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Cub Cadet 8454, Service Manual

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CHAPTER 3    8454

3-12

D569-W02   May-2003

6. INSPECTION AND REPAIR

6.1 WEAR AND DAMAGE ON CLUTCH

DISC

 (1) Disc

 (2) Rivet

6.2 CLEARANCE BETWEEN SPLINE

BOSS OF THE CLUTCH DISC AND
SHUTTLE SHAFT SPLINE

A. Install clutch disc (1) to shuttle shaft (2).

B. Fix shuttle shaft not to shift and slightly move clutch

disc to measure the clearance of spline by swing-
ing of the clutch disc’s circumference.

C. If the measurement is out of the allowable limit,

replace it.

 (1) Clutch  Disc

 (2) Shuttle Shaft

A. Measure the depth from clutch disc facing surface

(1) to rivet (2).

B. If the measurement is out of the allowable limit,

replace it.

C. If oil is sticking to clutch disc, or disc surface is

carbonized, replace the disc. In this case, inspect
transmission gear shift oil seal, engine rear oil seal
and other points for oil leakage.

Depth to
rivet (A)

Allowable limit

0.3 mm

0.0118 in.

Swinging of the
clutch disc’s
circumference

Allowable limit

0.2 mm

0.0078 in.

569W316A

569W317A

www.mymowerparts.com

K&T Saw Shop 606-678-9623 or 606-561-4983

Summary of Contents for 8454

Page 1: ...8 84 45 54 4 S SE ER RV VI IC CE E M MA AN NU UA AL L MTD Products LLC Product Training and Education Department www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 FORM NUMBER 769 00903 ...

Page 2: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 3: ...ICAL SYSTEM 1 10 5 7 TUBES AND RUBBERS 1 11 5 8 LUBRICANT 1 11 6 REGULAR CHECK LIST 1 12 7 OIL WATER SUPPLY LIST 1 13 CHAPTER 2 ENGINE 2 1 1 GENERAL 2 3 1 1 APPEARANCE 2 3 1 2 SPECIFICATIONS 2 4 1 3 PERFORMANCE CURVE 2 5 1 4 DIMENSIONS 2 6 1 5 GENERAL WARNING 2 6 2 STRUCTURE AND FUNCTION 2 7 2 1 BODY 2 7 2 2 LUBRICATION SYSTEM 2 11 2 3 COOLING SYSTEM 2 13 2 4 FUEL SYSTEM 2 15 2 5 INTAKE AND EXHAUS...

Page 4: ...EL ADJUSTMENT OF RELEASE BEARING 3 13 6 5 WEAR OR DAMAGES ON RELEASE BEARING RELEASE FORK AND RELEASE HUB 3 13 6 6 CLEARANCE BETWEEN CLUTCH PEDAL SHAFT AND CLUTCH PEDAL BUSHING 3 14 CHAPTER 4 TRANSMISSION SYSTEM 4 1 1 TROUBLESHOOTING 4 3 1 1 TROUBLESHOOTING FOR SHUTTLE SHIFT IN OPERATION ERROR 4 3 1 2 TROUBLESHOOTING FOR MAIN SHIFTS IN OPERATION ERROR 4 3 1 3 TROUBLESHOOTING FOR AUXILIARY AND CREE...

Page 5: ...N 4 56 6 3 LOCKING OF THE DIFFERENTIAL GEAR 4 57 CHAPTER 5 FRONT AXLE 5 1 1 TROUBLESHOOTING 5 3 2 SPECIFICATIONS 5 4 3 STRUCTURE 5 6 3 1 OPERATION 5 6 3 2 FRONT WHEEL ALIGNMENT 5 7 3 3 TOE IN ADJUSTMENT 5 8 3 4 DIRECTION CONTROL ANGLE FOR THE FRONT WHEEL 5 8 3 5 ROCKING FORCE OF THE FRONT AXLE DEFLECTION IN FRONT REAR DIRECTIONS 5 9 4 PREPARATION STAGE FOR DISASSEMBLING AND ASSEMBLING 5 10 4 1 SEP...

Page 6: ...MANTLE AND TO ASSEMBLE 6 58 4 HYDRAULIC PUMP 6 66 4 1 TROUBLESHOOTING 6 66 4 2 SPECIFICATIONS 6 66 4 3 STRUCTURE AND OPERATION 6 67 4 4 TO DISMANTLE AND TO ASSEMBLE 6 69 5 HYDRAULIC FILTER 6 71 5 1 STRUCTURE AND OPERATION 6 71 6 HYDRAULIC PRESSURE OPERATION PRINCIPLE AND TROUBLE SHOOTING 6 73 6 1 COMPOSITION OF HYDRAULIC DEVICE FLOW DIAGRAM OF HYDRAULIC OIL 6 73 6 2 STEERING DEVICES 6 75 6 3 PTO S...

Page 7: ...NG LIGHTS 8 4 2 TROUBEL SHOOTING 8 6 3 SERVICING SPECIFICATIONS 8 8 4 MECHANISM 8 9 4 1 STARTING SYSTEM 8 9 4 2 CHARGING SYSTEM 8 12 4 3 PREHEATING SYSTEM 8 14 4 4 FUSE 8 15 4 5 GAUGE AND SENSORS 8 16 CHAPTER 9 CABIN SYSTEM 9 1 1 DISASSEMBLY AND ASSEMBLY 9 3 2 HEATER 9 8 2 1 STRUCTURE 9 8 2 2 DISASSEMBLY AND ASSEMBLY 9 8 2 3 HEATER OPERATION DEVICE 9 8 3 AIR CONDITIONER 9 9 3 1 AIR CONDITIONER 9 9...

Page 8: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 9: ...CHAPTER 1 GENERAL INFORMATION www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 10: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 11: ...GENERAL INFORMATION 1 3 D569 W02 May 2003 1 TRACTOR VIEW 569W101A www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 12: ...0 4 6 6 4 7 4 11 0 12 8 17 0 19 5 25 0 29 0 34 0 40 0 lbf ft 5 79 6 87 13 0 15 2 29 0 33 2 46 3 53 5 79 6 92 5 123 141 181 210 246 289 N m 9 80 11 2 23 6 27 4 48 1 55 8 77 5 90 1 124 147 196 225 275 318 368 431 Kgf m 1 00 1 15 2 4 2 8 4 9 5 7 7 9 9 2 12 6 15 0 20 0 23 0 28 0 32 5 37 5 44 0 lbf ft 7 24 8 32 17 4 20 2 35 5 41 2 57 2 66 5 91 2 108 145 166 203 235 272 318 N m 12 3 14 2 29 4 34 3 60 8 ...

Page 13: ...8 0 to 23 1 lbf ft 25 3 to 36 1 lbf ft C TIGHTENING TORQUE FOR HIGH PRESSURE HOSE UNION NUTS Hose Size Inside Diameter Inches 1 8 3 16 1 4 5 16 3 8 1 2 5 8 3 4 1 Screw Size PF Tightening N m Torque kgf m lbf ft 1 8 9 8 1 7 2 1 4 24 5 2 5 18 0 1 4 24 5 2 5 18 0 3 8 49 0 5 36 1 3 8 49 0 5 36 1 1 2 58 8 6 43 3 3 4 117 7 12 86 8 1 137 3 14 101 2 www mymowerparts com K T Saw Shop 606 678 9623 or 606 56...

Page 14: ... Alternator 12V 50 AMPS Weight Dry 207 kg 456lb Capacities Fuel tank 40 L 10 6 gal Engine crankcase 7 0 L 1 9 gal Engine coolant 8 9 L 2 4 gal Transmission case 34 0 L 9 0 gal Front axle case 8 2 L 2 2 gal Dimensions Overall length without 3p 3 073mm 120 9 in with std tires Overall length with 3p 3 323mm 130 8 in Overall Length minimum tread 1 550mm 61 0 in Overall height Top of ROPS 2 235 mm 88 0...

Page 15: ... Mix control Pump Capacity Main Pump 31 2 L min 8 2 gal Power steering pump 18 7 L min 5 0 gal Three point hitch SAE Category 1 2 Maximum lifting capacity 1 800 kg 3 968 lb No of remote control valve ports option 2 4 PTO PTO shaft SEA 1 3 8 6 splines Revolution independent PTO 560 rpm Min turning radius without Brake 2 865 mm 112 7 in Traction system Fixed drawer or swing drawer Option Weight with...

Page 16: ...re Engine number fills the important role of providing it s record 4 2 SERIAL NUMBER OF THE TRACTOR Serial number of the tractor is stamped on the left side of the front axle frame as shown in the figure 569W103A 569W104A 1 Engine Serial Number 1 Tractor Serial Number 2 Transmission Serial Number www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 17: ...ts shall be arranged orderly 2 Sort out the parts to be replaced from the ones to be reused 3 Be sure to use standard bolts and nuts that are designated 4 When assembling snap rings or spring pin types take care of assembling direction 5 Split pin shall be spread surely not to escape when installed 6 When using sealant such as gasket bond on the assembled surfaces apply it evenly and consis tently...

Page 18: ...lling Disconnect battery negative terminal 4 Remove the connector by pulling the plastic section not the wiring 5 When connecting the connector insert it until it snaps 6 Be sure not to drop sensors and relays which are fragile 7 When replacing a broken fuse with a new one be sure to use the fuse of capacity as specified Be sure to turn the starting key OFF when connecting or disconnecting the cab...

Page 19: ...other petroleum products on the hoses and rubber parts this may cause damage When assembling and fixing apply designated lubri cant where specified in accordance with this repair manual 5 7 TUBES AND RUBBERS 5 8 LUBRICANT www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 20: ...ose s inlet bands if loosened Fuel pipe change Radiator hose change Hydraulic pipe joint change Steering hose change Toe in Deflection adjustment in front and rear of the front axle Direction control section Bolt nuts and pins of each part Battery positive code adjustment change Bleeding water in clutch housing Check injection nozzle 1yr 2yr Indicated Hours By Hour Meter Since Purchased 800 700 60...

Page 21: ...Supply when removed Recommended Spec No 2 D diesel fuel No 1 D diesel fuel if temperature is below 10 C 14 F Fresh clean water with antifreeze SAE 15 W 40 Universal tractor transmission hydraulic oil SAE multi purpose type grease Hydraulic control lever shaft section 3 point link section Brake pedal link section Bracket section in front and rear of the front axle Clutch release hub Applying grease...

Page 22: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 23: ...CHAPTER 2 ENGINE www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 24: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 25: ... three or four cylinders diesel engines they concentrate DAEDONG s foremost technologies With swirl combustion chamber bosch K type fuel in jection pump well balanced designs they feature greater power low fuel consumption less vibration and noise and low emission www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 26: ... engine 4 87 0 x 92 4 3 43 x 3 64 2 197 134 1 vortex chamber 43 2 700 30 9 2 700 2 900 850 900 1 3 4 2 Counterclockwise viewed from flywheel side Bosch K TYPE mini pump 140 150 kgf cm2 13 73 14 71 MPa 1991 2133 psi 18 22 1 Diesel fuel Engine oil SAE 15W 40 817 3 x 488 1 x 735 8 32 2 x 19 2 x 29 0 207 456 4A200T Vertical water cooled 4 cycle diesel engine Turbo 4 83 0 x 92 4 3 27 x 3 64 1 999 122 0...

Page 27: ...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 ...

Page 28: ...ing instruments to electrical equipment first disconnect battery negative terminal Replace gaskets or O rings with new ones when reassembling and apply grease on a O rings and the oil seals when reassembling When exchanging parts use genuine DAEDONG parts to maintain engine performance and safety To prevent oil and water leakage apply non drying adhesive to the gaskets according to this manual bef...

Page 29: ...The Daedong vortex type combustion chamber is de signed for high efficiency combustion and reducing fuel consumption The glow plugs assures easy engine starts even at 15 C 5 F B CYLINDER BLOCK The engine has a high durability tunnel type cylinder block Furthermore liner less type allows effective cool ing less distortion and greater wear resistance using special material The noise is reduced to a ...

Page 30: ...g fits well to the cylinder wall The second ring 2 is an undercut type which pre vents the oil from being carried up The oil ring 3 has chambered contact faces and an expander ring which increase the pressure of the oil ring against the cylin der wall to scrape the oil The top ring is plated with hard chrome to increase wear resistance The ring of 4A200T engine is mode of a special steel C CRANKSH...

Page 31: ...ged steel and its cams are hardened and tempered to increase wear resistance The cams on the fuel camshaft 1 drive the injection pump and the fuel transfer pump The governor balls are installed on the fuel camshaft to control the engine speed H ROCKER ARM ASSEMBLY The rocker arm assembly includes the rocker arms 1 and an adjusting screw 3 which is at the end of rocker arm and rests on the push rod...

Page 32: ...nter and the mark FI shows the fuel injection timing when they are aligned with the mark of window on the clutch hous ing I INTAKE AND EXHAUST VALVES The valve and its guide of the intake are different from those for the exhaust Other parts such as the spring spring retainers valve spring collets valve stem seals are the same for both the intake and the exhaust All contact or sliding surfaces are ...

Page 33: ...s such as the push rods 11 tappets 12 piston pins and timing gears B OIL PUMP The oil pump is a gear type Whose rotors have tro choid lobes The inner rotor 3 has 4 lobes and the outer rotor 4 has 5 lobes and they are eccentrically engaged to each other The inner rotor which is driven by the crankshaft through the gears rotates the outer rotor in the same direction varying the space between the lob...

Page 34: ...ricating oil When the oil pressure falls below the specified value the contacts of the oil pressure switch closes to turn on the warning lamp 1 C OIL FILTER AND RELIEF VALVE The lubricating oil force fed by the pump is filtered by the filter cartridge passing through the filter element from the outside to the inside When the filter element accumulates dirt and the pressure difference between the i...

Page 35: ...er from the radiator or from the cylinder head and forces it into cylinder block The thermostat open or closes according to the water temperature When the water temperature is high the thermostat opens to allow the water to flow from the cylinder block to the radiator When the water temperature is low the thermostat closes and the flow stays within the block The opening temperature of the thermost...

Page 36: ...ax in the pellet 3 turns liquid and expands repelling the spindle The pellet lowers and the valve 2 opens to send the cool ing water to the radiator D RADIATOR The radiator core consists of water carrying tubes 2 with fins 3 at a right angle to it The water in the radia tor is cooled by the air flowing through between the tube wall and the fin E RADIATOR CAP The pressure type cap is installed on t...

Page 37: ... through the injection nozzles 5 which inject the fuel into the cylinders for combustion The excessive fuel from the injection pump to the injection nozzles is collected in the fuel overflow pipes 6 and returns to the fuel tank B FUEL FILTER The fuel filter removes dirt and water with its fine filter paper which collects particles of 90 microns 0 0034 in at 20 kPa 0 2 kgf cm2 3 psi The fuel from t...

Page 38: ...ciprocated by the eccen tric cam on the fuel camshaft 7 A Inlet stroke When the diaphragm is pulled down by the spring vacuum in the chamber 5 causes the outlet valve 4 to close and the atmospheric pressure in the fuel tank forces the fuel into the chamber opening the inlet valve 1 B Discharge stroke When the diaphragm is pushed up by the cam the pressure in the chamber causes the inlet valve to c...

Page 39: ...delivery chamber 1 rises to push the deliv ery valve 3 open C Delivery While the plunger 2 is rising delivery of fuel continues D End of delivery When the plunger rises further and the control groove 6 on its periphery meets the feed hole the fuel re turns to the fuel chamber 5 from the delivery chamber 1 through the control groove 6 and the feed hole 4 a Pump Element The pump element 1 consists o...

Page 40: ...ot build up and no fuel is forced to the injection nozzle B Fuel delivery The plunger is rotated by the control rack and the feed hole is not aligned with the lengthwise slot When the plunger is pushed up the feed hole is closed by the plunger The pressure in the delivery chamber builds up and forces the fuel to the injection nozzle until the control groove 6 meets the feed hole The amount of the ...

Page 41: ...ifugal force of the steel ball 13 weights produced by rotation of the fuel camshaft 9 and ten sion of the governor spring 1 2 and 2 3 are balanced E FUEL INJECTION NOZZLE The nozzle is a throttle type It features low fuel con sumption and works well with DAEDONG combustion chamber The nozzle valve opening pressure is about 13 7 to 14 7 MPa 140 to 150 kgf cm2 1 991 to 2 134 psi the pressure overcom...

Page 42: ...f steel ball 13 Therefore the fork lever 1 4 and control rack 14 are moved to the rear by the governor sleeve 12 and then the idling adjusting spring 16 is compressed by the control rack 14 As a result the control rack 14 is kept at a position where the centrifugal force of steel ball 13 and forces of the start spring 1 governor spring 2 3 and idling limit spring are balanced pro viding stable idl...

Page 43: ...1 2 and 2 3 this increases the amount of fuel injected The fork lever 2 5 becomes ineffective in increasing the fuel injection when it is stopped by the adjusting bolt 17 After that when the force of torque spring 18 becomes greater than the centrifugal force of the steel balls fork lever 1 4 moves forward to increase fuel injection causing the engine to run continuously at a high torque d To stop...

Page 44: ... B AIR CLEANER The air cleaner is dry cyclone type and easy to maintain The air from the inlet port 2 circulates along the fin 3 and around the air cleaner element 4 and the heavier dust is carried to the evacuator 6 to the dust exhaust port The fine dust in the air is filtered with the air cleaner element 4 and the filtered air flows to the outlet port 1 A FLOW OF INTAKE AIR AND EXHAUST GAS a Int...

Page 45: ...bearings of the turbo charger To keep a capacity of turbocharger you should check the engine oil and air cleaner periodically Turbocharger is composed of precision parts Do not disassemble or repair without permission Turbocharger actuator pressure is 460 mmHg The structure of turbocharger is as above 569W244A 569W245A A Fresh Air Inlet B Exhaust Outlet C Exhaust Inlet 1 Compressed Air Outlet 2 Co...

Page 46: ...ter clogged or dirty Air cleaner clogged Fuel leak due to loose injection pipe retaining nut Injection pump malfunctioning Incorrect nozzle opening pressure Nozzle stuck or clogged Fuel over flow pipe clogged Governor malfunctioning Replenish fuel Vent air Change fuel and repair or flush fuel system Clean Clean or replace Use the specified fuel or engine oil Use the specified fuel Tighten nut Adju...

Page 47: ... oil clearance of crank pin bearings Excessive oil clearance of rocker arm bushings Oil passage closed Improper type of oil Oil pump defective Reduce to the specified level Repair or replace Adjust Adjust top clearance Lessen the load Use the specified fuel Clean or replace Clean or replace Adjust Repair or replace Repair or replace the injection pump Repair or replace the nozzle Replace head gask...

Page 48: ...rrect injection timing Unsuitable fuel used Battery electrolyte insufficient Fan belt slips Wiring disconnected Regulator defective Alternator defective Battery defective Use the specified type of oil Replace Replenish Replace or adjust Replenish Clean Clean or replace Clean or replace Replace Replace Replace Replace Replace Lesson the load Replace Adjust Use the specified fuel Replenish distilled...

Page 49: ...9 0 0197 in 0 040 0 070 mm 0 00157 0 00276 in 7 960 7 975 mm 0 31339 0 31398 in 8 015 8 030 mm 0 31555 0 31614 in 0 8 mm 0 0315 in 0 10 mm 0 0039 in Item Factory Specification Allowable Limit Valve Clearance Cold IN EX Valve Seat Angle IN EX Valve Face Angle IN EX Valve Recessing Clearance Between Valve Stem and Valve Guide Valve Stem O D Valve Stem I D c Valve Timing 0 140rad 8 before T D C 0 611...

Page 50: ...10 in 24 000 24 021 mm 0 94488 0 94571 in 0 07 mm 0 0028 in Item Factory Specification Allowable Limit Clearance between tappet and guide Tappet O D Tappet guide I D h Camshaft 0 01 mm 0 0004 in 33 90 33 59 mm 1 3346 1 3224 in 33 70 33 69 mm 1 3268 1 3264 in 0 050 0 091 mm 0 00197 0 00358 in 39 934 39 950 mm 1 57221 1 57284 in 40 000 40 025 mm 1 57480 1 57579 in 0 05 mm 0 0020 in 33 85 33 54 mm 1 ...

Page 51: ...0 07992 0 08070 in 1 97 1 99 mm 0 07756 0 07834 in 0 25 0 40 mm 0 0098 0 01570 in 0 55 0 70 mm 0 0217 0 0276 in 25 03 mm 0 9854 in 0 15 mm 0 0059 in 0 15 mm 0 0059 in 1 25 mm 0 0492 in 1 25 mm 0 0492 in Item Factory Specification Allowable Limit Piston pin bore I D Clearance between Oil ring and ring groove Oil ring groove width Oil ring width Clearance between 2nd ring and ring groove 2nd ring gr...

Page 52: ...aft bearing 1 I D Clearance between Crankshaft and crank shaft bearing 2 Crankshaft O D Crankshaft bearing 1 I D Clearance between Crank pin and crank pin bearing Crank pin O D Crank pin bearing I D Crankshaft side clearance B LUBRICATING SYSTEM a Oil Pump more than 49 0 kPa 0 5 kgf cm2 7 11 psi 245 441 kPa 2 5 4 5 kgf cm2 35 6 64 0 psi 0 10 0 16 mm 0 0039 0 0063 in 0 11 0 19 mm 0 0043 0 0078 in 0...

Page 53: ...s or more for pressure falling from 88 59 kPa from 0 9 0 6 kgf cm2 from 13 9 psi 7 9 mm 0 28 0 35 in D FUEL SYSTEM a Inject Pump b Injection Nozzle Fuel injection pressure Fuel tightness of nozzle valve seat 13 73 14 715 MPa 140 150 kgf cm2 1 991 2 134 psi No fuel leak for 5 sec at pressure 12 74 MPa 130 kgf cm2 1 849 psi NOTE Injection Sequence Four Cylinders 1 3 4 2 The cylinder number is given ...

Page 54: ... 0 48 1 55 9 32 4 37 3 19 6 24 5 14 7 19 6 49 1 68 7 24 5 34 3 kgf m 10 5 11 0 0 9 1 1 4 7 5 2 7 0 7 5 10 0 11 0 4 5 5 0 4 9 5 7 3 3 3 8 2 0 2 5 1 5 2 0 5 0 7 0 2 5 3 5 lbf ft 75 9 79 6 6 5 8 0 34 0 37 6 50 6 54 2 72 3 79 6 34 0 37 6 35 4 41 2 23 9 37 3 14 5 18 1 10 8 14 5 36 2 50 6 18 1 25 3 NOTE For marked screw bolts and nuts on the table apply engine oil to their threads and seats before tight...

Page 55: ...od 19 Tappet 20 Camshaft 21 Camshaft Gear 22 Idle Gear 23 Piston 24 Connecting Rod 25 Crankshaft 26 Flywheel 27 Flywheel Housing 28 Starter 29 Injection Pipe 30 Glow Plug 31 Nozzle 32 Fuel Injection Pump 33 Fuel Feed Pump 34 Fuel Camshaft 35 Fuel Camshaft Gear 36 Engine Stop Solenoid 37 Speed Control Plate 38 Fork Lever Governor 39 Impeller 40 Thermostat 41 Alternator 42 Fan Drive Pulley 43 Coolin...

Page 56: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 57: ...y 1 Remove the muffler and exhaust manifold 7 2 Remove the starter 9 and the oil pressure switch 8 3 Pull out the oil gauge 6 4 Remove the alternator 5 and the fan belt 1 5 Remove the hour meter unit 2 6 Loosen the oil filter 3 with a filter wrench and re move it and the oil filter flange 4 This figure does not show Hour meter Unit 2 cov ered with the cooling fan When reassembling Apply liquid gas...

Page 58: ...p lever 2 Pushing the solenoid 7 plunger to the bottom pull the stop lever 2 6 until the engine stop lever 2 is turned to the end then tighten the screws 3 Intake manifold and fuel pipes 1 Disconnect the fuel pipe 3 2 Loosen the injection pipe fitting with two wrenches and remove the injection pipes 2 3 Remove the intake manifold 1 and the fuel feed pump 4 IMPORTANT Tighten or loosen injection pip...

Page 59: ...sure does not reach the allowable limit apply a small amount of oil to the cylinder wall through the nozzle holder hole and check the pres sure again 7 If the pressure raises after oil is apply check the cylinder wall and piston ring 8 If the pressure is still low check the top clearance valve clearance and cylinder head NOTE Check the compression pressure with the specified valve clearance for pr...

Page 60: ...or 1 4 TC mark mark with the timing mark of window on the flywheel housing to position the 1st cylinder valves at the top head center during compression 3 Measure the clearance at the valves marked with in the table below with a feeler gauge 4 If the clearance is not within the factory specifications turn the adjusting screw to adjust 5 Turn the flywheel just one turn to position the 1st cylinder ...

Page 61: ...OTE Use a philips screw driver that has a diameter which is bigger than the heat seal hole 1 4 in approx φ 6mm 3 Rocker arm assembly 1 Loosen the nuts in several steps and the specified sequence shown in the figure and remove them 2 Remove the rocker arm assembly and the push rod When reassembling Rest the end of push rod at the indent of tappet and install the rocker arm assembly Tighten the nuts...

Page 62: ...RTANT Apply oil to the thread of screws and tighten in sev eral steps and the specified sequence shown in the figure to the specified torque Check the torque after 30 minutes operation of the assembled engine and adjust valve clearance Tightening torque Cylinder head screws 103 0 107 9 N m 10 5 11 0 kgf m 75 9 79 6 lbf ft 1 Cylinder Head 2 Water Flange 5 Valve 1 Compress the valve spring with a re...

Page 63: ... c Timing Gears and Camshafts 1 Injection pump 1 Remove the injection pump cover 3 with the en gine stop lever 2 2 Remove the injection pump When reassembling Apply liquid gasket to the both sides of injection pump cover gasket and install it Install the injection pump so that its control rack pin 4 engages with the groove 5 of fork lever 1 1 Install the injection pump cover with the arm of en gin...

Page 64: ...g 3 Start spring 1 Remove the start spring 1 from the fork lever 1 2 When reassembling Be careful not to drop the start spring into the gear case Hook the start spring so that the longer hook is on the fork lever side 4 Fan drive pulley 1 Install the stopper to the flywheel so that the crank shaft may not turn 2 Flatten the metal lock and loosen the crankshaft nut 2 3 Remove the fan drive fan driv...

Page 65: ...ear 1 3 Remove the crankshaft gear 2 with a special use puller set When reassembling Heat the crankshaft gear to approx 80 C 176 F and insert the crankshaft Apply oil to the O ring 5 Tightening torque Relief valve cover screw 32 4 36 3 N m 3 3 3 7 kgf m 23 9 26 8 lbf ft 1 Water Pump Body 2 Relief Valve Cover IMPORTANT Install the idle gear aligning the alignment marks referring to the figure 1 Idl...

Page 66: ... out the camshaft 1 3 Remove the cam gear 2 When reassembling Heat the cam gear to approx 80 C 176 F and insert the camshaft 1 9 Fuel camshaft 1 Remove the fuel camshaft stopper 2 Loosing the fork lever holder screws remove the fuel camshaft 4 with fork lever holder 5 fork lever 1 1 and 2 2 3 Remove the Injection pump gear 3 When reassembling Heat the injection pump gear to approx 80 C 176 F and i...

Page 67: ...and ring assembly in the cylinder compressing the rings not to damage the chrome plate on the piston rings If connecting rod cap screws can not be screwed to the end by hand replace the screw C Piston ring and piston pin 1 Remove the piston rings with a piston ring replac ing tool 2 Remove the piston pin When reassembling Clean all the parts before assembling Heat the piston in approx 80 C 176 F o...

Page 68: ... gap at every 2 09 rad 120 e Crankshaft A Flywheel 1 Install the stopper to the flywheel and loosen the screw 2 Remove the flywheel stopper and the flywheel When reassembling Clean the end of the crankshaft and the mating sur face of the flywheel Apply oil to flywheel screws Fit the flywheel hole to crankshaft hole and lighten the flywheel bolts to specified torque NOTE Screw longer screws into th...

Page 69: ...bling Apply oil to the bearing case screw 2 Clean the oil passage of the crankshaft with com pressed air 1 Bearing Case Cover Tightening torque Bearing case cover screw 23 5 27 5 N m 2 4 2 8 kgf m 17 4 20 3 lbf ft Tightening torque Main bearing case screw 2 68 7 73 6 N m 7 0 7 5 kgf m 50 6 54 2 lbf ft D Main bearing case 1 Remove the bearing case screws 1 4 and remove the main bearing case 1 2 3 1...

Page 70: ... surface 2 Place a straight edge on the cylinder head and mea sure the clearance with a feeler gage as shown in the figure 3 If the measurement exceeds the allowable limit re place the cylinder head IMPORTANT Do not place the straight edge on the combustion camber Flatness Allowable limit 0 05 mm 0 0019 in B Cylinder head surface flaw 1 Prepare an air spray red check 2 Clean the cylinder head surf...

Page 71: ...c Allowable limit Factory spec Factory spec 0 040 0 070 mm 0 00157 0 00276 in 0 1 mm 0 004 in 8 015 8 030 mm 0 31555 0 31614 in 7 960 7 975 mm 0 31339 0 31398 in Valve recessing Factory spec Allowance 0 2 0 5 mm 0 0078 0 0197 in 0 8 mm 0 0315 in E Valve seat 1 Coat the valve face lightly with red lead and put the valve on its seat to check the contact 2 If the valve does not seat all the way aroun...

Page 72: ...uare at its side 2 Measure the maximum distance A see figure rotating spring 3 If the measurement exceeds the allowable limit re place Valve spring square ness Allowable limit 1 0 mm 0 039 in Free length H Rocker arm bushing and shaft clearance 1 Measure the rocker arm I D with an inside micrometer 2 Measure the rocker arm shaft O D with an outside micrometer 3 If the clearance exceeds the allowab...

Page 73: ...o each end 2 Measure the clearance A between the idle gear and the idle gear collar 2 1 with a feeler gauge 3 If the clearance exceeds the allowable limit replace the idle gear collar 1 3 1 Idle Gear Collar 2 3 Idle Gear Collar 1 2 Idle Gear Side clearance 0 20 0 51 mm 0 0079 0 021 in 0 9 mm 0 035 in Factory spec Allowable limit C Cam gear side clearance 1 Pull the cam gear 2 with the camshaft 1 t...

Page 74: ... in F Replacing idle gear bushings 1 Press out the bushings using an idle gear bushing replacing tool 2 Clean the bushings and the bore and apply oil to them 3 Press in the bushing using the replacing tool E Idle gear oil clearance 1 Measure the idle gear shaft O D with an outside micrometer 2 Measure the idle gear bushings I D with an inside micrometer 3 If the clearance exceeds the allowable lim...

Page 75: ...oth end journals and set a dial indicator with its tip on the intermediate journal 2 Rotate the camshaft in the V block and get the ec centricity half of the measurement 3 If the eccentricity exceeds the allowable Eccentricity Allowable limit 0 05 mm 0 002 in I Cam height 1 Measure the height of the camshaft lobes at their largest O D with an outside micrometer 2 If the measurement is less than th...

Page 76: ...n the new bushing and the bore and apply oil to them 3 Press in the bushing using the replacing tool IMPORTANT Align the oil holes of the connecting rod and the bushing B Piston pin and brushing clearance 1 Measure the piston pin O D with an outside micrometer 2 Measure the piston pin busing I D with an inside micrometer 3 If the clearance exceeds the allowable limit with new bushing replace the p...

Page 77: ...n 1 25 mm 0 0492 in 2nd ring Top ring oil ring E Piston ring clearance 1 Clean the ring and the ring grooves and install each ring into its groove 2 Measure the clearance between the ring and the groove with a feeler gauge 3 If the clearance exceeds the allowable limit replace the piston ring 4 If the clearance still exceeds the allowable limit with a new ring replace the piston Piston ring clear ...

Page 78: ...020 in at 100 mm 3 94 in of gauge pin span d Crankshaft A Flywheel deflection and crankshaft end play 1 Set a dial indicator with its tip on the rear friction face of the flywheel near the edge 2 Turn the flywheel and measure the deflection or the uneven wear 3 If the measurement exceeds the allowable limit remove the flywheel and check the mating faces of the crankshaft and flywheel 4 If scored o...

Page 79: ...crometer 2 Measure the O D of the crankshaft journal with an outside micrometer 3 If the clearance exceeds the allowable limit replace the bearing referring to Replacing Crankshaft Bear ing 1 D Replacing crankshaft bearing 1 1 Press out the crankshaft bearing 1 with replacing tool 2 Clean a new crankshaft bearing 1 and bore and apply engine oil to them 3 Press fit a new bearing 1 using a inserting...

Page 80: ... 20 mm 0 0079 in 51 921 51 940 mm 2 04413 2 04488 in 51 980 52 025 mm 2 04646 2 04823 in F Crankpin and connecting rod bearing 2 oil clear ance 1 Put a strip of PLASTIGAGE lengthwise in the center of the crankpin 2 Install the connecting rod and tighten the screws to the specified torque once and remove the cap again 3 Measure the amount of the flattening with the scale and get the oil clearance 4...

Page 81: ... Measuring Points e Cylinder Bore A Cylinder bore diameter 1 Measure the cylinder liner I D at sit positions shown in the figure to find the maximum wear 4A200T 4A220 83 000 83 022 mm 3 2677 3 269 in 87 000 87 022 mm 3 4252 3 4261 in www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 82: ...ore than 49 kPa 0 5 kgf cm2 7 11 psi 294 441 kPa 2 5 4 5 kgf cm2 35 6 64 0 psi 245 kPa 2 5 kgf cm2 35 6 psi At idle speed At rated speed B Oil filter and relief valve 1 Drain the engine oil and remove the oil filter to check it 2 Check the relief valve for dirt and the seat 2 and ball 1 for damage 3 If damaged replace 4 Check the free length of spring 3 5 If it is less than the allowable limit rep...

Page 83: ... clearance between the outer and in ner rotor with a feeler gauge 2 Measure the clearance between the outer and the housing with a feeler gauge 3 If the clearance exceeds the allowable limit replace the pump Outer and inner rotor clearance Outer and inner housing clearance Factory spec Allowable limit Factory spec Allowable limit 0 10 0 16 mm 0 0039 0 0063 in 0 20 mm 0 0079 in 0 11 0 19 mm 0 0043 ...

Page 84: ... the water pressure to the specified pressure 3 Check the radiator for water leaks 4 For water leaks from a pin hole repair it with radia tor cement and for larger leaks replace the radiator C Radiator cap tightness 1 Set a radiator tester on the radiator cap 2 Apply 88 kPa 0 9 kgf cm2 13 psi of pressure and measure the pressure for 10 seconds 3 If the pressure falls below 59 kPa 0 6 kgf cm2 9 psi...

Page 85: ...eller and water pump shaft 3 5 Remove the impeller from the water pump shaft 6 Remove the mechanical seal 5 When reassembling Replace the mechanical seal 5 with new one c Servicing A Thermostat valve opening temperature 1 Suspend the thermostat in the water by a string with its end inserted between the valve and seat 2 Heating the water gradually read the temperatures when the valve starts to open...

Page 86: ...p turning when the fuel stops to flow to check the injection timing 5 If the Fl mark does not align with the mark of the window on flywheel housing add or remove the shim 2 to adjust NOTE Apply liquid gasket There Bond 1215 or equivalent to the shim when reassembling Reference The timing advances by removing 0 15 mm 0 006 in of shim and retards by adding one approx 0 26 rad 1 5 of crank angle Appr...

Page 87: ...new one and test again Fuel injection pressure Pressure drop Factory spec Allowable limit 14 71 MPa 150 kgf cm2 2134 psi 0 98 MPa 10 kgf cm2 142 psi 569W2C8A b Injection Nozzle Fuel injection pressure Factory spec 13 73 14 71 MPa 140 150 kgf cm2 1991 2134 psi 1 Adjustment Washer Never come in contact with spraying diesel fuel under pressure which can have sufficient force to penetrate the skin cau...

Page 88: ...he pump element the amount of fuel injection should be adjusted on specified bench B Fuel tightness of needle valve seat tightness 1 Set the injection nozzle to the nozzle tester 2 Apply a pressure 130 kgf cm2 12 75 mPa 1 849 psi After keeping the nozzle under this pressure for 10 seconds Check to see if fuel leaks from the nozzle 3 If the fuel should leak replace the nozzle 569W2D1A www mymowerpa...

Page 89: ...zle Nut 4 Push Rod 2 Injection nozzle Nozzle Holder 1 Secure the nozzle retaining nut 7 with a vise 2 Remove the nozzle holder 1 and take out the parts inside When reassembling Assemble the nozzle in clean fuel oil Install the push rod 4 nothing its direction www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 90: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 91: ...CHAPTER 3 CLUTCH www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 92: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 93: ...tion or damage in clutch disc pressure plate and flywheel Defective adjustment of clutch lever Missing or feeble spring of pressure plate Rust or wear in clutch disc hub and shaft spline part Wear and Abrasion in release bearing Wear in clutch disc hub and shaft spline part Missing torsion spring of clutch disc Clutch disc damaged Bending in shuttle shaft or PTO drive shaft Defective dynamic balan...

Page 94: ...en flywheel housing and clutch housing Inlet nuts between flywheel housing and clutch housing Inlet bolts between clutch housing and middle case Inlet nuts between clutch housing and middle case Inlet bolts of clutch cover Clutch release fork mounting bolts Item M12 9T M12 7T M12 9T M12 7T M8 7T M8 7T 10 3 117 7 77 5 90 2 103 0 117 7 77 5 90 2 23 5 27 4 23 5 27 4 N m 10 5 12 0 7 9 9 2 10 5 12 0 7 ...

Page 95: ... Ind styled clutch is applied available to operate the travel power and PTO power independently Travel clutch As dry single plated clutch traveling power is disconnected if the clutch pedal is stepped down PTO clutch As wet multi plated clutch based on oil pressure control PTO power is disconnected and connected by PTO switch over control 3 2 STRUCTURE 1 Clutch Release Fork 2 Release Hub 3 Release...

Page 96: ...te 7 Clutch Disc 8 Flywheel 9 Shuttle Shaft 10 Clutch Lever Shaft CLUTCH DISENGAGED When the clutch pedal is depressed the clutch rod is pulled to rotate the clutch lever shaft 10 Then the release fork 1 pushes the release hub 2 and re lease bearing 3 toward the flywheel Simultaneously the release bearing pushes the diaphragm spring 4 the frictional force among the flywheel 8 clutch disc 7 and pre...

Page 97: ...rator rod 11 5 Remove the panel frame cover 7 and disconnect the connectors 6 6 Remove the shuttle shaft lever 5 after disconnecting limit switch wire harness 7 Disconnect the 2P connector of alternator 1 jumper for fuel level sensor 3 and starter 9 8 Disconnect the meter cable 13 at the engine side 569W305A 1 2P Connector for Alternator 2 Clutch Rod 3 Jumper Lead For Fuel Level Sensor 4 Brake Rod...

Page 98: ...hose 2 right turning delivery hose 3 and left turning delivery hose 4 When reassembling In assembling the turning delivery hoses to the steering controller connect the delivery hose with identification mark type A to the L port of the steer ing controller Tightening torque Main delivery hose retaining nut Turning delivery hose retaining nut 46 6 50 9 N m 4 8 5 2 kgf m 34 4 37 6 lbf ft 24 5 29 4 N ...

Page 99: ...g 4 Propeller Shaft Cover 9 Bolt 5 Propeller Shaft Cover 10 Spring Pin 569W310A HYDRAULIC PIPES 1 Remove the brake rod 4 and suction pipe 3 2 Remove the rubber hose 2 3 Slide the return hose 1 When reassembling Reinstall the pipe clamp securely 1 Return hose 3 Suction Pipe 2 Rubber Hose 4 Brake Rod Tightening torque Joint bolt for delivery pipe 3 and hydraulic block Joint bolt for delivery pipe 2 ...

Page 100: ... When attaching or detaching clutch slowly remove and slowly tighten the clutch inlet bolts diagonally to secure operational safety and to prevent de formation of the clutch cover and clutch pressure plate Tightening torque Clutch cover assembling bolts CAUTION SEPARATION THE ENGINE FROM CLUTCH HOUSING 1 Place the jack under the clutch housing case 2 Hoist the engine by the nylon lift strap at the...

Page 101: ...measure the clearance between safe starting switch 4 and clutch pedal link section B If the measurement is out of the factory spec re move lock nut 6 and adjust while shifting the safe starting switch C In the state of stepped clutch pedal after adjust ment started if the starting key is ON In the state of clutch pedal not stepped confirm the start is impossible if the starting key is ON Deflectio...

Page 102: ...nt is out of the allowable limit replace it 1 Clutch Disc 2 Shuttle Shaft A Measure the depth from clutch disc facing surface 1 to rivet 2 B If the measurement is out of the allowable limit replace it C If oil is sticking to clutch disc or disc surface is carbonized replace the disc In this case inspect transmission gear shift oil seal engine rear oil seal and other points for oil leakage Depth to...

Page 103: ...rface of the flywheel for abnormal wear damage or scoring defect B Correct with specified sandpaper 180 or so if they are found slight but replace it if found remarkable 6 5 WEAR OR DAMAGES ON RELEASE BEARING RELEASE FORK AND RELEASE HUB A Check contact surface of the release diaphragm and diaphragm spring for wear or damage B Check release bearing while pushing to the axle direction and rotating ...

Page 104: ...g C If the measurement is out of the allowable limit replace it Clearance between clutch pedal shaft and clutch pedal bushing Factory spec Allowable limit 0 007 0 101 mm 0 0003 0 00 4 in 0 4 mm 0 0157 in Outer diameter of clutch pedal shaft Factory spec 24 980 24 993 mm 0 9834 09839 in Inner diameter of clutch pedal bushing Factory spec 25 000 25 081 mm 0 9842 09874 in www mymowerparts com K T Saw...

Page 105: ...CHAPTER 4 TRANSMISSION SYSTEM www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 106: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 107: ...emove the case and restructure Replace Replace Replace Regenerate Replace Replace Replace Solution 1 2 TROUBLESHOOTING FOR MAIN SHIFT SECTION IN OPERATION ERROR Gear shift disconnected Starting gets OFF when starting with Difficult to shift the main shift gear Symptom 1 Damaged jaw at chamfering section of main shift gear 2 Deficient traveling distance due to interference with the exterior lever t...

Page 108: ...rect interference Adjust Assemble Replace Remove the cause Replace Replace Solution Loose rear differential pedal Impossible returning of differential pedal Noise in rear differential section Differential pedal lock incapable Symptom 1 Unfixed mounting spring 2 Unfixed head pin which is assembled at differen tial mounting fork 1 Unfixed mounting spring 2 Differential mounting fork held 3 Different...

Page 109: ...dulator valve 3 No power supply to solenoid valve 4 Damaged O ring mounted on connecting pipe 5 Piston operation impossible due to O ring held between PTO clutch body and piston 6 Slipped due to clutch disc worn 7 Declined pressure due to oil leakage in sealed section Provable Causes Replace Replace Re assemble Replace Replace Replace Replace the damaged parts Solution PTO gear shift disconnected ...

Page 110: ... 77 5 90 2 60 8 70 6 196 2 245 2 260 0 304 1 N m M12 9T M12 6T M20 M8 7T M12 7T M10 7T M8 6T M10 7T M12 7T M10 7T M14 7T M14 7T M12 6T M12 7T M16 9T Inlet bolts and nuts between middle case and transmission case 17 gear shaft lock nuts Inlet bolts of bearing cover and bearing case Main gear shift section Inlet bolts of bearing case Auxiliary gear shift section Inlet bolts of main auxiliary shuttle...

Page 111: ...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 ...

Page 112: ... 2 STRUCTURE 1 Shuttle Shift Section 2 Main Gear Shift Section 3 Hi Low Range Shift Section 4 Clutch Pack for PTO 5 Front Wheel Drive Shift Section 6 Creep Shift Section 569W402B www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 113: ... C and the revolution is transmitted to 17 gear shaft 4 and then to 39 21 gear 5 Auxiliary shift stage is decided according to the operation of shifter D E and the power is transmitted to auxiliary shift shaft 6 and finally to spiral bevel pinion 7 If auxiliary shift is for creep the transmitted power to 39 21 gear 5 is transmitted to 43 21 gear 8 via 39 17 gear 9 of auxiliary shift shaft 6 and fi...

Page 114: ...CHAPTER 4 8454 4 10 D569 W02 May 2003 3 3 2SHUTTLE SHIFT SECTION 569W404A A Forward B Reverse www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 115: ...TRANSMISSION SYSTEM 4 11 D569 W02 May 2003 3 3 3MAIN SHIFT 569W405A A Forward B Reverse C 1st D 2nd E 3rd F 4th www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 116: ...CHAPTER 4 8454 4 12 D569 W02 May 2003 3 3 4AUXILIARY SHIFT 3 3 5FRONT WHEEL DRIVE 569W406A 569W407A A High B Low C Creep A Engaged www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 117: ...TRANSMISSION SYSTEM 4 13 D569 W02 May 2003 569W408A 3 3 6PTO SHIFT www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 118: ...zer Key 9 Shuttle Shaft 5 Shifter 569W410A 3 4 OPERATION Shuttle shift section 1 Shuttle Shaft 2 24 Gear 3 29 Gear 4 Shifter 5 Reverse Shaft 6 21 Gear Idle Gear 7 26 26 Gear 3 4 1FEATURES A SHUTTLE Synchro shuttle is applied with the features as below 1 As for forward reverse switching over the same stage in forward and reverse can be obtained if rais ing slightly the shuttle lever from neutral an...

Page 119: ...A Second Stage When the synchronizer keys 4 are prevented by the synchronizer ring 7 from sliding The synchronizer keys 4 are disengaged from the shifter 5 The synchronizer keys 4 go into the grooves provided in the synchronizer ring 7 However since the width of the grooves is wider than that of the keys the synchronizer keys begin rotating at the same speed with the shifter 5 and hub 3 with a tim...

Page 120: ...hen the speed of the shifter 5 becomes the same as that of the gear 8 the force of the synchronizer ring 7 in its rotating direction is not applied to the shifter 5 and the rotation of the synchronizer ring 7 is no longer transmitted to the shifter 5 Therefore the shifter 5 engages with the synchro nizer ring 7 and further engages with the gear 8 for complete connection 5 Shifter 8 Gear 7 Synchron...

Page 121: ...IVE Front wheel drive shift is structured simply to con nect or disconnect shafts where power is transmit ted to by the shift Front wheel drive shift section Operation principle of the front wheel drive Power is transmitted to 34 gear 3 fixed on front wheel drive shaft 4 via 26 gear 2 engaged with spiral bevel pin ion 1 and front wheel drive shaft 4 rotates as 34 gear 3 rotates If the front wheel ...

Page 122: ...n and in case the PTO switch is turned manual PTO power is connected regardless of the position of the hydraulic lift arm as structured as convenient for application according to the work conditions Modulator valve is equipped in the PTO clutch valve available to display the same effect as semi clutched while increasing slowly the clutch pressure In addition the brake installation on the main body...

Page 123: ...pushes the piston out as directed by the arrow above while pressing return spring 7 Power transmitted from PTO propeller shaft and PTO clutch shaft 16 as return plate 6 clutch disc 10 and clutch plate 11 are pushed toward pressure plate 8 is trans mitted to PTO drive shaft 25 3 Pressure in PTO clutch circuit increases as the modulating valve is shifted slowly up to 16 18 kgf cm2 controllable by th...

Page 124: ...ston Ring 10 Clutch Disk 4 Piston Ring 11 Clutch Plate 5 Brake Plate 12 Ball Bearing 6 Return Plate 13 Needle Bearing 7 Spring 14 Seal Ring 20 Bracket 15 Spline Hub 21 Ball Bearing 16 PTO Clutch Shaft 22 Snap Ring 17 Bush 23 Spacer 18 Snap Ring 24 Snap Ring 19 Snap Ring 25 PTO Drive Shift 569W420A Inertial Brake Brake disc 5 with a protuberance at one section there of is installed on PTO clutch Cl...

Page 125: ... engaged and then power from the engine is transmitted to PTO drive shaft 1 via PTO drive shaft 1 51 gear 2 is rotated as engaged with PTO drive shaft 1 which gets rotated subsequently If PTO switch is connected to automatic or manual con trol the tractor will not start as a safety device 569W421A 2 51 Gear 3 PTO Shaft www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 126: ...ng plug 1 until reaching the gauge 2 After running the engine for few minutes stop it and check the oil level again add the fluid to prescribed level if it is not correct level IMPORTANT Use only SAE 80 90 gear oil Use of other oils may damage the transmission or hydraulic system Refer to LUBRICANTS FUEL AND COOLING WA TER See page 4 10 Do not mix different blends fluid together A Oil Level is Acc...

Page 127: ...sconnect the connectors 6 6 Remove the shuttle shaft lever 5 after disconnecting limit switch wire harness 7 Disconnect the 2P connector of alternator 1 jumper for fuel level sensor 3 and starter 9 8 Disconnect the meter cable 13 at the engine side 1 2P Connector For Alternator 2 Clutch Rod 3 Jumper Lead For Fuel Level Sensor 4 Brake Rod LH 5 Shuttle Shaft Lever 6 Connectors 7 Panel Frame Cover 8 ...

Page 128: ...e 2 Return Hose 3 Right Turning Delivery Hose 4 Left Turning Delivery Hose Panel Frame and Steering Assembly 1 Remove the panel frame mounting crews Two screws a upper part Seven screws at lower part 2 Take out the panel frame and steering assembly as a unit When reassembling Do not get in the wiring harness between panel frame and platform Tightening torque Main delivery hose retaining nut Turnin...

Page 129: ... 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 1 Remove the fender 1 2 floor seat and platform as a unit 1 Bolt 3 Cover 2 Bolt 1 Bolt 2 Seat Assembly 569W431A 569W432A 569W433A www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 130: ...for delivery pipe 2 and regulator valve 49 0 58 8 N m 5 0 6 0 kgf m 36 2 43 4 lbf ft 34 3 39 2 N m 3 5 4 0 kgf m 25 3 28 9 lbf ft Tightening torque Engine and clutch housing mounting screws nuts Engine and clutch housing mounting stud bolts 77 5 90 2 N m 7 9 9 2 kgf m 57 1 66 5 lbf ft 39 2 49 0 N m 4 0 5 0 kgf m 28 9 36 2 lbf ft 569W438A 569W439A D SEPARATING CLUTCH HOUSING Propeller Shaft 1 Slide...

Page 131: ... pins 2 so that their split portion may face forward Hydraulic Pipes 1 Loosen the screws 1 Bolt 2 and remove the suc tion pipe 3 2 Remove the pipe 4 5 6 7 1 Screw 5 Pipe 1 2 Bolt 6 Pipe 2 3 Suction Pipe 7 PTO Pipe 2 4 PTO Pipe 1 1 Main Shift Rod 1 2 Spring Pins 569W440A 569W441A www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 132: ...r ring 5 Turning torque of spiral bevel pinion 6 Turning torque after assembling spiral bevel pinion and spiral bevel gear 7 Backlash of spiral bevel pinion and spiral bevel gear 8 Reaching up degree of spiral bevel pinion and spiral bevel gear Item Factory Spec 0 4 mm 0 0157 in 0 8 mm 0 0314 in 0 35 mm 0 0137 in 80 min Allowable limit 5 2 TO DISASSEMBLING AND TO ASSEMBLE A CLUTCH HOUSING a To Dis...

Page 133: ... fork 4 and clutch lever 3 1 Bolt 8 Case 2 Key 9 Oil Seal 3 Clutch Lever 10 O Ring 4 Release Fork 11 Seal Cap 5 Release Hub 12 Oil Seal 6 Release Bearing 13 Bolt 7 Clamp 14 Clutch Housing Assembling direction of oil seal 9 12 lip area is to face toward center of the clutch housing Tighten 2 bolts at both places evenly and slowly when fixing the tightening bolt 1 Diameter of main shift clutch lever...

Page 134: ...wo places 1 Clutch Housing 3 Bolt 2 Middle Case 4 Bolt 1 Carefully tighten M12 bolts when as sembling M12 x 40 four places middle case part A M12 x 60 two places middle case part B M12 stud bolts two places middle case part C 2 Parallel pin spec outer diameter x length 10 x 20 mm 0 393 to 0 787 in Tightening torque Tightening stud of clutch housing and middle case A Tightening bolt of clutch housi...

Page 135: ...1 Middle Case 3 Bolt 2 Transmission Case 4 Nut C MIDDLE CASE AND TRANSMISSION CASE a To Disassembling 1 Remove bolt 3 at 4 places and nuts 4 at 4 places on assembling surfaces of middle case 1 and transmission case 2 and separate the middle case and the transmission case Tightening torque Tightening stud A of middle case and transmission case Tightening bolt C of middle case and trans mission case...

Page 136: ...on the assembly section and insert shift fork 1 into shuttle shift groove to tighten shift cover 11 with M10 bolt 12 13 1 Fork 8 Shift Arm 2 Spring 9 Snap Ring 3 Ball 10 Gasket 4 Fork Rod 11 Shift Cover 5 Mounting bolt 12 Bolt 6 Plug 13 Bolt 7 O Ring 14 Shifter Replace O ring 7 with a new one where is greased on the surface for assembly Tighten mounting bolt 5 after apply ing adhesive on Three Bon...

Page 137: ...ain shift 1 2 fork 11 with fork rod 9 7 Place shift arm and main shift 1 2 stage 3 4 stage fork at the neutral position as aligned with the hole position of fork and fork rod to insert spring pin 13 8 Replace the gasket 15 with new one and tighten main shift cover ass y with M10 x 30 washer mount ing bolt 16 on the side assembling area of the middle case 1 Shift Cover 9 Fork Rod 2 Oil Seal 10 Spri...

Page 138: ... of auxil iary shift cover 10 3 Fix auxiliary shift cover with M10 washer mounting bolt 11 as aligning shift arms 7 of auxiliary shift cover 10 ass y with the fork groove 1 Shift Fork 7 Shift Arm 2 Fork Rod 8 Spacer 3 Spring Pin 9 Gasket 4 Ball 10 Shift Cover 5 Spring 11 Bolt 6 O Ring Tightening torque Tightening bolt of auxiliary shift cover 48 0 55 9 N m 4 9 5 7 kgf m 35 4 41 2 lbf ft Outer diam...

Page 139: ...ing 2 3 After greasing O ring 2 install shift arm 1 into the groove of shift front wheel 5 4 Install shift arm mounting stopper 3 to be fixed with washer mounting bolt 4 Replace O ring with a new one to be installed after greased on its surface 1 Shift Arm 5 Shifter 2 O Ring 6 Ball 3 Stopper 7 Spring 4 Bolt 8 Propeller Shaft 1 Tightening torque Tightening bolt of front wheel shift arm stopper 23 5...

Page 140: ...1gear 2 on the bottom part to be fixed with the sub assembled of bearing case at a time 7 Install and fix snap ring 18 in front of spline boss 16 8 Install 6208 ball bearing 1 on 39 21 gear 2 9 Insert shift fork for Hi Lo shift 26 into fork rod for Hi Lo shift 27 to be located on the groove of shifter 17 shift fork for creep shift 30 into fork rod for creep shift 31 to be located on the groove of ...

Page 141: ...g thrust collar 14 into shuttle shaft 3 place the sub assembly of propeller shaft case 2 in shuttle shaft 3 to tighten 4 washer mounting bolts 1 on middle case 18 1 Bolt 2 Propeller Bearing Shaft Case 3 Shuttle Shaft 4 29 Gear 5 24 Gear 6 Synchro Hub 7 Synchronizer Key 8 Synchronizer Ring 9 Spring 10 Shifter 11 Ball Bearing 12 Ball Bearing 13 Inner Ring 14 Collar 15 O Ring 16 Oil Seal 17 Ball Bear...

Page 142: ...r idle axle while drawing out rear idle shaft 2 to the front of the middle case b To Assemble 1 Locate spacer 8 thrust collar 5 rear idle 21 gear 7 and needle bearing 6 inside the middle case 2 Install O ring 3 on the groove of rear idle shaft 2 and apply grease Insert thrust collar 5 into the rear idle axle 3 When assembling align the fixing hole of rear idle shaft 2 with the inlet hole of mounti...

Page 143: ...der each sub assembled gear on the transmission case upside down as the engine faces toward the ground 6 Install thrust collar 9 between 33 gear 10 and 38 gear 8 7 Insert thrust collar 4 into 17 gear shaft 1 and fix downward 8 Tighten washer 19 6306 ball bearing 20 shim 21 and 28 nut 22 after placing the transmis sion case at the right position 9 Apply caulking around 28 nut 22 surely not to be re...

Page 144: ...l O ring 5 on bearing case 6 where greased to insert into the middle case and tighten with four M8 washer mounting bolts 7 4 Install 6005 ball bearing 9 on the hole of bearing case 6 and fix hole snap ring 8 5 Fix shaft snap ring 13 on propeller shaft 1 14 to be installed on the hole of bearing case 6 6 Install oil seal 10 on the hole of bearing case 6 while facing its lip area toward the middle c...

Page 145: ... 4 at a time 569W459A 4 Snap Ring 5 Snap Ring b To Assemble 1 Sub assemble snap ring 4 6005DD ball bearing 3 and snap ring 4 on PTO drive shaft 2 After applying grease on the oil seal 2 contacted section A of PTO drive shaft 1 perform assem bly by pushing forward from the back of the middle case while slowly rotating 3 Install mounting snap ring 5 of 6005DD ball bear ing 3 For assembling the PTO d...

Page 146: ... 12 Ball Bearing 3 Piston Ring 13 Needle Bearing 4 Piston Ring 14 Seal Ring 5 Brake Disc 15 Spline Hub 6 Return Plate 16 PTO Clutch Shaft 7 Spring 17 Bushing 8 Pressure Plate 18 Snap Ring 9 Snap Ring 19 Snap Ring 10 Clutch Disc N PTO CLUTCH a To Disassembling 1 Remove the middle case and the transmission case 2 Remove snap ring 1 and spacer 2 fixed of the PTO clutch shaft 3 Loosen φ 62 snap ring 3...

Page 147: ...tch Ass y 1 Install 6305DD ball bearing 3 on PTO clutch bracket 2 to tighten with φ 62 snap ring 4 2 Push PTO clutch ass y 1 through the top of the transmission case to be laid across the hole of the transmission case 3 Insert PTO clutch ass y 1 onto the hole of PTO clutch bracket 2 and install PTO clutch bracket 2 on the transmission case 4 With a replacing tool slightly knock the PTO shaft end o...

Page 148: ... on rear cover 2 O PTO SHAFT a To Disassembling 1 Loosen the bolts 1 and remove the PTO shaft as sembly 2 13 as a unit 2 Remove 6305 NR bearing 11 fixed on PTO shaft 9 3 Remove 6305 ball bearing 14 51 gear 10 PTO shaft 9 PTO drive shaft 13 Tightening torque Tightening bolt of the rear cover 77 5 90 2 N m 7 9 9 2 kgf m 57 1 66 5 lbf ft 1 Bolt 8 Ball Bearing 2 Rear Case 9 PTO Shaft 3 Packing 10 51 G...

Page 149: ...urface 2 Measure the gear I D rubbing surface 3 Measure the O D of the two needles installed di agonally in the needle bearing 4 Calculate the clearance Clearance Gear I D 2 x needle O D shaft O D 5 If the clearance exceeds the allowable limit replace them Clearance between gear and shaft Factory spec Allowable limit 0 021 0 054 mm 0 00083 0 00213 in 0 1 mm 0 004 in 569W467A Flaw on Synchronizer K...

Page 150: ...ferential Gear 1 Grip the spiral bevel pinion nut 1 with a torque wrench 2 and measure the turning torque 2 If the turning torque is not within the factory specifi cations check the differential gear turning force backlash and tooth contact again Turning torque with differential gear Factory spec 3 92 6 37 N m 0 40 0 65 kgf m 2 89 4 70 lbf ft 569W470A 569W471A Side Clearance Between Synchronizer R...

Page 151: ...ess of shims 4 0 4 mm 0 016 in 0 9 mm 0 035 in 0 5 mm 0 020 in 1 0 mm 0 039 in 0 6 mm 0 024 in 1 2 mm 0 047 in 0 7 mm 0 028 in 1 4 mm 0 055 in 0 8 mm 0 031 in Thickness of shims 5 0 4 mm 0 016 in 1 0 mm 0 039 in 0 6 mm 0 024 in 1 2 mm 0 047 in 0 8 mm 0 031 in 1 6 mm 0 063 in 1 Bevel Pinion Shaft 5 Shims 2 Nut 6 Bearing Support L 3 Bevel Gear 7 Bearing Support R 4 Shims 8 Shims 569W473A 569W474A Re...

Page 152: ... to move the bevel gear leftward Repeat above until the proper tooth contact and back lash are achieved Clutch Disc Steel Plate Wear 1 Measure the thickness of clutch disc with venire calipers 2 If the measurement less than the allowable limit replace it 3 If the thickness is less than the allowable limit re place it Thickness of independent PTO clutch disc Factory spec Allowable limit 2 10 2 3 mm...

Page 153: ...5 mm 0 098 in Flatness of Piston and Steel Plate 1 Place the part of a surface plate 2 Check it unable to insert a feeler gauge allowable limit size underneath it at least four points 3 If the gauge can be inserted replace it Flatness of independent PTO piston Allowable limit 0 10 mm 0 004 in Flatness of independent PTO piston Allowable limit 0 20 mm 0 007 in 569W480A 569W481A PTO Clutch Pack 569W...

Page 154: ... 10 Differential Gear Case 11 Differential Pinion 12 Differential Pinion Shift 1 13 Differential Pinion Shift 2 14 Differential Side Gear 15 Spiral Bevel Gear 569W483A Rear axle is driven as decelerated much by the plan etary gear while differential gear is applied to dis tribute suitable revolution considering related road and traveling conditions for the rear wheels left and right by the differe...

Page 155: ...TRANSMISSION SYSTEM 4 51 D569 W02 May 2003 A REAR AXLE 569W484A www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 156: ...r axle as decelerated once again is ap plied to the final reduction gear Internal gear mounted on the case is drawing revo lution power using planetary gear support carrier with planetary gear thereon by driving the brake shaft linear gear Since revolution force loaded on the rear axle of the tractor is transmitted as divided to 3 planetary gears this planetary gear equipment is compact excel lent...

Page 157: ...e three planetary gears 3 Since the internal gear 2 is fixed to the rear axle case the planetary gears 3 move around the teeth of the internal gear 2 while rotating on their axes The move ment of the planetary gears around the internal gear is transmitted to the rear axle 5 through the planetary gear support 1 As a result the planetary gear sup port 1 and rear axle 5 rotate in the same direction a...

Page 158: ...ential Gear Power is transmitted from spiral bevel pinion 1 via 39 spiral bevel gear 2 and through differential gear as sembly 3 to 13 gear shaft 4 13 gear shaft 4 is engaged with the gears of plan etary gear assembly 5 Planetary gears are operated in 68 internal gear 10 Consequently power trans mitted to 13 gear shaft 4 is transmitted to rear axle 6 via planetary gear assembly 5 Differential gear...

Page 159: ...s The differential gear assembly is composed of the dif ferential case differential pinions differential side gears differential pinion shaft spiral bevel gear etc 1 Differential Case Cover 2 Differential Case 3 Differential Lock Shifter 4 Spiral Bevel Gear 5 Differential Pinion Washer 6 Differential Pinion 7 Differential Side Gear 8 Differential Side Gear Washer 9 Differential Pinion Shaft 2 10 D...

Page 160: ...l pinion 7 is transmitted to the spiral bevel gear 2 bolted to the differential case 3 When road resistance to the right and left wheels are equal the differential pinions 4 and differential side gears 1 5 are carried around by the spiral bevel gear 2 and differential case 3 rotate as a unit Dif ferential gear shaft 6 8 receive the same rotation and both wheels travel at the same speed 1 Different...

Page 161: ...ted Since differential mounting fork 4 is moved to the left and connected with the dog of differential mounting shift 5 through the dog s groove of differential gear as sembly 10 while differential function is not operated along with 13 gear shafts left and right 6 revolved together If differential lock is operated 13 gear shafts both left and right rotate at the same speed and trans mit the same ...

Page 162: ...ntial side gear 5 through the holes in the differential case 4 to cause the differential case differential lock shifter and differential side gear to ro tate as a unit Therefore the differential pinions 6 9 can not rotate on their axles and the rotation of the spiral bevel pin ion is transmitted to the both rear axles evenly It means the tractor going straight ahead When the drive wheels regain eq...

Page 163: ...wheel drive shaft 1 at the back of the transmission case to remove at a time with 6305 ball bearing 4 b To Assemble 1 Install 6305 ball Bearing 4 on the transmission case 2 After sub assembly of snap ring 3 on front wheel rive shaft 1 push through the assembled area and insert into the spline of 34 gear 2 to fix front wheel drive shaft 1 with 6305 ball bearing 4 3 After installing 6305 ball bearin...

Page 164: ...unt 17 so to allow the turning torque of spiral bevel gear 3 to be 0 2 to 0 45 kgf m 5 Decide the shim amount 21 left and right so to allow the turning torque to be 0 09 to 0 12 kgf m after assem bling spiral bevel pinion 4 and spiral bevel gear 3 6 Fix spiral bevel pinion 4 and drive spiral bevel gear 3 to its turning direction to measure backlash Two place min Factory spec of backlash is 0 15 to...

Page 165: ...e tween differential side gear 6 and dif ferential pinion 11 to be 0 13 0 25 mm 0 005 0 0098 in Shim thick ness t1 5 t1 6 t11 7 Confirmation of Reaching Up Apply minimum lightly on several thrashing faces at 3 equally divided positions in the circle circumference of the spiral bevel gear and turn the shaft of the spiral bevel pinion with a load on the spiral bevel gear then to confirm its reaching...

Page 166: ...brake case 21 4 Insert packing 19 into the side of the transmis sion case and fix brake case ass y 21 5 Install O ring 23 on both sides of 68 internal gear 22 and apply grease to fix with rear axle ass y 24 6 Insert the rear axle ass y as aligned with the hole of brake case 21 to tighten with bolt 10 and nut 8 Tightening torque Tightening nut 14 of the brake cam lever Tightening bolt 10 of the rea...

Page 167: ... bore and O ring 18 assembly to fix on rear axle 21 2 Tighten nut 13 and apply caulking surely 3 Install rear axle case 17 and tighten bearing cover 19 of the rear axle with four M10 washer mount ing bolts 4 Insert spacer 12 and install 6211 ball bearing 11 5 Fix planetary gear support assembly 10 on the spline section of rear axle 21 and place fixing plate 7 to be tightened with UBS bolt 6 after ...

Page 168: ...netary gear shaft 2 and fix spring pin 6 to be at the same height as of the surface of the plan etary gear support three places Tightening torque Stud for assembly of the rear axle and the rim Mounting bolt of the bearing cover of the rear axle Mounting bolt of the rear axle assembly Mounting nut of the rear axle assembly Mounting bolt of the 13 gear shaft and the fixing plate Stud for assembly of...

Page 169: ...port nothing the num ber of left shims 2 Take out the differential gear assembly nothing the number of right shims When reassembling Check the spiral bevel gear for wear or damage If it is no longer serviceable replace it Then also replace the spiral bevel pinion Be sure to install the differential support to position the casting mark on it upward Use the same number of shims as before disassembli...

Page 170: ...onger serviceable replace it Then also re place the spiral bevel pinion Apply liquid lock Three Bond 1372 or equivalent to the spiral bevel gear UBS screws Differential Pinion Shaft and Differential Pinion 1 Draw out the differential pinion shaft 2 5 and take out the differential pinion 3 and differential pinion washer 4 2 Draw out the differential pinion shaft 1 and take out the differential pini...

Page 171: ...er 5 Differential Pinion Shaft 2 6 Differential Side Gear 7 Differential Side Gear Washer 8 Differential Cover 9 Differential Case 10 Differential Lock Shifter 11 Spiral bevel Gear Differential Side Gear 1 Take out the differential side gear 2 and differen tial side washer 1 When reassembling Check the thrust and bearing surface of both differ ential side gears 2 If they are worn or damaged bores ...

Page 172: ...it 0 1 0 3 N m 0 004 0 012 in 0 8 mm 0 031 in Clearance Between Gear and Spline or Hub and Spline 1 Select the gear or the hub in a vise 2 Set a dial gauge lever type with its finger on the spline 3 Move the shaft or hub to measure the clearance 4 If the clearance exceeds the allowable limit replace them Clearance between gear and spline or hub and spline Factory spec Allowable limit 0 030 0 078 N...

Page 173: ...llowable limit 0 05 0 151 mm 0 00197 0 00594 in 0 035 mm 0 0138 in Clearance between differen tial case bore and differential side gear boss Factory spec Allowable limit 40 5000 40 550 mm 1 59449 1 59646 in 40 388 40 450 mm 1 59008 1 59252 in Clearance between differential case cover bore and differential side gear boss Factory spec Allowable limit 0 05 0 151 mm 0 00197 0 00594 in 0 035 mm 0 0138 ...

Page 174: ...urement is not within the factory specifi cations adjust with the differential side gear washer Reference Thickness of differential side gear washers 1 5 mm 0 059 in 1 6 mm 0 063 in 1 7 mm 0 067 in Clearance between differen tial pinion shaft and differential pinion Factory spec Allowable limit 0 05 0 151 mm 0 00236 0 00402 in 0 25 mm 0 0098 in Differential pinion shaft O D Differential pinion I D...

Page 175: ...CHAPTER 5 FRONT AXLE www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 176: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 177: ...t Clearance between front axle case boss and front axle bracket front rear bushing excessive Front axle rocking force too small Front wheel sway excessive Tie rod end loose Air sucked in power steering circuit Propeller shaft broken Front wheel drive gears in transmission broken Front differential gear broken Shift fork broken Coupling displaced Gear backlash excessive Oil insufficient Bearings da...

Page 178: ...D Clearance O D I D 2 8 mm 0 08 0 32 in Less than 5 mm 0 20 in 49 0 117 7 N 5 0 12 0 kgf 11 0 26 5 lbf 0 025 0 160 mm 0 00098 0 00630 in 70 000 70 030 mm 2 75590 2 75708 in 70 095 70 145 mm 2 75964 2 76161 in 0 025 0 190 mm 0 00098 0 00748 in 85 000 85 035 mm 3 34645 3 34783 in 85 100 85 165 mm 3 35039 3 35295 in 0 016 0 052 mm 0 00063 0 00204 in 32 025 32 050 mm 1 26082 1 26181 in 32 025 32 050 m...

Page 179: ...ickness 0 1 0 3 mm 0 004 0 012 in 0 1 mm 0 0039 in 0 1mm 0 0078 in 0 2 mm 0 0157 in 1 6 mm 0 0630 in 1 27 1 667 N m 0 13 0 17 kgf m 0 94 1 23 lbf ft 0 2 0 3 mm 0 0078 0 0118 in 0 15 0 35 mm 0 0059 0 0138 in 0 1 mm 0 0039 in 0 2 mm 0 0078 in 0 4 mm 0 0157 in 0 8 mm 0 03149 in 1 0 mm 0 0393 in 0 15 0 35 mm 0 0059 0 0138 in 0 1 mm 0 0039 in 0 2 mm 0 0078 in 0 4 mm 0 0157 in 0 8 mm 0 03149 in 1 0 mm 0...

Page 180: ...xle of this is constructed as shown above Power is transmitted from the transmission through the propeller shaft and to the spiral bevel pinion shaft 16 then to the spiral bevel pinion gear 15 after that to the differential gear The power through the differential is transmitted to the differential shaft 4 and to the bevel gear shaft 6 in the bevel gear case 3 The revolution is greatly reduced by t...

Page 181: ...nclination The kingpin is tilted from the vertical as viewed from the front This inclination is called kingpin inclination As with the camber king pin inclination reduces rolling resistance of the wheels and prevents any shimmy motion of the steering wheel It also reduces steering effort 569W502A 569W503A 2 Caster The kingpin is tilted backward as viewed from the side That is the intersection a ma...

Page 182: ...n or less with the tightening bolts in F and R as contacted simultaneously with the bevel gear case or with the bolt in F as contacted with the bevel gear case when maximizing the direction control angle for the front wheel 3 4 DIRECTION CONTROL ANGLE FOR THE FRONT WHEEL 569W506A 569W507A 4 Toe in Viewing the front wheels from above reveals that the distance between the front wheels is less at the...

Page 183: ...t at the specified torque 3 After confirmation of rocking force fix with the mounting nut Tightening torque Nut 98 1 125 5 N m 10 0 12 8 kgf m 72 3 92 5 lbf ft Front axle rocking force Factory spec 49 0 117 7 N 5 0 12 0 kgf 11 0 26 5 lbf Tighten ing torque Adjusting bolt Lock nut 19 6 29 4 N m 2 3 kgf m 14 4 21 6 lbf ft 98 1 147 1 N m 10 15 kgf m 72 3 108 4 lbf ft 1 Washer 3 Nut 2 Bolt 569W508A 56...

Page 184: ...TING FRONT AXLE DRAINING FRONT AXLE CASE OIL 1 Place oil pans underneath the front axle case 2 Remove the drain plug 1 both sides and filling port plug 3 to drain the oil 3 After draining reinstall the drain plugs 1 and fill ing port plug 3 When refilling Remove the filling port plug 3 and check gauge 2 Fill with the new oil up to the check plug port After filling reinstall the check gauge 2 and f...

Page 185: ...nder the front axle and hang up the bumper by the hoist to support it 2 Remove the shaft bracket 1 mounting screws and shaft bracket 2 mounting screws 3 Separate the front axle from the front support 4 Remove the front wheels Tightening torque Front bracket bolts Rear bracket bolts Front wheel mounting nuts Front wheel mounting stud 123 6 147 1 N m 12 6 15 0 kgf m 91 1 108 5 lbf ft 123 6 147 1 N m...

Page 186: ...ting seal ass y 9 on the front axle with front axle 8 inserted to fix with 6209 ball bearing 7 4 Install mounting snap ring 6 of 6209 ball bearing 7 on front axle 8 5 Install 39 bevel gear 5 and then 6208 ball bearing 4 6 Install O ring 12 on the circumference of the front axle cover and apply grease 7 Insert front axle case 1 and front axle cover 2 into the assembly holes as aligned to tighten wi...

Page 187: ...g 8 Snap Ring 9 Shim 10 6208 Ball Bearing 11 13 Bevel Gear 12 Bevel Gear Shaft 13 6011 Ball Bearing 14 Snap Ring 15 Front Axle Case 16 Bevel Gear Case 17 6014 Ball bearing 18 Snap Ring 19 Housing 20 O Ring 21 Floating Seal 22 Snap Ring 3 Install front axle case 15 on bevel gear case 16 and tighten snap ring 14 at the bottom of 6011 ball bearing 13 4 Install 13 bevel gear 11 6208 ball bearing 10 sh...

Page 188: ... front axle support 8 as aligned 4 Tighten bevel gear case 1 and front axle support 8 with four bolt 2 and two nuts 3 1 Bevel Gear Case 6 Parallel Pin 2 Bolt 7 O Ring 3 Nut 8 Front Axle Support 4 Spring Washer 9 Differential Gear Shaft 5 Stud 10 Ball Bearing Tightening torque Stud bolt 5 for assembly of the front axle support and the bevel gear case Assembling bolt 2 of the front axle support and ...

Page 189: ...Fix front axle support 1 and differential gear case ass y 2 with inlet bolts 4 6 4 Install the bevel gear case ass y on both sides of front axle support 5 4 FRONT AXLE SUPPORT AND DIFFERENTIAL GEAR CASE 1 Front Axle Support 2 Differential Gear Case Ass y 3 Pipe Pin 4 Bolt 5 Spring Washer 6 Bolt Tightening torque Tightening bolt of the differential gear case ass y UBS bolt tighten ing of the differ...

Page 190: ...l gear 12 569W522A 5 Take parallel pin 21 out of front differential case 14 and remove differential pinion shaft 19 dif ferential side washer 16 differential pinion 15 differential side gear 17 and shim 18 6 Remove ball bearing 4 out of front differential case 14 7 Remove the caulking to loosen nut 29 8 Slightly knock the shaft part of 8 bevel pinion shaft 22 to take out and remove oil seal 28 oil...

Page 191: ...justment Turning torque 0 13 0 17 kgf m 1 27 1 667 N m 0 94 1 23 lbf ft 8 Sub assemble front differential case 14 section Install shim 18 differential side gear 17 differ ential side washer 16 differential pinion 15 in due order and then differential pinion shaft 19 in side front differential case 14 When assembling differential pinion shaft 19 let the section area located opposite to 27 bevel gea...

Page 192: ...bevel gear Turning torque of 8 bevel pinion shaft 22 48 0 55 9 N m 4 90 5 70 kgf m 35 4 41 2 lbf ft 77 5 90 2 N m 7 90 9 20 kgf m 57 1 66 5 lbf ft 29 4 34 3 N m 3 0 3 5 kgf m 21 6 25 3 lbf ft 1 27 1 667 N m 0 13 0 17 kgf m 0 94 1 23 lbf ft 569W524A 9 Install shim 10 ball bearing 11 two parallel pins 6 on differential gear case 5 and tighten case cover 7 with two M12 bolts 9 10 Sub assemble ball be...

Page 193: ...se nipple 9 seal washer 8 mount ing nut 7 and bolt 6 5 Install front bracket ass y 2 on front axle support 1 6 Apply grease to the inner bore of front bracket 2 via grease nipple 9 Knock the groove of DX bushing 4 into the nipple s groove of front bracket 2 aligned Install the lip area of oil seal 5 outward 1 Front Axle Support 6 Bolt 2 Front Bracket 7 Nut 3 Adjusting Plate 8 Seal Washer 4 DX Bush...

Page 194: ...ool 3 Install two oil seals 5 with a replacing tool and apply grease 4 Install grease nipple 6 5 Install Ø42 O ring 7 on the inner bore of rear bracket 2 and apply grease 6 Apply grease to the inner bore of rear bracket 2 via grease nipple 6 1 Front Axle Support 2 Rear Bracket 3 Thrust Collar 4 DX Bushing 5 Oil Seal 6 Grease Nipple 7 O Ring 569W526A CAUTION Knock the groove of DX bushing 4 into th...

Page 195: ...CHAPTER 6 HYDRAULIC SYSTEM www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 196: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 197: ...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 ...

Page 198: ...nce main control valve is available to con trol oil flowing in and out of the hydraulic cylinder so to control the implement up and down at a constant speed regardless of the implement load high work perfor mance can be achieved without impact while raised or lowered Several implements can be attached at a time for their applications owing to the outlet valve of the exterior oil pressure equipped ...

Page 199: ...distributor box Replace the gasket Adjust sensitivity or replace the valve Remove the distributor box and overhaul the valve Remove the distributor box and overhaul the valve Adjust controlled position limiting the upward boom ravel Adjust sensitivity Adjust controlled draft operation Adjust controlled draft operation Overhaul the Rockshaft Symptom Probable Cause Solution The Rockshaft lifts jerki...

Page 200: ...f Oil feeding By transmission oil g Oil filter not built in h Required degree of filtering 30µ B DIMENSIONAL FEATURES a Piston diameter 110 mm 4 33 in b Working stroke 102 mm 4 01 in c Piston displacement 969 cm3 d Angular excursion of lifting arms under drawbar pull control conditions 70 2 e Intervention value of automatic hydraulic limit stop 75 f Internal mechanical limit stop 78 C CALIBRATION ...

Page 201: ...HYDRAULIC SYSTEM 6 7 D569 W03 June 2003 www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 202: ...CHAPTER 6 8454 6 8 D569 W03 June 2003 www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 203: ...nstalled on the hydraulic cylin der body provide three different applications posi tion control draft control and mixed control 2 Take out hydraulic power from the front hydraulic block assembly 4 to operate an implement s hy draulic actuator 6 Control Valve 7 Hydraulic Cylinder 8 Oil Filter Cartridge 9 Oil Tank Transmission Case 3 Take out hydraulic power from the quick couplers 5 included in the...

Page 204: ...ion control valve 7 through the delivery pipe 1 Oil Tank Transmission Case 2 Hydraulic Oil Filter Cartridge 3 Hydraulic Pump 4 Engine 5 Relief Valve 6 Front Hydraulic Block 7 Position Control Valve 8 Hydraulic Cylinder 9 Auxiliary Control Valve If Equipped 10 Hydraulic Cylinder Block 4 The position control valve 7 switches the oil flow and oil is channeled to the hydraulic cylinder 8 for the three...

Page 205: ...ring of the lift arm at a constant speed always Since block ing of valve oil leakage is available inside oil lock grip per is necessary b Double Acting Valve This is generally applied to the implement attached on the double load cylinder while used for operation of the boom cylinder with a loader 1 Control Valve 2 Double Acting Valve 569W607A 569W608A www mymowerparts com K T Saw Shop 606 678 9623...

Page 206: ...CHAPTER 6 8454 6 12 D569 W03 June 2003 2 Circuit Diagram 569W609A www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 207: ...position to connect the chamber 15 directly to the discharge through hole 16 The oil coming from the pump will thus be able to move downward the small regulator piston 2 and thus flow to the chamber 22 and by opening the holes 17 it will flow to the tank 1 Spool 6 Fixed Throat 2 Piston 7 Safety Valve 3 Check Valve 8 Regulator 4 Valve 15 Chambers 5 Relief Valve 16 Hole 17 Hole 22 Chamber 18 Annular...

Page 208: ...18 and flows into the cylinder chamber 23 The small regulator piston 2 adjust the oil flow to the cylinder because chambers 15 and 22 are subject to the difference of pressure made by the oil passage through the fixed throat 6 and the variable throat made by the control spool 1 depending on its upward move ment caused by he internal levers of power lift The excessive flow is deviated at the liftin...

Page 209: ...the cylinder cham ber 23 flows from annular duct 18 to the lowering regulator 8 and through hole 24 it enters the dis charge valve 4 flowing to the discharge from the hole 25 therefore causing the lowering of arms In this phases the lowering speed of the implement is controlled automatically by the lowering regulator 8 that is sensible to the dynamic force of the discharge oil consequently modifyi...

Page 210: ...CHAPTER 6 8454 6 16 D569 W03 June 2003 www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 211: ...ver 2 Needle Bearing 3 Washer 4 Packing 5 Pin 6 Roller 3 7 Lock Screw 8 Oil Seal 9 Snap Ring 10 Link 4 11 Shaft 12 Spring Pin 13 Cam 14 Snap Ring 15 Link 1 16 Link 2 17 Roller 4 18 Plain Washer 19 Pin 20 Roller 1 21 Roller 2 22 Snap Ring 23 Link 3 24 Arm 25 Lock Screw 26 Cam 1 27 Pin 28 Nut 29 Link 30 Snap Ring 31 Arm 32 Nut 33 Bolt 34 Pin 35 Pin 36 Spring 37 Link 38 Pin 39 Snap Ring 40 Bush www m...

Page 212: ...e distributor shaft 21 into delivery position C thus causing the arms to be lifted 1 Position Control Lever 2 Draft Control Lever 3 Shaft 4 Arm 5 Roller 1 6 Cam 1 7 Lever 8 Friction Shock Absorber 9 Arm 10 Pin During the lifting movement of the arms crank 13 with pin 10 will rotate in a counter clockwise direction and via link 3 14 will cause the positioning cam 1 6 to rotate clockwise When roller...

Page 213: ...er 2 Draft Control Lever 3 Shaft 7 Lever 8 Friction Shock Absorber 9 Arm 11 Roller 4 12 Cam 15 Crank 16 Shaft 17 Rod 18 Tension Rod This causes the lever 7 to rotate clockwise of trans mission arm 9 thus setting the distributor shaft 21 in delivery position C and consequently lifting the arms The arms will come to a stop only as soon as the piston comes into contact with the pin of the limit stop ...

Page 214: ... system as previously explained c Combined Operation of Positioning and Drawbar Pull Fig 569W616A 569W617A To utilize the lifting device in this condition it is neces sary to observe the following instructions Move the positioning control lever 1 upwards in relation to the lower backstop on the sector until the maximum work ing depth has been attained Determine the desired minimum working depth by...

Page 215: ...m OUT port 2 and IN port 1 of the front hydraulic block 4 2 Install the hydraulic take off adaptors screw size PT3 8 to OUT port and IN port 3 Connect the hydraulic hose to the adaptor OUT port side and to the implement control valve IN port 4 Connect the other hydraulic hose to the adaptor IN port side an to the implement control valve TANK RETURN port 5 Turn the slit on the spool 3 end to the ar...

Page 216: ...en the auxiliary control valve operating lever is moved to the implement cylinder actuating position the spool is moved and the oil from the pump port flows into A to B causing the implement cylinder to operate The return oil from the implement cylinder flows out of the tank port through A of B and returns to the transmis sion case This type is equipped with a special non return valve which ensure...

Page 217: ...he inlet of hydraulic cylinder As the oil pressure of circuit increases that of damp ing chamber D C increases If pressure exceeds the specified valve and the spring tension the valve will open to flow oil through port T to transmission case If oil is discharged sufficiently and its pres sure is less than the specified the valve will be closed Relief valve setting pressure Engine speed Oil tempera...

Page 218: ... the linkage by plate 12 and tie rod 17 to raise the implement And oil flowing line is changed by the linkage of the control valve this time 1 Top Linkage bracket 7 Bolt 2 Flange 8 Lock Washer 3 Cover 9 Bolt 4 Spring 10 Pin 5 Roller 11 Snap Ring 6 Bolt 12 Plate 17 Tie Rod 13 Bolt 18 Spring Peaks 14 Lock Washer 19 Crank 15 Roller 20 Pin 16 Nut 21 Nut 569W627A www mymowerparts com K T Saw Shop 606 6...

Page 219: ...nd check the oil level again add the fluid to prescribed level if it is not correct level 2 Gauge Capacity Transmission fluid 38 0 40 1 U S gal IMPORTANT Use only SAE 80 90 gear oil Use of other oils may damage the transmission or hydraulic system Refer to LUBRICANTS FUEL AND COOLING WA TER Refer to the chapter 1 Do not mix different brands fluid together B SEPARATING REAR FENDERS AND PLATFORM ASS...

Page 220: ... FLOOR SEAT AND PLATFORM ASSEMBLY 1 Remove the fender 1 2 floor seat and platform as a unit Cover 1 Remove the bolts 1 2 and the cover assembly 3 1 Bolt 3 Cover 2 Bolt 569W631A 569W632A www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 221: ...n and remove the joint bolt 2 8 hydraulic pipes 1 2 bracket 5 and quick couplers 9 as a unit 2 Loosen and remove the auxiliary control valve mounting two nuts 18 washer 17 and take out the auxiliary valves 13 from the power lift body When refilling Take care not to damage the O rings 15 O Ring 16 Flange 12 Stud 17 Washer 13 Auxiliary Valve 18 Nut 14 O Ring www mymowerparts com K T Saw Shop 606 678...

Page 222: ...1 O Ring 23 Screw 12 Snap Ring 569W638A When reassembling Tightening torque Hydraulic cylinder mounting bolts and nuts 48 1 55 8 N m 4 9 5 7 kgf m 35 5 41 2 lbf ft B HYDRAULIC CYLINDER ASSEMBLY 1 Loosen the joint bolt 1 2 Loosen and remove the hydraulic cylinder assem bly mounting bolts 6 7 8 9 spring wash ers 5 and nuts 4 3 Support the hydraulic cylinder assembly with nylon lift strap and hoist a...

Page 223: ... and the crank mounting screw 6 2 Draw out the hydraulic arm shaft 8 and lift arm 3 as a unit 3 Take out the hydraulic cylinder 14 piston 11 con necting rod 10 and crank 7 When reassembling Install the piston seal 12 Apply transmission oil to the cylinder and then in stall the piston Apply grease to the piston button contacts with con necting rod Align the hole of the shaft 8 and crank 7 Apply gre...

Page 224: ...2 May 2003 F BUSHINGS 1 Remove the bushings 1 and 2 When reassembling Apply transmission oil to the hydraulic cylinder boss and bushings 1 Bushing 2 Bushing 569W641A www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 225: ...reful not to lose spacer 5 Do not remove valve 23 concerning any damage expected Pay attention to cover 10 which might fly up due to the spring tension Be careful not to drop the spool inside when dismantling CAUTION b To Assemble 1 Apply grease sufficiently on bolt 26 inside cover 10 2 Let all the parts applied with oil sufficiently when assembling 1 Control Valve Ass y 2 Spacer 3 Rubber 4 Lever ...

Page 226: ...ng 3 Spool 11 Valve Sheet 4 O Ring 12 Valve 5 Washer 13 Spring 6 Spring 14 Spacer 7 Spacer 15 Gasket 8 Adjusting Screw 16 Cover 17 Screw 24 Roller 18 Screw 25 Plug 19 Nut 26 O Ring 20 Lock Washer 27 Pin 21 Nut 28 O Ring 22 Ring 29 O Ring 23 Bent Arm 30 Plug b To Assemble 1 Clean with detergent oil thoroughly not to allow any foreign substance in when assembling 2 Apply grease sufficiently inside w...

Page 227: ...lange 8 Lock Washer 3 Cover 9 Bolt 4 Spring 10 Pin 5 Roller 11 Snap Ring 6 Bolt 12 Plate 17 Tie Rod 13 Bolt 18 Spring Peaks 14 Lock Washer 19 Crank 15 Roller 20 Pin 16 Nut 21 Nut b To Assemble 1 Apply grease sufficiently when assembling bolt 6 and spring 4 Do not change the former assembling position of the plate when dismantling as in the clause of 2 above Be careful not to drop top link bracket ...

Page 228: ...calculated clearance exceeds the allowable limits replace the bush Cylinder I D A 90 000 90 050 mm 3 54330 3 54527 in 90 150 mm 3 54921 in Reference dimension Allowable limit Hydraulic arm shaft O D 49 970 49 940 mm 1 96732 1 96614 in 44 975 44 950 mm 1 77066 1 76968 in Right B Left A Bush I D After assembled 50 075 50 115 mm 1 97145 1 97303 in 45 075 45 115 mm 1 77460 1 77618 in Right B1 Left A1 ...

Page 229: ... the control valve MLS valve into power lift body A dimension will be 112 mm 2 If adjusting control bolt 1 loosen nut 2 and then tighten lock nut 2 Reaction spring assembly initial length L 50 mm 1 9685 in Reference dimension A Setting length 112 mm 4 4094 in Reference dimension B Setting length 50 5 mm 1 9881 in Reference dimension www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 230: ... for operation and make sure it is located at the same position at the highest 4 With minimum rpm lower the position control lever 6 to stopper 8 and then slowly raise the Draft control lever 5 toward stopper 7 so that the el evating arm might be raised 5 Until smooth down of elevating arm is obtained de crease and adjust the length L of feedback rod gradually one rotation a time 6 After a complet...

Page 231: ...ve screw 2 counterclockwise using a hex wrench until elevating arm is swung 3 Rotate the preventative screw 2 clockwise until the elevating arm stops moving and make sure it is locked at that position 4 After a completion of the adjustment mentioned above rotate the preventative screw 2 1 4 turns clockwise to set into position firmly This time the sensitivity of the MLS valve will be set to the ma...

Page 232: ...l min Relief pressure kgf cm2 psi Oil flowing min gal min 65 17 17 7 1 1 88 16 18 228 256 7 1 85 8454 B DIAGRAM 569W650A 1 PTO Clutch 2 PTO Shaft 3 Position Control Lever 4 Detecting Sensor of the Implement 5 PTO Switch 6 PTO Monitor Lamp 7 Modulating Valve 8 Solenoid Valve 9 Interlocking Relay PTO at Neutral CLUTCH at Neutral E Engine www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983...

Page 233: ...ns from Port A to the tank transmission case after lubrication the idly ro tated PTO clutch via the modulating valve through in ner of the spool The spool is blocked by the springs at both ends from Port PI toward Port B in case of OFF 1 Tank Transmission Case 2 Filter 3 Pump 4 Shuttle Shift Cover 569W651A 569W652B 5 Solenoid Valve 6 Priority 7 Priority Valve www mymowerparts com K T Saw Shop 606 ...

Page 234: ...dulating valve through inner of the spool 6 as forced Oil at the modulating valve coming from Port A returns from Port T to the transmission case 5 Solenoid Valve 6 Spool 7 Priority Valve The spool 6 can be hardly operated only by the solenoid valve 5 if dust or the like is attached on the spool 6 In this case insert the manually operated pushpin to reinstate the normal application as available 56...

Page 235: ...ture 1 Body 2 Piston 3 Spring 4 Spring Gripper 5 Spool 6 Valve Seat 7 Cover 8 Packing 9 Lock Nut 10 Adjusting Bolt 11 O Ring 12 Bolt 13 Plug 14 Check Valve 15 Orifice 16 Washer 17 Filter 18 O Ring 569W653A www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 236: ...ide the hydraulic clutch comes back to Port C and returns from Port T1 via the solenoid valve 5 to the tank 5 Solenoid Valve 6 Spool 7 Spring 8 Piston Meanwhile as the circuit for pressing the piston 8 gets closed the piston 8 moves to the right as forced by the spring 7 At this moment the oil pressing the piston 8 leaves through the around of the check valve 10 to return to the tank while joined ...

Page 237: ...d to the check valve as forced owing to the low pressure Oil in amount constantly regulated at the orifice of the check valve through the filter compresses the inner spring of the piston by moving the piston to the left slowly Thus open and reinstated passage by pressing the spool is not returning back from Port B if not high pres surized The pressure at Port C as high pressurized proportionately ...

Page 238: ...l of the direction of the spool when assem bling Apply oil sufficiently to the spool body after washed not to cause damage thereon when assembling 569W656A Solenoid 1 Loosen the sectional end of the solenoid with a spanner 2 Take out the solenoid ass y and the spring Hold the body to Disassembling the cover however do not hold the sole noid section CAUTION Be careful of the direction of the sole n...

Page 239: ...ilter 569W657A Do not loosen the adjusting kit located to the cover Because the adjusting kit has set the relief pressure the lock nut shall not be removed if not required for adjustment of the pressure If the adjusted value is changed the modu lating time may be shorter PTO clutch gets connected in haste or the PTO clutch may be hardly connected In case the adjusting kit is removed by mistake per...

Page 240: ...k valve Replace the modulating valve ass y if the wet drive surface or the sheet is worn out or damaged 2 Filter Clean out dust or foreign substance if any thereon 3 Piston and spool Replace the modulating valve ass y if the wet drive surface or the sheet is worn out or damaged 4 O ring Replace if worn out or damaged 1 Solenoid 5 Spool 2 Spring 6 Plug 3 Spring 7 Wire Lead 4 Spool 1 Bolt 6 Valve Se...

Page 241: ...d reassembling 2 Pipe 1 Improper piping of port 4 1 Oil seal worn out 1 Contaminated delivering oil 2 O ring damaged 1 Damaged when dismantling and reassembling term unemployed Correct cause if the tightening bolt with orbitrol is loosened free Replace Tighten at the torque as specified evenly Repair Replace Reset pressure and oil amount Replace Reset Replace Correct Bleed air Bleed air Replace Co...

Page 242: ...is no mechanical conveyance such as steer ing gear pitman arm or drag link for simple implement 6 Steering Cylinder A To the Transmission Case B To the Hydraulic Block The exclusively hydraulic type of power steering is clas sified into Non Load Reaction model and Load Reac tion model according to the cylinder port disconnected or connected with the control valve at neutral position and the latter...

Page 243: ...steering circuit delivered to the steer ing valve 1 Gear Pump 2 Priority Valve 3 Power Steering Unit 4 Hydraulic Hose RH 5 Hydraulic Hose LH 6 Steering Cylinder 7 Hydraulic Block 8 Power Lift Ass y 3 The steering valve controls the direction of the front wheels by switching over the oil flow delivered by operation of the steering wheel and by moving the rod of the steering cylinder 569W661A 9 Cont...

Page 244: ...troller is composed of steering valve and relief valve b Hydraulic Pump Hydraulic pump for power steering employs a gear pump that is of efficient capacity and mechanism and power is delivered from the cam shaft gear on the right of the engine c Hydraulic Filter As an absorption filter with a case as installed on the inlet side of the gear pump it employs a permanent on the center of the element m...

Page 245: ...el is operated b Steering Valve The steering valve is divided into valve and metering installation The control valve is composed of housing 9 spool 2 and sleeve 5 and the metering installa tion is composed of the trochoid pump called as GEROTOR 6 1 Steering Valve Orbitrol Unit 2 Relief Valve 569W663A 569W664A 1 End Cap 6 GEROTOR 2 Spool 7 Centering Spring 3 Spacer 8 Pin 4 Bearing 9 Housing 5 Sleev...

Page 246: ... to the hydraulic system 2 Metering installation oil delivered from the hydrau lic pump to the steering cylinder passes this meter ing installation The metering installation composed of the trochoid pump while absorbing oil at 3 rooms sends out oil at different 3 rooms according to the capacity change of the pump room made up be tween the rotor and the GEROTOR if the rotor gets started Meanwhile t...

Page 247: ...control valve is con nected with GEROTOR 5 The stator of gerotor 5 turns by the amount corresponding to the turn of the steering wheel 2 and the gerotor performs the meter ing function and lets oil through it the amount of which corresponds to the turn of the steering wheel 2 The oil which has passed through GEROTOR 5 flows back to the control valve in which it is directed to cylin der port R to o...

Page 248: ... oil flows into and out of steering cylinder in the directions opposite to those at a right turn P Pump Port R Cylinder Port R T Tank Port L Cylinder Port T 1 Steering Controller 4 Centering Spring 2 Steering Wheel 5 GEROTOR 3 Valve Plate 6 Steering Cylinder 569W669A www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 249: ...ing the filling plug 1 until reaching the gauge 2 After running the engine for few minutes stop it and check the oil level again add the fluid to prescribed level if it is not correct level Capacity Transmission fluid 34 0 9 0 U S gal 569W670A IMPORTANT Use only SAE 80 90 gear oil Use of other oils may damage the transmission or hydraulic system Re fer to LUBRICANTS FUEL AND COOLING WATER Refer to...

Page 250: ...Cover RH LH 2 Bonnet 3 Front Grille 4 Side Skirt RH LH 5 Battery Negative Code Preparation 2 1 Disconnect the brake rods 4 10 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 shaft lever 5 after disconnecting limit switch wire harness 7 Disconnect the 2P conne...

Page 251: ...ose 2 Return Hose 3 Right Turning Delivery Hose 4 Left Turning Delivery Hose Panel Frame and Steering Assembly 1 Remove the panel frame mounting crews Two screws a upper part Seven screws at lower part 2 Take out the panel frame and steering assembly as a unit When reassembling Do not get in the wiring harness between panel frame and platform Tightening torque Main delivery hose retaining nut Turn...

Page 252: ...eeve 5 Spacer 13 Pin 6 O Ring 14 Centering Spring 7 Spacer 15 Spool 8 Spacer Plate 16 stop Ring 17 Retainer Ring 25 Poppet 18 Bearingless 26 Spring 19 Needle Bearing 27 Poppet 20 Housing 28 O Ring 21 Housing 29 Plug 22 Screw 30 O Ring 23 O Ring 31 O Ring 24 Inlet Check ValveAss y 32 Dust Seal 569W679A www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 253: ...y 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 cap 569W680A 569W681A Do not tighten the vise too firmly with a steel pate or the like applied to CAUTION 1 Screw 2 End cap 3 O ring www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 254: ...0 Remove O ring out of the housing 569W683A 6 Take out spacers 5 7 and O ring 6 located in side the inner spline of the rotor 10 in gerotor 4 569W682A CAUTION There is no spacer in the power steer ing units of outlet capacities of 31 cc rev and 51 cc rev 4 Stator 7 Spacer 5 Spacer 10 Rotor 6 O ring 8 Spacer Plate 11 Drive 9 O ring www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 255: ...leeve to be stuck in the inner bore of the housing this time 569W684A 12 Take pin 13 out of the spool and sleeve ass y CAUTION 569W685A Since the centering spring might fly out of the pool surely wear goggles 13 Push forward the spool in the sleeve a little to re move the centering spring out of the spool with hand carefully While turning around the sleeve carefully take it out of the spool A Posi...

Page 256: ...Spring 2 Retainer Pin 27 Damper Collar 3 Ball 28 O Ring 25 Poppet 29 Adjusting Plug CAUTION CAUTION Previously measure the depth from the flange faced and of the housing to the relief adjusting plug 7 with binary cali pers to easily perform adjustment of the pressure when reassembling Install the flat surface of the dust room downward 569W687A 569W688A 32 Dust Seal 2 With the flange face of the ho...

Page 257: ...ed a little off the sleeve with the opposite end of the centering spring compressed by hand into the groove of the spool and sleeve At this time slide the insertion tool at the same speed as the spring is inserted while compressed After the insertion align the spring end with the circumference of the sleeve CAUTION CAUTION 569W690A 569W691A 569W692A Check the number of centering springs prior to a...

Page 258: ...hreads of screw 1 to put end cap 2 on 569W693A 569W694A Check if the spool and sleeve ass y turns lightly inside the housing 7 Insert the drive 11 And align pin 13 with the york part of the drive this time 8 Install O ring on the Stator 4 Fd the gerotor star on the positioning groove Previously tighten 7 screws 1 at a torque of approx 1 0 kgf m 7 23 ft lbs CAUTION CAUTION 11 Drive 13 Pin 1 Screw 7...

Page 259: ...iable amount of pressure per revo lution of the relief adjusting plug 29 is 15 kgf cm2 213 psi CAUTION e Caution for Assembly of the Power Steer ing Unit 1 Be careful not to allow damages on the mechanically processed ends of the sleeve spool and housing 2 Perform disassembly and repair at a clean place and remove any dust or foreign substance on joints around the main body of the product with a w...

Page 260: ...ng length Factory spec Allowable limit 0 05 mm 0 00196 in Allowable limit 19 25 mm 0 75787 in Allowable limit 0 177 mm 0 00696 in Allowable limit 25 75 mm 1 01378 in 0 1 0 18 mm 0 00393 0 00708 in bushing length is short Measure sequence Install bushing on the main frame Fix drive shaft and idle gear Measure with a clearance gauge Measure the shaft diameter with a micrometer Measure the inner diam...

Page 261: ... 3 Cover Front 9 Bushing 4 Sealing 10 Drive Gear Shaft 1 5 Pin 11 Passive Gear 1 6 First Pump 12 Coupling 13 Cover 19 Sealing 14 Sealing 20 Second Pump 15 Sealing 21 Cover Rear 16 Bushing 22 Spring Washer 17 Drive Gear Shaft 2 23 Bolt 18 Passive Gear 569W696A www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 262: ...specified fluid amount for each revolution Outlet flowing amount increases as the revolution speed of the pump increases c Hydraulic pump is operated by the cam shaft drive gear of the engine and the pump gear C turns to allow the transmission oil to continue flowing in and out A vacuum is formed to let oil flow in the pump A when the gear is disconnected Oil continuously flows together with the g...

Page 263: ...e damages on the gasket If damaged replace it with a new one 4 4 TO DISASSEMBLING AND TO ASSEMBLE A GEAR PUMP ASSEMBLY 1 Remove hydraulic pipes 3 4 and inlet pipes 2 installed on gear pump 1 1 Gear Pump 4 Hydraulic Pipe 2 2 Inlet Pipe 5 Priority Valve 3 Hydraulic Pipe 1 569W698A CAUTION www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 264: ... 3 Front Cover 9 Bushing 4 O Ring 10 Drive Gear Shaft 1 5 Straight Pin 11 Passive Gear 6 First Pump 12 Coupling 13 Cover 19 O Ring 14 Sealing 20 Second Pump 15 Sealing 21 Cover 16 Bushing 22 Spring Washer 17 Drive Gear Shaft 2 23 Bolt 18 Passive Gear Tightening torque Bolt 23 48 0 55 9 N m 4 9 5 7 kgf m 35 4 41 2 lbf ft If the oil seal has been cracked or aged replace it with a new one when assemb...

Page 265: ...ket 4 Vacuum Sensor 5 Thermostat Sensor Hydraulic filter as of inlet filter on the inlet gear pump has permanent magnet installed on the center of the element and the filter mounted on the hydraulic lift is structured with a vacuum sensor and a thermo sensor to detect blockage 569W6A1A www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 266: ...e filtered at the element this time In addition a vacuum sensor and a thermo sensor are mounted thereon to detect blockage in the filter The vacuum sensor and the thermo sensor are always turned OFF under the pressure load of 500 30 mmHg and under 53 C respectively Two switches by applica tion of the transistor switch are turned ON over the flow ing oil temperature of 53 C and over the pressure lo...

Page 267: ...p Assembly 2 Orbitrol Unit 3 Steering Cylinder Ass y 4 Hydraulic Hose Ass y RH 5 Hydraulic Hose Ass y LH 6 Prior Valve Assembly 7 PTO Clutch Valve 7 1 Solenoid Valve Ass y 7 2 Modulator Valve Ass y 7 3 PTO Clutch Assembly 8 Hydraulic Block Ass y 9 Hydraulic Cylinder Ass y 9 1 MLS Valve Assembly 9 2 Double Acting Valve Assembly 10 Hydraulic Filter 569W6A3A www mymowerparts com K T Saw Shop 606 678 ...

Page 268: ...ter Hydraulic pump 2 7 2 cc rev Power steering unit 74 cc rev Steering cylinder Prior valve assembly 7 L min Solenoid valve assembly Modulator valve assembly PTO clutch assembly Transmission case hydraulic tank Hydraulic filter Hydraulic pump 1 12 cc rev Hydraulic block forward external output port Hydraulic cylinder assembly www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 269: ... Prior Valve Assembly 7 Hydraulic Filter 8 Transmission Case 6 2 STEERING DEVICE A SCHEMATIC DIAGRAM OF STEERING DEVICE A PTO Clutch Valve B Lift Line C Flow Rate Gauge D Pressure Gauge C DESCRIPTION OF COMPONENTS 1 Hydraulic filter filtering of contaminated materials 2 Hydraulic pump to supply the constant flow of hy draulic oil First Pump hydraulic pressure rise fall pump 12 cc rev Second Pump s...

Page 270: ...atic diagram 2 Rotate the handle till the noise of relief is generated 3 Check the pressure from the pressure gauge Standard pressure more than 120 kg cm2 1 707 psi In case that the rotation of handle is not available check the following 1 Check the leakage of oil from steering cylinder ass y 2 Check the connection of hydraulic hose 3 Check the pressure is below standard pressure 120 kg cm2 1 707 ...

Page 271: ...ch 1 3 At this time PTO clutch operation shall be controlled by electrical device of PTO ON OFF switch 2 Orbitrol Unit 3 Prior Valve Ass y 4 Gear Pump Ass y C DESCRIPTION OF COMPONENTS 1 Solenoid valve assembly to control the oil path by ON OFF electrically 2 Modulator valve assembly to generate the regular pressure 16 kg cm2 18 kg cm2 to operate the PTO clutch 3 Prior valve assembly to deliver th...

Page 272: ...ressure gauge refer to schematic diagram Standard pressure value 16 kg cm2 18 kg cm2 228 256 psi 3 How to adjust modulator valve when it does not reach standard pressure Adjust the adjusting screw of lock nut 7 1 to clockwise or counter clockwise to set the standard pressure of pressure gauge within 16 kg cm2 18 kg cm2 1 Bolt 2 Cover 3 Piston 4 Spring 5 Spool Poppet 6 Valve Seat 7 Adjusting Kit 8 ...

Page 273: ...mbly is avail able to work regardless of the load of the machine by controlling the incoming and outgoing flow rate 3 Hydraulic Pump 4 Hydraulic Filter 5 Transmission Case A Orbital Unit Steering Device C DESCRIPTION OF COMPONENTS 1 Hydraulic block valve to exhaust the front exterior hydraulic pressure 2 Double acting valve valve to exhaust the rear exte rior hydraulic pressure 3 MLS valve to cont...

Page 274: ...g hydraulic block please be noted that Use the external operating machine by turning the adjusting screw 5 to the CL direction Use the 3 point link by turning the adjusting screw 5 to the OP direction Hydraulic block Components Trouble Checking Remark 1 Hydraulic block How to adjust the pressure of hydraulic block When below standard pressure add the adjusting seam 2 to adjust check the pressure w...

Page 275: ...essure of rear external hydraulic pressure 165 kg cm2 190 kg cm2 engine rotation 2 600 rpm Double acting valve assembly Components Trouble Checking Remark 2 Double acting valve assembly After removing a nut 1 turn the adjusting screw 2 to clockwise or counterclockwise using a hexagonal wrench to check the pressure gauge and then adjust it to standard pressure value 569W6B3B www mymowerparts com K ...

Page 276: ... falls down by oil pressure to open the pipe line B and oil is exhausted to the transmission case neutral supply stage When pipe line A is open piston is lifted by a spring to close the pipe line B and oil is supplied to the cylinder supply stage 2 Spool spool is operated by a link device to control the open close of pipe line A and determine the exhaust supply and neutral stage 3 Check valve chec...

Page 277: ...ling valve 4 is operated by a spring to open the pipe line C and exhaust the oil of the cylinder which results in the fall of lift arm exhaust stage Components Trouble Checking Remark 2 Double acting valve assembly Operation of main components 1 Piston as spool 2 closes the pipe line A piston 1 falls down to open the pipe line B 2 Spool spool 2 is pushed by a link device to the direction of arrow ...

Page 278: ...ve does not work supply stage Components Trouble Checking Remark Operation of main components 1 Piston as spool 2 opens the pipe line A piston 1 closes the pipe line B when the rise of lift arm is completed piston 1 falls down by oil pressure to open the pipe line B 2 Spool spool 2 is pushed by a link device to the direction of arrows to open the pipe line A 3 Check valve opened by oil pressure Wh...

Page 279: ...o move and check if it is sealed on that position 4 After completion of the above adjustment turn the screw A to maximum 1 4 clockwise to seal it completely By doing this the sensitivity of MLS valve shall be set to maximum How to adjust the hydraulic lift arm hunting 1 Adjust the length of tie rod A in the state of attaching operating machine and if the hunting occurs after adjustment return to t...

Page 280: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 281: ...CHAPTER 7 BRAKE www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 282: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 283: ...late Item Free play Difference Clearance O D I D Flatness Height Thickness Thickness Factory Specifications Allowable Limit 1 TROUBLESHOOTING Uneven braking force Brake drags Poor braking force Symptom Brake pedal play unevenly adjusted Brake disc worn Cam Plate warped Brake pedal play too small Cam plate return spring weaken or broken Brake pedal return spring weaken or broken Brake camshaft rust...

Page 284: ...ing nut of brake case Mounting nut of brake rod 367 8 431 6 N m 37 5 44 0 kgf m 271 2 317 8 lbf ft 23 5 27 4 N m 2 4 2 8 kgf m 17 3 20 2 lbf ft 123 6 147 1 N m 12 6 15 0 kgf m 91 1 108 5 lbf ft 77 5 90 2 N m 7 9 9 2 kgf m 57 1 66 5 lbf ft 77 5 90 2 N m 7 9 9 2 kgf m 57 1 66 5 lbf ft 48 0 55 9 N m 4 9 5 7 kgf m 35 4 41 2 lbf ft www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 285: ...UCTURE 1 Brake Case 2 Packing 3 Guide Pin 4 Brake Cam 5 O Ring 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 Lever LH 569W701A www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 286: ... the pedal 1 located at the front of the driver s seat is stepped down brake rods 3 4 and brake cam lever 5 linked with brake lever by the hinge point are activated for ward while brake rod 3 is pulled upward The cam plate gets rotated as the brake cam connected to the brake cam lever turns to the direction as arrowed When the cam plate turns the cam plate while being pushed toward the steel ball ...

Page 287: ...ove as arrowed and apply braking with brake disc 8 as adhered closely to brake plate 9 For parking step the brake pedal completely and pull the parking brake lever 10 to hold the pedal 1 Brake Pedal 2 Connecting Rod 3 Link 4 Connecting Rod 5 Brake Lever 4 2 OPERATION 6 Brake Cam 7 Cam Plate 8 Brake Disc 9 Brake Plate 10 Parking Brake Lever 569W704A www mymowerparts com K T Saw Shop 606 678 9623 or...

Page 288: ...illing plug 1 until reaching the gauge 2 After running the engine for few minutes stop it and check the oil level again add the fluid to prescribed level if it is not correct level IMPORTANT Use only SAE 80 90 gear oil Use of other oils may damage the transmission or hydraulic system Refer to LUBRICANTS FUEL AND COOLING WA TER See page 1 13 Do not mix different brands fluid together Capacity Trans...

Page 289: ...3 and starter 9 8 Disconnect the meter cable 13 at the engine side 1 2P Connector for Alternator 2 Clutch Rod 3 Jumper Lead for Fuel Level Sensor 4 Brake Rod LH 5 Shuttle Shift Lever 6 Connectors 7 Panel Frame Cover 8 Jumper Lead for Oil Switch 9 Jumper Lead for Starter 10 Brake Rod RH 11 Food Accelerator Rod 12 Accelerator Rod 13 Meter Cable 569W710A 569W711A 5 2 SEPARATING PANEL FRAME ASSEMBLY P...

Page 290: ...livery Hose 2 Return Hose 3 Right Turning Delivery Hose 4 Left Turning Delivery Hose Tightening torque Main delivery hose retaining nut Turning delivery hoses retaining nut 46 6 50 9 N m 4 8 5 2 kgf m 34 4 37 6 lbf ft 24 5 29 4 N m 2 5 3 0 kgf m 18 1 21 7 lbf ft Panel Frame and Steering Assembly 1 Remove the panel frame mounting crews Two screws a upper part Seven screws at lower part 2 Take out t...

Page 291: ...it 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 Preparation 1 Remove the Rops 2 Remove the Bolts 1 and take out the seat Assem bly 2 1 Bolt 2 Seat Assembly 569W714A www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 292: ...elivery pipe 3 and front hydraulic block Join bolt for delivery pipe 2 and front hydraulic block 49 0 58 8 N m 5 0 6 0 kgf m 36 2 43 4 lbf ft 34 3 39 2 N m 3 5 4 0 kgf m 25 3 28 9 lbf ft D SEPARATING CLUTCH HOUSING Propeller Shaft 1 Slide the propeller shaft cover 4 5 after remov ing the screws 9 2 Tap out the spring pin 10 and then slide the cou pling 2 to the front When reassembling Apply grease...

Page 293: ...e nylon lift strap at the tank support 3 Remove the engine mounting screws and then pull the engine to the front When reassembling Apply grease to the splines Apply liquid gasket There Bond 1208D or equivalent to joint face of the engine and clutch housing Tightening torque Engine and clutch Housing mounting Screws nuts Engine and clutch Housing mounting Stud bolts 77 5 90 2 N m 7 9 9 2 kgf m 57 1...

Page 294: ...rom the tractor When reassembling Tightening torque Rear axle case mounting screws Rear axle case mounting nuts Brake shaft LH RH Parking brake shaft mounting bolt Brake rod mounting nut 77 5 90 2 N m 7 9 9 2 kgf m 57 1 66 5 lbf ft 77 5 90 2 N m 7 9 9 2 kgf m 57 1 66 5 lbf ft 367 8 431 8 N m 37 5 44 0 kgf m 271 2 318 2 lbf ft 23 5 27 4 N m 2 4 2 8 kgf m 17 3 20 2 lbf ft 48 0 55 9 N m 4 9 5 7 kgf m...

Page 295: ...mbling Apply grease to the brake ball seats 16 Do not grease excessively Before installing the brake case 7 to the transmis sion case install the cam plate 14 to the trans mission case 1 Nut 9 Disc 2 Spring Washer 10 Plate 3 Plain Washer 11 Snap Ring 4 Brake Cam Lever 12 O Ring 5 Bolt 13 Brake Cam 6 Spring Washer 14 Cam Plate 7 Brake Case 15 Ball 8 Gasket 16 Ball Seat 5 5 DISASSEMBLING BRAKE CASE ...

Page 296: ...ked 1 Brake Pedal 2 Brake Rod 3 Parking Brake Lever 4 Brake Lever Brake pedal free play A Factory spec 25 40 mm 0 984 1 574 in 569W727A The difference between the right and left pedal plays must be less than 5 mm 0 20 in CAUTION Clearance between the stop switch and the brake pedal B Factory spec 0 1 0 mm 0 0 0393 in 5 Brake Rod 6 Brake Cam Lever 7 Stop Switch 8 Nut 3 After the adjustment of the c...

Page 297: ... and balls 3 Inspect the ball holes of cam plate for uneven wear If the uneven wear is found replace it Cam plate flatness Allowable limit 0 3 mm 0 012 in Height of cam plate and ball Factory spec Allowable limit 20 9 21 1 mm 0 8228 0 8307 in 20 6 mm 0 8110 in 569W728A 569W729A 569W730A Cam Plate Flatness 1 Place the cam plate on the surface plate 2 Use a feeler gauge of 0 3 mm 0 012 in thick for ...

Page 298: ... Wear 1 Measure the plate thickness with venire calipers 2 If the thickness is less than the allowable limit re place it Brake disc thickness Factory spec Allowable limit 4 6 4 8 mm 0 181 0 189 in 4 0 mm 0 1574 in Plate thickness Factory spec Allowable limit 2 54 2 66 mm 0 1000 0 1047 in 2 0 mm 0 0787 in 569W731A 569W732A www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 299: ...CHAPTER 8 ELECTRIC SYSTEM www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 300: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 301: ...TER 1 Records the hours and portions of hours that tractor has been operated Use the hour meter as a guide to determine hourly service and maintenance intervals If the engine is operated in approx 2000RPM of engine speed for an hour 1 hour of hour meter will be accumulated The lowest numbers on white ground indicate one tenth of an hour 3 TEMPERATURE GAUGE 2 Indicates coolant temperature It is act...

Page 302: ...ank C DIFFERENTIAL LOCK OPERATION LAMP 6 The light will illuminate when the differential lock pedal is engaged 1 2 INDICATORS AND WARNING LIGHTS D ENGINE OIL PRESSURE LAMP 7 The light will illuminate when the engine oil pressure is below than set value As soon as the light illuminate stop the engine and in vestigate the cause And must visit the nearest main tenance facilities E BATTERY CHARGING LI...

Page 303: ...NG LAMP 10 If the hydraulic filter is restricted or the vacuum pres sure of filter is increased over specified level this lamp turns on Stop the engine and check the hydraulic line H HEADLAMP HIGH BEAM INDICATOR 11 The light will be illuminated when the headlamp switch is located at high beam position I PARKING BRAKE WARNING LAMP 12 The light will be illuminate when the parking lever is pulled up ...

Page 304: ...sible link blown Wiring harness disconnected or improperly connected Main switch defective Glow plug indicator defective Timer relay defective Fuse blown Regulator relay defective Wiring harness disconnected or improperly connected Wiring harness disconnected or improperly connected Alternator defective Regulator relay defective Fuse blown Bulb blown Wiring harness disconnected or improperly conne...

Page 305: ...fective Engine oil pressure too low Engine oil insufficient Oil pressure switch defective Short circuit between oil pressure switch lead and chassis Bulb blown Oil pressure switch defective Wiring harness disconnected or improperly connected Circuit in instrument panel defective Fuse blown Coolant temperature gauge or fuel gauge fuel sender defective Wiring harness disconnected or improperly conne...

Page 306: ...0kw 12V 50A 14V 3 4W 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 voltage Rated power www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 307: ...otor 4 Key s w 5 Safety s w 6 PTO safety relay 7 PTO fuse 8 Neutral 9 Auto 10 Manual 11 PTO control s w 12 Micro s w 13 PTO Lamp Switch 4 MECHANISM 569W804B 4 1 STARTING SYSTEM A CIRCUIT DIAGRAM FOR STARTING SYSTEM www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 308: ...low through the motor section It is composed of the pull in coil holding plunger drive lever contact plate etc 569W805A 569W806A 1 PC Pull in coil 6 Armature 2 HC Holding coil 7 Pole cor 3 S Switch 8 Commutator 4 Drive lever clutch 9 Contact plate 5 Screw spline A Construction B Starter circuit 1 lever 2 Internal Gear Ass y 3 Front Bracket Ass y 4 Needle Bearing 5 6 Roller ORC Ass y 6 Planet Gear ...

Page 309: ...ani cal power which turns the engine crankshaft At this time the pinion is moved forward by the screw spline for more contact Since the pull in coil ends are short circuited by the contact plate the plunger is held only by force of the holding coil 569W808A E When key switch is release When the key switch is release a current flows instan taneously through the pull in coil in the opposite direc ti...

Page 310: ...ow plugs are quick heating type which make starting easier with short pre heating time 1 Housing 3 Insulating powder 2 Metal tube 4 Heat coil 1 Key s w 2 Main Fuse 3 Alternator 569W811B 4 2 CHARGING SYSTEM A CIRCUIT DIAGRAM FOR CHARGING SYSTEM 4 Diode 5 Battery charge warning lamp 6 Regulator 7 Battery www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 311: ...for various electrical devices and also charges the battery while the engine runs The alternator generates AC alternating current and the regulator converts AC into DC direct current It also controls the output voltage for charging current to the battery The regulator is built in inside of alternator www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 312: ... Capacity of the preheating controller DC12V B OPERATION FOR PREHEATING SYSTEM If the key switch is in ON position preheating system is operated automatically according to the coolant temperature If the coolant temperature is bellow 60 É the glow plug is heated up for 15 seconds Due to this combustion chambers are also heated up so that the engine becomes easier to start If the coolant temperature...

Page 313: ... this fuse failure continued investigate the whole wirings whether there are any short circuit to the ground or not In the case of sub fuse failure in fuse box replace it with new one If the fuse failure continued test the re lated devices and wirings and replace if necessary Classifi cation Cable standard Connec tion terminal Appli cable fuse Remark 3 5 11 13 21 6 7 15 36 66 77 AVS3 OR AVS2 OW AV...

Page 314: ...the coolant Electri cal resistance of thermostat decreases as the tempera ture increase Current varies with changes in the cool ant temperature and the increase of decreases in the current move the point of gauge 569W816A 1 Terminal 3 Body 2 Insulator 4 Thermostat C FUEL SENDER FUEL LEVEL GAUGE The fuel sender consists of float variable resister thermostat which are installed in the fuel tank As t...

Page 315: ...CHAPTER 9 CABIN SYSTEM www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 316: ...www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 317: ...isengage 4 setting bolts for cabin assembly 1 Cabin Support Front 3 Bolt 2 Cabin Support Rear 4 Bolt 3 Remove steering hose L R steering cylinder assembly and steering hose P T gear pump assembly 1 Steering Unit 4 Steering Hose T 2 Steering Hose L 5 Steering Hose P 3 Steering Hose R 569W901A 569W902A 569W903A www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 318: ... rod 3 connected to brake lever left right Remove accelerator cable and instrument panel cable 6 Remove all knobs in cabin and then right hydraulic lever guide and plate Remove main transmission and PTO device from left of cabin 1 Aircon Unit 6 Heater Ass y 2 R D 7 Heater Hose 3 Compressor 8 Pipe 4 Aircon Hose 1 9 Wiring Jack 5 Aircon Hose 2 1 Clutch Pedal 3 Break Rod 2 Break Pedal 4 Clutch Rod 1 ...

Page 319: ...ver 1 in left lower of cabin and then remove front wheel driving lever 2 9 Remove differential rod and differential spring from right lower of cabin 1 Bracket Main Shift Lever 2 Lever Main Shift Lever 3 Pin Main Shift Lever 4 Pin Joint 1 Lever 1 Front Drive 3 Pin Joint 2 Lever 2 Front Drive 4 Snap Pin 1 Rod Differential 3 Pin Snap 2 Spring 569W907A 569W908A 569W909A www mymowerparts com K T Saw Sh...

Page 320: ... double acting lever and rod double acting 12 Remove head pin and snap pin connected to lever 1 2 switch of rod switch and then remove rod switch 1 Lever 2 Hi Low 3 Lever Hi low 2 Rod Hi Low 4 Shaft Lever 1 Lever 1 Double Acting 5 Lever 1 2 Rod 6 Lever 2 3 Bracket 7 Joint Pin 4 Shaft 8 Snap Pin 1 Plate Switch 4 Rod Switch 2 Bracket Switch 5 Lever 1 Switch 3 Lever 2 6 Lever 569W910A 569W911A 569W91...

Page 321: ...r arm 3 and then disconnect shuttle lever from shuttle lever arm 1 Cover Frame 3 Lever Shuttle 2 Pin Straight 14 Remove cabin 569W913A CAUTION Disassemble cabin carefully ensur ing that it would not interfere with other parts or there would be parts not disas sembled www mymowerparts com K T Saw Shop 606 678 9623 or 606 561 4983 ...

Page 322: ...EVICE Heater switch is operated in two stages of High and Low Heater operation makes the temperature in cabin controllable through increasing and decreasing the level of coolant circulated in engine Ventilating hole moves in right left front and rear and can control the direction of air into cabin freely Hot water type HI 2170 kcal h Low 1900 kcal h Hi 230 m3 h Low 130 m3 h Less than 65 W DC12 V 8...

Page 323: ...o maintain the low temperature of a refrigerant b When the gas is pressed the temperature of the gas increases For the increase of pressure in the air conditioning system the compressor shall be used c When the gas is cooled this shall be concentrated to the fluid In the air conditioning system the con denser shall be used to cool the gas and store the consequent fluid in the receiver drier d When...

Page 324: ...a state of high pressure When the fluid refrigerant passes through the mea surement hole of extension valve the refrigerant is changed from high pressure fluid to the low tempera ture and low pressure injection fluid Such low pressure low temperature and injected fluid enters into the coil of the vaporizer to absorb the heat from the hot air of the cabin and blow it to the coil and the pin by blow...

Page 325: ...he system and the filter prohibits the external particles to enter in Ref The humidity of air conditioning system is abso lutely harmful The humidity that is not absorbed by a drying agent shall be circulated with a refrigerant and able to cool down the hole of automatic temperature control extension valve Such action prevent the flow of refrigerant and stop the operation of cooling The hu midity ...

Page 326: ...cause the refrigerant may be emitted to cause severe frost bite and injury E SAFETY PREVENTION MEASURES Never emit the refrigerant to the air When checking the air conditioning equipment the authorized en gineer should operate the authorized refrigerant recovery device When discharging the refrigerant to the system you should check whether the ventilation status is good on the assumption that the ...

Page 327: ...IR CONDITIONER CONTROL Air conditioner switch consists of air flow and tempera ture control switches Airflow control switch is oper ated in three stages of LOW MIDDLE and HIGH Turn ing temperature control switch clockwise enables to select the highest temperature Air conditioner ventilating grill can be controlled freely in left right front and rear Air conditioner can be operated only with start ...

Page 328: ... motor is normal but the capacity of wind is small Contamination of vaporizer Check the assembly status of cooling unit case Check whether the vaporizer is frozen with a circuit tester Removal of obstacles cleaning Modification or adjustment Replacement Causes Checking Methods Action 1 Obstacles in the inlet of suction of vaporizer 2 Air leakage 3 Poor thermo switch 3 The extract airflow and revol...

Page 329: ...ercharging of refrigerant Refer to lack of refrigerant Replacement Adjustment Replacement Replacement repair of compres sor Adhere the wound box to the low pressure pipe Replacement Supplement of refrigerant Replacement of the receiver drier Replacement of extension valve Replacement of extension valve Cleaning of pipe or replacement Adjustment replacement Cleaning repair or replacement of fan Adj...

Page 330: ...enomena The pressure of high low pressure side is low The bubble in sight glass is seen Discharging temperature does not fall down Cause Refrigerant leakage Action Check with gas leakage detector and repair the leaked part and supplement the proper amount CONNECTION OF MANIFOLD GAUGE Exhaust the air by loosening the nut 1 Connect the manifold gauge to the high low pres sure connection section of t...

Page 331: ...of refrigerant 3 Air mixing lack of vacuum working Status Not cool Phenomena The pressure of high low pressure side is high The pipe of low pressure side is not cold Cause Air mixing in the refrigerating cycle In case of no vacuum working the graduation is shown on the left figure Action When charging the refrigerant by making a vacuum check the guide In case of operating for a long time in the st...

Page 332: ...e broken suction valve Action Disassemble and repair the compressor 2 Moisture mixing Status Sometimes cold sometimes not cold Phenomena The pressure of low pressure side is sometimes negative or sometimes returning normal Cause The moisture inside refrigerating cycle is frozen which makes the cycle closed in the exten sion valve and return to the normal by melting of ice Action Replace the receiv...

Page 333: ... is closed by moisture freezing or dust in the refrigerating cycle The cycle is blocked due to the poor wound box of extension valve Action Stop the operation once to check the clog ging by moisture or dust If found the moisture do the vacuum working Detach the extension valve and remove the dust by air Replace the receiver drier Charge the proper amount of refrigerant 1 0332 kgf cm2 14 696 psi 5 ...

Page 334: ...e following order 6 Pressure Switch 7 A C Blower Switch 8 Ass y Air Conditional 9 Blower Motor 10 Thermostat Main Switch 3 ON A C Blower Switch 7 ON Low Medium High Blower Motor 9 ON Thermostat 10 ON if the temperature of thermostat is less than 4 C 39 2 F Pressure Switch 6 OFF to cut the mag netic clutch of the compressor Pressure Switch 6 ON A C relay 4 ON Compressor 5 ON Mag netic Clutch ON in ...

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