Service manual

ManualsBrandsCub Cadet ManualsLawn Mower8454

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

Summary of content (334 pages)

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www.mymowerparts.com CONTENTS CHAPTER 1. GENERAL INFORMATION ........................................................................................ 1-1 1. TRACTOR VIEW ............................................................................................................................................... 1-3 2. TIGHTENING TORQUE FOR STANDARD BOLTS AND NUTS ................................................................. 1-4 2.1 TIGHTENING TORQUE ....................................................
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www.mymowerparts.com CHAPTER 3. CLUTCH ....................................................................................................................... 3-1 1. TROUBLE SHOOTING.................................................................................................................................... 3-3 2. SPECIFICATIONS,TIGHTENING TORQUES AND SPECIAL TOOLS ...................................................... 3-4 2.1 SPECIFICATIONS ............................................................
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www.mymowerparts.com 3.3 POWER TRAIN ...................................................................................................................................... 4-9 3.3.1 TRANSMISSION ......................................................................................................................... 4-9 3.3.2 SHUTTLE SHIFT SECTION ................................................................................................... 4-10 3.3.3 MAIN SHIFT .........................................
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www.mymowerparts.com CHAPTER 6. HYDRAULIC SYSTEMS ............................................................................................. 6-1 1. HYDRAULIC LIFT SYSTEM ............................................................................................................................ 6-3 1.1 TROUBLE SHOOTING ......................................................................................................................... 6-5 1.2 SPECIFICATIONS ............................................
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www.mymowerparts.com 5.3 SEPARATING REAR FENDERS AND PLATFORM ASSEMBLY ..................................................... 7-11 5.4 DISASSEMBLING REAR AXLE CASE .............................................................................................. 7-14 5.5 DISASSEMBLING BRAKE CASE ...................................................................................................... 7-15 6. ADJUSTMENT OF THE BRAKE .....................................................................................
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www.mymowerparts.com GENERAL INFORMATION 1.
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www.mymowerparts.com CHAPTER 1 8454 2. TIGHTENING TORQUE FOR STANDARD BOLTS AND NUTS 2.1 TIGHTENING TORQUE Screws, bolts and nuts whose tightening torques are not specified in this workshop manual should be tightened according to the table below. A. TIGHTENING TORQUE FOR STANDARD BOLTS AND NUTS Grade No grade 4T Unit Nominal Diameter M6 (6 mm, 0.24 in.) M8 (8 mm, 0.31 in.) M 10 (10 mm, 0.39 in.) M 12 (12 mm, 0.47 in.) M 14 (14 mm, 0.55 in.) M 16 (16 mm, 0.63 in.) M 18 (18 mm, 0.71 in.
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www.mymowerparts.com GENERAL INFORMATION B. TIGHTENING TORQUE FOR STUDS M8 11.7 to 15.7 N·m 1.2 to 1.6 kgf·m 8.6 to 11.5 lbf·ft M10 24.5 to 31.4 N·m 2.5 to 3.2 kgf·m 18.0 to 23.1 lbf·ft M12 34.3 to 49.0 N·m 3.4 to 5.0 kgf·m 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) 1/8″ 1/4″ 1/4″ 3/8″ 3/8″ 1/2″ 3/4″ 1″ Tightening (N·m) 9.8 24.5 24.5 49.0 49.
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www.mymowerparts.com CHAPTER 1 8454 3. SPECIFICATION MODEL Maximum PTO power Engine GROSS power Engine 8454 Model Type Number of cylinders Bore and stroke Total displacement Rated revolution Injection timing Injection order Compression ratio Lubricating system Cooling system Capacities Dimensions (with std.
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www.mymowerparts.com 3. SPECIFICATION CON'T Drive system Tire size (Std. Tires) Front Rear Clutch Steering Transmission Brake Hydraulic system Differential Hydraulic lift control system Pump Capacity Travel Parking Main Pump Power steering pump Three point hitch Maximum lifting capacity No. of remote control valve ports (option) PTO PTO shaft Revolution (independent PTO) Min.
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www.mymowerparts.com CHAPTER 1 8454 4. IDENTIFICATION 4.1 ENGINE NUMBER Engine number is engraved in the left side of the cylinder block as shown in the figure.Engine number fills the important role of providing it’s record. 569W103A (1) Engine Serial Number 4.2 SERIAL NUMBER OF THE TRACTOR Serial number of the tractor is stamped on the left side of the front axle frame as shown in the figure.
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www.mymowerparts.com GENERAL INFORMATION 5. CAUTION BEFORE REPAIR 5.1 BEFORE REPAIR OR INSPECTION 1. In case of repair or inspection, locate the tractor on the flat ground and pull the parking brake on. 2. Except for the items to be checked while the engine is running, be sure to stop the engine prior to the work. 7. Finish assembly within 20 minutes after applying sealant, after that, wait approx. 30 minutes later before filling with oil. 5.3 PARTS TO BE REPLACED 3.
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www.mymowerparts.com CHAPTER 1 8454 5.5 ASBESTOS PARTS Since dust out of asbestos fibrous parts is extremely dangerous to your health, be sure to clean such parts carefully, do not use compressed air. 5.6 ELECTRICAL SYSTEM 1. Check electrical wiring every year for any damage or short circuit at the connections. In addition, have your dealer inspection the electric system regularly. 2. Do not modify or reorganize the wiring of the electric field parts. 3.
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www.mymowerparts.com GENERAL INFORMATION 5.7 TUBES AND RUBBERS 5.8 LUBRICANT 569W111A Be cautious of oil or other petroleum products on the hoses and rubber parts, this may cause damage. 569W112A When assembling and fixing, apply designated lubricant where specified in accordance with this repair manual.
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www.mymowerparts.com CHAPTER 1 8454 6.
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www.mymowerparts.com GENERAL INFORMATION 7. OIL & WATER SUPPLY LIST Supply Items Fuel Capacity (42.3 U.S.gal.) 40 Recommended Spec. No. 2 - D diesel fuel No. 1 - D diesel fuel if temperature is below - 10 °C (14 °F) Coolant 8.9 (2.4 U.S.gal.) Fresh clean water with antifreeze Engine oil 7.0 (1.8 U.S.gal.) SAE 15 W - 40 Transmission oil 34 (9.0 U.S.gal.) Universal tractor/transmission Front axle section 8.2 (2.2 U.S.gal.
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www.mymowerparts.com ENGINE 1. GENERAL 1.1 APPEARANCE 569W201A The DAEDONG A series engines are vertical, watercooled, 4-cycle, three or four cylinders diesel engines, they concentrate DAEDONG’s foremost technologies. With swirl combustion chamber, bosch K type fuel injection pump, well-balanced designs, they feature greater power, low fuel consumption, less vibration and noise, and low emission.
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www.mymowerparts.com CHAPTER 2 8454 1.2 SPECIFICATIONS MODEL Type Number of cylinder Bore and stroke mm (in.) 3 Total displacement cc (in .) 4A220 4A200T Vertical, water-cooled, Vertical, water-cooled, 4-cycle diesel engine 4-cycle diesel engine (Turbo) 4 4 87.0 x 92.4 (3.43 x 3.64) 83.0 x 92.4 (3.27 x 3.64) 2,197(134.1 ) 1,999(122.0) vortex chamber vortex chamber 43/2,700 (30.9/2,700) 47/2,600 (34.
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www.mymowerparts.com ENGINE 1.
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www.mymowerparts.com CHAPTER 2 8454 1.4 DIMENSIONS 569W205A Sample/td Spec. mm (in.) A B C D E F 4A220 697.3 (27.45) 817.3 (32.18) 280 (11.02) φ 400 (15.75) 502.6 (19.79) 262.5 (10.33) 4A200T 697.3 (27.45) 817.3 (32.18) 280 (11.02) φ 400 (15.75) 519 (20.43) 282.4 (11.12) G H I J K L 4A220 736 (28.98) 260 (10.24) 240 (9.45) φ 321 (12.64) 104.5 (4.11) - 4A200T 736 (28.98) 260 (10.24) 240 (9.45) φ 321 (12.64) 104 (4.09) 542 (21.34) 1.
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www.mymowerparts.com ENGINE 2. STRUCTURE AND FUNCTION 2.1 BODY A. CYLINDER HEAD The cylinder head is made of special alloy cast iron which can resist high temperature and pressure caused by combustion. The intake and exhaust ports are arranged cross-flow type to get high combustion efficiency by protecting the suction air from being heated and expanded by heated exhaust air. The Daedong vortex type combustion chamber is designed for high efficiency combustion and reducing fuel consumption.
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www.mymowerparts.com CHAPTER 2 8454 C. CRANKSHAFT The crankshaft is made of forged steel and the journals, the crankpins and the bearing surface for the oil seal are induction-hardened to increase wear resistance. Each crankshaft journal is supported by the main bearing case (3) having a bearing inside. The front crankshaft bearing (2) is a solid type bushing and rear and intermediate bearings are a split type. The crankshaft’s bearings have oil holes for lubricant flow.
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www.mymowerparts.com ENGINE F. CAMSHAFT The camshaft (3) is made of forged steel and it’s journals and cams are hardened to increase wear resistance. The cams on the camshaft open and close the intake and exhaust valves with the push rods and rocker arms. The journals and their bearings are forcelubricated. 569W212A (1) Cam Gear (3) Camshaft (2) Camshaft Stopper G. FUEL CAMSHAFT This fuel camshaft is made of forged steel and its cams are hardened and tempered to increase wear resistance.
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www.mymowerparts.com CHAPTER 2 8454 I. INTAKE AND EXHAUST VALVES The valve and its guide of the intake are different from those for the exhaust. Other parts, such as the spring, spring retainers, valve spring collets, valve stem seals are the same for both the intake and the exhaust. All contact or sliding surfaces are hardened to increase wear resistance. 569W215A (1) Valve Spring Collet (4) Valve Stem Seal (2) Valve Spring Retainer (5) Exhaust Valve (3) Valve Spring (6) Intake Valve J.
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www.mymowerparts.com ENGINE 2.2 LUBRICATING SYSTEM A. FLOW OF LUBRICATING OIL The lubricating oil is forced to each journal through the oil passages of the cylinder block, cylinder head and shafts. The oil, splashed by the crankshaft or thrown off from the bearings, lubricates other engine parts such as the push rods (11), tappets (12), piston pins and timing gears.
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www.mymowerparts.com CHAPTER 2 8454 C. OIL FILTER AND RELIEF VALVE The lubricating oil force-fed by the pump is filtered by the filter cartridge, passing through the filter element from the outside to the inside. When the filter element accumulates dirt and the pressure difference between the inside and the outside rises more than 98 kPa (1.0 kgf/cm 2, 14 psi), the bypass valve (1) opens to allow the oil to flow from the inlet line to outlet line, bypassing the filter element.
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www.mymowerparts.com ENGINE 2.3 COOLING SYSTEM A. FLOW OF COOLING WATER The cooling system consists of a radiator (5), a centrifugal water pump (7), a cooling fan (6) and a thermostat (2). The water is cooled as it flows through the radiator core, and the fan behind the radiator pulls the cooling air through the radiator core. The water pump receives water from the radiator or from the cylinder head and forces it into cylinder block. The thermostat open or closes according to the water temperature.
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www.mymowerparts.com CHAPTER 2 8454 C. THERMOSTAT The thermostat is wax pellet type, which controls the flow of the cooling water to the radiator to keep the proper temperature. The case has a seat (1) and the pellet has a valve (2). The spindle attached to the case is inserted into the synthetic rubber in the pellet. The pellet is charged with wax. (A) At low temperature (lower than 71 °C (160 °F)).
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www.mymowerparts.com ENGINE 2.4 FUEL SYSTEM A. FLOW OF FUEL The fuel is fed from the fuel tank (1) through the fuel feed pump (7) to the injection pump (3) thru the fuel filter (2). The injection pump force-feds the fuel through the injection nozzles (5), which inject the fuel into the cylinders for combustion. 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.
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www.mymowerparts.com CHAPTER 2 8454 C. FUEL FEED PUMP The diaphragm (6) is linked to the tappet (3) with a push rod (2). The tappet is reciprocated by the eccentric 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).
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www.mymowerparts.com ENGINE a . Pump Element The pump element (1) consists of a plunger (3) and cylinder (2), their sliding surfaces are precision machined to maintain fuel tightness. The plunger (3) fits in the control sleeve (5) at the driving surface (7). The sleeve is engaged with the control rack, which rotate the plunger in the cylinder to control the amount of fuel delivery.
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www.mymowerparts.com CHAPTER 2 8454 c. Amount of Fuel Delivery (A) No fuel delivery At the engine stop position of the control rack (3), the lengthwise slot (1) on the plunger (2) aligns with the feed hole (5). The delivery chamber (4) is led to the feed hole during the entire stroke of the plunger. The pressure in the delivery chamber does not build up and no fuel is forced to the injection nozzle.
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www.mymowerparts.com ENGINE E. FUEL INJECTION NOZZLE The nozzle is a throttle-type. It features low fuel consumption 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 overcomes the counterforce of nozzle valve spring, and push the valve up instantly, the fuel is then injected in a proper quantity into the swirling air in the combustion chamber for combustion.
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www.mymowerparts.com CHAPTER 2 8454 b. Operation of Governor a) At start The steel balls (13) have no centrifugal force. As the fork lever 1 (4) is pulled by the start spring (1), the control rack (14) moves to the maximum injection position. At start, the sufficient injection of the fuel enables easy starting.
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www.mymowerparts.com ENGINE c) At High Speed Running with a Load When a load is applied to an engine running at high speed, the engine speed drops and the centrifugal force of steel ball (13) becomes less, the fork lever 2 (5) is pulled forward by the governor spring 1 (2) and 2 (3), this increases the amount of fuel injected. The fork lever 2 (5) becomes ineffective in increasing the fuel injection when it is stopped by the adjusting bolt (17).
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www.mymowerparts.com CHAPTER 2 8454 2.5 INTAKE AND EXHAUST SYSTEM A. FLOW OF INTAKE AIR AND EXHAUST GAS (a) Intake Air (b) Exhaust Gas (1) Intake Manifold (2) Air Cleaner (3) Cylinder Head (4) Muffler (5) Exhaust Manifold 569W241A B. AIR CLEANER The air cleaner is dry-cyclone type and easy to maintain. 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.
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www.mymowerparts.com ENGINE D. TURBOCHARGER (8454) The mechanism of turbocharger is the use of exhaust gas energy which rotates turbine and the power is transmitted to air compressor by a shaft. So it is possible to supply more fuel to a cylinders and this will increase the power. It is recommended not to accelerate suddenly just about starting or stopping the engine suddenly after driving.
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www.mymowerparts.com CHAPTER 2 8454 3. DISASSEMBLING AND SERVICING 3.
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www.mymowerparts.com ENGINE 3.2 SERVICING SPECIFICATIONS A. ENGINE BODY a . Cylinder Head Item Factory Specification Allowable Limit 0.05 mm / 100 mm Cylinder Head Surface Flatness 0.002 in. / 3.94 in. 0.75 ~ 0.9 mm Top Clearance - 0.0295 ~ 0.0354 in. Cylinder Head Gasket Thickness 1.3 ~ 1.5 mm Free 0.0512 ~ 0.0591 in. - 1.15 ~ 1.25 mm Tightened 0.0453 ~ 0.0492 in. Compression Pressure (When cranking with starting motor) 3.24 ~ 3.73 MPa 2.
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www.mymowerparts.com CHAPTER 2 8454 d. Cylinder Bore Item Cylinder bore inner diameter Factory Specification Allowable Limit 4A220 87.000 ~ 87.022 mm 3.4252 ~ 3.4261 in. 0.15 mm 4A200T 83.000 ~ 83.022 mm 0.0059 in. 3.2677 ~ 3.2690 in. e . Valve Spring Item Free length Assembling load / assembling length Squareness Factory Specification Allowable Limit 41.7 ~ 42.2 mm 41.2 mm 1.6417 ~ 1.6614 in. 1.6220 in. 12.0 kgf / 35.15 mm 10.2 kgf / 35.15 mm 26.46 lbs / 1.3839 in. 22.49 lbs / 1.
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www.mymowerparts.com ENGINE I. Timing Gear Item Timing gear backlash Idle gear side clearance Clearance between Factory Specification Allowable Limit 0.04 ~ 0.11 mm 0.15 mm 0.0016 ~ 0.0043 in. 0.0059 in. 0.20 ~ 0.51 mm 0.9 mm 0.0079 ~ 0.0201 in. 0.035 in. Idle gear shaft and idle gear bushing 0.025 ~ 0.066 mm 0.1 mm 0.00098 ~ 0.00260 in. 0.0039 in. Idle gear shaft O.D 37.959 ~ 37.975 mm - 1.49445 ~ 1.49508 in. Idle gear bushing I.D 38.000 ~ 38.025 mm - 1.49606 ~ 1.49705 in. j.
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www.mymowerparts.com CHAPTER 2 8454 l. Crankshaft Item Factory Specification Crankshaft Misalignment Clearance between Allowable Limit 0.08 mm - 0.0031 in. Crankshaft and crankshaft bearing 1 0.040 ~ 0.118 mm 0.20 mm 0.00157 ~ 0.00465 in. 0.0079 in. Crankshaft O.D 51.921 ~ 51.940 mm - 2.04414 ~ 2.04489 in. Crankshaft bearing 1 I.D 51.980 ~ 52.039 mm - 2.04646 ~ 2.04878 in. Clearance between Crankshaft and crankshaft bearing 2 Crankshaft O.D 0.040 ~ 0.104 mm 0.20 mm 0.00157 ~ 0.
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www.mymowerparts.com ENGINE C. COOLING SYSTEM a . Thermostat Valve opening temperature at beginning 69.5 ~ 72.5 °C (157.1 ~ 162.5 °F) Opened completely (height 8 mm 0.315 in.) 85 °C (185 °F) b. Radiator Radiator tightness No leak at 137 kPa, 1.4 kgf/cm2, 20 psi 10 seconds or more for pressure falling from 88 ~ 59 kPa from 0.9 ~ 0.6 kgf/cm 2 Radiator cap tightness from 13 ~ 9 psi Fan belt tension 7 ~ 9 mm [deflection at 98 N (10 kgf, 22 lbs) of force] 0.28 ~ 0.35 in. D. FUEL SYSTEM a .
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www.mymowerparts.com CHAPTER 2 8454 E. TIGHTENING TORQUES Size x Pitch N•m kgf•m lbf·ft Cylinder head screws M11 x 1.25 103.0 ~ 107.9 10.5 ~ 11.0 75.9 ~ 79.6 Head cover nuts M10 x 1.25 8.8 ~ 10.8 0.9 ~ 1.1 6.5 ~ 8.0 * Bearing case screw 1 M9 x 1.25 46.1 ~ 51.0 4.7 ~ 5.2 34.0 ~ 37.6 * Bearing case screw 2 M10 x 1.25 68.6 ~ 73.6 7.0 ~ 7.5 50.6 ~ 54.2 * Flywheel screw M12 x 1.25 98.1 ~ 107.9 10.0 ~ 11.0 72.3 ~ 79.6 * Connecting rod screws M8 x 1.0 46.1 ~ 51.0 4.5 ~ 5.0 34.
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ENGINE 3.3 CHECKING, DISASSEMBLING AND SERVICING A. ENGINE DISASSEMBLED VIEW www.mymowerparts.
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www.mymowerparts.com ENGINE B. EXTERNAL COMPONENTS a . Checking and Adjusting 1) Fan belt Measure the deflection, depressing the belt halfway between the fan drive pulley and the alternator pulley at 98 N (10 kgf, 22 lbs) of force. If the deflection is not between the factory specifications, loosen the bolts and nuts, and relocate the alternator to adjust. If the belt is damaged or worn (see figure), replace the belt. Belt tension (deflection) Factory spec 7 ~ 9 mm 569W249A 0.28 ~ 0.35 in. b.
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www.mymowerparts.com CHAPTER 2 8454 2) Solenoid 1. Disconnect the stop lever 1 (5) from the engine stop lever (2). 2. Remove the screw (3) and (4). 3. Remove the solenoid (7) with its support. (When reassembling) • Loosen the solenoid mounting screws. • Install the support and complete the linkage between the solenoid (7) and the engine stop lever (2).
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www.mymowerparts.com ENGINE C. ENGINE BODY a . Checking and Adjusting 1) Compression pressure 1. Run the engine until warmed up. 2. Stop the engine and remove the air cleaner, the muffler and all nozzle holders. 3. Connect a compression tester to the nozzle holder hole. 4. Pull the stop lever to cut the fuel and run the engine with the starter at 250 ~ 350 rpm for 5 ~ 10 seconds. 5. Measure the maximum pressure while running, several times. 569W253A 6.
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www.mymowerparts.com CHAPTER 2 8454 2) Valve clearance 1. Remove the cylinder head cover and the timing window cover on the flywheel housing and all glow plugs. 2. Turn the flywheel and align the 1 TC 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.
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www.mymowerparts.com ENGINE 2) Heat seal removal procedure 1. Drive screw driver lightly into the heat seal hole. 2. Turn screw driver three or four times each way. 3. While turning the screw driver, slowly pull the heat seal put together with the injection nozzle gasket. If the heat seal drops, repeat the above procedure. 4. Heat seal and injection nozzle gasket must be changed when the injection nozzle is removed for cleaning or for service.
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www.mymowerparts.com CHAPTER 2 8454 4) Cylinder head 1. Remove the screw in the specified sequence shown in the figure and remove the cylinder head (1) and head gasket. 2. Remove the water flange (2). 3. Take out the tappets from the cylinder block. NOTE: • Mark the cylinder number to the tappets to prevent interchanging. (When reassembling) • Apply liquid gasket (Three bond 1215 or equivalent) on the both sides of water flange gasket.
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www.mymowerparts.com ENGINE c. Timing Gears and Camshafts 1) Injection pump 1. Remove the injection pump cover (3) with the engine 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).
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www.mymowerparts.com CHAPTER 2 8454 3) Start spring 1. Remove the start spring (1) from the fork lever 1 (2). (When reassembling) • Be careful not to drop the start spring into the gear case. • Hook the start spring so that the longer hook is on the fork lever side. 569W266A (1) Start Spring (2) Fork Lever 1 4) Fan drive pulley 1. Install the stopper to the flywheel so that the crankshaft may not turn. 2. Flatten the metal lock and loosen the crankshaft nut (2). 3.
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www.mymowerparts.com ENGINE 6) Water pump and relief valve 1. Remove the water pump body (1). 2. Remove the relief valve cover (2) and take out the ball, spring and seat. (When reassembling) • Install the relief valve cover (2) with its mark up. Tightening Relief valve torque cover screw 32.4 ~ 36.3 N·m 3.3 ~ 3.7 kgf·m 23.9 ~ 26.8 lbf·ft 569W269A (1) Water Pump Body (2) Relief Valve Cover 7) Idle gear and crank gear 1.
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www.mymowerparts.com CHAPTER 2 8454 8) Camshaft 1. Align the holes on the cam gear (2) with the crews to loosen them through the holes with a T handle wrench. 2. Draw out the camshaft (1). 3. Remove the cam gear (2). (When reassembling) • Heat the cam gear to approx. 80 °C (176 °F) and insert the camshaft (1). 569W272A (1) Camshaft (2) Cam Gear 9) Fuel camshaft 1. Remove the fuel camshaft stopper. 2.
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www.mymowerparts.com ENGINE (B) Piston and connecting rod 1. Remove the screws and the connecting rod cap. 2. Push out the rod and piston assembly. (When reassembling) • Apply oil to the crankpin bearing, cylinder wall and connecting rod cap screw. • Insert the rod and piston assembly with the mark on the rod facing the injection pump, using a piston ring compressor. IMPORTANT: • Mark the cylinder number on the piston and connecting rod to prevent interchanging.
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www.mymowerparts.com CHAPTER 2 8454 • Install the piston and connecting rod with the mark FW on the piston to the flywheel and the mark on the connecting rod to the injection pump. • Install the piston rings with their manufacture’s mark to the top of the piston. • Install the expander in the oil ring with its gap opposite to the gap of oil ring. • Install the top ring with its gap at 1.57 rad (90°) from the piston pin to the exhaust port.
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www.mymowerparts.com ENGINE (B) Bearing case cover Loosen the screw first inside and next outside, and lift the cover (1) by screwing two screws gradually and evenly, referring to the photo. (When reassembling) • Apply grease to the oil seal lip and take care that it is not rolled when installing. Tightening torque Bearing case cover screw 23.5 ~ 27.5 N·m 2.4 ~ 2.8 kgf·m 17.4 ~ 20.3 lbf·ft 569W281A (1) Bearing Case Cover (C) Crankshaft 1. Remove the bearing case screw 2. 2.
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www.mymowerparts.com CHAPTER 2 8454 IMPORTANT: • Mark a location line (6) to the bearing case, to prevent interchanging. (When reassembling) • Clean the parts and the oil passage of the bearing case. • Apply oil to the journal, bearing inserts and the bearing case screws. • Place the thrust bearings on the bearing case with their oil groove outside. • Install the main bearing case with the mark “FLY WHEEL” toward the flywheel. Tightening torque Bearing case screw 1 46.1 ~ 51.
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www.mymowerparts.com ENGINE (C) Valve stem clearance 1. Remove the carbon from the valve guide. 2. Measure the valve stem O.D. with an outside micrometer. 3. Measure the valve guide I.D. of cylinder head, and calculate the clearance. 4. If the measurement exceeds the allowable limit, replace the valve guide of the valve. Valve stem clearance Factory spec. 0.040 ~ 0.070 mm 0.00157 ~ 0.00276 in. Allowable limit Valve guide bore I.D. Factory spec. Valve stem O.D. Factory spec. 0.1 mm 0.004 in.
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www.mymowerparts.com CHAPTER 2 8454 (F) Valve spring 1. Measure the free length of the spring with venire calipers. 2. Place the spring on a spring compression tester and compress to the specified length, and get the tension. 3. If the measurement is less than the allowable limit, replace the valve spring. Tension Factory spec. 117 N/35.15 mm 12.0 kgf/35.15 mm 26.5 lbs/1.3839 in. Allowable limit 100 N/35.15 mm 569W290A 10.2 kgf/35.15 mm 22.5 lbs/1.3839 in. Free length Factory spec. 41.7 ~ 42.
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www.mymowerparts.com ENGINE b. Timing Gears and Camshafts (A) Timing gear backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear. 3. If the backlash exceeds the allowable limit, check the oil clearance of the shafts and the gear. 4. If the oil clearance is proper, replace the gear. Clearance Factory spec. Allowable limit 0.04 ~ 0.11 mm 0.0016 ~ 0.0043 in. 0.15 mm 569W293A 0.0059 in. (B) Idle gear side clearance 1.
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www.mymowerparts.com CHAPTER 2 8454 (D) Injection pump gear side clearance 1. Pull the fuel camshaft and pull the injection pump gear (1) to each end. 2. Measure the clearance (A) between the injection pump gear (1) and the snap ring (2) on the fuel camshaft. 3. If the clearance exceeds the allowable limit, check the gear, the bearing and the key. Side clearance Factory spec. 0.15 ~ 0.57 mm 0.0059 ~ 0.0224 in. 0.9 mm Allowable limit 0.035 in.
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www.mymowerparts.com ENGINE (G) Camshaft oil clearance 1. Measure the I.D. of the camshaft bore on the crankcase with an inside micrometer. 2. Measure the O.D. of the camshaft journal with an outside micrometer. 3. If the clearance exceeds the allowable limit, replace the shaft. Factory spec. Oil clearance 0.050 ~ 0.091 mm 0.00197 ~ 0.00358 in. Allowable limit Journal O.D. Factory spec. Bore I.D. Factory spec. 0.15 mm 0.0059 in. 39.934 ~ 39.950 mm 569W299A 1.57221 ~ 1.57284 in. 40.000 ~ 40.
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www.mymowerparts.com CHAPTER 2 8454 c. Connecting Rod and Piston (A) Piston pin bore 1. Measure the I.D. of the piston pin bore in piston (lengthwise and widthwise of the piston) with a cylinder gauge. 2. If the measurement exceeds the allowable limit, replace the piston. Piston pin bore I.D. Factory spec. 25.000 ~ 25.006 mm Allowable limit 25.03 mm 0.9843 ~ 0.9845 in. 0.9854 in. 569W2A2A (B) Piston pin and brushing clearance 1. Measure the piston pin O.D. with an outside micrometer. 2.
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www.mymowerparts.com ENGINE (D) Piston ring end gap 1. Push the ring into the cylinder to the lower limit of the ring travel in the assembled engine with a piston. 2. Measure the ring gap with a feeler gauge. 3. If the gap exceeds the allowable limit, replace the piston ring. Piston ring end gap 2nd ring Factory spec. Allowable limit Top ring, oil ring Factory spec. Allowable limit 0.55 ~ 0.70 mm 0.0217 ~ 0.0276 in. 1.25 mm 0.0492 in. 0.25 ~ 0.40 mm 569W2A5A 0.0098 ~ 0.0157 in. 1.25 mm 0.0492 in.
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www.mymowerparts.com CHAPTER 2 8454 (F) Connecting rod alignment 1. Remove the connecting rod bearing and install the bearing cap. 2. Install the piston pin in the connecting rod. 3. Install the connecting rod on the connecting rod alignment tool. 4. Put a gauge over the piston pin and move it against the face plate. 5. If the gauge does not fit squarely against the face plate, measure the space between the pin of the gauge and the face plate. 6.
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www.mymowerparts.com ENGINE (B) Crankshaft alignment 1. Support the crankshaft with V blocks on the surface plate at its front and rear journals and set a dial indicator with its tip on the intermediate journal. 2. Rotate the crankshaft in the V blocks and get the misalignment (half of the measurement). 3. If the misalignment exceeds the allowable limit, replace the crankshaft. Misalignment allowable limit 0.08 mm 0.0031 in. 569W2A9A (C) Crankshaft journal and bearing 1 oil clearance 1. Measure the I.D.
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www.mymowerparts.com CHAPTER 2 8454 (E) Crankshaft Journal and Bearing 2 Oil Clearance 1. Put plastic gauge lengthwise in the center of the journal. 2. Install the bearing cap and tighten the screw to the specified torque once, and remove the cap again. 3. Measure the amount of the flattening with the scale and get the oil clearance. 4. If the clearance exceeds the allowable limit, replace replace the bearing. Oil clearance Factory spec. Allowable limit Journal O.D. Bearing 2 I.D.
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www.mymowerparts.com ENGINE e . Cylinder Bore (A) Cylinder bore diameter 1. Measure the cylinder liner I.D. at sit positions shown in the figure to find the maximum wear. 4A200T 83.000 ~ 83.022 mm . 3.2677 ~ 3.269 in. 87.000 ~ 87.022 mm 4A220 3.4252 ~ 3.4261 in.
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www.mymowerparts.com CHAPTER 2 8454 E. LUBRICATING SYSTEM a . Checking (A) Engine oil pressure 1. Remove the oil pressure switch and install adaptors and pressure tester. 2. Start the engine and run it until it is warmed up, and measure the oil pressure both at idling and rated speed. 3. If the oil pressure is less than the allowable limit, check the amount of oil, oil filter, oil pump relief valve, oil passages and oil clearance. Engine oil pressure At idle speed Factory spec.
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www.mymowerparts.com ENGINE b. Servicing (A) Rotor and lobe clearance of oil pump 1. Measure the clearance between the outer and inner 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. 569W2B7A 0.11 ~ 0.
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www.mymowerparts.com CHAPTER 2 8454 F. COOLING SYSTEM a . Checking Adjusting (A) Fan belt 1. Measure the deflection, by depressing the belt halfway between the fan drive pulley and the alternator pulley at 98 N (10 kgf, 22 lbs) of force. 2. If the deflection is not between the factory specifications, loosen the bolts and nuts, and relocate the alternator to adjust. 3. If the belt is damaged or worn (see figure), replace the belt. Belt tension (direction) Factory spec 7 ~ 9 mm 569W2C0A 0.28 ~ 0.35 in.
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www.mymowerparts.com ENGINE b. Disassembling and Assembling (A) Thermostat 1. Remove the thermostat cover (2). 2. Take out the thermostat (1). (When reassembling) • Apply liquid gasket (Three Bond 1215 or equivalent) to the gasket. 569W2C3A (1) Thermostat (2) Thermostat Cover (B) Water pump 1. Remove the fan and fan pulley. 2. Remove the water pump body from gear case cover. 3. Remove the water pump flange (1). 4. Remove the impeller and water pump shaft (3). 5.
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www.mymowerparts.com CHAPTER 2 8454 G. FUEL SYSTEM a . Checking and Adjusting 1) Injection pump (A) Injection term (Injection timing) 1. Remove the injection pipes. 2. Set the speed control lever to the maximum fuel discharge position. 3. Turn the flywheel counterclockwise (facing the flywheel) until the fuel flows through the hole of the delivery valve holder (1). 4. Turn the flywheel further and stop turning when the fuel stops to flow, to check the injection timing. 5.
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www.mymowerparts.com ENGINE (B) Delivery valve fuel tightness 1. Remove the injection pipes, glow plugs and the inlet manifold, and install a pressure tester. 2. With the speed control lever at the fuel injection position, turn the crankshaft counterclockwise (facing the flywheel) until the pressure builds up to the fuel injection pressure. 3. Release the pressure in the delivery chamber by moving down the plunger to bottom dead center (turn the crankshaft clockwise approx 1.
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www.mymowerparts.com CHAPTER 2 8454 (B) Fuel tightness of needle valve seat tightness 1. Set the injection nozzle to the nozzle tester. 2. Apply a pressure 130 kgf/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 c.
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www.mymowerparts.com ENGINE 2) Injection nozzle Nozzle Holder 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1), and take out the parts inside. (When reassembling) • Assemble the nozzle in clean fuel oil. • Install the push rod (4), nothing its direction.
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www.mymowerparts.com CLUTCH 1.
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www.mymowerparts.com CHAPTER 3 8454 2. SPECIFICATIONS, TIGHTENING TORQUES AND SPECIAL TOOLS 2.1 SPECIFICATIONS Item Factory Specifications Free Play Clutch pedal Allowable Limit 20 ~ 30 mm - 0.79 ~ 1.18 in. Clearance Safety switch 2 ~ 5 mm - 0.079 ~ 0.197 in. Clutch disc spline boss to shuttle shaft Backlash 2.0 mm Depth Clutch disc surface to rivet 0.079 in. 0.3 mm - 0.012 in. Flatness Pressure plate 0.2 mm - 0.008 in. 2.
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www.mymowerparts.com CLUTCH 3. STRUCTURE AND OPERATION The clutch is located between the engine and the transmission and is operated by stepping on the clutch pedal. When the clutch pedal is depressed, the clutch is disengaged and when it is released, the clutch is engaged and power from the engine is transmitted to the transmission. These tractors are equipped with a single plate clutch. 3.1 FEATURES • Ind. styled clutch is applied available to operate the travel power and PTO power independently.
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www.mymowerparts.com CHAPTER 3 8454 3.3 OPERATION CLUTCH “ENGAGED” When the clutch pedal is not depressed, the clutch release bearing (3) and the fingers of diaphragm spring (4) are not connected to each other. Accordingly, the pressure plate (6) is tightly pressed against the flywheel (8) by the diaphragm spring (4).
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www.mymowerparts.com CLUTCH 4. PREPARATION STAGE FOR DISASSEMBLING AND ASSEMBLING 4.1 SEPARATING PANEL FRAME ASSEMBLY PREPARATION 1 1. Removing the following parts. • Bonnet • Side Cover (RH, LH) • Side Skirt (RH, LH) • Battery Negative Code 569W303A (1) Side Cover (RH, LH) (4) Side Skirt (RH, LH) (2) Bonnet (5) Battery Negative Code (3) Front Grille PREPARATION 2 1. Disconnect the brake rods (4), (10). 2. Disconnect the clutch rod (2). 3. Remove the accelerator cable (12). 4.
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www.mymowerparts.com CHAPTER 3 8454 HYDRAULIC HOSES 1. Disconnect the main delivery hose (1), return hose (2), right turning delivery hose (3) and left turning delivery hose (4). (When reassembling) • In assembling the turning delivery hoses to the steering controller, connect the delivery hose with identification mark (type) “A” to the L port of the steering controller. Tightening torque Main delivery hose retaining nut 46.6 ~ 50.9 N·m 4.8 ~ 5.2 kgf·m 569W307A 34.4 ~ 37.
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www.mymowerparts.com CLUTCH 4.2 SEPARATING ENGINE AND CLUTCH HOUSING CASE PROPELLER SHAFT 1. Slide the propeller shaft covers (4), (5) after removing to bolt (9). 2. Tap out the spring pin (10), and then slide the coupling (2) the front. (When reassembling) • Apply grease to the splines of the propeller shaft. 569W310A (1) Propeller Shaft (6) O-Ring (2) Coupling (7) O-Ring (3) Cir-Clip (8) O-Ring (4) Propeller Shaft Cover (9) Bolt (5) Propeller Shaft Cover (10) Spring Pin HYDRAULIC PIPES 1.
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www.mymowerparts.com CHAPTER 3 8454 SEPARATION THE ENGINE FROM CLUTCH HOUSING 1. Place the jack under the clutch housing case. 2. Hoist the engine by the nylon lift strap at the tank support. 3. Remove the engine mounting screws, and then pull the engine to the front. (When reassembling) 1. Apply grease to the splines. 2. Apply liquid gasket (Three Bond 1,208D or equivalent) to joint face of the engine and clutch housing. Tightening torque Engine and clutch housing mounting screws, nuts 77.5 ~ 90.
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www.mymowerparts.com CLUTCH 5. ADJUSTMENT OF PEDAL 5.1 DEFLECTION OF CLUTCH PEDAL A. Measure deflection of pedal by pushing clutch pedal (1) with hand. B. If the measurement is out of the factory spec, remove lock nut (2) on clutch wire and adjust the length. Deflection of clutch pedal (A) Factory spec 20 ~ 30 mm 0.79 ~ 1.18 in.
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www.mymowerparts.com CHAPTER 3 8454 6. INSPECTION AND REPAIR 6.1 WEAR AND DAMAGE ON CLUTCH DISC A. Measure the depth from clutch disc facing surface (1) to rivet (2). B. If the measurement is out of the allowable limit, replace it. 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.
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www.mymowerparts.com CLUTCH 6.3 FLATNESS OF CLUTCH PRESSURE PLATE, DAMAGES A. Measure several clearances with a space gauge along with a feeler gauge placed on the surface of the clutch pressure plate. B. If the measurement is out of the allowable limit, replace clutch cover assembly. C. In case only the outer circumference of the pressure plate has been worn and the inner circumference is being contacted with the feeler gauge, just replace it regardless of the clearance size. D.
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www.mymowerparts.com CHAPTER 3 8454 6.6 CLEARANCE BETWEEN CLUTCH PEDAL SHAFT AND CLUTCH PEDAL BUSHING A. Measure the outer diameter of clutch pedal shaft. B. Obtain the clearance by measuring the inner diameter of clutch pedal bushing. C. If the measurement is out of the allowable limit, replace it. Clearance between clutch pedal shaft and clutch pedal bushing. Factory spec. 0.007 ~ 0.101 mm 0.0003 ~ 0.00 4 in. Allowable limit 0.4 mm 0.0157 in. Outer diameter of clutch pedal shaft Factory spec. 24.
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www.mymowerparts.com TRANSMISSION SYSTEM 1. TROUBLESHOOTING 1.1 TROUBLESHOOTING FOR SHUTTLE SHIFT IN OPERATION ERROR Symptom Noise when the shuttle is shifted Gear is disconnected when shifted Difficult to shift Solution Provable Causes 1. Excessive deflection in the shuttle synchro assembly (SPEC: 78.2) Replace 2. Chamfering section damaged in the forward gear (29 gear) and the reverse gear (24 gear) Replace 1. Improper adjustment of the exterior lever 2.
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www.mymowerparts.com CHAPTER 4 8454 1.3 TROUBLESHOOTING FOR AUXILIARY AND CREEP SHIFTS IN OPERATION ERROR Provable Causes Symptom Gear shift disconnected Starting gets OFF when starting with gear shifted Difficult to shift the auxiliary and creep shift gears (if equipped) 1. Damaged jaw at chamfering section of auxiliary shift gear Solution Replace 2. Deficient traveling distance due to interference with the exterior lever auxiliary shift: 10 mm, creep shift (if equipped): 10.
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www.mymowerparts.com TRANSMISSION SYSTEM 1.6 TROUBLESHOOTING FOR FRONT WHEEL DRIVE IN OPERATION ERROR Symptom Gear shift disconnected Provable Causes Solution 1. Separated or unfixed φ 25 snap ring of front wheel drive shaft Assemble 2. Deficient traveling distance due to interference with the exterior lever traveling distance: 20 mm (0.78 in.) Difficult to shift the front wheel drive lever 1. Held when shifted due to damages on spline part of the shifter’s inside diameter 2.
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www.mymowerparts.com CHAPTER 4 8454 2. SPECIFICATIONS 2.1 TIGHTENING TORQUES Middle case • Inlet bolts and nuts between middle case and transmission case. • 17 gear shaft lock nuts. Transmission case Rear axle/ brake M12 (9T) 103.0 ~ 117.7 kgf·m lbf·ft 10.5 ~ 12.0 75.9 ~ 86.8 M12 (6T) 77.5 ~ 90.2 7.9 ~ 9.2 57.1 ~ 66.5 • Inlet bolts of bearing cover and bearing case (Main gear shift section). • Inlet bolts of bearing case (Auxiliary gear shift section). M20 M8 (7T) 127.5 ~ 176.5 23.5 ~ 27.
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www.mymowerparts.com TRANSMISSION SYSTEM 3. STRUCTURE 3.
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www.mymowerparts.com TRANSMISSION SYSTEM 3.3 POWER TRAIN 3.3.
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www.mymowerparts.com CHAPTER 4 8454 3.3.
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www.mymowerparts.com TRANSMISSION SYSTEM 3.3.
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www.mymowerparts.com CHAPTER 4 8454 3.3.4AUXILIARY SHIFT 569W406A (A) High (B) Low (C) Creep 3.3.
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www.mymowerparts.com TRANSMISSION SYSTEM 3.3.
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www.mymowerparts.com CHAPTER 4 8454 3.4 OPERATION 3.4.1FEATURES A. SHUTTLE • Synchro shuttle is applied with the features as below. 1. As for forward reverse switching over, the same stage in forward and reverse can be obtained if raising slightly the shuttle lever from neutral and moving forward and reverse straightly. 2. Structure is so applied conveniently to operate the shuttle lever as installed on the steering column side. 3.
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www.mymowerparts.com TRANSMISSION SYSTEM First Stage An effort to place the main gear shift lever to the 3rd or 4th speed causes the shifter (5) and synchronizer keys (4) to move slightly. Then, the end surface of the synchronizer key (4) presses the synchronizer ring (7) against the coneshaped portion of the gear (8). The frictional force generated at the cone-shaped portion rotates the synchronizer ring (7), synchronizer keys (4) and hub (3) which is splined to the counter shaft.
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www.mymowerparts.com CHAPTER 4 8454 Final Stage When the speed of the shifter (5) becomes the same as that of the gear (8), the force of the synchronizer ring (7) in its rotating direction is not applied to the shifter (5) and the rotation of the synchronizer ring (7) is no longer transmitted to the shifter (5). Therefore, the shifter (5) engages with the synchronizer ring (7) and further engages with the gear (8) for complete connection. 569W413A (5) Shifter (8) Gear (7) Synchronizer Ring B.
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www.mymowerparts.com TRANSMISSION SYSTEM C. AUXILIARY GEAR SHIFT • Composed of constant mesh with Hi/Low/Creep (option) rang shift available. 569W415A (1) 17 Gear Shaft (5) 39-21 Gear (2) Auxiliary Gear Shifter Shaft (6) 43-21 Gear (3) Shifter (Hi/Low) (7) 39-17 Plain Gear (4) Shifter (Creep) (8) 39 Gear D. OPERATION OF THE FRONT WHEEL DRIVE • Front wheel drive shift is structured simply to connect or disconnect shafts where power is transmitted to by the shift.
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www.mymowerparts.com CHAPTER 4 8454 E. PTO • PTO gear shift composed of constant mesh is available to shift gear while PTO clutch is OFF. 569W417A (1) PTO Clutch Shaft (4) 51 Gear (2) PTO Clutch (5) PTO Shaft (3) PTO Drive Shaft (6) PTO Clutch Valve F. PTO CLUTCH SYSTEM INTRODUCTION • PTO clutch valve on the main body of the PTO clutch as of the hydraulic wet multi-disc type can be turned ON and OFF by the PTO switch control to disconnect and connect power to PTO.
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www.mymowerparts.com TRANSMISSION SYSTEM [PTO CLUTCH VALVE] A.
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www.mymowerparts.com CHAPTER 4 • 8454 In case PTO clutch switch is OFF 569W420A (1) Clutch Body (2) Piston (8) Pressure Plate (14)Seal Ring (20) Bracket (9) Snap Ring (15) Spline Hub (21) Ball Bearing (3) Piston Ring (10) Clutch Disk (16) PTO Clutch Shaft (22) Snap Ring (4) Piston Ring (11) Clutch Plate (17) Bush (23) Spacer (5) Brake Plate (12) Ball Bearing (18) Snap Ring (24) Snap Ring (6) Return Plate (13) Needle Bearing (19) Snap Ring (25) PTO Drive Shift (7) Spring 1.
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www.mymowerparts.com TRANSMISSION SYSTEM F. PTO SYSTEM a . Related Parts With the PTO Operation 569W421A (1) PTO Drive Shaft (2) 51 Gear (3) PTO Shaft b. Operation Principle of PTO If PTO switch is activated PTO clutch is engaged and then power from the engine is transmitted to PTO drive shaft (1) via PTO drive shaft 1. 51 gear (2) is rotated as engaged with PTO drive shaft (1) which gets rotated subsequently.
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www.mymowerparts.com CHAPTER 4 8454 4. PREPARATION STAGE FOR DISASSEMBLING AND ASSEMBLING TRANSMISSION 4.1 DRAINING THE TRANSMISSION FLUID Draining the Transmission Fluid 1. Place oil pans underneath the transmission case. 2. Remove the drain plugs. 3. Drain the transmission fluid. 4. Reinstall the drain plugs (When refilling) • Fill up from filling port after removing the filling plug (1) until reaching the gauge (2).
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www.mymowerparts.com TRANSMISSION SYSTEM 4.2 SEPARATING PANEL FRAME ASSEMBLY Preparation 1 1. Removing the following parts. 569W424A (1) Side Cover (RH, LH) (2) Bonnet (3) Front Grille (4) Side Skirt (RH, LH) (5) Battery Negative Code Preparation 2 1. Disconnect the brake rods (4). 2. Disconnect the clutch rod (2). 3. Remove the accelerator cable (12). 4. Disconnect the foot accelerator rod (11). 5. Remove the panel frame cover (7) and disconnect the connectors (6). 6.
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www.mymowerparts.com CHAPTER 4 8454 Hydraulic Pipes 1. Disconnect the main delivery hose (1), return hose (2), right turning delivery hose (3) and left turning delivery hose (4). (When reassembling) • In assembling the turning delivery hoses to the steering controller, connect the delivery hose with identification mark (tape) to the L port of the steering controller. Tightening torque Main delivery hose retaining nut 46.6 ~ 50.9 N·m 4.8 ~ 5.2 kgf·m 34.4 ~ 37.
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www.mymowerparts.com TRANSMISSION SYSTEM 4.3 SEPARATING REAR FENDERS AND PLATFORM ASSEMBLY Preparation 1. Remove the Rops. 2. Remove the Bolts (1) and take out the seat Assembly (2). 569W431A (1) Bolt (2) Seat Assembly Cover 1. Remove the bolts (1), (2) and the cover assembly (3). 569W432A (1) Bolt (3) Cover (2) Bolt Fender, Floor Seat and Platform Assembly 1. Remove the fender (1, 2), floor seat and platform as a unit.
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www.mymowerparts.com CHAPTER 4 8454 D. SEPARATING CLUTCH HOUSING Propeller Shaft 1. Slide the propeller shaft cover (4), (5) after removing the bolt (9). 2. Tap out the spring pin (10) and then slide the coupling (2) to the front. (When reassembling) • Apply grease to the splines of the propeller shaft. 569W437A (1) Propeller Shaft (6) O-Ring (2) Coupling (7) O-Ring (3) Cir-Clip (8) O-Ring (4) Propeller Shaft Cover (9) Bolt (5) Propeller Shaft Cover (10) Spring Pin Hydraulic Pipes 1.
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www.mymowerparts.com TRANSMISSION SYSTEM Hydraulic Pipes 1. Loosen the screws (1), Bolt (2) and remove the suction pipe (3). 2. Remove the pipe (4), (5), (6), (7). 569W440A (1) Screw (5) Pipe 1 (2) Bolt (6) Pipe 2 (3) Suction Pipe (7) PTO Pipe 2 (4) PTO Pipe 1 Shift Levers 1. Tap out the spring pins (2) of main shift rod 1 (1). (When reassembling) • Tap in the spring pins (2) so that their split portion may face forward.
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www.mymowerparts.com CHAPTER 4 8454 5. TO DISASSEMBLING AND TO ASSEMBLE 5.1 STANDARD TABLE FOR REPAIR Item 1. Clearance between thrust directions of shuttle shaft and 17 gear shaft Factory Spec Allowable limit 0 ~ 0.1 mm 0 ~ 0.0039 in. 2. Backlash of gear 0.1 ~ 0.2 mm 0.0039 ~ 0.0078 in. 0.4 mm 0.0157 in. 3. Clearance between shift fork and shift groove 0.2 ~ 0.4 mm 0.0078 ~ 0.0157 in. - 0.8 mm 0.0314 in. 0.35 mm - 0.0137 in. 0.88 ~ 1.17 N·m 0.09 ~ 0.12 kgf·m 0.65 ~ 0.86 lbf·ft 80 % min 4.
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www.mymowerparts.com TRANSMISSION SYSTEM b. To Assemble 1. Assemble seal cap (11) and oil seal (12) using a jig on both sides of the clutch housing. 2. Assemble clutch lever (3) and release fork (4) after greasing the lip area of oil seal (12). 3. Assemble mounting bolt (1) and fork key (2) while aligning the position of clutch release fork (4) and clutch lever (3). 569W443A 4.
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www.mymowerparts.com CHAPTER 4 8454 B. CLUTCH HOUSING AND MIDDLE CASE a. To Disassembling 1. Remove M12 bolts (3) at six places and nuts (4) at two places to loosen clutch housing (1) and middle case (2). 569W444A (1) Clutch Housing (3) Bolt (2) Middle Case (4) Bolt b. To Assemble 1. Remove any foreign substance cleanly out of assembling surfaces of clutch housing (1) and middle case (2) and replace the packing with new one for assembly. 2.
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www.mymowerparts.com TRANSMISSION SYSTEM C. MIDDLE CASE AND TRANSMISSION CASE a. To Disassembling 1. Remove bolt (3) at 4 places and nuts (4) at 4 places on assembling surfaces of middle case (1) and transmission case (2), and separate the middle case and the transmission case. 569W446A (1) Middle Case (3) Bolt (2) Transmission Case (4) Nut b. To Assemble 1. Remove any foreign substance cleanly out of assembling surfaces of middle case (1) and transmission case (2) and replace the gasket with new one.
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www.mymowerparts.com CHAPTER 4 8454 D. SHUTTLE SHIFT COVER a. To Disassembling 1. Remove washer mounting bolts (12), (13) at 4 place to loosen shuttle shift cover (11). 2. Loosen snap ring (9) to draw shift arm (8) out of shift cover (11). 3. Remove mounting bolt (5) to Disassembling shift fork (1), fork rod (4), spring (2) and steel ball (3). b. To Assemble 1. Insert spring (2), steel ball (3) and fork rod replacing tool into shift fork (1) . 2.
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www.mymowerparts.com TRANSMISSION SYSTEM E. MAIN SHIFT FORK a. To Disassembling 1. Remove main shift cover bolts (16) at 8 places on the middle case side to loosen main shift cover (1). 2. Loosen fork mounting spring pin (13). 3. Remove fork rod (9) to Disassembling pin (10), steel ball (8) and spring (7). 4. Remove the caulking on tongue mounting washer (5) and Disassembling mounting bolts (6). 5. Draw shift rod (3) outside or be separated from shift arm (4). 569W449A b. To Assemble 1.
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www.mymowerparts.com CHAPTER 4 8454 F. AUXILIARY SHIFT COVER a. To Disassembling 1. Remove auxiliary shift cover bolt (11) on the middle case side to loosen auxiliary shift cover (10) in a body. 2. Disassembling the shifting arm (7) from the auxiliary shift cover (10). b. To Assemble 1. Fix bush (8) with shift arm (7). 2. After fixing O-ring (6) with shift arms (7), where greased, insert shift arms (7), into the hole of auxiliary shift cover (10). 3.
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www.mymowerparts.com TRANSMISSION SYSTEM G. FRONT WHEEL DRIVE LEVER a. To Disassembling 1. Loosen shifter (front wheel) (5), and Disassembling 2 shift mounting steel balls (6) and spring (7). 2. Loosen stopper mounting bolt (4) and remove stopper (3). 3. Draw out shift arm (1) by pushing inside the middle case. b. To Assemble 1. Insert spring (7) and steel ball (6) into propeller shaft 1 (8) and fix shift (front wheel) (5). 2. Insert shift arm (1) outward from the middle case to be fixed with O-ring (2).
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www.mymowerparts.com CHAPTER 4 8454 H. AUXILIARY SHIFT GEAR a. To Disassembling 1. Remove middle case and transmission case. 2. Remove middle case and main shift cover. 3. Loosen with washer bolt (23) and Disassembling the auxiliary shift gear fixed on middle case and bearing case (for auxiliary shift) (22).
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www.mymowerparts.com TRANSMISSION SYSTEM 10. Locate fork rod (for Hi-Lo shift) (27) and shift fork (for Hi-Lo shift) (26) at right position. 11. After pushing the sub-assembled of bearing case (22) forward from the back of the middle case to be aligned with the position of parallel pin (21), knock in and fix it with four with washer bolts (23). 12. Insert steel ball (32) and stopper spring (33) into the hole area of middle case for main shift cover assembling.
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www.mymowerparts.com CHAPTER 4 8454 J. REVERSE IDLE SHAFT AND IDLE GEARS a . To Disassembling 1. Remove mounting bolt (1) and seal washer (4) at the side of the middle case. 2. Remove thrust collar (5), needle bearing (6), 21 gear (7) and spacer (8) in due order with M8 x P 1.25 replacing tool led to the side of the rear idle axle, while drawing out rear idle shaft (2) to the front of the middle case. b. To Assemble 1.
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www.mymowerparts.com TRANSMISSION SYSTEM a . To Disassembling 1. Remove four M8 washer mounting bolts to loosen bearing cover (23). 2. Remove the caulking on 28 nut (22) to loosen the nut. 3. Slightly knock the end part of 17 gear shaft (1) backward (toward the transmission case) to remove 17 gear shaft (1). b. To Assemble 1. Install 6307HL ball bearing (2) on 17 gear shaft (1). 2.
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www.mymowerparts.com CHAPTER 4 8454 L. SHAFT 2 569W457A (1) Snap Ring (5) O-Ring (2) Ball Bearing (6) Bearing Case (10) Oil Seal (13) Snap Ring (3) 29-23-18-14 Gear (7) Bolt (11) Snap Ring (14) Propeller Shaft 1 (4) Ball Bearing (8) Snap Ring (9) Ball Bearing (12) Ball Bearing a. To Disassembling 1. Remove the middle case and the transmission case and Disassembling snap ring (11) fixed on propeller shaft 1 (14). 2.
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www.mymowerparts.com TRANSMISSION SYSTEM M . PTO DRIVE SHAFT 569W459A (1) PTO Drive Shaft (4) Snap Ring (2) Oil Seal (5) Snap Ring (3) Ball Bearing a. To Disassembling b. To Assemble 1. Separate the middle case and the transmission case. 1. Sub-assemble snap ring (4), 6005DD ball bearing (3) and snap ring (4) on PTO drive shaft. 2. Remove snap ring (5) on the back of PTO drive shaft (1). 2.
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www.mymowerparts.com CHAPTER 4 8454 N. PTO CLUTCH a. To Disassembling 1. Remove the middle case and the transmission case. 2. Remove snap ring (1) and spacer (2) fixed of the PTO clutch shaft. 3. Loosen φ 62 snap ring (3) on PTO clutch bracket (5). 4. Loosen four M12 bolts on PTO clutch bracket (5) and the transmission case to Disassembling PTO clutch bracket. 5. Take out the PTO clutch ass’y.
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www.mymowerparts.com TRANSMISSION SYSTEM b. To Assemble 1. Install piston rings (3), (4) on the inner and outer sections of the piston bore, and apply grease. 2. Fix piston (2) on PTO clutch body (1). 3. Install needle bearing (13) on the inner bore and sealing (14) on the outer bore of PTO clutch body (1), and apply grease. 4. Install snap ring (18) and 6006 ball bearing (12) on PTO clutch shaft (16), push the PTO clutch body forward to fix, and then tighten with snap ring (19).
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www.mymowerparts.com CHAPTER 4 8454 O. PTO SHAFT a . To Disassembling 1. Loosen the bolts (1) and remove the PTO shaft assembly (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).
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www.mymowerparts.com TRANSMISSION SYSTEM Clearance Between Gear and Shaft 1. Measure the shaft O.D. (rubbing surface). 2. Measure the gear I.D. (rubbing surface). 3. Measure the O.D. of the two needles installed diagonally 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. 0.021 ~ 0.054 mm 0.00083 ~ 0.00213 in. Allowable limit 0.
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www.mymowerparts.com CHAPTER 4 8454 Side Clearance Between Synchronizer Ring and Gear (In Contact) 1. Press the synchronizer ring against the tapered portion of the gear, and measure the side clearance. 2. Apply thin film of red lead to the tapered portion, press the ring against it by hand, rub them together a few times, and check the contact. 3. Check the tooth surface and key grooves of the ring for wear. 4.
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www.mymowerparts.com TRANSMISSION SYSTEM 5. Apply red lead lightly over several teeth at three positions equally spaced on the spiral bevel gear (3). 6. Turn the spiral bevel pinion (1) while pressing a wooden piece against the periphery of the spiral bevel gear (3). 7. Check the tooth contact. If not proper, adjust according to the instructions below. (Reference) • Thickness 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.
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www.mymowerparts.com CHAPTER 4 8454 Replace adjusting shim (8) with thinner one to move the bevel pinion shaft forward. And place the right side shim (5) to the left to move the bevel gear leftward. Repeat above until the proper tooth contact and backlash are achieved. 569W476A 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, replace it.
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www.mymowerparts.com TRANSMISSION SYSTEM Thickness of Seal Ring 1. Measure the thickness of seal rings with an outside micrometer. 2. If the measurement is less than the allowable limit, replace it Thickness of seal ring Factory spec. 2.95 ~ 3.0 mm 0.116 ~ 0.118 in. Allowable limit 2.5 mm 0.098 in. 569W480A 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.
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www.mymowerparts.com CHAPTER 4 8454 P. REAR AXLE • Rear axle to transmit power shifted at the transmission to the rear wheels finally is composed of brake, differential lock and final reduction gear.
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www.mymowerparts.com TRANSMISSION SYSTEM A.
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www.mymowerparts.com CHAPTER 4 8454 DIFFERENTIAL GEAR • Differential gear is structured with four pin type. • Differential gear is operated by sharing out suitable revolution considering related conditions for the wheels left and right to lead turning of the tractor and traveling on curved or uneven road to be smooth. • A pin type deferential lock is mounted to stop the differential function so not to allow just one wheel to be slipped and moved considering of road surface and pavement.
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www.mymowerparts.com TRANSMISSION SYSTEM B. OPERATION OF THE REAR AXLE The final reduction system has a planetary gear system. It is compact, and is durable under heavy loads since torque loads are spread over three gears, decreasing the load on each tooth. And this system also spreads the load evenly around the circumference of the system, eliminating the sideways stress on the shafts. Power, transmitted from the differential side gear (6) to the brake shaft (4), drives the three planetary gears (3).
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www.mymowerparts.com CHAPTER 4 8454 C. POWER FLOW OF THE REAR DIFFERENTIAL GEAR 569W489A a . Related Parts with the Rear Differential Gear (1) Spiral Bevel Pinion (2) 39 Spiral Bevel Gear (3) Differential Gear Assembly (4) 13 Gear Shaft (5) Planetary Gear Assembly (6) Rear Axle (7) Differential Side Gear (8) Differential Pinion (9) Planetary Gear b.
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www.mymowerparts.com TRANSMISSION SYSTEM 6. DIFFERENTIAL GEAR 6.1 STRUCTURE The differential gear assembly is a mechanism to provide smooth steering. It automatically provides different optimum torques to the right and left wheels according to road resistance and braking friction at the wheels. The differential gear assembly is composed of the differential case, differential pinions, differential side gears, differential pinion shaft, spiral bevel gear, etc.
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www.mymowerparts.com CHAPTER 4 8454 6.2 OPERATION TRAVELING STRAIGHT AHEAD Rotation of the spiral bevel pinion (7) is transmitted to the spiral bevel gear (2) bolted to the differential case (3). When road resistance to the right and left wheels 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.
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www.mymowerparts.com TRANSMISSION SYSTEM 6.3 LOCKING OF THE DIFFERENTIAL GEAR 569W493A a . Related Parts with the Operation of the Differential Gear (1) Differential Pedal (2) Differential Rod (3) Differential Mounting Fork Shaft (4) Differential Mounting Fork (5) Differential Mounting Shift (6) 13 Gear Shaft (7) Planetary Gear Assembly (8) Rear Axle b.
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www.mymowerparts.com CHAPTER 4 8454 Differential Lock When resistances to the right and left tires are different due to ground conditions or type of work, the wheel with less resistance slips and prevents the tractor from moving ahead. To compensate for this, the differential lock restricts the differential function and causes both rear axles to rotate as a unit.
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www.mymowerparts.com TRANSMISSION SYSTEM A. DIFFERENTIAL LOCK ASSEMBLY a . To Disassembling 1. Remove spring pin (7). 2. Take out snap pin (3) and Disassembling plane washer and pin (2). 3. Take out differential lock fork shaft (4) and remove differential lock fork (1). b. To Assemble 1. Install oil seal (6) on both sides of the transmission case and apply grease on the lip area. 2. Insert differential lock fork (1) into differential lock shift (8). 3.
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www.mymowerparts.com CHAPTER 4 8454 C.
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www.mymowerparts.com TRANSMISSION SYSTEM Confirmation of Reaching Up Apply minimum lightly on several thrashing faces at 3 equally divided positions in the circle circumference of the spiral bevel gear and turn the shaft of the spiral bevel pinion with a load on the spiral bevel gear, then to confirm its reaching up. - Degree of reaching up: As of 35 % min. the center is 1/3 ~ 2/3 away from minor section Tightening torque Tightening bolt of the differential bearing case 48.0 ~ 55.9 N·m 4.90 ~ 5.
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www.mymowerparts.com CHAPTER 4 8454 E. BRAKE CASE 569W4A0A (1) Straight Pin (8) Nut (14) Nut (20) 13 Gear Shaft (2) Ball Sheet (9) Spring Washer (15) Bolt (21) Brake Case (3) Ball (10) Bolt (16) Spring Washer (22) 68 Internal Gear (4) Brake Cam (11) Brake Cam Lever (17) Plate (23) O-Ring (5) O-Ring (12) Washer, Plain (18) Brake Disk (24) Rear Axle Case (6) Stud Bolt (13) Spring Washer (19) Packing (25) C a m (7) Spring Washer a . To Disassembling 1.
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www.mymowerparts.com TRANSMISSION SYSTEM F. REAL AXLE ASSEMBLY 569W4A1A (1) Bolt (7) Plate (13) Nut (18) O-Ring (2) Spring Washer (8) 13 Gear Shaft (14) Ball Bearing (19) Bearing Cover (3) Stud (9) 68 Internal Gear (15) Oil Seal (20) Bolt (4) Nut (10) Planetary Gear Support (16) Planetary Gear (21) Rear Axle (5) O-Ring (11) Ball Bearing (17) Rear Axle Case (22) Stud (6) Bolt (12) Collar a. To Disassembling 1.
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www.mymowerparts.com CHAPTER 4 Tightening torque 8454 Stud for assembly of the rear axle and the rim 196.2 ~ 225.6 N·m 20.0 ~ 23.0 kgf·m 144.7 ~ 166.3 lbf·ft Mounting bolt of the bearing cover of the rear axle 48.0 ~ 55.9 N·m 4.90 ~ 5.70 kgf·m 35.4 ~ 41.2 lbf·ft Mounting bolt of the rear axle assembly 77.5 ~ 90.2 N·m 7.90 ~ 9.20 kgf·m 57.1 ~ 66.5 lbf·ft Mounting nut of the rear axle assembly 77.5 ~ 90.2 N·m 7.90 ~ 9.20 kgf·m 57.1 ~ 66.
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www.mymowerparts.com TRANSMISSION SYSTEM • Differential Gear Assembly 1. Remove the differential support, nothing the number 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.
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www.mymowerparts.com CHAPTER 4 • 8454 Spiral Bevel Gear 1. Remove the spiral bevel gear. (When reassembling) • Check the spiral bevel gear for wear or damage. If it is no longer serviceable, replace it. Then, also replace the spiral bevel pinion. • Apply liquid lock (Three Bond 1372 or equivalent) to the spiral bevel gear UBS screws. Tightening torque Spiral bevel gear UBS Screws 68.6 ~ 88.3 N·m 7.0 ~ 9.0 kgf·m 50.6 ~ 65.1 lbf·ft • 569W4A6A Differential Pinion Shaft and Differential Pinion 1.
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www.mymowerparts.com TRANSMISSION SYSTEM [A] FIT Groove (1) Differential Pinion Shaft (2) Differential Pinion (3) Differential Pinion (4) Differential Pinion Washer (5) Differential Pinion Shaft 2 (6) Differential Side Gear (7) Differential Side Gear Washer (8) Differential Cover (9) Differential Case (10) Differential Lock Shifter 569W4A9A (11) Spiral bevel Gear • Differential Side Gear 1. Take out the differential side gear (2) and differential side washer (1).
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www.mymowerparts.com CHAPTER 4 • 8454 Clearance Between Gear and Spline or Hub and Spline 1. Select the gear or the hub in a vise. 2. Set a dial gauge (lever type) with its finger on the spline. 3. Move the shaft (or hub) to measure the clearance. 4. If the clearance exceeds the allowable limit, replace them. Clearance between gear and spline or hub and spline • Factory spec. 0.030 ~ 0.078 N·m 0.00118 ~ 0.00307 in. 0.2 mm Allowable limit 0.008 in.
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www.mymowerparts.com TRANSMISSION SYSTEM • Clearance Between Differential Case Bore (Differential Case Cover Bore) and Differential Side Boss 1. Measure the bore I.D. of the differential case and differential case cover. 2. Measure the differential side gear boss O.D. and calculate the clearance. 3. If the clearance exceeds the allowable limit, replace them. Clearance Factory between differenspec. tial case bore and Allowable differential side limit gear boss 0.05 ~ 0.151 mm 0.00197 ~ 0.00594 in. 0.
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www.mymowerparts.com CHAPTER 4 • 8454 Clearance Between Differential Pinion Shaft and Differential Pinion 1. Measure the differential pinion shaft O.D 2. Measure the differential pinion I.D and calculate the clearance. 3. If the clearance exceeds the allowable limit, replace them. Clearance between differential 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. 569W4B5A Differential pinion shaft O.D Factory spec.
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www.mymowerparts.com FRONT AXLE 1.
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www.mymowerparts.com CHAPTER 5 8454 2. SPECIFICATIONS Item Front wheel alignment Toe-in Factory Specification Allowable Limit 2 ~ 8 mm - 0.08 ~ 0.32 in. Front wheel Axial sway - Less than 5 mm 0.20 in. Front axle Rocking force - 49.0 ~ 117.7 N 5.0 ~ 12.0 kgf 11.0 ~ 26.5 lbf Front axle case boss (front) Clearance to bracket bushing Front axle case boss (front) O.D. 0.025 ~ 0.160 mm 0.35 mm 0.00098 ~ 0.00630 in. 0.0138 in. 70.000 ~ 70.030 mm - 2.75590 ~ 2.75708 in. Busing I.D.
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www.mymowerparts.com FRONT AXLE Item Differential pinion to differential side Backlash gear shim Factory Specification Allowable Limit 0.1 ~ 0.3 mm - 0.004 ~ 0.012 in. Thickness 0.1 mm - 0.0039 in. 0.1mm - 0.0078 in. 0.2 mm - 0.0157 in. 1.6 mm - 0.0630 in. Spiral bevel pinion shaft Turning Torque (Pinion shaft only) 1.27 ~ 1.667 N·m - 0.13 ~ 0.17 kgf·m 0.94 ~ 1.23 lbf·ft Spiral bevel pinion shaft to spiral bevel gear Backlash 0.2 ~ 0.3 mm - 0.0078 ~ 0.0118 in.
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www.mymowerparts.com CHAPTER 5 8454 3. STRUCTURE 3.
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www.mymowerparts.com FRONT AXLE 3.2 FRONT WHEEL ALIGNMENT Front wheel alignment is a term given to mean four angle settings in three dimensions: camber, kingpin inclination, toe-in and caster angle. These angle settings are made for the following purposes. (1) Camber The front wheels are tilted from the vertical as viewed from the front, the wheels are farther apart at the top than at the bottom. This inclination is called camber.
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www.mymowerparts.com CHAPTER 5 8454 (4) Toe-in Viewing the front wheels from above reveals that the distance between the front wheels is less at the front than at the rear. This turning in of the front wheels is called toe-in. The front wheels tend to roll outward due to the camber, but toe-in offsets this and ensures parallel rolling of the front wheels. Another purpose of toe-in is to prevent excessive and uneven wear of tires. 569W504A (A) Front Width (B) Rear Width 3.
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www.mymowerparts.com FRONT AXLE 2. If the difference between direction control angles left and right exceeds 1.5 °, adjust it with adjusting washer (1) in F. The direction control angle increases, if the number of adjusting washers decreases, and vice versa. • CAUTION • Adjustment of the direction control angle shall be achieved under the range of the maximum control angle. Fix firmly the tightening bolt (2) in R with the tightening nut (3) after adjusted. Tightening torque Nut 98.1 ~ 125.5 N·m 10.
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www.mymowerparts.com CHAPTER 5 8454 4. PREPARATION STAGE FOR DISSEMBLING AND ASSEMBLING 4.1 SEPARATING FRONT AXLE DRAINING FRONT AXLE CASE OIL 1. Place oil pans underneath the front axle case. 2. Remove the drain plug (1) both sides and filling port plug (3) to drain the oil. 3. After draining, reinstall the drain plugs (1) and filling 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.
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www.mymowerparts.com FRONT AXLE TIE-ROD 1. Remove the tie-rod. In this case, take special care not to damage the tie-rod (1) and slotted nuts (2). (When reassembling) Tightening Slotted nut torque 245.2 ~ 284.5 N·m 25.0 ~ 29.0 kgf·m 180.8 ~ 209.8 lbf·ft Tie-rod lock nut 245.2 ~ 284.5 N·m 25.0 ~ 29.0 kgf·m 180.8 ~ 209.8 lbf·ft 569W516A (1) Tie-Rod (3) Tie-Rod Lock Nut (2) Slotted Nut (4) Split Pin FRONT AXLE 1.
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www.mymowerparts.com CHAPTER 5 8454 5. TO DISASSEMBLING AND TO ASSEMBLE 5.1 FRONT AXLE CASE AND FRONT AXLE A. TO DISASSEMBLING 1. Remove sixteen M8 washer mounting bolts (3) on front axle case (1) and front axle cover (2) to Disassembling the front axle group out of front axle case (1). 2. Remove 6208 ball bearing (4) and Disassembling 39 bevel gear (5). 3. Take mounting snap ring (6) out of 6209 ball bearing. 4. Lightly knock Disassembling. front axle (8) forward to 5.
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www.mymowerparts.com FRONT AXLE 5.2 BEVEL GEAR CASE AND FRONT AXLE CASE 569W519A (1) Bolt (2) Bearing Cover (8) Snap Ring (13) 6011 Ball Bearing (18) Snap Ring (9) Shim (14) Snap Ring (19) Housing (3) Shim (10) 6208 Ball Bearing (15) Front Axle Case (20) O-Ring (4) Ball Bearing (11) 13 Bevel Gear (16) Bevel Gear Case (21) Floating Seal (5) 16 Bevel Gear (12) Bevel Gear Shaft (17) 6014 Ball bearing (22) Snap Ring (7) Plug A. TO DISASSEMBLING 1.
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www.mymowerparts.com CHAPTER 5 8454 5.3 BEVEL GEAR CASE AND FRONT AXLE SUPPORT A. TO DISASSEMBLING 1. Remove four M14 bolt and two nuts (3) to separate separate bevel gear case (1) and front axle support (8). B. TO ASSEMBLE 1. Install two parallel pins (6) and two stud (5) on bevel gear case (1). 2. Install O-ring (7) on the rim of 6309 ball bearing (10) in the bevel gear case ass’y and apply grease. 3.
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www.mymowerparts.com FRONT AXLE 5.4 FRONT AXLE SUPPORT AND DIFFERENTIAL GEAR CASE A. TO DISASSEMBLING 1. Remove bolts (4), (6) on the assembly of front axle support (1) and differential gear case to Disassembling differential gear case ass’y (2) in a body. B. TO ASSEMBLE 1. Apply liquid gasket evenly on the assembling surface of front axle support (1) and differential gear case (2). 2. Install two pipe pins (3) on front axle support. 3.
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www.mymowerparts.com CHAPTER 5 8454 5.
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www.mymowerparts.com FRONT AXLE B. TO ASSEMBLE 1. Sub-assemble the inner rim of taper roller bearing (23) on 8 bevel pinion shaft (22). 2. Sub-assemble the outer rim of taper roller bearing (23), shim (24) and the outer rim of taper roller bearing (25) on differential gear case ass’y (5). 3. Install the sub-assembled 8 bevel pinion shaft (22) on differential gear case ass’y (5). 4. Support the gear side of 8 bevel pinion shaft (22) and knock the inner rim of taper roller bearing (25) into the opposite side.
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www.mymowerparts.com CHAPTER 5 8454 9. Install shim (10), ball bearing (11), two parallel pins (6) on differential gear case (5) and tighten case cover (7) with two M12 bolts (9). 10. Sub-assemble ball bearing (4) on front differential bearing support (1) and push into differential gear case ass’y (5) to tighten with five M10 bolts (3). • Check for backlash and reaching up of 27 bevel gear (12) and 8 bevel pinion shaft (22).
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www.mymowerparts.com FRONT AXLE 5.6 FRONT BRACKET A. TO DISASSEMBLING 1. Remove mounting nut (7), bolt (6) and seal washer (8). 2. Separate front bracket (2) from front axle support (1). 3. Remove two oil seals (5), DX bush (4) and adjusting plate (3) in front bracket (2). 4. Remove grease nipple (9). B. TO ASSEMBLE 1. Insert adjusting plate (3) into the inner bore of front bracket (2). 2. Install DX bushing (4) with a replacing tool 3. Install two oil seals (5) with a replacing tool and apply grease.
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www.mymowerparts.com CHAPTER 5 8454 5.7 REAR BRACKET A. TO DISASSEMBLING 1. Separate front axle support (1) and rear bracket ass’y (2). 2. Remove thrust collar (3), DX bushing (4) and two oil seals (5). 3. Remove O-ring (7). 4. Remove grease nipple (6). B. TO ASSEMBLE 1. Insert thrust collar (3) into the inner bore of rear bracket (2). 2. Install DX bushing (4) with a replacing tool. 569W526A 3. Install two oil seals (5) with a replacing tool and apply grease. (1) Front Axle Support 4.
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www.mymowerparts.com HYDRAULIC SYSTEM 1.
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www.mymowerparts.com CHAPTER 6 8454 569W602A (1) Control Valve (2) Double Acting Valve Hydraulic lift system to raise the implement connected to the 3 point link provides three applications of position control, draft control and mixed control by the control valve and the linkage installed on the hydraulic cylinder body.
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www.mymowerparts.com HYDRAULIC SYSTEM 1.1 TROUBLESHOOTING Symptom Probable Cause Solution • Insufficient oil level in the tank. • Pump inlet filter clogged. • Top up the level. • Clean or replace the filter. • Infiltration of air into the pump inlet pipe. • Check the inlet pipe and any couplings and gaskets. Rockshaft does not operate. • Adjusting piston sticked. The rockshaft start to lift but stops as soon as if feels the load, but the overpressure valve does not intervene.
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www.mymowerparts.com CHAPTER 6 8454 1.2 SPECIFICATIONS A. TECHNICAL FEATURES a. Operation with drawbar pull and position control. b. Drawbar pull survey at hitch point. c. Implement lowering speed adjusted by control valve lowering regulator. d. Automatic hydraulic limit stop of angular excursion of lifting arms. e. Dual lever sector control: One positioning lever plus one drawbar pull lever. f. Oil feeding: By transmission oil. g. Oil filter not built-in. h. Required degree of filtering: 30µ B.
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www.mymowerparts.com HYDRAULIC SYSTEM 1.3 STRUCTURE AND OPERATION A. STRUCTURE 569W605A (1) Gear Pump (6) Control Valve (2) Orbital Unit (7) Hydraulic Cylinder (3) PTO Clutch Valve (8) Oil Filter Cartridge (4) Front Hydraulic Block (9) Oil Tank (Transmission Case) (5) Quick Couplers (If Equipped) The hydraulic system of the 8454 tractor is composed of the main components as shown in the figure. This system has the following three functions. 1.
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www.mymowerparts.com CHAPTER 6 8454 B. HYDRAULIC CIRCUIT FOR THREE POINT HYDRAULIC SYSTEM 569W606B (1) Oil Tank (Transmission Case) (6) Front Hydraulic Block (2) Hydraulic Oil Filter Cartridge (7) Position Control Valve (3) Hydraulic Pump (8) Hydraulic Cylinder (4) Engine (9) Auxiliary Control Valve (If Equipped) (5) Relief Valve (10) Hydraulic Cylinder Block Hydraulic Oil Flow 1.
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www.mymowerparts.com HYDRAULIC SYSTEM C. HYDRAULIC CYLINDER VALVES a . Control Valve Control valve detects load on the implement as composed of such valve to control the lifting and lowering of the lift arm at a constant speed always. Since blocking of valve oil leakage is available inside, oil lock gripper 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.
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www.mymowerparts.com CHAPTER 6 8454 2.
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www.mymowerparts.com HYDRAULIC SYSTEM 3. Operation Principle Since the control valve of the hydraulic cylinder is available to control oil flowing in and out of the hydraulic cylinder so to control the implement up and down at a constant speed regardless of the implement load, high work performance can be achieved without impact, along with the operation principle classified into 3 phases of neutral, delivery and discharge.
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www.mymowerparts.com CHAPTER 6 8454 569W611A (1) Control Spool (18) Annular Duct (2) Regulator Piston (19) Annular Duct (3) Check Valve (20) Hole (6) Fixed Throat (21) Hole (7) Safety Valve (22) Chamber (15) Chamber (23) Cylinder Chamber (17) Hole b. Delivery Phase During this phase the control valve supplies the oil on pressure to the cylinder and it consequently lifts the arms.
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www.mymowerparts.com HYDRAULIC SYSTEM 569W612A (1) Control Spool (17) Hole (2) Regulator Piston (18) Annular Duct (4) Exhaust Valve (23) Cylinder Chamber (8) Regulator (24) Hole (15) Chamber (25) Hole (16) Exhaust Hole c. Discharge Phase During this phases the control valve supplies at the same time the oil coming from the pump and the oil contained in the cylinder to the discharge causing the lowering of the arms.
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www.mymowerparts.com HYDRAULIC SYSTEM D. CONNECTION SYSTEM OF THE INTERNAL LEVERAGE a.
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www.mymowerparts.com CHAPTER 6 8454 E. OPERATION Operation is Divided Into Position Control, Draft Control and Mixed Operation. a .
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www.mymowerparts.com HYDRAULIC SYSTEM b. Draft Control (Fig.
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www.mymowerparts.com CHAPTER 6 8454 When roller 4 (11) meets the inclined plane of the drawbar pull cam (12), it permits the counterclockwise rotation of lever (7) which by means of shock absorbers (8) will rotate transmission arm (9) in a clockwise manner thus releasing the distributor shaft (21) to move into neutral position “N”. In discharge position “S”, the lever (2) will continue its downward movement and cause the arms to lower.
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www.mymowerparts.com HYDRAULIC SYSTEM F. HYDRAULIC POWER TAKE OFF If necessary, hydraulic power for implements can be taken out from front hydraulic block or using auxiliary control valves and quick couplers. • Hydraulic power for the front loader can be taken out from hydraulic block. • On 8454tractor’s auxiliary control valve assembly. IMPORTANT: • When taking out hydraulic power, replenish transmission oil in the quantity equal to the flow rate required for the implement cylinder.
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www.mymowerparts.com CHAPTER 6 8454 b. Auxiliary Control Valve A double acting detent type auxiliary control valve is used, and the construction is shown in the figure right. When the auxiliary control valve operating lever is moved to the implement cylinder actuating position, the spool is moved and the oil from the pump port flows into A to B, causing the implement cylinder to operate.
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www.mymowerparts.com HYDRAULIC SYSTEM e . Relief Valve (Hydraulic Block) • As shown in the figure, a guide is attached at poppet (6) and valve chamber D.C (damping chamber) located at the bottom of the guide piston. Intake of valve enable through sliding part of guide and clearance of seat (5) to chamber and minimizes valve vibration as damping effect of chamber.
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www.mymowerparts.com CHAPTER 6 8454 G. TOP LINKAGE BRACKET a . Structure 569W627A (1) Top Linkage bracket (7) Bolt (12) Plate (17) Tie Rod (2) Flange (8) Lock Washer (13) Bolt (18) Spring Peaks (9) Bolt (3) Cover (14) Lock Washer (19) Crank (4) Spring (10) Pin (15) Roller (20) Pin (5) Roller (11) Snap Ring (16) Nut (21) Nut (6) Bolt b.
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www.mymowerparts.com HYDRAULIC SYSTEM 1.4 PREPARATION STAGE FOR DISASSEMBLING AND ASSEMBLING A. DRAINING THE TRANSMISSION FLUID 1. Place oil pans underneath the transmission case. 2. Remove the drain plugs. 3. Drain the transmission fluid. 4. Reinstall the drain plugs (When refilling) • Fill up from filling port after removing the filling plug (1) until reaching the gauge (2).
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www.mymowerparts.com CHAPTER 6 8454 Cover 1. Remove the bolts (1), (2) and the cover assembly (3). 569W631A (1) Bolt (3) Cover (2) Bolt C. FENDER, FLOOR SEAT AND PLATFORM ASSEMBLY 1. Remove the fender (1, 2), floor seat and platform as a unit.
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www.mymowerparts.com HYDRAULIC SYSTEM 1.5 DISASSEMBLING AND ASSEMBLING A. AUXILIARY CONTROL VALVES 569W635B (1) Pipe A (2) Pipe B (8) Joint Bolt 2 (15) O-Ring (16) Flange (9) Quick Coupler (12) Stud (17) Washer (5) Bracket (10) Bolt (13) Auxiliary Valve (18) Nut (6) O-Ring (11) Seal Washer (14) O-Ring (if equipped) 1. Loosen and remove the joint bolt 2 (8), hydraulic pipes ((1), (2)), bracket (5) and quick couplers (9) as a unit. 2.
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www.mymowerparts.com CHAPTER 6 8454 B. HYDRAULIC CYLINDER ASSEMBLY 1. Loosen the joint bolt (1). 2. Loosen and remove the hydraulic cylinder assembly mounting bolts ((6), (7), (8), (9)), spring washers (5) and nuts (4). 3. Support the hydraulic cylinder assembly with nylon lift strap and hoist, and then take out it. (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.
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www.mymowerparts.com HYDRAULIC SYSTEM D. DISTRIBUTOR VALVE (CONTROL VALVE) 1. Loosen and remove the control valve (distributor valve) mounting screws (1). 2. Take out the control valve (3). (When reassembling) • Take care not to damage the O-ring. Tightening torque Mounting bolt 23.6 ~ 27.4 N·m 2.4 ~ 2.8 kgf·m 17.4 ~ 20.2 lbf·ft 569W639A (1) Screw (2) Lock Washer (3) Distributor Valve (Control Valve) (4) Power Lift Body (Hydraulic Cylinder Block) E. LIFT ARM, HYDRAULIC ARM AND HYDRAULIC ARM SHAFT 1.
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www.mymowerparts.com CHAPTER 6 8454 F. BUSHINGS 1. Remove the bushings (1) and (2). (When reassembling) • Apply transmission oil to the hydraulic cylinder boss and bushings.
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www.mymowerparts.com HYDRAULIC SYSTEM G.
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www.mymowerparts.com CHAPTER 6 8454 H. DOUBLE ACTING VALVE 569W643B (1) Double Acting Valve Ass’y (9) Valve (17) Screw (24) Roller (2) Valve Body (10) Spring (18) Screw (25) Plug (3) Spool (11) Valve Sheet (19) Nut (26) O-Ring (4) O-Ring (12) Valve (20) Lock Washer (27) Pin (5) Washer (13) Spring (21) Nut (28) O-Ring (6) Spring (14) Spacer (22) Ring (29) O-Ring (7) Spacer (15) Gasket (23) Bent Arm (30) Plug (8) Adjusting Screw (16) Cover a . To Disassembling b.
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www.mymowerparts.com HYDRAULIC SYSTEM I. TOP LINK BRACKET 569W644A (1) Top Link Bracket (7) Bolt (12) Plate (17) Tie Rod (2) Flange (8) Lock Washer (13) Bolt (18) Spring Peaks (3) Cover (9) Bolt (14) Lock Washer (19) Crank (4) Spring (10) Pin (15) Roller (20) Pin (5) Roller (11) Snap Ring (16) Nut (21) Nut (6) Bolt a . To Disassembling b. To Assemble 1. Remove the socket support and coupler socket ass’y prior to the top link bracket ass’y. 1.
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www.mymowerparts.com CHAPTER 6 8454 J. CHECK AND ADJUSTMENT a . Hydraulic Cylinder Bore 1. Check the cylinder inside surface for scratches or damage. 2. Using a cylinder gauge, measure cylinder I.D. 3. If the measured exceeds the allowable limits, replace the hydraulic cylinder block. Cylinder I.D. “A” Reference dimension 90.000 ~ 90.050 mm 3.54330 ~ 3.54527 in. 90.150 mm Allowable limit 569W645A 3.54921 in. b. Clearance Relationship Between Hydraulic Arm Shaft and Bush 1. Using a O.D.
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www.mymowerparts.com HYDRAULIC SYSTEM c. Reaction Spring Assembly Reference Dimension Reaction spring assembly initial length (L) Reference dimension 50 mm 1.9685 in. 569W647A (1) Spring (3) Nut (2) Hex. Bolt d. Dimensional Setting of Position Control Bolt 1. When assembling the control valve (MLS valve) into power lift body, “A” dimension will be 112 mm. 2. If adjusting control bolt (1), loosen nut (2) and then tighten-lock nut (2).
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www.mymowerparts.com CHAPTER 6 8454 e . Lever Position Setting Adjustment of Position Control Lever The position control lever can be adjusted with a little load applied to the elevating arm. 1. Loosen the position control shaft (3), and lever tightening bolt (4). 2. Using a 13 mm spanner, rotate the position control shaft (3) counterclockwise until the elevating arm has stopped to climb by inside hydraulic limit. Because of safety, the area remained though the elevating arm moved to its max.
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www.mymowerparts.com HYDRAULIC SYSTEM f. Sensitivity Control of Control Valve (MLS) 1. Apply the elevating arm with load of 500 kg (1100 lbs) and move control lever upward to be the center. This time, the MLS valve is positioned at neutral. 2. Perform a sensitivity control while rotating the preventative 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.
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www.mymowerparts.com CHAPTER 6 8454 2. PTO CLUTCH VALVE SYSTEM 2.1 SPECIFICATIONS AND DIAGRAM A. SPECIFICATION 8454 Maximum oil flowing ( /min, gal/min) Solenoid valve 65 (17.17) Rated oil flowing ( /min, gal/min) Relief pressure (kgf/cm2, psi) Modulating valve 7.1 (1.88) 16 ~ 18 (228 ~ 256) Oil flowing ( /min, gal/min) 7 (1.85) B.
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www.mymowerparts.com HYDRAULIC SYSTEM 2.2 STRUCTURE AND OPERATION A. SOLENOID VALVE a . Structure (1) Block (2) Solenoid (3) Ring (4) Plug (5) Bolt (6) O-Ring 569W651A b.
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www.mymowerparts.com CHAPTER 6 • 8454 In case PTO clutch switch is ON 569W6B9B (1) Tank (Transmission Case) (5) Solenoid Valve (2) Filter (6) Spool (3) Pump (7) Priority Valve (4) Shuttle Shift Cover The spool (6) gets moved to the left by electric current on the solenoid valve (5). The spool (6) can be hardly operated only by the solenoid valve (5) if dust or the like is attached on the spool (6).
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www.mymowerparts.com HYDRAULIC SYSTEM B. MODULATING VALVE a .
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www.mymowerparts.com CHAPTER 6 8454 b. Operation • In case PTO clutch switch is OFF 569W654A (1) Tank (Transmission Case) (5) Solenoid Valve (2) Filter (6) Spool (3) Gear Pump (7) Spring (11) PTO Clutch (4) Shuttle Shift Cover (8) Piston (12) Priority Valve Oil at Port PI (gear pump) returns from Port T2 to the tank (1) after lubricating the PTO clutch via the solenoid valve (5) through the valve inside.
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www.mymowerparts.com HYDRAULIC SYSTEM • In case PTO clutch switch is ON 569W655B Oil at Port PI comes back to Port P of the solenoid valve through the valve inside returns as forced from Port B to the valve. Right after the PTO clutch switch is turned ON, the oil from Port B of the valve returns from Ports T2 and A by moving the spool to the right with the oil applied to the spool.
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www.mymowerparts.com CHAPTER 6 8454 2.3 ASSEMBLING AND DISASSEMBLING A. SOLENOID VALVE a . To Disassembling 569W656A (1) Solenoid Ass’y (5) Spool (2) Spring (6) Plug (3) Spring (7) Wire Lead (4) Spool Spool Solenoid 1. Loosen the bolt on the cover (1) and remove the cover. 1. Loosen the sectional end of the solenoid with a spanner. 2. Take out the spring and spool. 2. Take out the solenoid ass’y and the spring.
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www.mymowerparts.com HYDRAULIC SYSTEM C. MODULATING VALVE a . To Disassembling 1. Loosen bolt (1) to remove cover (2). 2. Take out piston (3), spring (4), spool (5) and valve sheet (6). 3. Take out check valve ass’y (8) and filter (9). • CAUTION 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.
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www.mymowerparts.com CHAPTER 6 8454 2.4 TO CHECK AND TO REPAIR A. SOLENOID VALVE 1. Replace the solenoid valve ass’y if the wet-drive sFurface of the spool is worn out or damaged. 2. Perform electric conduction test on the solenoid with a tester and if not conductive, replace the solenoid valve ass’y. 3. Replace the O-ring if worn out or damaged. 569W658A (1) Solenoid (5) Spool (2) Spring (6) Plug (3) Spring (7) Wire Lead (4) Spool B. MODULATING VALVE 1.
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www.mymowerparts.com HYDRAULIC SYSTEM 3. POWER STEERING SYSTEM 3.1 TROUBLESHOOTING Symptom Probable Cause - Steering wheel is heavy to operate Solution 1) Orbitrol unit (1) Deflected center from the column. (2) Abrasion due to dust on spool or sleeve. (3) Excessive tightening torque of bolts (7 places) on end cover. • Correct (cause if the tightening bolt with orbitrol is loosened free). • Replace • Tighten at the torque as specified evenly. 2) Pump (1) Incapable drive.
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www.mymowerparts.com CHAPTER 6 8454 3.
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www.mymowerparts.com HYDRAULIC SYSTEM Oil Flow 569W661A (9) Control Valve (1) Gear Pump (5) Hydraulic Hose (LH) (2) Priority Valve (6) Steering Cylinder (10) Filter (3) Power Steering Unit (7) Hydraulic Block (11) PTO Clutch Valve (4) Hydraulic Hose (RH) (8) Power Lift Ass’y (12) Transmission Case 1. If the engine starts and the hydraulic pump turns, oil in T/M case is absorbed and delivered compulsorily to the steering controller via the priority valve. 2.
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www.mymowerparts.com CHAPTER 6 8454 3.3 STRUCTURE AND OPERATION A. MAIN PARTS a . Power Steering Unit The steering controller is composed of steering valve and relief valve. b. Hydraulic Pump Hydraulic pump for power steering employs a gear pump that is of efficient capacity and mechanism, and power is delivered from the cam shaft gear on the right of the engine. c.
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www.mymowerparts.com HYDRAULIC SYSTEM b. Steering Valve The steering valve is divided into valve and metering installation. The control valve is composed of housing (9), spool (2) and sleeve (5), and the metering installation is composed of the trochoid pump called as GEROTOR (6). 569W663A (1) Steering Valve (Orbitrol Unit) (2) Relief Valve 1. Control valve: Control valve of rotary type is kept at neutral by the centering spring if the valve is not operated.
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www.mymowerparts.com CHAPTER 6 8454 2. Metering installation oil delivered from the hydraulic pump to the steering cylinder passes this metering 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 between the rotor and the GEROTOR if the rotor gets started. Meanwhile, to the rotor, oil is directly delivered via the steering shaft for turning of the steering wheel.
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www.mymowerparts.com HYDRAULIC SYSTEM OIL FLOW Neutral Position When the steering wheel (2) is not being turned valve plate (3) is held in the neutral position by centering springs (4). Under this condition an oil passage is formed between port P (from pump) and port T (to transmission case) in the control valve and all oil from the hydraulic pump flows to port T. Also the passage from cylinder ports R and L are closed off in the control valve.
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www.mymowerparts.com CHAPTER 6 8454 Left Turn The steering system operates in this same way at a left-turn as well, except that oil flows into and out of steering cylinder in the directions opposite to those at a right-turn.
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www.mymowerparts.com HYDRAULIC SYSTEM 3.4 PREPARATION STAGE FOR DISASSEMBLING AND ASSEMBLING DRAINING THE TRANSMISSION FLUID Draining the Transmission Fluid 1. Place oil pans underneath the transmission case. 2. Remove the drain plugs. 3. Drain the transmission fluid. 4. Reinstall the drain plugs. (When refilling) • Fill up from filling port after removing the filling plug (1) until reaching the gauge (2).
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www.mymowerparts.com CHAPTER 6 8454 Preparation 1 1. Removing the following parts. 569W672A (1) Side Cover (RH, LH) (2) Bonnet (3) Front Grille (4) Side Skirt (RH, LH) (5) Battery Negative Code Preparation 2 1. Disconnect the brake rods (4), (10). 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.
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www.mymowerparts.com HYDRAULIC SYSTEM Hydraulic Pipes 1. Disconnect the main delivery hose (1), return hose (2), right turning delivery hose (3) and left turning delivery hose (4). (When reassembling) • In assembling the turning delivery hoses to the steering controller, connect the delivery hose with identification mark (tape) “A” to the L port of the steering controller. Tightening torque Main delivery hose retaining nut 46.6 ~ 50.9 N·m 4.8 ~ 5.2 kgf·m 569W677A 34.4 ~ 37.
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www.mymowerparts.com CHAPTER 6 8454 3.
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www.mymowerparts.com HYDRAULIC SYSTEM a . To Disassemble the Gerotor Parts 1. Let the port face of the tractor’s body housing vised slightly with the end cap upward. 2. Loosen 2 screws to Disassembling housing (21). • Do not tighten the vise too firmly with a steel pate or the like applied to. CAUTION 569W680A 3. Loosen 7 screws (1). 4. Remove end cap (2). 5. Remove O-ring (3) out of the end cap.
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www.mymowerparts.com CHAPTER 6 8454 6. Take out spacers (5), (7) and O-ring (6) located inside the inner spline of the rotor (10) in gerotor (4). • There is no spacer in the power steering units of outlet capacities of 31 cc/ rev and 51 cc/rev. CAUTION 569W682A (4) Stator (5) Spacer (7) Spacer (10) Rotor (6) O-ring 7. Disassembling the gerotor. Be careful not to drop the rotor from the outer ring of the gerotor. 8. Take out spacer plate (8) and O-ring (9). 9. Take out drive (11). 10.
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www.mymowerparts.com HYDRAULIC SYSTEM 11. Take out the spool and sleeve ass’y at the opposite side to the flange of the housing while pushing the inner spline of the spool with the thumb. Be careful not to allow the circumference of the sleeve to be stuck in the inner bore of the housing this time. 569W684A (A) Positioning Marks (13) Pin 12. Take pin (13) out of the spool and sleeve ass’y. • Since the centering spring might fly out of the pool, surely wear goggles. CAUTION 13.
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www.mymowerparts.com CHAPTER 6 8454 b . To Disassembling the Relief Valve 1. Loosen retainer screw (1) on plug (29) area of housing (20) and take out retainer pin (2) and ball (3). 2. Loosen relief adjusting plug (29) with the flange face of housing (20) upward and remove O-ring (28). 3. Remove damper collar (8) and spring (5) out. 4. Take poppet (4) out of housing (20) using a pin set.
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www.mymowerparts.com HYDRAULIC SYSTEM 3. While turning around spool (15), insert it slowly into sleeve (12), Take up the spline area to the spool to check if the spool turns lightly inside the sleeve. 569W690A (10) Sleeve (A) Positioning Marks (11) Spool (D) Spring Slot 4. Keep two spring groove at an angle of 18 0 respectively in the spool and the sleeve on a level plane as aligned.
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www.mymowerparts.com CHAPTER 6 8454 6. Insert pin (13) onto the sleeve groove and insert the spool and sleeve ass’y from the gerotor side of the housing. • Check if the spool and sleeve ass’y turns lightly inside the housing. CAUTION 7. 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. 569W693A (11) Drive (13) Pin 9.
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www.mymowerparts.com HYDRAULIC SYSTEM d. To Assemble the Relief Valve 1. Pick up the spring guide part with a pin set to insert poppet (25) into the flange area of the housing. 2. Insert spring (26) and damper collar (27). 3. Insert O-ring into the relief adjusting plug (29) to tighten with the housing. • CAUTION Adjust pressure of the steering relief valve when the assembly is completed. Variable amount of pressure per revolution of the relief adjusting plug (29) is 15 kgf/cm2 (213 psi). 569W695A e .
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www.mymowerparts.com CHAPTER 6 8454 4. HYDRAULIC PUMP 4.1 TROUBLE SHOOTING No. Repair item Clearance between drive gear and main frame 1 • Allowable limit → 0.05 mm (0.00196 in.) Drive shaft parts worn out • Allowable limit → 19.25 mm (0.75787 in.) 2 3 Factory spec. 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.
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www.mymowerparts.com HYDRAULIC SYSTEM 4.3 STRUCTURE AND OPERATION A.
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www.mymowerparts.com CHAPTER 6 8454 B. OPERATION a. Hydraulic pump delivers constant oil flow to operate the steering wheel and the hydraulic cylinder, and the hydraulic pump ass’y is composed of 2 pumps with different displacement respectively. b. Two pump applicable in the same way are as designed as of the exterior gear to displace the fluid amount and to transmit the specified fluid amount for each revolution. Outlet flowing amount increases as the revolution speed of the pump increases. c.
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www.mymowerparts.com HYDRAULIC SYSTEM 4.4 TO DISASSEMBLING AND TO ASSEMBLE A. GEAR PUMP ASSEMBLY 1. Remove hydraulic pipes (3), (4) and inlet pipes (2) installed on gear pump (1). 569W698A (1) Gear Pump (4) Hydraulic Pipe 2 (2) Inlet Pipe (5) Priority Valve (3) Hydraulic Pipe 1 2. Loosen and remove bolt (2), gear pump (1) and gasket. • Be careful not to cause damages on the gasket. If damaged, replace it with a new one.
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www.mymowerparts.com CHAPTER 6 8454 B. GEAR PUMP 569W6A0A (1) Snap Ring (7) Sealing (13) Cover (19) O-Ring (2) Bearing (8) Sealing (14) Sealing (20) Second Pump (3) Front Cover (9) Bushing (15) Sealing (21) Cover (4) O-Ring (5) Straight Pin (6) First Pump (10) Drive Gear Shaft 1 (11) Passive Gear (12) Coupling 1. Fix the gear pump ass’y with a vise. 2. Loosen 4 bolts (23) and remove rear cover (21). 3. Disassembling snap ring (1) and bearing (2) of the drive shaft. 4.
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www.mymowerparts.com HYDRAULIC SYSTEM 5. HYDRAULIC FILTER 5.1 STRUCTURE AND OPERATION A. STRUCTURE 569W6A1A (1) Hydraulic Filter (2) Magnetic Ass’y (3) Filter Bracket (4) Vacuum 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.
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www.mymowerparts.com CHAPTER 6 8454 B. OPERATION a . Function It filters any particle or contaminated substance out of oil. b. Operation Principle The filtering system as of an inlet filter installed on the inlet gear pump is composed of filter bracket, magnet ass’y and element ass’y. The filter used 8000 series is by itself applicable to both hydraulic lift and direction control of the steering wheel.
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www.mymowerparts.com HYDRAULIC SYSTEM 6. HYDRAULIC PRESSURE OPERATION PRINCIPLE AND TROUBLE SHOOTING 6.1 COMPOSITION OF HYDRAULIC DEVICE & FLOW DIAGRAM OF HYDRAULIC OIL A.
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www.mymowerparts.com CHAPTER 6 8454 B. FLOW DIAGRAM OF TRANSMISSION OIL a . STEERING DEVICE & PTO CLUTCH SYSTEM Transmission Case (Hydraulic Tank) Hydraulic filter Prior valve assembly (7 L/min) Steering cylinder Modulator valve assembly Hydraulic pump 2 (7.2 cc/rev) Power steering unit (74 cc/rev) Solenoid valve assembly PTO clutch assembly b.
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www.mymowerparts.com HYDRAULIC SYSTEM 6.2 STEERING DEVICE A. SCHEMATIC DIAGRAM OF STEERING DEVICE 569W6A4A (1) Gear Pump Assembly [A] PTO Clutch Valve (2) Power Steering Unit [B] Lift Line (3) Steering Cylinder Ass’y [C] Flow Rate Gauge (4) Hydraulic Hose Ass’y (RH) [D] Pressure Gauge (5) Hydraulic Hose Ass’y (LH) (6) Prior Valve Assembly (7) Hydraulic Filter (8) Transmission Case B.
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www.mymowerparts.com CHAPTER 6 8454 D. TROUBLE SHOOTING Components Hydraulic pump Trouble Checking Remark 1. Install the flow rate gauge on the outlet of pump (refer to the schematic Diagram). 2. Check the discharged flow rate. First pump rated flow rate: normal if over 26.5 /min. (7.0 U.S.gal/min) Second pump rated flow rate: normal if over 15.9 /min (4.2 U.S.gal/min) (engine rotation: 2600, based on pump efficiency 85 %) ref.
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www.mymowerparts.com HYDRAULIC SYSTEM 6.3 PTO SYSTEM A. SCHEMATIC DIAGRAM OF PTO SYSTEM 569W6A6A (2) Orbitrol Unit (A) Steering Cylinder (1-1) Solenoid Valve Ass’y (1) PTO Clutch Valve (3) Prior Valve Ass’y (B) Pressure Gauge (1-2) Modulator Valve Ass’y (4) Gear Pump Ass’y (1-3) PTO Clutch Ass’y B. PRINCIPLES OF OPERATION C.
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www.mymowerparts.com CHAPTER 6 8454 D. TROUBLE SHOOTING Components PTO clutch does not work. Trouble Checking Remark 1. Press the push button of solenoid valve assembly to check the fitting of spool. 569W6A7A (Solenoid valve assembly) 2. After installing the pressure gauge on PTO hydraulic pipe, check the standard pressure value (installation position of pressure gauge: refer to schematic diagram). - Standard pressure value: 16 kg/cm 2 ~ 18 kg/cm2, (228 ~ 256 psi) 3.
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www.mymowerparts.com HYDRAULIC SYSTEM 6.4 HYDRAULIC PRESSURE RISE & FALL DEVICE A. SCHEMATIC DIAGRAM OF HYDRAULIC PRESSURE RISE & FALL DEVICE 569W6A9A (1) Hydraulic Cylinder Ass’y (3) Hydraulic Pump (1-1) MLS Valve (4) Hydraulic Filter (1-2) Double Acting Valve (5) Transmission Case (2) Hydraulic Block (A) Orbital Unit (Steering Device) B. PRINCIPLE OF OPERATION C.
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www.mymowerparts.com CHAPTER 6 8454 D. TROUBLE SHOOTING Components 1. Hydraulic block Trouble Checking Remark Checking of hydraulic block 1. Install the pressure gauge on coupler socket assembly to check the pressure value. - Standard pressure value : 165 kg/cm2 ~ 190 kg/cm2 (2,347 ~ 2,700 psi) (engine rotation: 2,600 rpm). - Installation of pressure gauge: (ref. schematic diagram) - when pressure is below 50 kg/cm2 (711 psi), replace or clean hydraulic block. Ref.
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www.mymowerparts.com HYDRAULIC SYSTEM Components Trouble Checking 2. Double-acting valve assembly Remark How to adjust the pressure of double-acting valve 1. Install the pressure in the coupler socket to check the standard pressure of external hydraulic pressure (Refer to schematic diagram). 2. Standard pressure of rear external hydraulic pressure: 165 kg/cm2 ~ 190 kg/cm2 (engine rotation: 2,600 rpm).
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www.mymowerparts.com CHAPTER 6 8454 Components 3. MLS valve assembly (operation principle) Trouble Checking Remark (Neutral Stage) 569W6B4A (1) Piston (3) Check Valve (2) Spool (4) Falling Valve Operation principle of MLS valve neutral stage The supply oil is exhausted to the transmission case as Spool (2) closes the pipe line (A) and piston (1) falls down by oil pressure to open the pipe line (B), the falling valve (4) shall be neutral stage as the pipe line (C) is closed.
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www.mymowerparts.com HYDRAULIC SYSTEM Components Trouble Checking 2. Double-acting valve assembly Remark (4) Falling valve: as spool (1) is operated, the falling valve (4) falls down by a spring to open the pipe line (C) and the oil is exhausted from the cylinder.
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www.mymowerparts.com CHAPTER 6 8454 Components Trouble Checking Remark Operation principle of MLS valve supply stage Spool (1) is operated by a link to open the pipe line (A) and the oil supplied from the pump flows into the cylinder through check valve (3) while falling valve (4) closes the pipe line (C) to prevent the exhaust of oil which results in the rise of the lift arm.
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www.mymowerparts.com HYDRAULIC SYSTEM Components Trouble Checking 4. Hydraulic cylinder assembly Remark How to adjust the sensitivity 569W6B7A (MLS valve assembly) 1. Apply the load of 500 kg to the lift arm and move the adjusting lever up to be placed on the middle of the whole adjustment range. 2. The sensitivity shall be adjusted by turning the loosening-prevention screw “A” to counter clockwise with a hexagonal wrench till the lift arm continues to move. 3.
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www.mymowerparts.com BRAKE 1.
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www.mymowerparts.com CHAPTER 7 8454 3. TIGHTENING TORQUE Tightening torque Brake shaft 367.8 ~ 431.6 N·m 37.5 ~ 44.0 kgf·m 271.2 ~ 317.8 lbf·ft Mounting bolt of parking brake shaft 23.5 ~ 27.4 N·m 2.4 ~ 2.8 kgf·m 17.3 ~ 20.2 lbf·ft Mounting nut of brake cam lever 123.6 ~ 147.1 N·m 12.6 ~ 15.0 kgf·m 91.1 ~ 108.5 lbf·ft Mounting bolt of brake case 77.5 ~ 90.2 N·m 7.9 ~ 9.2 kgf·m 57.1 ~ 66.5 lbf·ft Mounting nut of brake case 77.5 ~ 90.2 N·m 7.9 ~ 9.2 kgf·m 57.1 ~ 66.
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www.mymowerparts.com BRAKE 4. STRUCTURE AND OPERATION 4.
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www.mymowerparts.com CHAPTER 7 8454 569W702A (1) Pedal (6) Cam Plate (2) Shaft (7) Plate (3) Brake Rod (8) Brake Disk (4) Brake Rod 3 (9) Brake Case (5) Brake Cam Lever a . Brake b. Parking Brake The brake is of mechanical wet-disc type with its two pedals left and right operated respectively.
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www.mymowerparts.com BRAKE 4.
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www.mymowerparts.com CHAPTER 7 8454 5. DISASSEMBLING AND ASSEMBLING 5.1 DRAINING THE TRANSMISSION FLUID Draining the Transmission Fluid 1. Place oil pans underneath the transmission case. 2. Remove the drain plugs. 3. Drain the transmission fluid. 4. Reinstall the drain plugs (When refilling) • Fill up from filling port after removing the filling plug (1) until reaching the gauge (2).
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www.mymowerparts.com BRAKE 5.2 SEPARATING PANEL FRAME ASSEMBLY Preparation 1 1. Removing the following parts. 569W707A (1) Side Cover (RH, LH) (4) Side Skirt (RH, LH) (2) Bonnet (5) Battery Negative Code (3) Front Grille Preparation 2 1. Disconnect the brake rods (4), (10). 2. 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.
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www.mymowerparts.com CHAPTER 7 8454 Hydraulic Pipes 1. Disconnect the main delivery hose (1), return hose (2), right turning delivery hose (3) and left turning delivery hose (4). (When reassembling) • In assembling the turning delivery hoses to the steering controller, connect the delivery hose with identification mark (tape) “A” to the L port of the steering controller. Tightening torque Main delivery hose retaining nut 46.6 ~ 50.9 N·m 4.8 ~ 5.2 kgf·m 569W712A 34.4 ~ 37.
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www.mymowerparts.com BRAKE 5.3 SEPARATING REAR FENDERS AND PLATFORM ASSEMBLY Preparation 1. Remove the Rops. 2. Remove the Bolts (1) and take out the seat Assembly (2). 569W714A (1) Bolt (2) Seat Assembly Cover 1. Remove the blots (1), (2) and the cover assembly (3). 569W715A (1) Bolt (3) Cover (2) Bolt Fender, Floor Seat and Platform Assembly 1. Remove the fender (1, 2), floor seat and platform as a unit.
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www.mymowerparts.com CHAPTER 7 8454 D. SEPARATING CLUTCH HOUSING Propeller Shaft 1. Slide the propeller shaft cover, (4), (5), after removing the screws (9). 2. Tap out the spring pin (10) and then slide the coupling (2) to the front. (When reassembling) • Apply grease to the splines of the propeller shaft. 569W720A (1) Propeller Shaft (6) O-Ring (2) Coupling (7) O-Ring (3) Cir-Clip (8) O-Ring (4) Propeller Shaft Cover (9) Bolt (5) Propeller Shaft Cover (10) Spring Pin Hydraulic Pipes 1.
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www.mymowerparts.com BRAKE Separating the Engine from Clutch Housing 1. Place the jack under the clutch housing case. 2. Hoist the engine by the nylon lift strap at the tank support. 3. Remove the engine mounting screws, and then pull the engine to the front. (When reassembling) • • Apply grease to the splines. Apply liquid gasket (There equivalent) to joint face of the housing.
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www.mymowerparts.com CHAPTER 7 8454 5.4 DISASSEMBLING REAR AXLE CASE Rear Axle Case 1. Support the transmission case with nylon lift strap and hoist. 2. Loosen and remove the rear axle case mounting screws (1), spring washer (3) and nuts (2). 3. Support the rear axle case (4) with nylon lift strap and hoist. 4. Carefully move the axle assembly out and away from the tractor. (When reassembling) Tightening torque Rear axle case mounting screws Rear axle case mounting nuts 77.5 ~ 90.2 N·m 569W724A 7.
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www.mymowerparts.com BRAKE 5.5 DISASSEMBLING BRAKE CASE Brake Case 1. Loosen and remove the nut (1), spring washer (2), plain washer (3), brake can lever (4), bolt (5) and spring washer (6). 2. Separate the brake case (7), tapping the brake case lightly. (When reassembling) • Apply grease to the brake ball seats (16). (Do not grease excessively.) • Before installing the brake case (7) to the transmission case, install the cam plate (14) to the transmission case.
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www.mymowerparts.com CHAPTER 7 8454 6. ADJUSTMENT OF THE BRAKE 569W727A (1) Brake Pedal (5) Brake Rod (2) Brake Rod (6) Brake Cam Lever (3) Parking Brake Lever (7) Stop Switch (4) Brake Lever (8) Nut Brake Pedal Free Play Adjustment of the Brake Stop Switch 1. Press the center of the pedal with a force of approx. 39.2 ~ 58.8 N (4 ~ 6 kgf, 8.8 ~ 13.2 lbs), and measure the free play of the brake pedal edge. 1. Install the stop switch on the bracket. 2.
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www.mymowerparts.com BRAKE 7. SERVICING Brake Can Lever Movement 1. Move the brake cam lever by hand to check the movement. 2. If the movement is heavy, refine the brake cam with sandpaper. 569W728A Cam Plate Flatness 1. Place the cam plate on the surface plate. 2. Use a feeler gauge of 0.3 mm (0.012 in.) thick for judgment of the cam plate flatness. 3. If the measurement is above the allowable limit, replace it. Cam plate flatness Allowable limit 0.3 mm 0.012 in.
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www.mymowerparts.com CHAPTER 7 8454 Brake Disc Wear 1. Measure the brake disc thickness with venire calipers. 2. If the thickness is less than the allowable limit, replace it. Brake disc thickness Factory spec. Allowable limit. 4.6 ~ 4.8 mm 0.181 ~ 0.189 in. 4.0 mm 0.1574 in. 569W731A Brake Dise Wear 1. Measure the plate thickness with venire calipers. 2. If the thickness is less than the allowable limit, replace it. Plate thickness Factory spec. Allowable limit. 2.54 ~ 2.66 mm 0.1000 ~ 0.1047 in.
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www.mymowerparts.com ELECTRICAL SYSTEM 1. ELECTRONIC INSTRUMENTATION 569W801B (1) Tachometer (8) Battery Charge Warning Lamp (2) Temperature Gauge (9) Grow Plug Indicator (3) Fuel Gauge (10) Hydraulic Filter Warning Lamp (4) PTO On Indicator (11) Upward Indicator (5) Engine Coolant Low Level Warning lamp (12) Parking Brake Indicator (6) Differential Lock Operation lamp (13) 4WD Lamp (7) Engine Oil Pressure Warning Lamp (14, 15) Turning Signal Indicator 1.1 INSTRUMENT GAUGE 1.
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www.mymowerparts.com CHAPTER 8 8454 1.2 INDICATORS AND WARNING LIGHTS A. POWER-TAKE-OFF OPERATION LAMP (4) Light will illuminate when the PTO selection switch is located at Auto or Manual mode. Before you start the engine, be sure that the PTO selection switch is located at the Neutral position. B. ENGINE COOLANT LOW LEVEL WARNING LAMP (5) Light will illuminate when the engine coolant is not enough to operate the tractor. As soon as the light illuminate, stop the engine and investigate the cause.
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www.mymowerparts.com ELECTRICAL SYSTEM F. PRE-HEAT CONTROL OPERATION LAMP (9) When the key switch is in the “ON” position, light will illuminate. When the whether is cold, remain the key switch in the “ON” position before starting for a while or until the lamp goes out. During this period, glow plug and combustion chambers are heated up and the engine becomes easier to start. G.
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www.mymowerparts.com CHAPTER 8 8454 2.
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www.mymowerparts.com CHAPTER 8 8454 3. SERVICING SPECIFICATIONS Capacity (factory spec.) Item Battery Rated voltage capacity Feature 12V 80AH Start motor Alternator Indicator bulb 8-8 Rated voltage 12V Rated power 2.0kw Rated voltage 12V Rated current 50A Rated voltage 14V Rated power 3.
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www.mymowerparts.com ELECTRICAL SYSTEM 4. MECHANISM 4.1 STARTING SYSTEM A.
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www.mymowerparts.com CHAPTER 8 8454 B. OPERATION OF START MOTOR a. Starter The magnet-switch type starter is composed of two main sections. The first section converts battery current into mechanical rotation to turn the engine crankshaft. It is composed of the field coil, armature, brush, commutator, pinion, overrunning clutch, etc. The second section allows the pinion and flywheel to engage together and current to flow through the motor section.
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www.mymowerparts.com ELECTRICAL SYSTEM (C) When key switch is on: When the key switch is turned on, a current flows from the battery through the pull-in coil in the magnet switch section to the holding coil, energizing the plunger to pull it in. At this time, the pinion moves by the lever to engage with the ring gear.
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www.mymowerparts.com CHAPTER 8 8454 b. Glow plugs Glow plugs are used for each pre-combustion chamber of the cylinder head to make starting easier. The glow plugs are quick-heating type, which make starting easier with short pre-heating time. 569W810A (1) Housing (3) Insulating powder (2) Metal tube (4) Heat coil 4.2 CHARGING SYSTEM A.
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www.mymowerparts.com ELECTRICAL SYSTEM B. CIRCUIT DIAGRAM FOR ALTERNATOR UNIT 569W812A C. OPERATION OF CHARGING SYSTEM · The charging system supplies electric power for various electrical devices and also charges the battery while the engine runs. · The alternator generates AC (alternating current) and the regulator converts AC into DC (direct current). It also controls the output voltage for charging current to the battery. · The regulator is built in inside of alternator.
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www.mymowerparts.com CHAPTER 8 8454 4.3 PREHEATING SYSTEM A. CIRCUIT DIAGRAM FOR PREHEATING SYSTEM 569W813A (1) Alternator (5) Glow plug indicator (2) Key s/w (6) Glow plug (3) Preheating Controller (7) Glow Relay (4) Coolant temp. sensor PARTS SPECIFICATION (1) Capacity of the preheating relay : DC12V 70A (2) Capacity of the preheating controller : DC12V B.
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www.mymowerparts.com ELECTRICAL SYSTEM 4.4 FUSE A. FUSE BOX DIAGRAM Classifi- Cable cation standard Connec- Appli- Remark tion cable terminal fuse 3 AVS3.OR 5 5 AVS2.OW 3 11 AVS3.ORL 21 13 AVS2.OWR 6 20A 21 AVS0.85YR 11 10A 6 AVS3.ORW 7,13,15, 6WAY 36,66,77 TERMINAL 25A AVS0.85BY 6 10A 15 AVS2.OOR 6 20A 36 AVS0.85RG 6 10A 66 AVS0.85RW 6 10A 77 AVS0.85YW 6 10A 7 569W814A B. CAUTION FOR FUSE REPLACEMENT There are two kinds of fuse in this tractor.
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www.mymowerparts.com CHAPTER 8 8454 4.5 GAUGE AND SENSORS A. OIL PRESSURE SWITCH The oil pressure switch is installed on the cylinder block and leads to the oil passage of the lubricating oil. When the oil pressure falls below the specified value, the contacts of the oil pressure switch closes to turn on the warning lamp. 569W815A (1) Terminal contact (2) Diaphragm B. COOLANT TEMPERATURE SENSOR The coolant temperature sensor consists of terminal, thermostat, insulator.
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www.mymowerparts.com CABIN SYSTEM 1. DISASSEMBLY AND ASSEMBLY 1. Loosen 6 setting bolts for chair assembly support and disconnect seat assembly in a body. 569W901A (1) Seat Assembly 2. Disengage 4 setting bolts for cabin assembly. 569W902A (1) Cabin Support (Front) (3) Bolt (2) Cabin Support (Rear) (4) Bolt 3. Remove steering hose L.R (steering cylinder assembly) and steering hose P.T (gear pump assembly).
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www.mymowerparts.com CHAPTER 9 8454 4. Open drain cock located in right of front axle frame, drain coolant, remove heat hose 2 pieces (7) connected to connecting pipe, and then remove air conditioner hose (4, 5). Remove wiring jack connected to the bottom of cabin. 569W904A (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 5.
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www.mymowerparts.com CABIN SYSTEM 7. Loosen head pin and snap pin connected to main transmission lever at left bottom of cabin and remove main transmission lever. 569W908A (1) Lever 1, Front Drive (3) Pin, Joint (2) Lever 2, Front Drive (4) Snap Pin 8. Remove joint pin and snap pin connected to front wheel driving lever 1 in left lower of cabin and then remove front wheel driving lever 2. 569W907A (1) Bracket, Main Shift Lever (2) Lever, Main Shift Lever (3) Pin, Main Shift Lever (4) Pin, Joint 9.
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www.mymowerparts.com CHAPTER 9 8454 10. Remove head pin and snap pin from Hi-Low shift lever connector and remove Hi-Low shift lever. 569W910A (1) Lever 2, Hi-Low (3) Lever, Hi-low (2) Rod, Hi-Low (4) Shaft, Lever 11. Remove head pin and snap pin and then remove hydraulic control rod. Remove and disconnect head pin and snap pin connected between double acting lever and rod (double acting).
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www.mymowerparts.com CABIN SYSTEM 13. Remove frame cover (1) in left of frame assembly and parallel pin connected with shuttle lever arm (3) and then disconnect shuttle lever from shuttle lever arm. 569W913A (1) Cover, Frame (3) Lever, Shuttle (2) Pin, Straight 14. Remove cabin. • CAUTION Disassemble cabin carefully, ensuring that it would not interfere with other parts or there would be parts not disassembled.
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www.mymowerparts.com CHAPTER 9 8454 2. HEATER 2.1 STRUCTURE Item Heater 8454 Type Hot water type Radiating (kcal/h) HI: 2170 kcal/h Low:1900 kcal/h Air flow Hi: 230 m3/h Low:130 m3/h Power consumption Coolant Capacity Air conditioner Used refrigerator Level of refrigerator Compressor oil (compressor) Level of oil (compressor) Less than 65 W (DC12 V) 8.9 , 2.4 U.S.gal HFC-134 A 0.95 ~ 1.0 kg, 2.1 ~ 2.2 lbs VCON488 150 CC 2.2 DISASSEMBLY AND ASSEMBLY 1.
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www.mymowerparts.com CABIN SYSTEM 3. AIRCONDITIONER 3.1 AIR CONDITIONER A. STRUCTURE 569W916A (1) Compressor (4) Expansion Valve (2) Condenser (5) Vaporizer (3) Receiver Drier (6) Refrigerant B. PRINCIPLE OF AIRCONDITIONING The function of air-conditioning system is to cool the air inside the cabin and lower the humidity to promote the convenience of operator.
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www.mymowerparts.com CHAPTER 9 8454 569W917A The above figure shows the circulation diagram of a refrigerant which passes through the 5 main components of the air-conditioning system. The refrigerant shall be flowed into the compressor as the compressed cold low-pressure steam and then ejected as the hot high-pressure steam and get into the condenser.
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www.mymowerparts.com CABIN SYSTEM C. OPERATION PRINCIPLES OF SYSTEM COMPONENTS As the drier contains a drying agent, it absorbs all humidity in the system and the filter prohibits the external particles to enter in. a . Refrigerant Ref.) The humidity of air-conditioning system is absolutely 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.
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www.mymowerparts.com CHAPTER 9 8454 D. AIR-CONDITIONING COMPONENTS 569W918A (1) Aircon. Unit (5) Compressor (2) Duct, Aircon. (6) R/D (10) Hose, Drain (13) Hose 1, Heater (3) Hose 3, Aircon (7) Condenser (11) Heater (14) Pipe 1, 2 (4) Hose 4, Aircon. (8) Hose 2, Aircon. E. SAFETY PREVENTION MEASURES • WARNING Before disassembling and inspecting the air-conditioning system, please read and obey the following safety prevention measures.
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www.mymowerparts.com CABIN SYSTEM F. OIL I. AIR CONDITIONER CONTROL - Air conditioner switch consists of air flow and temperature control switches. Airflow control switch is operated in three stages of LOW, MIDDLE and HIGH. Turning temperature control switch clockwise enables to select the highest temperature.
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www.mymowerparts.com CHAPTER 9 f. 8454 Abnormal noise from the blower motor In case of the generation of abnormal noise from the blower motor and the poor revolution, change the blower motor with the new one. In case of generation of the abnormal noise caused by the foreign material in the blower or by the poor tightening, pay attention to work. B. EARLY FINDING OF TROUBLE SHOOTING a . Poor Air-Conditioning 1) Fan motor does not revolve. Causes Checking Methods Action 1. Fuse cutting 2.
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www.mymowerparts.com CABIN SYSTEM Causes 4. The pressure of inlet of the compressor Checking Methods Normal pressure High pressure: 14 ~ 15 kg/cm2G (199 ~ 213 psi) Action Replacement Low pressure: 1.5 ~ 2.0 kg/cm2G (21 ~ 28 psi) Ambient temperature: 30 ~ 35 °C, Engine : about 1,500 rpm 4-1. The pressure of low pressure is high. Magnetic clutch is off before the extract air temperature falls down enough. When magnetic clutch is off, the pressure of high/low pressure gauge is balanced promptly.
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www.mymowerparts.com CHAPTER 9 8454 4) The compressor does not revolve or hard to revolve. Causes Checking Methods Action The vibration of belt is large. The belt is sliding. Tension adjustment Repair/replacement 3-1. Drop of battery voltage 3-2. Layer shot of coil Sliding when revolving Sliding when revolving Battery charging Replacement of magnetic clutch 3-3.
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www.mymowerparts.com CABIN SYSTEM 2.
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www.mymowerparts.com CHAPTER 9 8454 4. Poor extension valve Status: Not cool Phenomena: - The pressure of high /low pressure side is high. Cause: Poor extension valve, poor control of refrigerant flow rate by poor assembling of the wound box. Action: Check the assembly status, location and insulation status of the wound box. With no failure, replace the extension valve. 2.3 kgf/cm2 Low poor extension valve 32.7 psi 569W923A 19 ~ 20 kgf/cm 2 High poor extension valve 270.2 ~ 284.5 psi b.
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www.mymowerparts.com CABIN SYSTEM 3. The refrigerant does not circulate. Status: not cool (sometimes cool) Phenomena: - The pressure of low pressure side is negative and the pressure of high pressure side shows the pressure 5 ~ 6 kg/cm2. - Frost or dew forming in the receiver drier or the front/rear pipe connection section of extension valve. Cause: - The cycle is closed by moisture freezing or dust in the refrigerating cycle. - The cycle is blocked due to the poor wound box of extension valve.
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www.mymowerparts.com CHAPTER 9 8454 D. ELECTRICAL CIRCUIT a . Air Conditioner System 569W927A (1) Battery (6) Pressure Switch (2) Slow Blow Fuse (7) A/C Blower Switch (3) Main Switch (8) Ass’y Air-Conditional (4) Compressor Relay (9) Blower Motor (5) Compressor (10) Thermostat The above figure shows the circuit composing the air conditioning system. The magnetic clutch of the compressor is operated by the following order.