES (1) Pipe A (8) Joint Bolt 2 (2) Pipe B (9) Quick

CHAPTER 6 84546-28D569-W02 May-2003C. HYDRAULIC LIFT CONTROL LEVERS1. Remove the screw (1).2. Loosen and remove the bolts (2) and take out thecom

HYDRAULIC SYSTEM6-29D569-W02 May-2003D. DISTRIBUTOR VALVE (CONTROL VALVE)1. Loosen and remove the control valve (distributorvalve) mounting screws (

CHAPTER 6 84546-30D569-W02 May-2003F. BUSHINGS1. Remove the bushings (1) and (2).(When reassembling)• Apply transmission oil to the hydraulic cyl

HYDRAULIC SYSTEM6-31D569-W03 June-2003G. CONTROLa. To Disassembling1. Loosen 3 adjusting screws (27) with a 5mm wrench.2. Remove disc (8), spool (6)

CHAPTER 6 84546-32D569-W03 June-2003H. DOUBLE ACTING VALVEa. To Disassembling1. Remove O-rings (7), (8).2. Remove Roller (25) and pin (18) and th

HYDRAULIC SYSTEM6-33D569-W02 May-2003I. TOP LINK BRACKETa. To Disassembling1. Remove the socket support and coupler socket ass’yprior to the top lin

CHAPTER 6 84546-34D569-W02 May-2003569W645A569W646AJ. CHECK AND ADJUSTMENTa. Hydraulic Cylinder Bore1. Check the cylinder inside surface for scra

HYDRAULIC SYSTEM6-35D569-W02 May-2003569W648A569W647Ac. Reaction Spring Assembly ReferenceDimension(1) Spring (3) Nut(2) Hex. Boltd. Dimensional Set

CHAPTER 2ENGINE

CHAPTER 6 84546-36D569-W02 May-2003569W649A(1) Position Control Lever(2) Draft Control Lever(3) Position Control Shaft(4) Hex. Bolt(5) Lifting Ar

HYDRAULIC SYSTEM6-37D569-W02 May-2003569W622Af. Sensitivity Control of Control Valve (MLS)1. Apply the elevating arm with load of 500 kg (1100lbs)

CHAPTER 6 84546-38D569-W02 May-20032. PTO CLUTCH VALVE SYSTEM2.1 SPECIFICATIONS AND DIAGRAMA. SPECIFICATIONSolenoid valveModulating valveMaximum

HYDRAULIC SYSTEM6-39D569-W03 June-20032.2 STRUCTURE AND OPERATIONA. SOLENOID VALVEa. Structure (1) Block (2) Solenoid (3) Ring (4) Plug (5) Bolt (6)

CHAPTER 6 84546-40D569-W03 June-2003• In case PTO clutch switch is ON (1) Tank (Transmission Case) (2) Filter (3) Pump (4) Shuttle Shift CoverTh

HYDRAULIC SYSTEM6-41D569-W02 May-2003B. MODULATING VALVEa. Structure (1) Body (2) Piston (3) Spring (4) Spring Gripper (5) Spool (6) Valve Seat (7)

CHAPTER 6 84546-42D569-W02 May-2003b. Operation• In case PTO clutch switch is OFF (1) Tank (Transmission Case) (2) Filter (3) Gear Pump (4) Shut

HYDRAULIC SYSTEM6-43D569-W03 June-2003• In case PTO clutch switch is ONOil at Port PI comes back to Port P of the solenoid valvethrough the valve in

CHAPTER 6 84546-44D569-W02 May-20032.3 ASSEMBLING AND DISASSEMBLINGA. SOLENOID VALVEa. To Disassembling (1) Solenoid Ass’y (2) Spring (3) Spring

HYDRAULIC SYSTEM6-45D569-W02 May-2003C. MODULATING VALVEa. To Disassembling1. Loosen bolt (1) to remove cover (2).2. Take out piston (3), spring (4)

CHAPTER 6 84546-46D569-W02 May-20032.4 TO CHECK AND TO REPAIRA. SOLENOID VALVE1. Replace the solenoid valve ass’y if the wet-drivesFurface of the

HYDRAULIC SYSTEM6-47D569-W02 May-20033. POWER STEERING SYSTEM3.1 TROUBLESHOOTING1) Orbitrol unit(1) Deflected center from the column.(2) Abrasion du

CHAPTER 6 84546-48D569-W02 May-20033.2 INTRODUCTION (1) Gear Pump (2) Priority Valve (3) Power Steering Unit (4) Hydraulic Hose (RH) (5) Hydrauli

HYDRAULIC SYSTEM6-49D569-W02 May-2003Oil Flow1. If the engine starts and the hydraulic pump turns,oil in T/M case is absorbed and delivered compul-s

CHAPTER 6 8454 6-50D569-W02 May-20033.3 STRUCTURE AND OPERATIONB. STRUCTUREa. Power Steering UnitThe steering controller for power steering is com

HYDRAULIC SYSTEM6-51D569-W02 May-20031. Control valve: Control valve of rotary type is kept atneutral by the centering spring if the valve is notope

CHAPTER 6 84546-52D569-W02 May-2003569W666AC. OPERATIONa. Hydraulic Circuit for Power Steering System1. Power steering pump (3), driven by the en

HYDRAULIC SYSTEM6-53D569-W02 May-2003OIL FLOWNeutral PositionWhen the steering wheel (2) is not being turned valveplate (3) is held in the neutral p

CHAPTER 6 84546-54D569-W02 May-2003Left TurnThe steering system operates in this same way at aleft-turn as well, except that oil flows into and o

HYDRAULIC SYSTEM6-55D569-W02 May-20033.4 PREPARATION STAGE FORDISASSEMBLING ANDASSEMBLINGDRAINING THE TRANSMISSION FLUIDDraining the Transmission Fl

ENGINE2-3D569-W02 May-20031. GENERAL1.1 APPEARANCE569W201AThe DAEDONG A series engines are vertical, water-cooled, 4-cycle, three or four cylinders

CHAPTER 6 84546-56D569-W02 May-2003 (1) 2P Connector for Alternator (2) Clutch Rod (3) Jumper Lead For Fuel Level Sensor (4) Brake Rod (LH) (5)

HYDRAULIC SYSTEM6-57D569-W02 May-2003Hydraulic Pipes1. Disconnect the main delivery hose (1), return hose(2), right turning delivery hose (3) and le

CHAPTER 6 84546-58D569-W02 May-20033.5 TO DISASSEMBLING AND TO ASSEMBLEPOWER STEERING UNIT (1) Screw (9) O-Ring (2) End Cap (10) Rotor (3) O-Ri

HYDRAULIC SYSTEM6-59D569-W02 May-2003a. To Disassemble the Gerotor Parts1. Let the port face of the tractor’s body housing visedslightly with the en

CHAPTER 6 84546-60D569-W02 May-20037. Disassembling the gerotor. Be careful not to dropthe rotor from the outer ring of the gerotor.8. Take out s

HYDRAULIC SYSTEM6-61D569-W02 May-200314. Take out two bearinglesses (18), needle bearing(19) and oil seal.Surely insert the needle bearing between t

CHAPTER 6 84546-62D569-W02 May-2003c. To Assemble the Control1. Insert the dust seal into the flange section of thehousing.b .To Disassembling th

HYDRAULIC SYSTEM6-63D569-W02 May-20033. While turning around spool (15), insert it slowlyinto sleeve (12), Take up the spline area to thespool to ch

CHAPTER 6 84546-64 D569-W02 May-20036. Insert pin (13) onto the sleeve groove and insertthe spool and sleeve ass’y from the gerotor sideof the ho

HYDRAULIC SYSTEM6-65D569-W02 May-2003d. To Assemble the Relief Valve1. Pick up the spring guide part with a pin set to insertpoppet (25) into the fl

CHAPTER 2 84542-4D569-W02 May-20031.2 SPECIFICATIONS* NOTE: Change of parts are not subject to advance notice.MODELTypeNumber of cylinderBore and

CHAPTER 6 84546-66D569-W02 May-20034.2 SPECIFICATIONS• Reference: [ First: for hydraulic lift, Second: for steering cylinder ]Tandem14.4 (First)

HYDRAULIC SYSTEM6-67D569-W02 May-20034.3 STRUCTURE AND OPERATIONA. STRUCTURE (1) Snap Ring (7) Sealing (2) Bearing (8) Sealing (3) Cover (Front)

CHAPTER 6 84546-68D569-W02 May-2003B. OPERATIONa. Hydraulic pump delivers constant oil flow to oper-ate the steering wheel and the hydraulic cyli

HYDRAULIC SYSTEM6-69D569-W02 May-20032. Loosen and remove bolt (2), gear pump (1) andgasket. (1) Gear Pump Assembly (2) Bolt569W699A• Be careful no

CHAPTER 6 84546-70D569-W02 May-2003B. GEAR PUMP1. Fix the gear pump ass’y with a vise.2. Loosen 4 bolts (23) and remove rear cover (21).3. Disass

HYDRAULIC SYSTEM6-71D569-W02 May-20035. HYDRAULIC FILTER5.1 STRUCTURE AND OPERATIONA. STRUCTURE (1) Hydraulic Filter (2) Magnetic Ass’y (3) Filter B

CHAPTER 6 84546-72 D569-W02 May-2003B. OPERATIONa. FunctionIt filters any particle or contaminated substance out ofoil.b. Operation PrincipleThe

HYDRAULIC SYSTEM6-73D569-W02 May-20036. HYDRAULIC PRESSURE OPERATION PRINCIPLEAND TROUBLE SHOOTING6.1 COMPOSITION OF HYDRAULIC DEVICE & FLOW DIA

CHAPTER 6 84546-74D569-W02 May-2003B. FLOW DIAGRAM OF TRANSMISSION OILa. STEERING DEVICE & PTO CLUTCH SYSTEMb. Hydraulic pressure Lift Device

HYDRAULIC SYSTEM6-75D569-W02 May-2003B. PRINCIPLES OF OPERATIONThe steering device shall be operated by supplying theoperating oil in the transmissi

ENGINE2-5D569-W02 May-2003569W204A 569W203A1.3 PERFORMANCE CURVE

CHAPTER 6 84546-76D569-W02 May-2003D. TROUBLE SHOOTING1.Install the flow rate gauge on the outlet of pump (refer to the sche-matic Diagram).2.Che

HYDRAULIC SYSTEM6-77D569-W02 May-20036.3 PTO SYSTEMA. SCHEMATIC DIAGRAM OF PTO SYSTEM (1) PTO Clutch Valve(1-1) Solenoid Valve Ass’y(1-2) Modulator

CHAPTER 6 84546-78D569-W02 May-2003D. TROUBLE SHOOTING1.Press the push button of solenoid valve assembly to check thefitting of spool.Components

HYDRAULIC SYSTEM6-79D569-W02 May-20036.4 HYDRAULIC PRESSURE RISE & FALL DEVICEA. SCHEMATIC DIAGRAM OF HYDRAULIC PRESSURE RISE & FALL DEVICE

CHAPTER 6 84546-80D569-W02 May-2003D. TROUBLE SHOOTINGChecking of hydraulic block1.Install the pressure gauge on coupler socket assembly to check

HYDRAULIC SYSTEM6-81D569-W03 June-2003How to adjust the pressure of double-acting valve1.Install the pressure in the coupler socket to check the sta

CHAPTER 6 84546-82D569-W02 May-2003 (Neutral Stage)Components Trouble Checking Remark3.MLS valve assem-bly (operationprinciple)Operation principl

HYDRAULIC SYSTEM6-83D569-W02 May-2003(4) Falling valve: as spool (1) is operated, the falling valve (4) fallsdown by a spring to open the pipe line

CHAPTER 6 84546-84D569-W02 May-2003Operation principle of MLS valve supply stageSpool (1) is operated by a link to open the pipe line (A) and the

HYDRAULIC SYSTEM6-85D569-W02 May-2003How to adjust the sensitivityComponents Trouble Checking Remark4.Hydraulic cylinderassembly (MLS valve assembly

CHAPTER 2 84542-6D569-W02 May-2003569W205A1.4 DIMENSIONS4A2204A200T4A2204A200TSample/td Spec.A697.3 (27.45)697.3 (27.45)G736 (28.98)736 (28.98)B8

CHAPTER 7BRAKE

BRAKE7-3D569-W02 May-200325 ~ 40 mm0.984 ~ 1.574 in.Less than 5 mm0.20 in.0.007 ~ 0.101 mm0.00027 ~ 0.00397 in.24.980 ~ 24.993 mm0.9834 ~ 0.9839 in2

CHAPTER 7 84547-4D569-W02 May-20033. TIGHTENING TORQUETightening torque Brake shaftMounting bolt of parking brake shaftMounting nut of brake cam

BRAKE7-5D569-W02 May-20034. STRUCTURE AND OPERATION4.1 STRUCTURE (1) Brake Case (2) Packing (3) Guide Pin (4) Brake Cam (5) O-Ring (6) Cam Plate

CHAPTER 7 84547-6D569-W02 May-2003b. Parking BrakeThe parking brake is operated mechanically.If the hand lever located at the lower part of the i

BRAKE7-7D569-W02 May-2003• If brake pedal (1) is stepped down, brake lever (5)is pulled to the direction as arrowed through con-necting rods (2), (4

CHAPTER 7 84547-8D569-W02 May-20035. DISASSEMBLING AND ASSEMBLING5.1 DRAINING THE TRANSMISSIONFLUIDDraining the Transmission Fluid1. Place oil pa

BRAKE7-9D569-W02 May-2003Preparation 21. Disconnect the brake rods (4), (10).2. Disconnect the clutch rod (2).3. Remove the accelerator rod (12).4.

ENGINE2-7D569-W02 May-2003569W208A569W207A569W206A2. STRUCTURE AND FUNCTION2.1 BODYA. CYLINDER HEADThe cylinder head is made of special alloy cast i

CHAPTER 7 84547-10D569-W02 May-2003569W712AHydraulic Pipes1. Disconnect the main delivery hose (1), return hose(2), right turning delivery hose (

BRAKE7-11D569-W02 May-2003Fender, Floor Seat and Platform Assembly1. Remove the fender (1, 2), floor seat and platform asa unit.569W716ACover1. Remo

CHAPTER 7 84547-12D569-W02 May-2003Hydraulic Pipes1. Remove the brake rod (4) and suction pipe (3).2. Remove the rubber hoss (2).3. Slide the ret

BRAKE7-13D569-W02 May-2003Hydraulic Pipes1. Loosen the screws (1), bolt (2) and remove the suc-tion pipe (3).2. Remove the pipe (4), (5), (6), (7).

CHAPTER 7 84547-14D569-W02 May-20035.4 DISASSEMBLING REAR AXLECASERear Axle Case1. Support the transmission case with nylon lift strapand hoist.2

BRAKE7-15D569-W02 May-2003It is Possible to Disassemble as Shown in theFigure Above.(When reassembling)• Place the brake discs (9) so that the hole

CHAPTER 7 84547-16D569-W02 May-20036. ADJUSTMENT OF THE BRAKEBrake Pedal Free Play1. Press the center of the pedal with a force of approx.39.2 ~

BRAKE7-17D569-W02 May-20037. SERVICINGBrake Can Lever Movement1. Move the brake cam lever by hand to check themovement.2. If the movement is heavy,

CHAPTER 7 84547-18D569-W02 May-2003Brake Disc Wear1. Measure the brake disc thickness with venirecalipers.2. If the thickness is less than the al

CHAPTER 8ELECTRIC SYSTEM

CONTENTSCHAPTER 1. GENERAL INFORMATION ...1-11. TRACTOR VIEW...

CHAPTER 2 84542-8D569-W02 May-2003569W211A569W210A569W209A(1) Top Ring (3) Oil Ring(2) Second Ring(1) Small End Bushing (3) Crankpin Bearing(2) C

ELECTRICAL SYSTEM8-3D569-W03 June-20031. ELECTRONIC INSTRUMENTATION1.1 INSTRUMENT GAUGE569W801B(1) Tachometer(2) Temperature Gauge(3) Fuel Gauge(4)

CHAPTER 8 84548-4D569-W02 May-2003569W802A(1) Differential Lock Operation Pedal(A) PushA. POWER-TAKE-OFF OPERATION LAMP (4)Light will illuminate

ELECTRICAL SYSTEM8-5D569-W03 June-2003K. TURN SIGNAL LAMP INDICATOR (14 AND 15)Light will be flash when operating the turn signal switchto the left

CHAPTER 8 84548-6D569-W02 May-2003All electrical equipmentdoes not operateFuse blown frequentlyBattery discharges toofastStarter motor does notop

ELECTRICAL SYSTEM8-7D569-W02 May-2003Brake light does not lightCoolant level lamp doesnot light when coolingwater is insufficientCoolant level lamp

CHAPTER 8 84548-8D569-W03 June-20033. SERVICING SPECIFICATIONSItem12V80AH12V2.0kw12V50A14V3.4WCapacity (factory spec.)Regulator built - in typeFe

ELECTRICAL SYSTEM8-9D569-W03 June-2003(1) Main fuse(2) Start Relay(3) Start motor(4) Key s/w(5) Safety s/w(6) PTO safety relay(7) PTO fuse(8) Neutra

CHAPTER 8 84548-10 D569-W02 May-2003B. OPERATION OF START MOTORa. StarterThe magnet-switch type starter is composed of two main sections. The fi

ELECTRICAL SYSTEM8-11D569-W02 May-2003(C) When key switch is on:When the key switch is turned on, a current flows fromthe battery through the pull-i

ENGINE2-9D569-W02 May-2003569W214A569W213A569W212A(1) Rocker Arm (4) Rocker Arm Bracket(2) Lock Nut (5) Rocker Arm Shaft(3) Adjusting ScrewF. CAMSHA

CHAPTER 8 84548-12D569-W03 June-2003569W810Ab. Glow plugsGlow plugs are used for each pre-combustion chamberof the cylinder head to make starting

ELECTRICAL SYSTEM8-13D569-W02 May-2003569W812AB. CIRCUIT DIAGRAM FOR ALTERNATOR UNITC. OPERATION OF CHARGING SYSTEM· The charging system supplies el

CHAPTER 8 84548-14D569-W02 May-2003(1) Alternator(2) Key s/w(3) Preheating Controller(4) Coolant temp. sensor569W813A4.3 PREHEATING SYSTEMA. CIRC

ELECTRICAL SYSTEM8-15D569-W02 May-20034.4 FUSEA. FUSE BOX DIAGRAM569W814AB. CAUTION FOR FUSE REPLACEMENTThere are two kinds of fuse in this tractor.

CHAPTER 8 84548-16D569-W02 May-20034.5 GAUGE AND SENSORS569W815A(1) Terminal contact (2) DiaphragmA. OIL PRESSURE SWITCHThe oil pressure switch i

CHAPTER 9CABIN SYSTEM

CABIN SYSTEM9-3D569-W02 May-20031. DISASSEMBLY AND ASSEMBLY1. Loosen 6 setting bolts for chair assembly supportand disconnect seat assembly in a bod

CHAPTER 9 84549-4D569-W02 May-20034. Open drain cock located in right of front axle frame,drain coolant, remove heat hose 2 pieces (7) con-nected

CABIN SYSTEM9-5D569-W02 May-20037. Loosen head pin and snap pin connected to maintransmission lever at left bottom of cabin and re-move main transmi

CHAPTER 2 84542-10D569-W02 May-2003569W217A569W216A569W215A(1) Valve Spring Collet (4) Valve Stem Seal(2) Valve Spring Retainer (5) Exhaust Valve

CHAPTER 9 84549-6D569-W02 May-200310. Remove head pin and snap pin from Hi-Low shiftlever connector and remove Hi-Low shift lever.11. Remove hea

CABIN SYSTEM9-7D569-W02 May-2003 13. Remove frame cover (1) in left of frame assemblyand parallel pin connected with shuttle lever arm(3) and then d

CHAPTER 9 84549-8D569-W02 May-20032. HEATER2.1 STRUCTURE2.2 DISASSEMBLY AND ASSEMBLY1. Open drain cock in right of front axle frame and draincool

CABIN SYSTEM9-9D569-W02 May-20033. AIRCONDITIONER3.1 AIR CONDITIONERA. STRUCTUREB. PRINCIPLE OF AIRCONDITIONINGThe function of air-conditioning syst

CHAPTER 9 84549-10D569-W02 May-2003569W917AThe above figure shows the circulation diagram of arefrigerant which passes through the 5 main compo-n

CABIN SYSTEM9-11D569-W02 May-2003C. OPERATION PRINCIPLES OF SYSTEMCOMPONENTSa. RefrigerantIn order to accomplish the intrinsic function of air-con-d

CHAPTER 9 84549-12D569-W02 May-2003D. AIR-CONDITIONING COMPONENTS (1) Aircon. Unit (2) Duct, Aircon. (3) Hose 3, Aircon (4) Hose 4, Aircon.IMPORT

CABIN SYSTEM9-13D569-W02 May-2003F. OIL- Checking of compressor oilThe oil used to lubricate the compressor shall besupplemented when the components

CHAPTER 9 84549-14D569-W02 May-2003f. Abnormal noise from the blower motorIn case of the generation of abnormal noise fromthe blower motor and th

CABIN SYSTEM9-15D569-W02 May-2003Normal pressureHigh pressure: 14 ~ 15 kg/cm2G(199 ~ 213 psi)Low pressure: 1.5 ~ 2.0 kg/cm2G(21 ~ 28 psi)Ambient tem

ENGINE2-11D569-W02 May-2003569W219A569W218A2.2 LUBRICATING SYSTEM(1) Inlet (3) Inner Rotor(2) Outlet (4) Outer Rotor(1) Piston (9) Rocker Arm Shaft(

CHAPTER 9 84549-16D569-W02 May-20034) The compressor does not revolve or hard to revolve.The vibration of belt is large.The belt is sliding.Slidi

CABIN SYSTEM9-17D569-W02 May-2003569W921A569W922A• When exhausting the refrigerant, ex-haust it to the low pressure side slowlyand check the pressur

CHAPTER 9 84549-18D569-W02 May-2003569W923A569W924A569W925A4. Poor extension valveStatus: Not coolPhenomena:- The pressure of high /low pressure

CABIN SYSTEM9-19D569-W02 May-2003569W926A3. The refrigerant does not circulate.Status: not cool (sometimes cool)Phenomena:- The pressure of low pres

CHAPTER 9 84549-20D569-W02 May-2003D. ELECTRICAL CIRCUITa. Air Conditioner System (1) Battery (2) Slow Blow Fuse (3) Main Switch (4) Compressor

CHAPTER 2 84542-12D569-W02 May-2003569W221A569W220A(1) Bypass Valve(2) Bypass Adjusting Spring(3) Filter Element(4) Relief Valve Ball(5) Relief A

ENGINE2-13D569-W02 May-2003569W222A569W223A2.3 COOLING SYSTEM(1) Water Return Pipe(2) Thermostat(3) Cylinder Head Water Jacket(4) Cylinder Block Wat

CHAPTER 2 84542-14D569-W02 May-2003569W226A569W225A569W224A(1) Seat (6) Wax (Solid)(2) Valve (7) Spring(3) Pellet (8) Leak Hole(4) Spindle (9) Wa

ENGINE2-15D569-W02 May-2003569W228A569W227A(1) Fuel Tank (5) Injection Nozzle(2) Fuel Filter (6) Fuel Overflow Pipe(3) Injection Pump (7) Fuel Feed

CHAPTER 2 84542-16D569-W02 May-2003569W230A569W229A(a) From Fuel Tank(b) To Fuel Filter(1) Inlet Valve (5) Chamber(2) Push Rod (6) Diaphragm(3) T

ENGINE2-17D569-W02 May-2003569W231A569W232A(1) Pump Element (5) Control Sleeve(2) Cylinder (6) Control Groove(3) Plunger (7) Driving Surface(4) Feed

CHAPTER 3. CLUTCH ...3-11. TROUBLE

CHAPTER 2 84542-18D569-W02 May-2003569W234A569W233A(1) Slot (4) Delivery Chamber(2) Plunger (5) Feed Hole(3) Control Rack (6) Control Groove(1) V

ENGINE2-19D569-W02 May-2003569W235A569W236A(1) Nozzle Holder Ass’y (6) Nozzle Body(2) Adjusting Washer (7) Needle Valve(3) Nozzle Spring (8) Heat Se

CHAPTER 2 84542-20D569-W02 May-2003569W238A569W237Ab. Operation of Governora) At startThe steel balls (13) have no centrifugal force. As thefork

ENGINE2-21D569-W02 May-2003569W239A569W240A(2) Governor Spring 1 (13) Steel Ball(3) Governor Spring 2 (17) Adjusting Bolt(4) Fork Lever 1 (18) Torqu

CHAPTER 2 84542-22D569-W02 May-2003569W243A569W242A569W241A(a) Inlet Air(b) To Intake Manifold(c) Heavier Dust(1) Outlet Port (4) Air Cleaner Ele

ENGINE2-23D569-W02 May-2003D. TURBOCHARGER (8454)The mechanism of turbocharger is the use of exhaustgas energy which rotates turbine and the power i

CHAPTER 2 84542-24D569-W02 May-20033. DISASSEMBLING AND SERVICING• Not fuel• Air in the fuel system• Water in the fuel system• Fuel pipe clogged•

ENGINE2-25D569-W02 May-2003• Excessive engine oil• Piston ring and bore worn orpiston ring stuck• Incorrect injection timing• Insufficient compressi

CHAPTER 2 84542-26D569-W02 May-2003• Improper type of oil• Relief valve defective• Engine oil insufficient• Fan belt broken or tensionedimproperl

ENGINE2-27D569-W02 May-20033.2 SERVICING SPECIFICATIONSA. ENGINE BODYa. Cylinder Head0.75 ~ 0.9 mm0.0295 ~ 0.0354 in.1.3 ~ 1.5 mm0.0512 ~ 0.0591 in.

3.3 POWER TRAIN ...

CHAPTER 2 84542-28D569-W02 May-2003d. Cylinder BoreCylinder bore innerdiameter 87.000 ~ 87.022 mm3.4252 ~ 3.4261 in. 83.000 ~ 83.022 mm 3.2677 ~

ENGINE2-29D569-W02 May-2003I. Timing Gear0.04 ~ 0.11 mm0.0016 ~ 0.0043 in.0.20 ~ 0.51 mm0.0079 ~ 0.0201 in.0.025 ~ 0.066 mm0.00098 ~ 0.00260 in.37.9

CHAPTER 2 84542-30D569-W02 May-2003l. Crankshaft-0.040 ~ 0.118 mm0.00157 ~ 0.00465 in.51.921 ~ 51.940 mm2.04414 ~ 2.04489 in.51.980 ~ 52.039 mm2.

ENGINE2-31D569-W02 May-2003C. COOLING SYSTEMa. ThermostatValve opening temperature at beginningOpened completely (height 8 mm 0.315 in.)69.5 ~ 72.5

CHAPTER 2 84542-32D569-W02 May-2003E. TIGHTENING TORQUESItemCylinder head screwsHead cover nuts* Bearing case screw 1* Bearing case screw 2* Flyw

ENGINE2-33D569-W02 May-2003615WA18A3.3 CHECKING, DISASSEMBLING AND SERVICINGA. ENGINE DISASSEMBLED VIEW(1) Cylinder Block(2) Oil Pressure Switch(3)

ENGINE2-35D569-W02 May-2003569W250A569W249A(1) Fan Belt (6) Oil Gauge(2) Hour Meter Unit (7) Exhaust Manifold(3) Oil Filter (8) Oil PressureSwitch(4

CHAPTER 2 84542-36D569-W03 May-2003569W251A569W252A(1) Screw (5) Stop Lever 1(2) Engine Stop Lever (6) Stop Lever 2(3) Screw (7) Solenoid(4) Scre

ENGINE2-37D569-W02 May-2003569W253AC. ENGINE BODYa. Checking and Adjusting1) Compression pressure1. Run the engine until warmed up.2. Stop the engin

CHAPTER 6. HYDRAULIC SYSTEMS...6-11. HYDRAULIC LIFT SYSTEM..

CHAPTER 2 84542-38D569-W03 May-2003569W256A569W255B569W254A(1) Injection Nozzle (3) Heat Seal(2) Gasketb. Disassembling and Assembling1) Cylinder

ENGINE2-39D569-W03 May-2003569W259A569W258B569W257A (1) Philips Screw Driver (2) Nozzle (3) Injection Nozzle Gasket (4) Heat Seal(1) Rocker Arm Sh

CHAPTER 2 84542-40D569-W03 May-2003569W262A569W261B569W260A4) Cylinder head1. Remove the screw in the specified sequence shownin the figure and r

ENGINE2-41D569-W02 May-2003569W265A569W264A569W263A2) Governor spring and Speed control plate1. Disconnect the governor spring 1 (1) and 2 (2) fromt

CHAPTER 2 84542-42D569-W02 May-2003569W266A569W267A569W268A5) Gear case1. Remove the gear case.(When reassembling)• Stick the O-ring (1) to the g

ENGINE2-43D569-W02 May-2003569W271A569W270A569W269A6) Water pump and relief valve1. Remove the water pump body (1).2. Remove the relief valve cover

CHAPTER 2 84542-44D569-W02 May-2003569W272A569W273A569W274Ad. Connecting Rod and Piston(A) Oil pan and oil filter1. Remove the engine stand and t

ENGINE2-45D569-W02 May-2003569W277A(B) Piston and connecting rod1. Remove the screws and the connecting rod cap.2. Push out the rod and piston assem

CHAPTER 2 84542-46D569-W02 May-2003569W280A569W279A569W278A• Install the piston and connecting rod with the markFW on the piston to the flywheel

ENGINE2-47D569-W02 May-2003569W283A569W282A569W281A(B) Bearing case coverLoosen the screw first inside and next outside, and liftthe cover (1) by sc

5.3 SEPARATING REAR FENDERS AND PLATFORM ASSEMBLY ... 7-115.4 DISASSEMBLING REAR AXLE CASE ...

CHAPTER 2 84542-48D569-W02 May-2003569W286A569W285A569W284A(6) Bearing CaseIMPORTANT:• Mark a location line (6) to the bearing case, to pre-vent

ENGINE2-49D569-W02 May-200312 13111078210 65439569W289A569W288A569W287AValve stemclearanceValve guidebore I.D.Valve stemO.D.(D) Valve recessing1. Cl

CHAPTER 2 84542-50D569-W02 May-200311109569W291A569W292A569W290A(F) Valve spring1. Measure the free length of the spring with venirecalipers.2. P

ENGINE2-51D569-W02 May-2003569W295A569W294A569W293Ab. Timing Gears and Camshafts(A) Timing gear backlash1. Set a dial indicator (lever type) with it

CHAPTER 2 84542-52D569-W02 May-2003569W297A569W298A569W296A(1) Injection Pump Gear (2) Snap Ring(A) Clearance(D) Injection pump gear side clearan

ENGINE2-53D569-W02 May-2003569W2A1A569W2A0A569W299A(G) Camshaft oil clearance1. Measure the I.D. of the camshaft bore on the crank-case with an insi

CHAPTER 2 84542-54D569-W02 May-200311109569W2A4A569W2A3A569W2A2Ac. Connecting Rod and Piston(A) Piston pin bore1. Measure the I.D. of the piston

ENGINE2-55D569-W02 May-2003569W2A6A569W2A5A(D) Piston ring end gap1. Push the ring into the cylinder to the lower limit ofthe ring travel in the ass

CHAPTER 2 84542-56D569-W02 May-2003569W2A8A569W2A7A(F) Connecting rod alignment1. Remove the connecting rod bearing and install thebearing cap.2.

ENGINE2-57D569-W02 May-200311109569W2B1A569W2B0A(1) Seam569W2A9A(B)Crankshaft alignment1. Support the crankshaft with V blocks on the surfaceplate a

CHAPTER 2 84542-58D569-W02 May-2003569W2B2A(E) Crankshaft Journal and Bearing 2 Oil Clearance1. Put plastic gauge lengthwise in the center of the

ENGINE2-59D569-W02 May-2003569W2B3A569W2B4A(A) Axial Direction(B) Transverse Direction1,2,3 Measuring Pointse. Cylinder Bore(A) Cylinder bore diamet

CHAPTER 2 84542-60D569-W02 May-2003569W2B6A569W2B5A(1) Relief Valve Ball (3) Relief Valve Spring(2) Relief Valve SeatE. LUBRICATING SYSTEMa. Chec

ENGINE2-61D569-W02 May-2003569W2B7A569W2B8A569W2B9A(B) Rotor end clearance of oil pump1. Put a strip of PLASTIGAGE on the rotor and as-semble the pu

CHAPTER 2 84542-62D569-W02 May-2003569W2C2A569W2C0AF. COOLING SYSTEMa. Checking Adjusting(A) Fan belt1. Measure the deflection, by depressing th

ENGINE2-63D569-W02 May-2003569W2C3A569W2C4A569W2C5A(1) Thermostat (2) Thermostat Cover(1) Water Pump Flange (4) Water Pump Body(2) Water Pump Bearin

CHAPTER 2 84542-64D569-W02 May-2003569W2C6A(1) Delivery Valve Holder (2) ShimG. FUEL SYSTEMa. Checking and Adjusting1) Injection pump(A) Injectio

ENGINE2-65D569-W02 May-2003569W2C7A(B) Delivery valve fuel tightness1. Remove the injection pipes, glow plugs and the in-let manifold, and install a

CHAPTER 2 84542-66D569-W02 May-2003569W2C9A(1) Pump Body (5) Delivery Valve(2) Control Rack (6) Tappet Roller(3) Delivery Valve Holder (7) Cylind

ENGINE2-67D569-W02 May-2003569W2D0A(1) Nozzle Holder (5) Distance Piece(2) Adjusting Washer (6) Nozzle(3) Nozzle Spring (7) Nozzle Nut(4) Push Rod2)

CHAPTER 1GENERAL INFORMATION

CHAPTER 3CLUTCH

CLUTCH3-3D569-W02 May-20031. TROUBLESHOOTINGClutch slipClutch disconnectionabnormalStarting is not smoothClutch noiseClutch vibrationClutch gets con

CHAPTER 3 84543-4D569-W03 June-20032. SPECIFICATIONS, TIGHTENING TORQUES ANDSPECIAL TOOLS2.1 SPECIFICATIONSClutch pedalSafety switchClutch disc s

CLUTCH3-5D569-W02 May-20033. STRUCTURE AND OPERATIONThe clutch is located between the engine and the trans-mission and is operated by stepping on th

CHAPTER 3 84543-6D569-W02 May-20033.3 OPERATIONCLUTCH “ENGAGED”When the clutch pedal is not depressed, the clutch re-lease bearing (3) and the fi

CLUTCH3-7D569-W02 May-20034. PREPARATION STAGE FOR DISASSEMBLING ANDASSEMBLING4.1 SEPARATING PANEL FRAMEASSEMBLYPREPARATION 11. Removing the followi

CHAPTER 3 84543-8 D569-W02 May-2003PANEL FRAME AND STEERING ASSEMBLY1. Remove the panel frame mounting crews (Twoscrews a upper part. Seven screw

CLUTCH3-9D569-W02 May-20034.2 SEPARATING ENGINE ANDCLUTCH HOUSING CASEPROPELLER SHAFT1. Slide the propeller shaft covers (4), (5) after remov-ing to