Cub Cadet 8454 User Manual

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FORM NUMBER 769-00903

88445544 SSEERRVVIICCEE M

MAANNUUAALL

MTD Products, LLC Product Training and Education Department

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........................................................................................................................ 1-4

3. SPECIFICATIONS............................................................................................................................................ 1-6

4. IDENTIFICATIONS........................................................................................................................................... 1-8

4.1 ENGINE NUMBER ................................................................................................................................ 1-8

4.2 SERIAL NUMBER OF THE TRACTOR ............................................................................................... 1-8

5. CAUTION BEFORE REPAIR .......................................................................................................................... 1-9

5.1 BEFORE REPAIR OR INSPECTION .................................................................................................. 1-9

5.2 ASSEMBLY AND DISASSEMBLY......................................................................................................... 1-9

5.3 PARTS TO BE REPLACED.................................................................................................................. 1-9

5.4 PARTS..................................................................................................................................................... 1-9

5.5 ASBESTOS P ARTS .............................................................................................................................1-10

5.6 ELECTRICAL SYSTEM....................................................................................................................... 1-10

5.7 TUBES AND RUBBERS ..................................................................................................................... 1-11

5.8 LUBRICANT ......................................................................................................................................... 1-11

6. REGULAR CHECK LIST............................................................................................................................... 1-12

7. OIL & WATER SUPPLY LIST........................................................................................................................ 1-13

CHAPTER 2. ENGINE ........................................................................................................................2-1

1. GENERAL ......................................................................................................................................................... 2-3

1.1 APPEARANCE....................................................................................................................................... 2-3

1.2 SPECIFICATIONS .................................................................................................................................2-4

1.3 PERFORMANCE CURVE..................................................................................................................... 2-5

1.4 DIMENSIONS......................................................................................................................................... 2-6

1.5 GENERAL WARNING ........................................................................................................................... 2-6

2. STRUCTURE AND FUNCTION ..................................................................................................................... 2-7

2.1 BODY ...................................................................................................................................................... 2-7

2.2 LUBRICATION SYSTEM..................................................................................................................... 2-11

2.3 COOLING SYSTEM............................................................................................................................. 2-13

2.4 FUEL SYSTEM..................................................................................................................................... 2-15

2.5 INTAKE AND EXHAUST SYSTEM...................................................................................................... 2-22

3. DISASSEMBLING AND SERVICING .......................................................................................................... 2-24

3.1 TROUBLIE SHOOTING...................................................................................................................... 2-24

3.2 SERVICING SPECIFICA TIONS......................................................................................................... 2-27

3.3 CHECKING, DISASSEMBLING AND SERVICING..........................................................................2-33

CHAPTER 3. CLUTCH ....................................................................................................................... 3-1

1. TROUBLE SHOOTING.................................................................................................................................... 3-3

2. SPECIFICATIONS,TIGHTENING TORQUES AND SPECIAL TOOLS ...................................................... 3-4

2.1 SPECIFICATIONS .................................................................................................................................3-4

2.2 TIGHTENING TORQUES ..................................................................................................................... 3-4

2.3 SPECIAL TOOLS................................................................................................................................... 3-4

3. STRUCTURE AND OPERATION ................................................................................................................... 3-5

3.1 FEATURES ............................................................................................................................................. 3-5

3.2 STRUCTURE......................................................................................................................................... 3-5

3.3 OPERATION........................................................................................................................................... 3-6

4. PREPARA TION STAGE FOR DISASSEMBLING AND ASSEMBLING........................................................ 3-7

4.1 SEP ARATING PANEL FRAME ASSEMBL Y... ... . . ... . ... . . ... . ... . . ... . ... . . ... . ... . . ... . ... . ... . . ... . ... . . ... . ... . . ... . ... . . ... . . 3-7

4.2 SEPARATING ENGINE AND CLUTCH HOUSING CASE................................................................. 3-9

4.3 DISASSEMBLY..................................................................................................................................... 3-10

5. ADJUSTMENT OF PEDALS ......................................................................................................................... 3-11

5.1 DEFLECTION OF CLUTCH PEDAL ................................................................................................. 3-11

5.2 CLEARANCE BETWEEN SAFETY STAR TING SWITCH AND LINK............................................. 3-11

6. INSPECTION AND REPAI R..........................................................................................................................3-12

6.1 WEAR AND DAMAGE ON CLUTCH DISC ....................................................................................... 3-12

6.2 CLEARANCE BETWEEN SPLINE BOSS OF THE CLUTCH DISC AND

SHUTTLE SHAFT SPLINES.............................................................................................................. 3-12

6.3 FLATNESS OF CLUTCH PRESSURE PLATE, DAMAGES............................................................3-13

6.4 DAMAGES T O FLYWHEEL, ADJUSTMENT OF RELEASE BEARING.. .... ....................................3-13

6.5 WEAR OR DAMAGES ON RELEASE BEARING, RELEASE FORK AND RELEASE HUB ........ 3-13

6.6 CLEARANCE BETWEEN CLUTCH PEDAL SHAFT AND CLUTCH PEDAL BUSHING ............3-14

CHAPTER 4. TRANSMISSION SYSTEM ........................................................................................4-1

1. TROUBLESHOOTING..................................................................................................................................... 4-3

1.1 TROUBLESHOOTING FOR SHUTTLE SHIFT IN OPERATION ERROR ...................................... 4-3

1.2 TROUBLESHOOTING FOR MAIN SHIFTS IN OPERATION ERROR ............................................ 4-3

1.3 TROUBLESHOOTING FOR AUXILIARY AND CREEP SHIFTS IN OPERATION ERROR........... 4-4

1.4 TROUBLESHOOTING FOR REAR DIFFERENTIAL GEAR IN OPERA TION ERROR ................. 4-4

1.5 TROUBLESHOOTING FOR REAR DIFFERENTIAL IN OPERATION ERROR............................. 4-4

1.6 TROUBLESHOOTING FOR FRONT WHEEL DRIVE IN OPERATION ERROR ........................... 4-5

1.7 TROUBLESHOOTING FOR PTO CLUTCH IN OPERATION ERROR ........................................... 4-5

1.8 TROUBLESHOOTING FOR PTO IN OPERATION ERROR............................................................. 4-5

1.9 TROUBLESHOOTING FOR PARKING BRAKE IN OPERATION ERROR...................................... 4-5

2. SPECIFICATIONS............................................................................................................................................ 4-6

2.1 TIGHTENING TORQUES ..................................................................................................................... 4-6

3. STRUCTURE ................................................................................................................................................... 4-7

3.1 POWER TRAIN DIAGRAM.................................................................................................................... 4-7

3.2 STRUCTURE......................................................................................................................................... 4-8

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 .............................................................................................................................. 4-11

3.3.4 AUXILIARY SHIFT .................................................................................................................... 4-12

3.3.5 FRONT WHEEL DRIVE........................................................................................................... 4-12

3.3.6 PTO SHIFT................................................................................................................................4-13

3.4 OPERATION ......................................................................................................................................... 4-14

3.4.1 FEATURES.................................................................................................................................4-14

4. PREPARATION STAGE FOR DISASSEMBLING AND ASSEMBLING TRANSMISSION........................ 4-22

4.1 DRAINING THE TRANSMISSION FLUID......................................................................................... 4-22

4.2 SEPARATING PANEL FRAME ASSEMBLY ....................................................................................... 4-23

4.3 SEPARATING REAR FENDERS AND PLATFORM ASSEMBLY ..................................................... 4-25

5. TO DISMANTLE AND TO ASSEMBLE ......................................................................................................... 4-28

5.1 STANDARD TABLE FOR REPAIR ..................................................................................................... 4-28

5.2 TO DISMANTLE AND TO ASSEMBLE............................................................................................... 4-28

6. DIFFERENTIAL GEAR ................................................................................................................................... 4-55

6.1 STRUCTURE....................................................................................................................................... 4-55

6.2 OPERATION ......................................................................................................................................... 4-56

6.3 LOCKING OF THE DIFFERENTIAL GEAR ...................................................................................... 4-57

CHAPTER 5. FRONT AXLE ...............................................................................................................5-1

1. TROUBLESHOOTING..................................................................................................................................... 5-3

2. SPECIFICATIONS ............................................................................................................................................ 5-4

3. STRUCTURE ................................................................................................................................................... 5-6

3.1 OPERATION ........................................................................................................................................... 5-6

3.2 FRONT WHEEL ALIGNMENT.............................................................................................................. 5-7

3.3 TOE-IN ADJUSTMENT.......................................................................................................................... 5-8

3.4 DIRECTION CONTROL ANGLE FOR THE FRONT WHEEL .......................................................... 5-8

3.5 ROCKING FORCE OF THE FRONT AXLE, DEFLECTION IN FRONT & REAR DIRECTIONS.. 5-9

4. PREPARATION STAGE FOR DISASSEMBLING AND ASSEMBLING...................................................... 5-10

4.1 SEPARATING FRONT AXLE.............................................................................................................. 5-10

5. TO DISMANTLE AND TO ASSEMBLE ......................................................................................................... 5-12

5.1 FRONT AXLE CASE AND FRONT AXLE........................................................................................... 5-12

5.2 BEVEL GEAR CASE AND FRONT AXLE CASE .............................................................................. 5-13

5.3 BEVEL GEAR CASE AND FRONT AXLE SUPPORT......................................................................5-14

5.4 FRONT AXLE SUPPORT AND DIFFERENTIAL GEAR CASE....................................................... 5-15

5.5 FRONT DIFFERENTIAL GEAR ......................................................................................................... 5-16

5.6 FRONT BRACKET .............................................................................................................................. 5-19

5.7 REAR BRACKET ................................................................................................................................. 5-20

CHAPTER 6. HYDRAULIC SYSTEMS.............................................................................................6-1

1. HYDRAULIC LIFT SYSTEM............................................................................................................................ 6-3

1.1 TROUBLE SHOOTING ......................................................................................................................... 6-5

1.2 SPECIFICATIONS .................................................................................................................................6-6

1.3 STRUCTURE AND OPERATION......................................................................................................... 6-9

1.4 PREPARA TION STAGE FOR DISASSEMBLING AND ASSEMBLING ........................................... 6-25

1.5 DISMANTLE AND ASSEMBLING....................................................................................................... 6-27

2. PTO CLUTCH VALVE SYSTEM..................................................................................................................6-38

2.1 SPECIFICA TIONS AND DIAGRAM ....................................................................................................6-38

2.2 STRUCTURE AND OPERATION.......................................................................................................6-39

2.3 ASSEMBLING AND DISASSEMBLING .... .. .. .....................................................................................6-44

2.4 TO CHECK AND TO REPAIR............................................................................................................. 6-46

3. POWER STEERING SYSTEM......................................................................................................................6-47

3.1 TROUBLE SHOOTING......................................................................................................................... 6-47

3.2 INTRODUCTION ................................................................................................................................. 6-48

3.3 STRUCTURE AND OPERATION.......................................................................................................6-50

3.4 PREPARA TION STAGE FOR DISASSEMBLING AND ASSEMBLING ........................................... 6-55

3.5 TO DISMANTLE AND TO ASSEMBLE............................................................................................... 6-58

4. HYDRAULIC PUMP ....................................................................................................................................... 6-66

4.1 TROUBLESHOOTING ........................................................................................................................ 6-66

4.2 SPECIFICATIONS ...............................................................................................................................6-66

4.3 STRUCTURE AND OPERATION.......................................................................................................6-67

4.4 TO DISMANTLE AND TO ASSEMBLE............................................................................................... 6-69

5. HYDRAULIC FILTER..................................................................................................................................... 6-71

5.1 STRUCTURE AND OPERATION.......................................................................................................6-71

6. HYDRAULIC PRESSURE OPERATION PRINCIPLE AND TROUBLE SHOOTING .............................6-73

6.1 COMPOSITION OF HYDRAULIC DEVICE & FLOW DIAGRAM OF HYDRAULIC OIL................6-73

6.2 STEERING DEVICES .........................................................................................................................6-75

6.3 PTO SYSTEM....................................................................................................................................... 6-77

6.4 HYDRAULIC PRESSURE RISE & FALL DEVICE...........................................................................6-79

CHAPTER 7. BRAKE..........................................................................................................................7-1

1. TROUBLESHOOTING..................................................................................................................................... 7-3

2. SPECIFICATIONS............................................................................................................................................ 7-3

3. TIGHTENING TORQUE .................................................................................................................................. 7-4

4. STRUCTURE AND OPERATION ................................................................................................................... 7-5

4.1 STRUCTURE......................................................................................................................................... 7-5

4.2 OPERATION........................................................................................................................................... 7-7

5. DISASSEMBLING AND ASSEMBLING .......................................................................................................... 7-8

5.1 DRAINING THE TRANSMISSION FLUID........................................................................................... 7-8

5.2 SEP ARATING PANEL FRAME ASSEMBL Y... ... . . ... . ... . . ... . ... . . ... . ... . . ... . ... . . ... . ... . ... . . ... . ... . . ... . ... . . ... . ... . . ... . . 7-9

5.3 SEP ARATING REAR FENDERS AND PLA TFORM ASSEMBL Y..................................................... 7-11

5.4 DISASSEMBLING REAR AXLE CASE ..............................................................................................7-14

5.5 DISASSEMBLING BRAKE CASE ...................................................................................................... 7-15

6. ADJUSTMENT OF THE BRAKE................................................................................................................... 7-16

7. SERVICING ....................................................................................................................................................7-17

CHAPTER 8 ELECTRIC SYSTEM ....................................................................................................8-1

1. ELECTRONIC INSTRUMENTA TION............................................................................................................. 8-3

1.1 INSTRUMENT GAUGE............................................................................................................................ 8-3

1.2 INDICA TORS AND WARNING LIGHTS................................................................................................. 8-4

2. TROUBEL SHOOTING.................................................................................................................................... 8-6

3. SERVICING SPECIFICATIONS ..................................................................................................................... 8-8

4. MECHANISM..................................................................................................................................................... 8-9

4.1 STARTING SYSTEM ................................................................................................................................ 8-9

4.2 CHARGING SYSTEM.............................................................................................................................8-12

4.3 PREHEATING SYSTEM......................................................................................................................... 8-14

4.4 FUSE ....................................................................................................................................................... 8-15

4.5 GAUGE AND SENSORS .......................................................................................................................8-16

CHAPTER 9. CABIN SYSTEM .........................................................................................................9-1

1. DISASSEMBLY AND ASSEMBLY.................................................................................................................... 9-3

2. HEATER ............................................................................................................................................................ 9-8

2.1 STRUCTURE......................................................................................................................................... 9-8

2.2 DISASSEMBLY AND ASSEMBLY......................................................................................................... 9-8

2.3 HEATER OPERATION DEVICE........................................................................................................... 9-8

3. AIR CONDITIONER ......................................................................................................................................... 9-9

3.1 AIR CONDITIONER .............................................................................................................................. 9-9

3.2 TROUBLE SHOOTING ....................................................................................................................... 9-13

CHAPTER 1

GENERAL INFORMATION

1. TRACTOR VIEW

GENERAL INFORMA TION

D569-W02 May-2003

569W101A

1-3

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 ST ANDARD BOLTS AND NUTS

Grade No grade 4T 7T 9T

Unit

Nominal Diameter

M 6

(6 mm, 0.24 in.)

M 8

(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.)

M 20

(20 mm, 0.79 in.)

N·m

7.85 ~

9.30

17.7 ~

20.5

39.2 ~

45.0

62.8 ~

72.5

108

125 167

191 245

284 334

392

Kgf·m

47 9

lbf·ft

9.1 ~

10.5

21.7 ~

25.3

44.9 ~

52.1

76.0 ~

86.8

123

144 192

224 254

297 362

420

0.80 ~

0.95

1.8 ~

2.1

4.0 ~

4.6

6.4 ~

7.4

11.0 ~

12.8

17.0 ~

19.5

25.0 ~

29.0

34.0 ~

40.0

lbf·ft

5.79 ~

6.87

13.0 ~

15.2

29.0 ~

33.2

46.3 ~

53.5

79.6 ~

92.5

123

141 181

210 246

289

N·m

9.80 ~

11.2

23.6 ~

27.4

48.1 ~

55.8

77.5 ~

90.1

124

147 196

225 275

318 368

431

Kgf·m

1.00 ~

1.15

2.4 ~

2.8

4.9 ~

5.7

7.9 ~

9.2

12.6 ~

15.0

20.0 ~

23.0

28.0 ~

32.5

37.5 ~

44.0

lbf·ft

7.24 ~

8.32

17.4 ~

20.2

35.5 ~

41.2

57.2 ~

66.5

91.2 ~

108 145

166 203

235 272

318

N·m

12.3 ~

14.2

29.4 ~

34.3

60.8 ~

70.5

103

117 167

196 260

303 343

401 490

568

Kgf·m

1.25 ~

1.45

3.0 ~

3.5

6.2 ~

7.2

10.5 ~

12.0

17.0 ~

20.2

26.5 ~

31.0

35.0 ~

41.0

50.0 ~

58.0

* The figures on the table above are indicated the top of screw of bolt.

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D569-W02 May-2003

B. TIGHTENING TORQUE FOR STUDS

GENERAL INFORMA TION

M8 M10 M12

11.7 to 15.7 N·m

24.5 to 31.4 N·m

34.3 to 49.0 N·m

1.2 to 1.6 kgf·m

2.5 to 3.2 kgf·m

3.4 to 5.0 kgf·m

C. TIGHTENING TORQUE FOR HIGH PRESSURE HOSE UNION NUTS

Hose Size (Inside Diameter: Inches)

Screw Size (PF) Tightening (N·m) Torque (kgf·m)

(lbf·ft)

1/8″ 3/16″ 1/4″ 5/16″ 3/8″ 1/2″ 5/8″, 3/4″ 1″ 1/8″

9.8 1

7.2

1/4″

24.5

2.5

18.0

1/4″

24.5

2.5

18.0

3/8″

49.0 5

36.1

3/8″

49.0 5

36.1

8.6 to 11.5 lbf·ft

18.0 to 23.1 lbf·ft

25.3 to 36.1 lbf·ft

1/2″

58.8 6

43.3

3/4″

117.7 12

86.8

1″

137.3 14

101.2

D569-W02 May-2003

1-5

CHAPTER 1 8454

MODEL

8454

38 HP

45 HP

4A220

Indirect injection, vertical, water-cooled,

87 x 92.4 (3.425 x 3.638in.)

2,197

2,600 RPM

18 before T.D.C.

3. SPECIFICATION

Maximum PTO power Engine GROSS power Engine

Model

Capacities

Dimensions (with std.tires)

Track width

Type Number of cylinders

Bore and stroke Total displacement Rated revolution Injection timing Injection order 1-3-4-2 Compression ratio 22:01 Lubricating system Forced lubrication by trochoida pump

Cooling system Alternator 12V, 50 AMPS

Weight (Dry) 207 kg (456lb) Fuel tank 40 L (10.6 gal.) Engine crankcase 7.0 L (1.9 gal.) Engine coolant 8.9 L (2.4 gal.) Transmission case 34.0 L (9.0 gal.) Front axle case 8.2 L (2.2 gal.) Overall length (without 3p) 3,073mm (120.9 in.) Overall length (with 3p) 3,323mm (130.8 in.) Overall Length (minimum tread) 1,550mm (61.0 in.) Overall height (Top of ROPS) 2,235 mm (88.0 in.) Overall height (Top of CABIN) 2,337 mm (92.0 in.) Overall height (Top of steering wheel) 1,610 mm (63.3 in.) Wheelbase 1,820 mm (71.6 in.) Ground clearance 370 mm (14.5 in.) Front 1,265 mm (49.8 in) Rear

Pressurized radiator, Forced circulation

1,180 - 1,490mm (46.4 - 58.6 in.)

4cycle diesel

with water pump

1-6

3. SPECIFICATION CON'T

Synchronized shuttle

Power steering

Maximum lifting capacity

Drive system

Hydraulic system

PTO

Min. turning radius ( without Brake) Traction system Weight (with ROPS) Traveling speed ( at rated engine speed with Std tires)

Tire size (Std. Tires) Front 9.5 - 16.6 Rear 14.9 - 24.8 Clutch Dry single disc Steering Hydrostatic steering system

Transmission Brake Travel Wet disc type

Differential Bevel gear Hydraulic lift control system Position, Draft and Mix control Pump Capacity Main Pump 31.2 L/min (8.2 gal.)

Three point hitch SAE Category 1 & 2

No. of remote control valve ports (option) 2-4 PTO shaft SEA 1 3/8, 6 splines Revolution (independent PTO) 560 rpm

12 forward and 12 reverse speeds

Parking Connected with the traveling brake

pump

Fixed drawer (or swing drawer Option)

0.37 - 24.6 km/h (0.23 - 15.29 mph)

18.7 L/min (5.0 gal.)

1,800 kg (3,968 lb)

2,865 mm (112.7 in.)

1,720 kg (3,792 lb)

1-7

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.

569W104A

(1) Tractor Serial Number (2) Transmission Serial Number

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D569-W02 May-2003

5. CAUTION BEFORE REPAIR

C C

GENERAL INFORMATION

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.

3. When washing parts, use parts washing solvent for industrial use (avoid using gasoline so to prevent environmental pollution). For the hydraulic parts, apply designated hydraulic oil in washing.

4. When disassembling and assembling of the hydraulic apparatus, pay special attention not to allow dust or foreign substance to be attached or intermixed.

5.2 ASSEMBLY AND DISASSEMBLY

To check a failure, try to find out its underlying cause. If assembly or disassembly is needed, perform the work in regular sequence as specified in this repair manual.

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

569W106A

The following parts should be replaced with new ones when removed.

(1) Oil Seal (2) Gasket (3) Lock Nut (4) Split Pin (5) O-Ring

227W105A

1. Disassembled parts shall be arranged orderly.

2. Sort out the parts to be replaced from the ones to be reused.

3. Be sure to use standard bolts and nuts that are designated.

4. When assembling snap rings or spring pin types, take care of assembling direction.

5. Split pin shall be spread surely not to escape when installed.

6. When using sealant (such as gasket bond) on the assembled surfaces, apply it evenly and consistently in a height of 3 ~ 5 mm (0.12 ~ 0.2 in.) on the contact surface after removing the old bond and cleaning the sealing surface with solvent. Apply sealant on the center of the contact surface for the space between the bolt holes of the contact surface, and on the more inner side than the bolt hole for the bolt area.

D569-W02 May-2003

5.4 PARTS

569W107A

When replacing part only genuine Cub Cadet parts.

1-9

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. When disconnecting the battery cable, disconnect negative cable first, reinstall the positive cable first when reinstalling.

Disconnect battery negative terminal

• Be sure to turn the starting key OFF when connecting or disconnecting the cable.

CAUTION

569W109A

5. When connecting the connector, insert it until it snaps.

569W108A

4. Remove the connector by pulling the plastic section, not the wiring.

569W110 A

6. Be sure not to drop sensors and relays which are fragile.

7. When replacing a broken fuse with a new one, be sure to use the fuse of capacity as specified.

1-10

D569-W02 May-2003

5.7 TUBES AND RUBBERS 5.8 LUBRICANT

GENERAL INFORMA TION

569W112 A569W11 1 A

Be cautious of oil or other petroleum products on the hoses and rubber parts, this may cause damage.

When assembling and fixing, apply designated lubricant where specified in accordance with this repair manual.

D569-W02 May-2003

1-11

CHAPTER 1 8454

6. REGULAR CHECK LIST

Check Items

Engine oil change Engine oil filter cartridge change Transmission oil change Hydraulic oil filter change Front axle oil change Applying grease Clutch pedal deflection Brake pedal deflection Fan belt tension Fuel filter element change Air cleaner element change Battery electrolyte Oil pressure fuel pipe’s inlet screw

if loosened Radiator hose’s inlet bands if

loosened Fuel pipe change Radiator hose change Hydraulic pipe joint change

Steering hose change Toe-in Deflection adjustment in front and

rear of the front axle Direction control section

Bolt, nuts and pins of each part Battery positive code adjustment &

change Bleeding water in clutch housing

Check injection nozzle*

Indicated Hours By Hour Meter

the first periodically

Since

Purchased

80070060050045040035030025020015010050

1500hr

1yr 2yr

* Maintenance intervals in basis on the EPA instructions.

1-12

D569-W02 May-2003

7. OIL & WATER SUPPLY LIST

GENERAL INFORMA TION

Supply Items

Fuel

Coolant Engine oil Transmission oil Front axle section Applying

grease

Hydraulic control lever shaft section

3 point link section Brake pedal link section Bracket section in front

and rear of the front axle Clutch release hub

Capacity

(42.3 U.S.gal.)

8.9

(2.4 U.S.gal.) (1.8 U.S.gal.)

7.0 34

(9.0 U.S.gal.)

8.2

(2.2 U.S.gal.)

Small quantity

Until grease exits

Supply when removed

Recommended Spec.

No. 2 - D diesel fuel No. 1 - D diesel fuel if temperature

is below - 10 °C (14 °F) Fresh clean water with antifreeze SAE 15 W - 40 Universal tractor/transmission hydraulic oil SAE multi-purpose type grease

D569-W02 May-2003

1-13

CHAPTER 2

ENGINE

1. GENERAL

1.1 APPEARANCE

ENGINE

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.

569W201A

D569-W02 May-2003

2-3

CHAPTER 2 8454

1.2 SPECIFICATIONS

MODEL

Type

Number of cylinder Bore and stroke mm (in.)

Total displacement cc (in

.) Combustion chamber POWER (NET) PS/rpm (kW. rpm) Maximum idling speed rpm Minimum idling speed rpm Order of firing Direction of rotation

Injection pump Injection pressure

Injection timing (Before T.D.C) Compression ratio Fuel Lubricant Dimensions mm (length x width x height) (in.) Dry weight kg (kg, lbs.)

4A220

Vertical, water-cooled,

4-cycle diesel engine

87.0 x 92.4 (3.43 x 3.64) 2,197(134.1

)

vortex chamber

43/2,700 (30.9/2,700)

2,900

850 ~ 900

1-3-4-2

Counterclockwise

(viewed from flywheel side)

Bosch K TYPE mini pump

140 ~ 150 kgf/cm

(13.73 ~ 14.71 MPa, 1991 ~ 2133 psi)

18°

22 : 1

Diesel fuel

Engine oil SAE 15W-40

817.3 x 488.1 x 735.8 (32.2 x 19.2 x 29.0)

207 (456)

4A200T

Vertical, water-cooled,

4-cycle diesel engine (Turbo)

83.0 x 92.4 (3.27 x 3.64) 1,999(122.0)

vortex chamber

47/2,600 (34.6/2,600)

2,800

850 ~ 900

1-3-4-2

Counterclockwise

(viewed from flywheel side)

Bosch K TYPE mini pump

140 ~ 150 kgf/cm

(13.73 ~ 14.71 MPa, 1991 ~ 2134 psi)

12°

22 : 1

Diesel fuel

Engine oil SAE 15W-40

817.3 x 542.0 x 735.8 (32.2 x 19.2 x 29.0)

211 (465)

* NOTE: Change of parts are not subject to advance notice.

2-4

D569-W02 May-2003

1.3 PERFORMANCE CURVE

ENGINE

569W204A 569W203A

D569-W02 May-2003

2-5

CHAPTER 2 8454

1.4 DIMENSIONS

569W205A

Sample/td Spec.

4A220

4A200T

4A220

4A200T

697.3 (27.45)

736 (28.98) 736 (28.98)

817.3 (32.18)

260 (10.24) 260 (10.24)

280 (11.02) 280 (11.02)

240 (9.45) 240 (9.45)

1.5 GENERAL WARNING

• When disassembling, arrange each part on a clean place. Do not mix them up. Replace bolts and nuts where they were.

• When connecting instruments to electrical equipment, first disconnect battery negative terminal.

• Replace gaskets or O-rings with new ones when reassembling, and apply grease on a O-rings and the oil seals when reassembling.

• When exchanging parts, use genuine DAEDONG parts to maintain engine performance and safety.

• To prevent oil and water leakage, apply non-drying adhesive to the gaskets according to this manual before reassembling.

• When hoisting up the engine, use the hook provided on the cylinder head.

• When installing the engine, use the hook provided on the cylinder head.

• When installing external cir-clips or internal cir-clips, direct corner end to the non- loosening direction.

mm (in.)

400 (15.75)

321 (12.64)

502.6 (19.79) 519 (20.43)

104.5 (4.11) 104 (4.09)

262.5 (10.33)

282.4 (11.12)

542 (21.34)

2-6

D569-W02 May-2003

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. The glow plugs assures easy engine starts even at (-) 15 °C (5 °F).

(1) Combustion Chamber (2) Inlet Port (3) Exhaust Port (4) Injection Nozzle (5) Glow Plug (6) Cylinder Head

ENGINE

569W206A

B. CYLINDER BLOCK

The engine has a high durability tunnel-type cylinder block. Furthermore, liner less type, allows effective cooling, less distortion, and greater wear-resistance using special material. The noise is reduced to a minimum because each cylinder had its chamber.

D569-W02 May-2003

569W207A

569W208A

2-7

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.

D. PISTON AND PISTON RINGS

The piston are made of an aluminum alloy which is temperature and pressure resistant. Three rings installed in grooves of the piston. The top ring (1) is a keystone type, which can withstand heavy loads, and the barrel face on the ring fits well to the cylinder wall. The second ring (2) is an undercut type, which prevents the oil from being carried up. The oil ring (3) has chambered contact faces and an expander ring, which increase the pressure of the oil ring against the cylinder wall to scrape the oil. The top ring is plated with hard chrome to increase wear resistance (The ring of 4A200T engine is mode of a special steel).

569W209A

(1) Crankshaft (4) Crankshaft Bearing 2 (2) Crankshaft Bearing (5) Thrust Bearing (3) Main Bearing Case

E. CONNECTING ROD

The connecting rod (2), which converts the reciprocating motion of the pistons caused by the fuel combustion into the rotating motion of the crankshaft, is made of harden forged steel. The connecting rod has bearings at both ends. The small end has a solid type bearing (small end bushing (2)) and the big end has a split type bearing (crankpin bearing (3)).

569W210A

(1) Top Ring (3) Oil Ring (2) Second Ring

569W211A

(1) Small End Bushing (3) Crankpin Bearing (2) Connecting Rod

2-8

D569-W02 May-2003

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.

G. FUEL CAMSHAFT

This fuel camshaft is made of forged steel and its cams are hardened and tempered to increase wear resistance. The cams on the fuel camshaft (1) drive the injection pump and the fuel transfer pump. The governor balls are installed on the fuel camshaft to control the engine speed.

ENGINE

569W212A

(1) Cam Gear (3) Camshaft (2) Camshaft Stopper

H. ROCKER ARM ASSEMBL Y

The rocker arm assembly includes the rocker arms (1) and an adjusting screw (3), which is at the end of rocker arm and rests on the push rod, rocker arm brackets (4) and rocker arm shaft (5). The rocker arms are activated by the reciprocating motion of the push rods and open or close the intake and exhaust valves. The rocker arm and other parts are lubricated through the drilled holes of the brackets and the rocker arm shaft.

569W213A

(1) Fuel Camshaft (2) Injection Pump Gear

569W214A

(1) Rocker Arm (4) Rocker Arm Bracket (2) Lock Nut ( 5 ) Rocker Arm Shaft (3) Adjusting Screw

D569-W02 May-2003

2-9

CHAPTER 2 8454

I. INTAKE AND EXHAUST VAL VES

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.

J. TIMING GEARS

The crankshaft drives the oil pump and the idle gear engaged fuel camshaft and camshaft. The timing for opening and closing the valves is extremely important to achieve effective air intake and sufficient gas exhaust. The appropriate timing can be obtained by aligning the mark on the crankshaft gear (6) with one the idle gear (5), idle gear with camshaft gear, idle gear with injection pump gear, when assembling.

569W215A

(1) Valve Spring Collet (4) Valve Stem Seal (2) Valve Spring Retainer ( 5) Exhaust Valve (3) Valve Spring (6) Intake Valve

K. FLYWHEEL

The flywheel is installed on the rear end of the crankshaft. Its inertia keeps the engine turning at a constant speed, while the crankshaft tends to speed up during the power stroke and to slow down during other stokes. The flywheel has a ring gear (1), which meshes with the drive pinion of the starter.

The flywheel has marks “TC” and “FI” on its outer rim. The mark TC shows the piston’s top dead center and the mark FI shows the fuel injection timing, when they are aligned with the mark of window on the clutch housing.

569W216A

(1) Injection Pump Gear (5) Idle Gear (2) Fuel Camshaft (6) Crankshaft Gear (3) Camshaft Gear (7) Crankshaft (4) Camshaft

569W217A

(1) Ring Gear (3) Crankshaft (2) Flywheel

2-10

D569-W02 May-2003

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.

ENGINE

B. OIL PUMP

The oil pump is a gear type. Whose rotors have trochoid lobes. The inner rotor (3) has 4 lobes and the outer rotor (4) has 5 lobes, and they are eccentrically engaged to each other. The inner rotor, which is driven by the crankshaft through the gears, rotates the outer rotor in the same direction, varying the space between the lobes.

While the rotors rotate from (A) to (B), the space leading to the inlet port increases, which causes the oil to flow through the inlet port. When the rotors rotate to (C), the port to which the space leads is changed from inlet to outlet. At (D), the space decreases and oil is discharged though the outlet port.

569W218A

(1) Piston (9) Rocker Arm Shaft (2) Idle Gear (10) Rocker Arm (3) Oil Pump (11) Push Rod (4) Relief Valve (12) Tappet (5) Strainer (13) Oil Pressure Switch (6) Oil Filter Element (14) Camshaft (7) Bypass Valve (15) Crankshaft (8) Oil Pan

569W219A

D569-W02 May-2003

(1) Inlet (3) Inner Rotor (2) Outlet (4) Outer Rotor

2-11

CHAPTER 2 8454

C. OIL FIL TER AND RELIEF V ALVE

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 allow the oil to flow from the inlet line to outlet line, bypassing the filter element. The relief valve ball (4) in the inlet line allows oil to prevent damage to the lubricating system, when the oil pressure rises more than 441 kPa (4.5 kgf/cm

, 14 psi), the bypass valve (1) opens to

, 64 psi).

569W220A

(1) Bypass Valve (2) Bypass Adjusting Spring (3) Filter Element (4) Relief Valve Ball (5) Relief Adjusting Spring

(a) To Idle Gear, Camshaft and Rocker Arm (b) From Oil Pump

(d) Drain of Relief Valve

D. 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 (1).

569W221A

(A) At lower Oil Pressure

(49 kPa (0.5 kgf/cm

, 7 psi) or less)

(B) At Proper Oil Pressure

(1) Warning Lamp (6) Rubber washer (2 ) Battery (7 ) Oil Pressure (3) Contact Movable (8) Cylinder Block (4) Contact Cup (9) Pressure (5) Diaphragm

2-12

D569-W02 May-2003

2.3 COOLING SYSTEM

A. FLOW OF COOLING WA TER

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. When the water temperature is high, the thermostat opens to allow the water to flow from the cylinder block to the radiator. When the water temperature is low, the thermostat closes and the flow stays within the block. The opening temperature of the thermostat is approx. 70 °C (160 °F).

ENGINE

569W222A

(1) Water Return Pipe (2) Thermostat (3) Cylinder Head Water Jacket (4) Cylinder Block Water Jacket (5) Radiator (6) Cooling Fan (7) Water Pump

B. WA TER PUMP

The water pump is driven with the fan drive pulley, which is on the water pump shaft and driven by the crankshaft with a belt. The water pump sucks the cooled water, forces into the cylinder block and draws out the hot water to the radiator repeatedly. The mechanical seal (3) prevents the water from entering the bearing (1).

569W223A

(a) From the Thermostat (b) To the Cylinder Block

D569-W02 May-2003

(1) Bearing (3) Mechanical Seal (2) Pump Body (4) Pump Impeller

2-13

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)). The valve (2) is seated by the spring (7) and the cooling water circulates in the engine through the water return pipe but does not enter the radiator.

(B) At high temperature (higher than 71 °C (160° F)). As the water temperature rises, the wax in the pellet (3) turns liquid and expands, repelling the spindle. The pellet lowers and the valve (2) opens to send the cooling water to the radiator.

569W224A

(1) Seat (6) Wax (Solid) (2) Valve (7) Spring (3) Pellet ( 8) Leak Hole (4) Spindle (9) Wax (Liquid) (5) Synthetic Rubber

D. RADIATOR

The radiator core consists of water carrying tubes (2) with fins (3) at a right angle to it. The water in the radiator is cooled by the air flowing through between the tube wall and the fin.

E. RADIAT OR CAP

The pressure type cap is installed on the radiator, which prevents the pressure difference between the inside and the outside of the radiator from deforming the radiator.

(A) At high pressure

Higher than 88 kPa (0.9 kgf/cm ant temperature rises and the pressure in the radiator increase above the specified pressure, the pressure valve (1) opens to reduce the internal pressure.

(B) At low pressure When the coolant temperature falls and a vacuum is

formed in the radiator, the vacuum valve (2) opens to allow coolant stored in the over flow tank to enter the radiator.

, 13 psi) when the cool-

569W225A

(1) Cooling Air (3 ) Fi n (2) Tube

569W226A

(1) Pressure Valve (2) Vacuum Valve

2-14

D569-W02 May-2003

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.

ENGINE

569W227A

(1) Fuel Tank (5) Injection Nozzle (2) Fuel Filter ( 6) Fuel Overflow Pipe (3) Injection Pump ( 7) Fuel Feed Pump (4) Injection Pipe

B. FUEL FILTER

The fuel filter removes dirt and water with its fine filter paper, which collects particles of 90 microns (0.0034 in.) at 20 kPa (0.2 kgf/cm feed pump is filtered by the filter element (6), while flowing through the filter body (3). The air vent (2) returns the air in the fuel to the fuel tank to prevent the engine from stopping or running irregularly.

, 3 psi). The fuel from the fuel

569W228A

(a) To Fuel Tank (b) From Fuel Feed Pump

(1) Cock (4) Retainer Ring (2) Ai r V e n t (5) Pot (3) Filter Body (6) Filter Element

D569-W02 May-2003

2-15

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).

(B) Discharge stroke When the diaphragm is pushed up by the cam, the

pressure in the chamber causes the inlet valve to close and forces out the fuel, opening the outlet valve.

569W229A

(a) From Fuel Tank (b) To Fuel Filter

(1) Inlet Valve (5) Chamber (2) Push Rod (6) Diaphragm (3) Tappet (7) Fuel Camshaft (4) Outlet Valve

D. FUEL INJECTION PUMP

The injection pump is bosch K type mini injection pump. It features a compact and light weight design.

569W230A

(a) To Injection Nozzle (b) From Fuel Filter

(1) Delivery Valve Holder (5 ) Plunger (2) Delivery Valve Spring (6) Control Rack (3) Delivery Valve (7) Plunger Spring (4) Cylinder (8) Tappet

2-16

D569-W02 May-2003

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.

ENGINE

569W231A

b. Operation of Pump Element

(A) Before delivery As the taper lowers, the plunger (2) lowers and fuel is

drawn into the delivery chamber (1) through the feed hole (4) from the fuel chamber (5).

(B) Beginning of delivery When the plunger is pushed up by the cam and the

head of the plunger closes the feed hole (4), the pressure in the delivery chamber (1) rises to push the delivery valve (3) open.

(C) Delivery While the plunger (2) is rising, delivery of fuel continues. (D) End of delivery When the plunger rises further and the control groove

(6) on its periphery meets the feed hole, the fuel returns to the fuel chamber (5) from the delivery chamber (1) through the control groove (6) and the feed hole (4).

(1) Pump Element (5) Control Sleeve (2) Cylinder (6) Control Groove (3) Plunger (7) Driving Surface (4) Feed Hole

D569-W02 May-2003

569W232A

(1) Delivery Chamber (4) Feed Hole (2) Plunger (5) Fuel Chamber (3) Delivery Valve (6) Control Groove

2-17

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.

(B) Fuel delivery The plunger is rotated by the control rack and the feed

hole is not aligned with the lengthwise slot. When the plunger is pushed up, the feed hole is closed by the plunger. The pressure in the delivery chamber builds up and forces the fuel to the injection nozzle until the control groove (6) meets the feed hole. The amount of the fuel to be forced into the nozzle corresponds to distance A.

569W233A

d. Delivery Valve

The delivery valve prevents the fuel in the injection pipe from flowing back into the delivery chamber and the fuel in the injection nozzle from dribbling after injection.

(1) Slot (4) Delivery Chamber (2) Plunger (5) Feed Hole (3) Control Rack ( 6) Control Groove

2-18

569W234A

(1) Valve Spring (4) Fuel Chamber (2) Valve (5) Valve Face (3) Valve Seal (6) Relief Plunger

D569-W02 May-2003

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/cm 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. Addition or reduction of adjusting shims can adjust the opening pressure. A washer of 0.1 mm corresponds to 980 kPa (10 kgf/cm

, 142 psi) change in opening pressure. The heat seal is employed to improve the durability and reliability of the nozzle.

, 1,991 to 2,134

ENGINE

569W235A

F. GOVERNOR AND IDLE COMPENSATING

a. Disassembled View

The governor serves to keep engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in the load. The engine employs an all-speed governor which is controlled by the centrifugal force of the steel ball (13) weights, produced by rotation of the fuel camshaft (9), and tension of the governor spring 1 (2) and 2 (3) are balanced.

(1) Nozzle Holder Ass’y (6) Nozzle Body (2) Adjusting Washer (7) Needle Valve (3) Nozzle Spring (8) Heat Seal (4) Push Rod (9) Packing (5) Retaining Nut

569W236A

D569-W02 May-2003

(1) Start Spring (8) Governor Lever (2) Governor Spring 1 (9 ) Fuel Camshaft (3) Governor Spring 2 (10) Governor Ball Case (4) Fork Lever 1 (11) Steel Ball (5) Fork Lever 2 (12) Governor Sleeve (6) Fork Lever Shaft (13) Steel Ball (7) Fork Lever Holder

2-19

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.

b) At idling

At the idling position of the speed control lever (15), the governor spring 1 (2) is free and the governor spring 2 (3) only acts slightly. The governor sleeve (12) is pushed leftward by a centrifugal force of steel ball (13). Therefore, the fork lever 1 (4) and control rack (14) are moved to the rear by the governor sleeve (12) and then the idling adjusting spring (16) is compressed by the control rack (14). As a result, the control rack (14) is kept at a position where the centrifugal force of steel ball (13) and forces of the start spring (1), governor spring 2 (3) and idling limit spring are balanced, providing stable idling.

569W237A

(1) Start Spring (13) Steel Ball (4) Fork Lever 1 (14) Control Rack

IMPORTANT:

• The idling speed has been factory-set. The idling adjusting screw (20) and spring (16) should not be disassembled and readjusted.

2-20

569W238A

(1) Start Spring (13) Steel Ball (2) Governor Spring 1 (14) Control Rack (3) Governor Spring 2 (15) Speed Control Lever (4) Fork Lever 1 (16) Idle Adjusting Spring

(12) Governor Sleeve (20) Idle Adjusting Screw

D569-W02 May-2003

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). After that, when the force of torque spring (18) becomes greater than the centrifugal force of the steel balls, fork lever 1 (4) moves forward to increase fuel injection, causing the engine to run continuously at a high torque.

ENGINE

569W239A

(2) Governor Spring 1 (13) Steel Ball (3) Governor Spring 2 (17) Adjusting Bolt (4) Fork Lever 1 (18) Torque Spring (5) Fork Lever 2

d) To stop engine

When the stop lever (19) is moved to the STOP position, fork lever 1 (4) is moved rearward and the control rack (14) is moved to the non-injection position, causing the engine to stop.

569W240A

(4) Fork Lever 1 (19) Stop Lever

(14) Control Rack

D569-W02 May-2003

2-21

CHAPTER 2 8454

2.5 INTAKE AND EXHAUST SYSTEM

A . FLOW OF INT AKE AIR AND EXHAUST GAS

(a) Intake Air (b) Exhaust Gas

(1) Intake Manifold (2) Air Cleaner (3) Cylinder Head (4) Muffler (5) Exhaust Manifold

B. AIR CLEANER

The air cleaner is dry-cyclone type and easy to maintain. The air from the inlet port (2) circulates along the fin (3) and around the air cleaner element (4) and the heavier dust is carried to the evacuator (6), to the dust exhaust port. The fine dust in the air is filtered with the air cleaner element (4), and the filtered air flows to the outlet port (1).

569W241A

C. MUFFLER

The exhaust noises are absorbed, while the gases are passed through a series of holes on the inner tube and glass wool of the muffler.

569W242A

(a) Inlet Air (b) To Intake Manifold

(1) Outlet Port (4) Air Cleaner Element (2) Inlet Port (5) Body (3) F in (6) Evacuator

569W243A

2-22

D569-W02 May-2003

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. Since the turbocharger runs above 100,000 rpm it is necessary to allow the engine to idle for 1 or 2 minutes before stopping, this protect the bearings of the turbocharger.

To keep a capacity of turbocharger you should check the engine oil and air cleaner periodically. Turbocharger is composed of precision parts. Do not disassemble or repair without permission.

Turbocharger actuator pressure is 460 mmHg. The structure of turbocharger is as above.

ENGINE

569W244A

(A) Compressor Ambient Air Inlet

(B) Compressor Air Discharge (C) Turbine Exhaust Gas Inlet (C) Turbine Exhaust Gas Inlet

(1) Turbine Wheel

(2) Compressor Wheel

(A) Fresh Air Inlet

(B) Exhaust Outlet (C) Exhaust Inlet

569W245A

D569-W02 May-2003

(1) Compressed Air Outlet

(2) Compressor Seal

(3) Oil Inlet

(4) Journal Bearing

(5) Turbine Seal

(6) Turbine Wheel

(7) Compressor Wheel

(8) Thrust Bearing

(9) Oil Drain

2-23

CHAPTER 2 8454

3. DISASSEMBLING AND SERVICING

3.1 TROUBLESHOOTING

Symptom Probable Cause

Engine Does Not Start

(Starter Does Not Run)

Engine Revolution is Not Smooth

• Not fuel

• Air in the fuel system

• Water in the fuel system

• Fuel pipe clogged

• Fuel filter clogged

• Excessively high viscosity of fuel or engine oil at low temperature

• Fuel with low cetane number

• Fuel leak due to loose injection pipe retaining nut

• Incorrect injection timing

• Fuel camshaft worn

• Injection nozzle clogged

• Injection pump malfunctioning

• Fuel transfer pump malfunctioning

• Seizure of transfer pump malfunctioning piston, cylinder bore or bearing

• Compression leak from cylinder

• Improper valve seating, valve spring broken, valve seized

• Improper valve timing

• Piston ring and bore worn

• Excessive valve clearance

• Battery discharged

• Starter malfunction

• Starter switch malfunction

• Wiring disconnected

• Fuel filter clogged or dirty

• Air cleaner clogged

• Fuel leak due to loose injection pipe retaining nut

• Injection pump malfunctioning

• Incorrect nozzle opening pressure

• Nozzle stuck or clogged

• Fuel over flow pipe clogged

• Governor malfunctioning

Solution

Replenish fuel Vent air Change fuel and repair or flush

fuel system Clean Clean or replace Use the specified fuel or engine

oil Use the specified fuel Tighten nut

Adjust Replace Clean or replace Repair or replace Repair or replace

Repair or replace

Replace head gasket, tighten cylinder head screws, glow plug and nozzle holder

Repair or replace

Correct or replace timing gear Repair or replace Adjust Charge Repair or replace Repair or replace Connect Clean or replace Clean or replace Tighten nut

Repair or replace Adjust

Repair or replace Clean Repair

2-24

D569-W02 May-2003

Symptom Probable Cause Solution

Either White or Blue Exhaust Gas is Observed

Either Black or Dark Gray Exhaust Gas is Observed

Insufficient Output

Excessive Lubrication Oil Consumption

Fuel Mixed into Lubricating Oil

Water Mixed Into Lubricating oil

Low Oil Pressure

• Excessive engine oil

• Piston ring and bore worn or piston ring stuck

• Incorrect injection timing

• Insufficient compression

• Over heated

• Low grade fuel used

• Fuel filter clogged

• Air cleaner clogged

• Incorrect injection timing

• Engine’s moving parts seem to be seizing

• Uneven fuel injection

• Insufficient nozzle injection

• Compression leak

• Piston ring’s gap facing the same direction

• Oil ring worn or stuck

• Piston ring groove worn

• Valve stem and guide worn

• Crankshaft bearings, and crank pin bearings worn

• Injection pump plunger worn

• Fuel transfer pump broken

• Head gasket defective

• Cylinder block or cylinder head cracked

• Engine oil insufficient

• Oil strainer closed

• Oil filter cartridge clogged

• Relief valve stuck with dirt

• Relief valve spring weak or broken

• Excessive oil clearance of crankshaft bearings

• Excessive oil clearance of crank pin bearings

• Excessive oil clearance of rocker arm bushings

• Oil passage closed

• Improper type of oil

• Oil pump defective

ENGINE

Reduce to the specified level Repair or replace

Adjust Adjust top clearance Lessen the load Use the specified fuel Clean or replace Clean or replace Adjust Repair or replace

Repair or replace the injection pump

Repair or replace the nozzle Replace head gasket, tighten

cylinder head screws and nuts, glow plug and nozzle holder

Shift ring gap direction

Replace Replace the piston Replace Replace

Replace pump element or pump Replace Replace Replace

Replenish Clean Replace Clean Replace

Replace

Clean Use the specified type of oil Repair or replace

D569-W02 May-2003

2-25

CHAPTER 2 8454

Symptom Probable Cause Solution

High Oil Pressure

Engine Overheating

Battery Quickly Discharge

• Improper type of oil

• Relief valve defective

• Engine oil insufficient

• Fan belt broken or tensioned improperly

• Cooling water insufficient

• Radiator net and radiator fin clogged with dirt

• Inside of radiator corroded

• Cooling water flow route corroded

• Radiator cap defective

• Water pipe damaged

• Thermostat defective

• Water pump defective

• Mechanical seal defective

• Overload running

• Head gasket defective

• Incorrect injection timing

• Unsuitable fuel used

• Battery electrolyte insufficient

• Fan belt slips

• Wiring disconnected

• Regulator defective

• Alternator defective

• Battery defective

Use the specified type of oil Replace Replenish Replace or adjust

Replenish Clean

Clean or replace Clean or replace

Replace Replace Replace Replace Replace Lesson the load Replace Adjust Use the specified fuel Replenish distilled water and

charge Adjust belt tension or replace Connect Replace Replace Replace

2-26

D569-W02 May-2003

3.2 SERVICING SPECIFICATIONS

A. ENGINE BODY

a. Cylinder Head

Item Factory Specification Allowable Limit

Cylinder Head Surface Flatness

Top Clearance

Cylinder Head Gasket Thickness Free

Tightened

Compression Pressure (When cranking with starting motor)

* Variance of compression pressure among cylinders should be 10% or less.

0.75 ~ 0.9 mm

0.0295 ~ 0.0354 in.

1.3 ~ 1.5 mm

0.0512 ~ 0.0591 in.

1.15 ~ 1.25 mm

0.0453 ~ 0.0492 in.

3.24 ~ 3.73 MPa 33 ~ 38 kgf/cm

469 ~ 540 psi

ENGINE

0.05 mm / 100 mm

0.002 in. / 3.94 in.

2.55 MPa

26 kgf/cm

370 psi

b. Valves

Item

Valve Clearance (Cold) IN.

V alve Seat Angle IN.

V alve Face Angle IN.

Valve Recessing

Clearance Between Valve Stem and Valve Guide V alve Stem O.D

V alve Stem I.D

c. Valve Timing

0.25 mm 0.0098 in.

EX.

0.30 mm 0.0118 in.

1.047 rad. 60°

0.785 rad. 45°

1.047 rad. 60°

0.785 rad. 45°

0.2 ~ 0.5 mm

0.0079 ~ 0.0197 in.

0.040 ~ 0.070 mm

0.00157 ~ 0.00276 in.

7.960 ~ 7.975 mm

0.31339 ~ 0.31398 in.

8.015 ~ 8.030 mm

0.31555 ~ 0.31614 in.

Factory Specification

4A220 4A200T

015 mm 0.0059 in.

0.15 mm 0.0059 in.

1.047 rad. 60°

0.785 rad. 45°

1.047 rad. 60°

0.785 rad. 45°

0.2 ~ 0.5 mm

0.0079 ~ 0.0197 in.

0.040 ~ 0.070 mm

0.00157 ~ 0.00276 in.

7.960 ~ 7.975 mm

0.31339 ~ 0.31398 in.

8.015 ~ 8.030 mm

0.31555 ~ 0.31614 in.

Allowable Limit

0.8 mm

0.0315 in.

0.10 mm

0.0039 in.

Item Factory Specification Allowable Limit

Inlet V alve Open

Exhaust V alve Open

D569-W02 May-2003

0.140rad 8° before T.D.C

0.611rad 35° after B.D.C

0.785rad 45° before B.D.C

0.140rad 8° after T.D.C

2-27

CHAPTER 2 8454

d. Cylinder Bore

Item Factory Specification Allowable Limit

Cylinder bore inner diameter

e. Valve Spring

Free length

Assembling load / assembling length

Squareness

f. Rocker Arm

Rocker arm shaft O.D

Rocker arm bushing I.D

4A220

4A200T

Item Factory Specification Allowable Limit

87.000 ~ 87.022 mm

3.4252 ~ 3.4261 in.

83.000 ~ 83.022 mm

3.2677 ~ 3.2690 in.

41.7 ~ 42.2 mm

1.6417 ~ 1.6614 in.

12.0 kgf / 35.15 mm

26.46 lbs / 1.3839 in.

18.955 ~ 18.980 mm

0.74600 ~ 0.74724 in.

19.0 ~ 19.035 mm

0.74803 ~ 0.74941 in.

0.15 mm

0.0059 in.

41.2 mm

1.6220 in.

10.2 kgf / 35.15 mm

22.49 lbs / 1.3839 in.

1.0 mm

0.0394 in.

g. Tappet

Item Factory Specification Allowable Limit

Clearance between tappet and guide

Tappet O.D

Tappet guide I.D

h. Camshaft

Item Factory Specification Allowable Limit

Camshaft alignment

Cam height IN. (4A200T, 4A220)

EX. (4A200T, 4A220)

Clearance between camshaft

Camshaft journal O.D

Camshaft counter bore I.D

0.020 ~ 0.062 mm

0.00079 ~ 0.00244 in.

23.959 ~ 23.980 mm

0.94327 ~ 0.94410 in.

24.000 ~ 24.021 mm

0.94488 ~ 0.94571 in.

0.01 mm

0.0004 in.

33.90, 33.59 mm

1.3346, 1.3224 in.

33.70, 33.69 mm

1.3268, 1.3264 in.

0.050 ~ 0.091 mm

0.00197 ~ 0.00358 in.

39.934 ~ 39.950 mm

1.57221 ~ 1.57284 in.

40.000 ~ 40.025 mm

1.57480 ~ 1.57579 in.

0.07 mm

0.0028 in.

0.05 mm

0.0020 in.

33.85, 33.54 mm

1.3327, 1.3205 in.

33.65, 33.64 mm

1.3248, 1.3244 in.

0.15 mm

0.0059 in.

39.88 mm

1.5701 in.

2-28

D569-W02 May-2003

I. Timing Gear

Item Factory Specification Allowable Limit

Timing gear backlash

Idle gear side clearance

Clearance between Idle gear shaft and idle

gear bushing

Idle gear shaft O.D

Idle gear bushing I.D

j. Piston Ring

Item Factory Specification Allowable Limit

Piston pin-bore I.D

Clearance between Oil ring and ring groove

Oil ring groove width

Oil ring width

Clearance between 2nd ring and ring groove

2nd ring groove width

2nd ring width

Top ring, oil ring end gap

2nd ring end gap

0.04 ~ 0.11 mm

0.0016 ~ 0.0043 in.

0.20 ~ 0.51 mm

0.0079 ~ 0.0201 in.

0.025 ~ 0.066 mm

0.00098 ~ 0.00260 in.

37.959 ~ 37.975 mm

1.49445 ~ 1.49508 in.

38.000 ~ 38.025 mm

1.49606 ~ 1.49705 in.

25.000 ~ 25.006 mm

0.98425 ~ 0.98448 in.

0.020 ~ 0.060 mm

0.00079 ~ 0.00236 in.

3.010 ~ 3.030 mm

0.11850 ~ 0.11929 in.

2.97 ~ 2.99 mm

0.11693 ~ 0.11772 in.

0.04 ~ 0.08 mm

0.00157 ~ 0.00315 in.

2.03 ~ 2.05 mm

0.07992 ~ 0.08070 in.

1.97 ~ 1.99 mm

0.07756 ~ 0.07834 in.

0.25 ~ 0.40 mm

0.0098 ~ 0.01570 in.

0.55 ~ 0.70 mm

0.0217 ~ 0.0276 in.

ENGINE

0.15 mm

0.0059 in.

0.9 mm

0.035 in.

0.1 mm

0.0039 in.

25.03 mm

0.9854 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

k. Connecting Rod

Item Factory Specification Allowable Limit

Connecting rod misalignment

Clearance between Piston and small end

bushing Piston pin O.D

Small end bushing I.D

D569-W02 May-2003

0.014 ~ 0.038 mm

0.00055 ~ 0.00150 in.

25.002 ~ 25.011 mm

0.98433 ~ 0.98469 in.

25.025 ~ 25.040 mm

0.98524 ~ 0.98583 in.

0.05 mm

0.0020 in.

0.15 mm

0.0059 in.

2-29

CHAPTER 2 8454

l. Crankshaft

Item Factory Specification Allowable Limit

Crankshaft Misalignment

Clearance between Crankshaft and crank-

shaft bearing 1

Crankshaft O.D

Crankshaft bearing 1 I.D

Clearance between Crankshaft and crank-

shaft bearing 2

Crankshaft O.D

Crankshaft bearing 1 I.D

Clearance between Crank pin and crank pin

bearing Crank pin O.D

Crank pin bearing I.D

Crankshaft side clearance

0.040 ~ 0.118 mm

0.00157 ~ 0.00465 in.

51.921 ~ 51.940 mm

2.04414 ~ 2.04489 in.

51.980 ~ 52.039 mm

2.04646 ~ 2.04878 in.

0.040 ~ 0.104 mm

0.00157 ~ 0.00409 in.

51.921 ~ 51.940 mm

2.04414 ~ 2.04488 in.

51.980 ~ 52.025 mm

2.04646 ~ 2.04823 in.

0.025 ~ 0.087 mm

0.00098 ~ 0.00343 in.

46.959 ~ 46.975 mm

1.84876 ~ 1.84947 in.

47.000 ~ 47.046 mm

1.85040 ~ 1.85221 in.

0.15 ~ 0.31 mm

0.0059 ~ 0.0122 in.

0.08 mm

0.0031 in.

0.20 mm

0.0079 in.

0.20 mm

0.0079 in.

0.20 mm

0.0079 in.

0.5 mm

0.020 in.

B. LUBRICA TING SYSTEM

a. Oil Pump

Item Factory Specification Allowable Limit

Engine oil pressure (oil temp. 85 ~ 95 °C, 185 ~ 203 °F)

Clearance between inner rotor and outer rotor

Radial clearance between outer rotor and pump

End clearance between inner rotor and cover

At idle speed

At rated speed

more than 49.0 kPa

0.5 kgf/cm

7.11 psi

245 ~ 441 kPa

2.5 ~ 4.5 kgf/cm

35.6 ~ 64.0 psi

0.10 ~ 0.16 mm

0.0039 ~ 0.0063 in.

0.11 ~ 0.19 mm

0.0043 ~ 0.0078 in.

0.105 ~ 0.150 mm

0.00413 ~ 0.00591 in.

245 kPa

2.5 kgf/cm

35.6 psi

0.2 mm

0.0079 in.

0.25 mm

0.0098 in.

0.2 mm

0.00787 in.

2-30

D569-W02 May-2003

C. COOLING SYSTEM

a. Thermostat

ENGINE

Valve opening temperature at beginning

69.5 ~ 72.5 °C (157.1 ~ 162.5 °F)

Opened completely (height 8 mm 0.315 in.)

b. Radiator

Radiator tightness

No leak at 137 kPa, 1.4 kgf/cm

10 seconds or more for pressure

Radiator cap tightness

Fan belt tension [deflection at 98 N (10 kgf, 22 lbs) of force]

D. FUEL SYSTEM

a. Inject Pump

Injection timing (BTDC) 4A220

4A200T

b. Injection Nozzle

Fuel injection pressure

Fuel tightness of nozzle valve seat

85 °C (185 °F)

falling from 88 ~ 59 kPa

from 0.9 ~ 0.6 kgf/cm

from 13 ~ 9 psi

7 ~ 9 mm

0.28 ~ 0.35 in.

13.73 ~ 14.715 MPa 140 ~ 150 kgf/cm

1,991 ~ 2,134 psi

No fuel leak for 5 sec.

at pressure

12.74 MPa

130 kgf/cm

1,849 psi

, 20 psi

18° 12°

NOTE:

• Injection Sequence Four Cylinders: 1 → 3 → 4 → 2 (The cylinder number is given in order from the gear case end.)

D569-W02 May-2003

2-31

CHAPTER 2 8454

E. TIGHTENING TORQUES

Item

Cylinder head screws Head cover nuts * Bearing case screw 1 * Bearing case screw 2 * Flywheel screw * Connecting rod screws Rocker arm bracket studs Drain plug Glow plugs Oil switch Nozzle locating screws Injection pipe nuts

Size x Pitch

M11 x 1.25

M10 x 1.25

M9 x 1.25 M10 x 1.25 M12 x 1.25

M8 x 1.0 M10 x 1.25 M12 x 1.25 M10 x 1.25

PT1/8 M20 x 1. 5 M12 x 1. 5

NOTE:

• For *marked screw, bolts and nuts on the table, apply engine oil to their threads and seats before tightening.

• The letter “M” in Size x Pitch means that the screw, bolt or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between two threads.

N•m

103.0 ~ 107.9

8.8 ~ 10.8

46.1 ~ 51.0

68.6 ~ 73.6

98.1 ~ 107.9

46.1 ~ 51.0

48.1 ~ 55.9

32.4 ~ 37.3

19.6 ~ 24.5

14.7 ~ 19.6

49.1 ~ 68.7

24.5 ~ 34.3

kgf•m

10.5 ~ 11.0

0.9 ~ 1.1

4.7 ~ 5.2

7.0 ~ 7.5

10.0 ~ 11.0

4.5 ~ 5.0

4.9 ~ 5.7

3.3 ~ 3.8

2.0 ~ 2.5

1.5 ~ 2.0

5.0 ~ 7.0

2.5 ~ 3.5

lbf·ft

75.9 ~ 79.6

6.5 ~ 8.0

34.0 ~ 37.6

50.6 ~ 54.2

72.3 ~ 79.6

34.0 ~ 37.6

35.4 ~ 41.2

23.9 ~ 37.3

14.5 ~ 18.1

10.8 ~ 14.5

36.2 ~ 50.6

18.1 ~ 25.3

2-32

D569-W02 May-2003

3.3 CHECKING, DISASSEMBLING AND SERVICING

A . ENGINE DISASSEMBLED VIEW

ENGINE

(1) Cylinder Block (2) Oil Pressure Switch (3) Oil Pump (4) Oil Pan (5) Oil Strainer (6) Oil Gauge

D569-W02 May-2003

(7) Cylinder Head (8) Head Bolt

(9) Gear case (10) Oil Filter (11) Main bearing Case

Cover

(12) Bearing Case Bolt 1 (13) Main Bearing Case (14) Bearing Case Bolt 2 (15) Rocker Arm (16) Inlet, Exhaust Valve (17) Cylinder Hear Cover

(18) Push Rod (19) Tappet (20) Camshaft (21) Camshaft Gear (22) Idle Gear (23) Piston

(24) Connecting Rod (25) Crankshaft (26) Flywheel (27) Flywheel Housing (28) Starter (29) Injection Pipe

(30) Glow Plug (31) Nozzle (32) Fuel Injection Pump (33) Fuel Feed Pump (34) Fuel Camshaft (35) Fuel Camshaft Gear

(36) Engine Stop Solenoid (37) Speed Control Plate (38) Fork Lever (Governor) (39) Impeller (40) Thermostat (41) Alternator

(42) Fan Drive Pulley (43) Cooling Fan (44) Radiator (45) Reserve Tank Ass’y (46) Inlet Manifold (47) Muffler

615WA18A

(48) Exhaust Manifold (49) Air Cleaner (50) Turbo Charger (51) Air Conditioner

Compressor

2-33

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.

ENGINE

Belt tension (deflection)

Factory spec 7 ~ 9 mm

0.28 ~ 0.35 in.

b. Disassembly and Assembly

1) Engine body

Drain the oil and the water, if disassemble the engine body.

1. Remove the muffler and exhaust manifold (7).

2. Remove the starter (9) and the oil pressure switch (8).

3. Pull out the oil gauge (6).

4. Remove the alternator (5) and the fan belt (1).

5. Remove the hour meter unit (2).

6. Loosen the oil filter (3) with a filter wrench and remove it and the oil filter flange (4).

* This figure does not show Hour meter Unit (2) cov-

ered with the cooling fan.

(When reassembling) Apply liquid gasket (three bond 1,215 or equivalent) on

the thread of the oil pressure switch (8). Apply liquid gasket to the both sides of the hour meter

gasket. Apply oil to the O-ring and tighten the oil filter not with

wrench but by hand. Adjust the fan belt tension (See fan belt).

569W249A

569W250A

(1) Fan Belt (6) Oil Gauge (2) Hour Meter Unit (7) Exhaust Manifold (3) Oil Filter (8) Oil Pressure

Switch (4) Oil Filter Flange (9) Starter (5) Alternator

Tightening torque

D569-W02 May-2003

Oil pressure

switch

14.7 ~ 19.6 N·m

1.5 ~ 2.0 kgf·m

10.8 ~ 14.4 lbf·ft

2-35

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).

• Pushing the solenoid (7) plunger to the bottom, pull the stop lever 2 (6) until the engine stop lever (2) is turned to the end, then tighten the screws.

3) Intake manifold and fuel pipes

1. Disconnect the fuel pipe (3).

2. Loosen the injection pipe fitting with two wrenches and remove the injection pipes (2).

3. Remove the intake manifold (1) and the fuel feed pump (4).

569W251A

(1) Screw (5) Stop Lever 1 (2) Engine Stop Lever (6 ) Stop Lever 2 (3) Screw (7) Solenoid (4) Screw

IMPORTANT:

• Tighten or loosen injection pipe fittings using the one-hand two-wrench squeeze method.

• Cap the nozzle hole to prevent entrance of foreign materials.

Tightening torque

Injection pipe

nut 19 mm

(0.75 in.)

cross flats

24.5 ~ 34.3 N·m

2.5 ~ 3.5 kgf·m

18.0 ~ 25.3 lbf·ft

569W252A

(1) Intake Manifold (3) Fuel Pipe (2) Injection Pipe ( 4) Fuel Feed Pump

2-36

D569-W03 May-2003

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, sev-

eral times.

6. If the pressure does not reach the allowable limit,

apply a small amount of oil to the cylinder wall through the nozzle holder hole and check the pressure again.

7. If the pressure raises after oil is apply, check the

cylinder wall and piston ring.

8. If the pressure is still low, check the top clearance,

valve clearance and cylinder head.

ENGINE

569W253A

Compression pressure

Factory spec.

3.24 ~ 3.73 MPa 33 ~ 38 kgf/cm

469 ~ 540 psi

Allowable limit

2.55 MPa

26 kgf/cm

370 psi

Difference

Allowable limit

10 % between two cylinders

NOTE:

• Check the compression pressure with the specified valve clearance for proper air in taking.

D569-W02 May-2003

2-37

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. If the clearance is not within the factory specifications, turn the adjusting screw to adjust.

5. Turn the flywheel just one turn to position the 1st cylinder valves at the top head center during overlap.

6. Measure the clearance at the valves marked with in the table below with a feeler gauge.

7. If the clearance is not within the factory specifications, adjust it.

569W254A

V alve clearance

Factory

spec.

4A220

4A200T

In. : 0.25 mm 0.0098 in. Ex. : 0.30 mm 0.0118 in. In. : 0.15 mm 0.0059 in. Ex. : 0.15 mm 0.0059 in.

Cylinder NO. Valve

IN. EX.2IN. EX.3IN. EX.4IN. EX.

Checking

b. Disassembling and Assembling

1) Cylinder head cover, glow plugs and fuel overflow pipes.

1. Remove the injection pipes and over flow pipe.

2. Remove the glow plugs.

3. Remove the injection nozzles and gaskets, heat seals.

4. Remove the cylinder head cover.

(When reassembling)

• Check that the cylinder head cover gasket is not defective.

• Tighten the cylinder head cover cap nuts in several steps.

569W255B

569W256A

(1) Injection Nozzle ( 3 ) Heat Seal (2) Gasket

2-38

D569-W03 May-2003

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.

NOTE:

• Use a philips screw driver that has a diameter

which is bigger than the heat seal hole 1/4 in.

(approx.

6mm).

3) Rocker arm assembly

1. Loosen the nuts in several steps and the specified

sequence shown in the figure and remove them.

2. Remove the rocker arm assembly and the push rod.

ENGINE

569W257A

(1) Philips Screw Driver (2) Nozzle (3) Injection Nozzle Gasket (4) Heat Seal

(When reassembling)

• Rest the end of push rod at the indent of tappet and

install the rocker arm assembly.

• Tighten the nuts in several steps and in the speci-

fied sequence to the specified torque. As shown in the figure.

• Adjust the valve clearance after assembling the

rocker arm assembly.

IMPORTANT:

• When assembling the rocker arm assembly, locate

the groove of rocker arm shaft on stud bolt.

Tightening torque

Stud, nut

48.1 ~ 55.9 N·m

4.9 ~ 5.7 kgf·m

35.3 ~ 41.2 lbf·ft

569W258B

569W259A

(1) Rocker Arm Shaft (3) Rocker Arm Bracket (2) Rocker Arm (4) Screw

D569-W03 May-2003

2-39

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.

• Replace the head gasket with new one and place on the cylinder block, be careful of its direction and side.

• When using the head gasket shim, assemble the shim first on the cylinder head.

• Before installing the tappets apply engine oil around them.

569W260A

(1) Cylinder Head (2) Water Flange

IMPORTANT:

• Apply oil to the thread of screws and tighten in several steps and the specified sequence shown in the figure to the specified torque.

• Check the torque after 30 minutes operation of the assembled engine, and adjust valve clearance.

Tightening torque

Cylinder

head

screws

103.0 ~ 107.9 N·m

10.5 ~ 11.0 kgf·m

75.9 ~ 79.6 lbf·ft

5) Valve

1. Compress the valve spring with a replaces and remove the collect (2).

2. Remove the retainer (3), valve spring (4), valve stem seal (5) and the valve (1).

IMPORTANT:

• Do not interchange valves and valve parts.

• Mark the cylinder number on the valve and the parts

to prevent interchanging.

(When reassembling)

• Apply oil to the stem of valve and install in the cylinder head.

• Lubricate the valve and the parts after reassembling.

569W261B

569W262A

(1) Valve (4) Valve Spring (2) Collect (5) Valve Stem Seal (3) Retainer

2-40

D569-W03 May-2003

c. Timing Gears and Camshafts

1) Injection pump

1. Remove the injection pump cover (3) with the en-

gine stop lever (2).

2. Remove the injection pump.

(When reassembling)

• Apply liquid gasket to the both sides of injection

pump cover gasket and install it.

• Install the injection pump so that its control rack pin

(4) engages with the groove (5) of fork lever 1 (1).

• Install the injection pump cover with the arm of en-

gine stop lever (2) at the right of the arm of fork lever 1 (1).

2) Governor spring and Speed control plate

1. Disconnect the governor spring 1 (1) and 2 (2) from

the governor lever (4).

2. Remove the speed control plate.

3. Remove the governor spring.

ENGINE

569W263A

(1) Fork Lever 1 (4) Control Rack Pin (2) Engine Stop Lever (5 ) Groove (3) Injection Pump Cover (6) Shim

(When reassembling)

• Be careful not to drop the governor springs 1, 2 into

the gear case.

• Fix the governor springs (1), (2) to the fork lever 2

(3) and pull the springs, hook on to the governor lever(4).

• Apply a liquid gasket both side of speed control plate

gasket.

569W265A

569W264A

(1) Governor Spring 1 (3 ) Fork Lever 2 (2) Governor Spring 2 (4 ) Governor Lever

D569-W02 May-2003

2-41

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.

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. Remove the fan drive fan drive pulley (1).

569W266A

(1) Start Spring (2) Fork Lever 1

Tightening torque

Crankshaft

nut

137.3 ~ 156.9 N·m

14.0 ~ 16.0 kgf·m

101.3 ~ 115.7 lbf·ft

5) Gear case

1. Remove the gear case.

(When reassembling)

• Stick the O-ring (1) to the gear case with thin grease to prevent from coming off during reassembling.

• Apply grease to the crankshaft oil seal lip on the gear case and take care not to damage it when installing.

• Apply liquid gasket (three bond 1215 or equivalent) to the both sides of gear case gasket.

569W267A

(1) Fan Drive Pulley (2) Crankshaft Nut

569W268A

2-42

(1) O-Ring

D569-W02 May-2003

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.

ENGINE

Tightening torque

Relief valve cover screw

32.4 ~ 36.3 N·m

3.3 ~ 3.7 kgf·m

23.9 ~ 26.8 lbf·ft

7) Idle gear and crank gear

1. Remove the crankshaft collar (6), O-ring (5), oil

slinger (4) and crank gear collar (3) in the order.

2. Remove the idle gear (1).

3. Remove the crankshaft gear (2) with a special use

puller set.

(When reassembling)

• Heat the crankshaft gear to approx. 80 °C (176 °F)

and insert the crankshaft.

• Apply oil to the O-ring (5).

569W269A

(1) Water Pump Body (2) Relief Valve Cover

569W270A

IMPORTANT:

• Install the idle gear, aligning the alignment marks

referring to the figure.

569W271A

(1) Idle Gear (6) Crankshaft Collar (2) Crankshaft Gear (7) Oil Pump Gear (3) Crank Gear Collar (8 ) Injection Pump Gear (4) Oil Slinger (9 ) Cam Gear (5) O-Ring

D569-W02 May-2003

2-43

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).

9) Fuel camshaft

1. Remove the fuel camshaft stopper.

2. Loosing the fork lever holder screws, remove the fuel camshaft (4) with fork lever holder (5), fork lever 1 (1) and 2 (2).

3. Remove the Injection pump gear (3).

569W272A

(1) Camshaft (2) Cam Gear

(When reassembling)

• Heat the injection pump gear to approx. 80 °C (176 °F) and insert the camshaft (4).

d. Connecting Rod and Piston

(A)Oil pan and oil filter

1. Remove the engine stand and the oil pan.

2. Remove the oil strainer (1).

(When reassembling)

• Be sure to install the O-ring (2) between the oil strainer and the cylinder block.

569W273A

(1) Fork Lever 1 (4 ) Camshaft (2) Fork Lever 2 (5 ) Fork Lever Holder (3) Injection Pump Gear

2-44

569W274A

(1) Oil Strainer (2) O-Ring

D569-W02 May-2003

(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 con-

necting rod to prevent interchanging.

• Carefully insert the piston and ring assembly in the

cylinder, compressing the rings not to damage the chrome-plate on the piston rings.

• If connecting rod cap screws can not be screwed to

the end by hand, replace the screw.

1. Remove the piston rings with a piston ring replac-

ing tool.

2. Remove the piston pin.

ENGINE

569W276A569W275A

(When reassembling)

• Clean all the parts before assembling.

• Heat the piston in approx. 80 °C (176 °F) of oil for 10

to 15 minutes, when inserting the piston pin into the piston.

569W277A

(1) Piston Pin (2) Piston (3) Piston Pin Snap Ring (4) Compression Ring 1 = Top Ring (5) Compression Ring 2 = Second Ring (6) Oil Ring (7) Connecting Rod

D569-W02 May-2003

2-45

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.

• Install the second ring and oil ring with their gap at every 2.09 rad (120°).

569W278A

e. Crankshaft

(A)Flywheel

1. Install the stopper to the flywheel and loosen the screw.

2. Remove the flywheel stopper and the flywheel.

(When reassembling)

• Clean the end of the crankshaft and the mating surface of the flywheel.

• Apply oil to flywheel screws.

• Fit the flywheel hole to crankshaft hole and lighten the flywheel bolts to specified torque.

NOTE:

• Screw longer screws into the flywheel to carry. It if needed.

Tightening torque

Flywheel

screw

98.1 ~ 107.9 N·m

10.0 ~ 11.0 kgf·m

72.3 ~ 79.6 lbf·ft

569W279A

(7) Connecting Rod (11 ) Expander Joint (8) Connecting Rod Cap (12) Oil Ring Gap (9) Casting Mark (13) Manufacturer’s Mark

(10) Mark(The Side Face)

569W280A

2-46

D569-W02 May-2003

(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.

ENGINE

Tightening torque

Bearing

case

cover screw

23.5 ~ 27.5 N·m

2.4 ~ 2.8 kgf·m

17.4 ~ 20.3 lbf·ft

1. Remove the bearing case screw 2.

2. Pull out the crankshaft, taking care not to damage

the crankshaft bearing 1.

(When reassembling)

• Apply oil to the bearing case screw 2.

• Clean the oil passage of the crankshaft with com-

pressed air.

Tightening torque

Main bearing

case screw

68.7 ~ 73.6 N·m

7.0 ~ 7.5 kgf·m

50.6 ~ 54.2 lbf·ft

(D) Main bearing case

1. Remove the bearing case screws 1 (4) and remove

the main bearing case 1, 2, 3 (1).

2. Remove the thrust bearing from the flywheel end of

the bearing case.

569W281A

(1) Bearing Case Cover

569W282A

D569-W02 May-2003

569W283A

(1) Main Bearing Case 1, 2, 3 (2) Thrust Bearings (3) Main Bearing Case Assembly 1 (4) Bearing Case Screw 1 (5) Crankshaft Bearing 2

2-47

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

46.1 ~ 51.0 N·m

4.7 ~ 5.2 kgf·m

34.0 ~ 37.6 lbf·ft

D. SERVICING

a. Cylinder Head and Valve

(A) Cylinder head surface flatness

1. Thoroughly clean the cylinder head surface.

2. Place a straight edge on the cylinder head and measure the clearance with a feeler gage as shown in the figure.

3. If the measurement exceeds the allowable limit, replace the cylinder head.

569W284A

(6) Bearing Case

IMPORTANT:

• Do not place the straight edge on the combustion camber.

Flatness

Allowable

limit

0.05 mm

0.0019 in.

(B) Cylinder head surface flaw

1. Prepare an air spray red check.

2. Clean the cylinder head surface with the detergent (B).

3. Spray the cylinder head surface with the red permeative liquid (A).

4. Wash away the red permeative liquid on the cylinder head surface with the detergent (B) after ten minutes.

5. Spray the cylinder head surface with the white developer (C).

6. If any flaw is found such as a red mark, replace the cylinder head.

569W285A

569W286A

(A) Red Permeative Liquid ( C) White Developer

(B) Detergent

2-48

D569-W02 May-2003

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

V alve guide bore I.D.

Valve stem O.D.

Factory

spec.

Allowable

limit

Factory

spec.

Factory

spec.

0.040 ~ 0.070 mm

0.00157 ~ 0.00276 in.

0.1 mm

0.004 in.

8.015 ~ 8.030 mm

0.31555 ~ 0.31614 in.

7.960 ~ 7.975 mm

0.31339 ~ 0.31398 in.

(D) Valve recessing

1. Clean the cylinder head, the valve face and the seat.

2. Insert the valve in the guide.

3. Measure the valve recessing with a depth gauge.

4. If the recessing exceeds the allowable limit, replace

the valve and check the valve seating.

ENGINE

569W287A

12 13111078210 65439

Valve recessing

Factory

spec.

Allowance

0.2 ~ 0.5 mm

0.0078 ~ 0.0197 in.

0.8 mm

0.0315 in.

(E)Valve seat

1. Coat the valve face lightly with red lead and put the

valve on its seat to check the contact.

2. If the valve does not seat all the way around the

valve seat or the valve contact is less than 70%, correct the valve seating as follows.

3. Apply compound on the valve face evenly.

4. Put the valve on its seat hold it with the valve flapper.

5. Turn and flap the valve back and forth on the valve

seat to lap.

6. Remove the compound and clean the valve and the

seat.

7. Apply oil on the valve face and finish to complete

fitting.

8. Repeat lapping until the valve seats correctly.

569W288A

569W289A

D569-W02 May-2003

2-49

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

10.2 kgf/35.15 mm

22.5 lbs/1.3839 in.

Free length

Factory

spec.

Allowable

limit

41.7 ~ 42.2 mm

1.6417 ~ 1.6614 in.

41.2 mm

1.622 in.

(G) Valve spring squareness (Tilt)

1. Place the spring on the surface plate, and a square at its side.

2. Measure the maximum distance “A” (see figure), rotating spring.

3. If the measurement exceeds the allowable limit replace.

Valve spring square ness

Allowable

limit

1.0 mm

0.039 in.

569W290A

(H) Rocker arm bushing and shaft clearance

1. Measure the rocker arm I.D. with an inside micrometer.

2. Measure the rocker arm shaft O.D. with an outside micrometer.

3. If the clearance exceeds the allowable limit, replace the rocker arm.

4. If the clearance still exceeds the allowable limit after replacing the rocker arm replace the rocker arm shaft.

Clearance

Rocker arm shaft O.D.

Rocker arm I.D.

Factory

spec.

Allowable

limit

Factory

spec.

Factory

spec.

0.020 ~ 0.070 mm

0.00079 ~ 0.00276 in.

0.15 mm

0.0059 in.

18.955 ~ 18.980 mm

0.74626 ~ 0.74724 in.

19.000 ~ 19.025 mm

0.74803 ~ 0.74902 in.

2-50

D569-W02 May-2003

569W291A

569W292A

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.

ENGINE

Clearance

Factory

spec.

Allowable

limit

0.04 ~ 0.11 mm

0.0016 ~ 0.0043 in.

0.15 mm

0.0059 in.

(B) Idle gear side clearance

1. Pull the idle gear collar 2 (1) and push the idle gear

(2) to each end.

2. Measure the clearance A between the idle gear and

the idle gear collar 2 (1) with a feeler gauge.

3. If the clearance exceeds the allowable limit, replace

the idle gear collar 1 (3).

Side clearance

Factory

spec.

Allowable

limit

0.20 ~ 0.51 mm

0.0079 ~ 0.021 in.

0.9 mm

0.035 in.

569W293A

569W294A

1. Pull the cam gear (2) with the camshaft (1) to its

end.

2. Measure the clearance A between the cam gear (2)

and the camshaft stopper (3).

3. If the clearance exceeds the allowable limit, replace

the camshaft stopper (3).

Side clearance

Factory

spec.

Allowable

limit

0.07 ~ 0.22 mm

0.0028 ~ 0.0087 in.

0.3 mm

0.0118 in.

D569-W02 May-2003

(1) Idle Gear Collar 2 ( 3) Idle Gear Collar 1 (2) Idle Gear

569W295A

(1) Camshaft (3) Camshaft Stopper (2) Cam Gear

2-51

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.

Allowable

limit

0.15 ~ 0.57 mm

0.0059 ~ 0.0224 in.

0.9 mm

0.035 in.

(E) Idle gear oil clearance

1. Measure the idle gear shaft O.D. with an outside micrometer.

2. Measure the idle gear bushings I.D. with an inside micrometer.

3. If the clearance exceeds the allowable limit, replace the bushing.

Oil clearance

Shaft O.D.

Bushing I.D.

Factory

spec.

Allowable

limit

Factory

spec.

Factory

spec.

0.025 ~ 0.066 mm

0.00098 ~ 0.00259 in.

0.1 mm

0.004 in.

37.959 ~ 37.975 mm

1.4944 ~ 1.4950 in.

38.000 ~ 38.025 mm

1.4961 ~ 1.4970 in.

569W296A

(1) Injection Pump Gear (2) Snap Ring

(A) Clearance

569W297A

(F) Replacing idle gear bushings

1. Press out the bushings using an idle gear bushing replacing tool.

2. Clean the bushings and the bore, and apply oil to them.

3. Press in the bushing using the replacing tool.

2-52

569W298A

D569-W02 May-2003

(G) Camshaft oil clearance

1. Measure the I.D. of the camshaft bore on the crank-

case 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.

ENGINE

Oil clearance

Journal O.D.

Bore I.D.

Factory

spec.

Allowable

limit

Factory

spec.

Factory

spec.

0.050 ~ 0.091 mm

0.00197 ~ 0.00358 in.

0.15 mm

0.0059 in.

39.934 ~ 39.950 mm

1.57221 ~ 1.57284 in.

40.000 ~ 40.025 mm

1.57480 ~ 1.57579 in.

(H) Camshaft alignment

1. Support the camshaft with V blocks on the surface

plate at both end journals and set a dial indicator with its tip on the intermediate journal.

2. Rotate the camshaft in the V block and get the ec-

centricity (half of the measurement).

3. If the eccentricity exceeds the allowable

Eccentricity

Allowable

limit

0.05 mm

0.002 in.

569W299A

(I) Cam height

1. Measure the height of the camshaft lobes at their

largest. O.D. with an outside micrometer.

2. If the measurement is less than the allowable limit,

replace the camshaft.

Cam height

4A220

4A200T

(IN.)

(EX.)

(IN.)

(EX.)

specification

allowable limit

specification

allowable limit

specification

allowable limit

specification

allowable limit

33.59 mm 1.322 in.

33.54 mm 1.320 in.

33.69 mm 1.326 in.

33.64 mm 1.324 in.

33.90 mm 1.335 in.

33.85 mm 1.333 in.

33.70 mm 1.327 in.

33.65 mm 1.325 in.

569W2A0A

569W2A1A

D569-W02 May-2003

2-53

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.

Allowable

limit

25.000 ~ 25.006 mm

0.9843 ~ 0.9845 in.

25.03 mm

0.9854 in.

(B) Piston pin and brushing clearance

1. Measure the piston pin O.D. with an outside micrometer.

2. Measure the piston pin busing I.D. with an inside micrometer.

3. If the clearance exceeds the allowable limit with new bushing, replace the piston pin.

Piston pin and bushing clearance

Piston pin O.D.

Bushing I.D.

Factory

spec.

Allowable

limit

Factory

spec.

Factory

spec.

0.014 ~ 0.038 mm

0.00055 ~ 0.00150 in.

0.15 mm

0.0059 in.

25.002 ~ 25.011 mm

0.98433 ~ 0.98469 in.

25.025 ~ 25.040 mm

0.98524 ~ 0.98583 in.

569W2A2A

569W2A3A

1. Press out the bushing, using a piston pin bushing replacing tool.

2. Clean the new bushing and the bore and apply oil to them.

3. Press in the bushing, using the replacing tool.

IMPORTANT:

• Align the oil holes of the connecting rod and the bushing.

2-54

569W2A4A

D569-W02 May-2003

(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.

ENGINE

Piston ring end gap

2nd ring

Top

ring,

oil ring

Factory

spec.

Allowable

limit

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

0.0098 ~ 0.0157 in.

1.25 mm

0.0492 in.

(E) Piston ring clearance

1. Clean the ring and the ring grooves, and install each

ring into its groove.

2. Measure the clearance between the ring and the

groove with a feeler gauge.

3. If the clearance exceeds the allowable limit, replace

the piston ring.

4. If the clearance still exceeds the allowable limit with

a new ring, replace the piston.

Piston ring clearance

2nd ring

Oil ring

Factory

spec.

Allowable

limit

Factory

spec.

Allowable

limit

0.04 ~ 0.08 mm

0.00157 ~ 0.00314 in.

0.15 mm

0.0059 in.

0.02 ~ 0.06 mm

0.00079 ~ 0.00236 in.

0.15 mm

0.0059 in.

569W2A5A

569W2A6A

D569-W02 May-2003

2-55

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. If the measurement exceeds the allowable limit, replace the connecting rod.

569W2A7A

Space between gauge pin and face plate

Allowable

limit

0.05 mm (0.0020 in.) at 100 mm (3.94 in.)

of gauge pin span

d. Crankshaft

(A) Flywheel deflection and crankshaft end play

1. Set a dial indicator with its tip on the rear friction face of the flywheel near the edge.

2. Turn the flywheel and measure the deflection or the uneven wear.

3. If the measurement exceeds the allowable limit, remove the flywheel and check the mating faces of the crankshaft and flywheel.

4. If scored of worn excessively, resurface or replace the flywheel.

5. Move the crankshaft with flywheel back and forth to each end and measure the end play.

6. If the play exceeds the allowable limit, replace the side bearing.

Deflection

End play

Allowable

limit

Factory

spec.

Allowable

limit

0.05 mm

0.0020 in.

0.15 ~ 0.31 mm

0.0059 ~ 0.0122 in.

0.5 mm

0.020 in.

569W2A8A

2-56

D569-W02 May-2003

(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, re-

place the crankshaft.

ENGINE

Misalignment

allowable

limit

0.08 mm

0.0031 in.

1. Measure the I.D. of the crankshaft bearing 1 with an

inside micrometer.

2. Measure the O.D. of the crankshaft journal with an

outside micrometer.

3. If the clearance exceeds the allowable limit, replace

the bearing referring to Replacing Crankshaft Bearing 1.

Oil clearance

Journal O.D.

Bearing 1 I.D.

Factory

spec.

Allowable

limit

Allowable

limit

Allowable

limit

0.040 ~ 0.118 mm

0.00157 ~ 0.00465 in.

0.20 mm

0.0079 in.

51.921 ~ 51.940 mm

2.04413 ~ 2.04488 in.

51.980 ~ 52.039 mm

2.04646 ~ 20.4878 in.

569W2A9A

569W2B0A

(D) Replacing crankshaft bearing 1

1. Press out the crankshaft bearing 1 with replacing

tool.

2. Clean a new crankshaft bearing 1 and bore, and

apply engine oil to them.

3. Press fit a new bearing 1 using a inserting tool,

taking due care to see that the seam of bearing 1 faces the exhaust manifold side.

D569-W02 May-2003

569W2B1A

(1) Seam

2-57

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

Journal O.D.

Bearing 2 I.D.

(F) Crankpin and connecting rod bearing 2 oil clear-

ance

1. Put a strip of PLASTIGAGE lengthwise in the center of the crankpin.

2. Install the connecting rod and tighten the screws to the specified torque once, and remove the cap again.

3. Measure the amount of the flattening with the scale and get the oil clearance.

4. If the clearance exceeds the allowable limit, replace the bearing.

Oil clearance

Journal O.D.

Bearing 1 I.D.

Factory

spec.

Allowable

limit

Allowable

limit

Factory

spec

Factory

spec.

Allowable

limit

Factory

spec.

Factory

spec.

0.040 ~ 0.104 mm

0.00157 ~ 0.00409 in.

0.20 mm

0.0079 in.

51.921 ~ 51.940 mm

2.04413 ~ 2.04488 in.

51.980 ~ 52.025 mm

2.04646 ~ 2.04823 in.

0.025 ~ 0.087 mm

0.00098 ~ 0.00343 in.

0.20 mm

0.0079 in.

46.959 ~ 46.975 mm

1.84878 ~ 1.84941 in.

47.000 ~ 47.046 mm

1.85040 ~ 1.85221 in.

569W2B2A

2-58

D569-W02 May-2003

e. Cylinder Bore

(A) Cylinder bore diameter

1. Measure the cylinder liner I.D. at sit positions shown

in the figure to find the maximum wear.

4A200T

4A220

83.000 ~ 83.022 mm

3.2677 ~ 3.269 in.

87.000 ~ 87.022 mm

3.4252 ~ 3.4261 in.

ENGINE

569W2B3A

(A) Axial Direction (B) Transverse Direction

1,2,3 Measuring Points

569W2B4A

D569-W02 May-2003

2-59

CHAPTER 2 8454

E. LUBRICA TING 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 pres-

sure

At idle speed

At rated

speed

Factory

spec.

Factory

spec.

Allowable

limit

more than 49 kPa

0.5 kgf/cm

7.11 psi

294 ~ 441 kPa

2.5 ~ 4.5 kgf/cm

35.6 ~ 64.0 psi 245 kPa

2.5 kgf/cm

35.6 psi

569W2B5A

(Reference)

Tightening torque

Oil

pressure

switch

14.7 ~ 19.6 N·m

1.5 ~ 2.0 kgf·m

10.8 ~ 14.5 lbf·ft

(B) Oil filter and relief valve

1. Drain the engine oil and remove the oil filter to check it.

2. Check the relief valve for dirt, and the seat (2) and ball (1) for damage.

3. If damaged, replace.

4. Check the free length of spring (3).

5. If it is less than the allowable limit, replace it.

Spring free length

Factory

spec

Allowable

limit

35 mm

1.38 in. 30 mm

1.18 in.

NOTE:

• Install the relief valve cover with the mark up.

569W2B6A

(1) Relief Valve Ball (3 ) Relief Valve Spring (2) Relief Valve Seat

Tightening torque

2-60

Relief

cover

32.4 ~ 36.3 N·m

3.3 ~ 3.7 kgf·m

23.9 ~ 36.8 lbf·ft

D569-W02 May-2003

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.

ENGINE

Outer and inner rotor clearance

Outer and inner housing clearance

Factory

spec.

Allowable

limit

Factory

spec.

Allowable

limit

0.10 ~ 0.16 mm

0.0039 ~ 0.0063 in.

0.20 mm

0.0079 in.

0.11 ~ 0.19 mm

0.0043 ~ 0.0075 in.

0.25 mm

0.0098 in.

(B) Rotor end clearance of oil pump

1. Put a strip of PLASTIGAGE on the rotor and assemble the pump.

2. Disassemble the pump and measure the amount of the flattening with the scale to get the clearance.

3. If the clearance exceeds the allowable limit, replace the pump.

569W2B7A

569W2B8A

End clearance

Factory

spec.

Allowable

limit

D569-W02 May-2003

0.105 ~ 0.150 mm

0.00423 ~ 0.00591 in.

0.20 mm

0.0079 in.

569W2B9A

2-61

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

0.28 ~ 0.35 in.

at 98 N (10 kgf, 22 lbs)

of force

(B) Radiator water tightness

1. Fill the radiator with water to the specified amount and warm up the engine.

2. Set a radiator tester and raise the water pressure to the specified pressure.

3. Check the radiator for water leaks.

4. For water leaks from a pin hole, repair it with radiator cement, and for larger leaks, replace the radiator.

Radiator water tightness

Factory

spec

No leaks at 137 kPa

(1.4 kgf/cm2, 20 psi)

1. Set a radiator tester on the radiator cap.

2. Apply 88 kPa (0.9 kgf/cm

, 13 psi) of pressure and

measure the pressure for 10 seconds.

3. If the pressure falls below 59 kPa (0.6 kgf/cm

, 9

psi),replace the radiator cap.

569W2C0A

569W2C1A

Radiator cap tightness

2-62

Factory

spec

more than 10 seconds

for pressure fall

from 88 ~ 59 kPa

(0.9 ~ 0.6 kgf/cm2, 13 ~ 9 psi)

569W2C2A

D569-W02 May-2003

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.

(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. Remove the impeller from the water pump shaft.

6. Remove the mechanical seal (5).

ENGINE

569W2C3A

(1) Thermostat (2 ) Thermostat Cover

(When reassembling)

• Replace the mechanical seal (5) with new one.

c. Servicing

(A) Thermostat valve opening temperature

1. Suspend the thermostat in the water by a string with

its end inserted between the valve and seat.

2. Heating the water gradually, read the temperatures

when the valve starts to opens and when the valve is completely opened approx 8 mm (0.315 in.).

3. If the measurements are not within the factory speci-

fications, replace the thermostat.

Opening temperature

Factory

spec.

71 ± 1.5 °C

(160 ± 3 °F)

at beginning

Lower than 85 °C (185 °F)

at 8 mm (0.315 in.)

of opening

569W2C4A

(1) Water Pump Flange (4) Water Pump Body (2) Water Pump Bearing (5) Mechanical Seal (3) Water Pump Shaft (6 ) Impeller

569W2C5A

D569-W02 May-2003

2-63

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. If the Fl mark does not align with the mark of the window on flywheel housing, add or remove the shim (2) to adjust.

569W2C6A

(1) Delivery Valve Holder (2 ) Shim

Injection timing

4A220

4A200T

0.31 rad, 18° before T.D.C

0.21 rad, 12° before T.D.C

NOTE:

• Apply liquid gasket (There Bond 1215 or equivalent) to the shim, when reassembling.

(Reference)

• The timing advances by removing 0.15 mm (0.006 in.) of shim and retards by adding one, approx 0.26 rad (1.5°) of crank angle.

• Approx 3.6 mm (0.142 in.) of turn at outer rim of flywheel equals 0.26 rad (1.5°) of crank angle.

2-64

D569-W02 May-2003

(B)Delivery valve fuel tightness

1. Remove the injection pipes, glow plugs and the in-

let manifold, and install a pressure tester.

2. With the speed control lever at the fuel injection po-

sition, 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 1.57 rad (90°) from the FI timing).

4. If the pressure drops for 5 seconds exceeds the

allowable limit, replace the delivery valve or pump assembly.

5. If the pressure does not built up, replace the pump

element with new one and test again.

ENGINE

569W2C7A

Fuel injection pressure

Factory

spec.

14.71 MPa

150 kgf/cm

2134 psi

Pressure drop

Allowable

limit

0.98 MPa

10 kgf/cm

142 psi

b. Injection Nozzle

• Never come in contact with spraying diesel fuel under pressure, which can have sufficient force to penetrate the

CAUTION

skin, causing serious personal injury.

• Be sure nobody is in direction of the spray.

(A) Fuel injection pressure

1. Set the injection nozzle to the nozzle tester.

2. Measure the injection pressure.

3. If the measurement is not within the factory specifications, adjust with the adjustment washer (1) inside the nozzle holder.

(Reference) Pressure variation with 0.1 mm (0.004 in.) difference of

adjusting washer thickness is approx. 10 kgf/cm

Fuel injection pressure

Factory

spec.

13.73 ~ 14.71 MPa 140 ~ 150 kgf/cm

1991 ~ 2134 psi

D569-W02 May-2003

569W2C8A

(1) Adjustment Washer

2-65

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/cm 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.

c. Disassembling and Assembling

1) Injection pump

IMPORTANT:

• If replacing the pump element, the amount of fuel injection should be adjusted on specified bench.

(12.75 mPa, 1,849 psi).

569W2D1A

2-66

569W2C9A

(1) Pump Body (5) Delivery Valve (2) Control Rack (6) Tappet Roller (3) Delivery Valve Holder (7 ) Cylinder (4) Delivery Valve Spring (8) Plunger

D569-W02 May-2003

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.

ENGINE

569W2D0A

(1) Nozzle Holder (5) Distance Piece (2) Adjusting Washer (6) Nozzle (3) Nozzle Spring (7) Nozzle Nut (4) Push Rod

D569-W02 May-2003

2-67

CHAPTER 3

CLUTCH

1. TROUBLESHOOTING

CLUTCH

Symptom

Clutch slip

Clutch disconnection abnormal

Starting is not smooth

Clutch noise

Clutch vibration

Clutch gets connected suddenly

Provable Causes

• Clutch pedal play too small

• Clutch disc facing worn

• Grease or oil on clutch disc facing

• Distortion or damaged in clutch pressure plate and flywheel

• Missing or feeble spring of clutch pressure plate

• Excessive clutch pedal defection

• Grease or oil on clutch disc facing

• Vibration or distortion in clutch disc

• Rust developed in clutch disc hub and shaft splice part

• Clutch lever deformation, defective adjustment

• Abrasion and breakage in release bearing

• Fixation of clutch disc and flywheel or pressure plate, rust developed

• Foreign substance intermixed in clutch

• Grease or oil on clutch disc facing

• Loosened riveting in clutch disc facing

• Distortion or damage in clutch disc, pressure plate and flywheel

• Defective adjustment of clutch lever

• Missing or feeble spring of pressure plate

• Rust or wear in clutch disc hub and shaft spline part

• Wear and Abrasion in release bearing

• Wear in clutch disc hub and shaft spline part

• Missing torsion spring of clutch disc

• Clutch disc damaged

• Bending in shuttle shaft or PTO drive shaft

• Defective dynamic balance in clutch assembly

• Damages on other clutch related parts

• Grease or oil on clutch disc facing

• Distortion in clutch pressure plate and flywheel

• Damage on torsion spring of clutch disc

Solution

Adjust

Replace

Clean or replace

Correct or replace

Replace

Adjust

Clean or replace

Replace

Remove rust or replace

Adjust or replace

Replace

Remove rust or replace

Clean

Clean or replace

Replace

Correct or replace

Adjust

Replace

Remove rust or replace

Replace Replace Replace Replace Replace Replace Replace

Clean or replace

Correct or replace

Replace

D569-W02 May-2003

3-3

CHAPTER 3 8454

2. SPECIFICATIONS, TIGHTENING TORQUES AND SPECIAL TOOLS

2.1 SPECIFICATIONS

Item

Clutch pedal

Safety switch

Clutch disc spline boss to shuttle shaft

Clutch disc surface to rivet

Pressure plate

2.2 TIGHTENING TORQUES

Item

• Inlet bolts between flywheel

housing and clutch housing

• Inlet nuts between flywheel

housing and clutch housing

• Inlet bolts between clutch

housing and middle case

• Inlet nuts between clutch

housing and middle case

• Inlet bolts of clutch cover

• Clutch release fork mounting

bolts

Free Play

Clearance

Backlash

Depth

Flatness

Nominal

Diameter (Type)

M12 (9T)

M12 (7T)

M12 (9T)

M12 (7T)

M8 (7T) M8 (7T)

Factory Specifications

20 ~ 30 mm

0.79 ~ 1.18 in. 2 ~ 5 mm

0.079 ~ 0.197 in.

Tightening T orques

N·m

10.3 ~ 117.7

77.5 ~ 90.2

103.0 ~ 117.7

77.5 ~ 90.2

23.5 ~ 27.4

10.5 ~ 12.0

7.9 ~ 9.2

10.5 ~ 12.0

7.9 ~ 9.2

2.4 ~ 2.8

kgf·m

Allowable Limit

2.0 mm

0.079 in.

0.3 mm

0.012 in.

0.2 mm

0.008 in.

lbf·ft

76.0 ~ 86.8

57.2 ~ 66.5

76.0 ~ 86.8

57.2 ~ 66.5

17.4 ~ 20.2

2.3 SPECIAL TOOLS

Clutch center guide

3-4

569W301A

D569-W03 June-2003

3. STRUCTURE AND OPERA TION

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 F EATURES

• Ind. styled clutch is applied available to operate the travel power and PTO power independently.

• Travel clutch: As dry-single plated clutch, traveling power is disconnected if the clutch pedal is stepped down.

• PTO clutch: As wet-multi plated clutch based on oil pressure control, PTO power is disconnected and connected by PTO switch over control.

CLUTCH

3.2 STRUCTURE

(1) Clutch Release Fork (2) Release Hub (3) Release Bearing (4) Diaphragm Spring (5) Clutch Cover (6) Clutch Pressure Plate (7) Clutch Disc (8) Flywheel (9) Shuttle Shaft

(10) Clutch Lever Shaft

569W302A

D569-W02 May-2003

3-5

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).

As a result, rotation of the flywheel (8) is transmitted to the transmission through the shuttle shaft (9) due to the frictional force among the flywheel (8), clutch disc (7) and pressure plate (6).

(1) Clutch Release Fork (2) Release Hub (3) Release Bearing (4) Diaphragm Spring (5) Clutch Cover (6) Clutch Pressure Plate (7) Clutch Disc (8) Flywheel (9) Shuttle Shaft

(10) Clutch Lever Shaft

569W302A

CLUTCH “DISENGAGED”

When the clutch pedal is depressed, the clutch rod is pulled to rotate the clutch lever shaft (10). Then, the release fork (1) pushes the release hub (2) and release bearing (3) toward the flywheel. Simultaneously the release bearing pushes the diaphragm spring (4), the frictional force among the flywheel (8), clutch disc (7) and pressure plate (6) disappears.

Therefore, rotation of the flywheel (8) is not transmitted to the clutch disc (7) stopping the rotation of the shuttle shaft (9).

(1) Clutch Release Fork (2) Release Hub (3) Release Bearing (4) Diaphragm Spring (5) Clutch Cover (6) Clutch Pressure Plate (7) Clutch Disc (8) Flywheel (9) Shuttle Shaft

(10) Clutch Lever Shaft

569W319A

3-6

D569-W02 May-2003

4. PREP ARA TION ST AGE FOR DISASSEMBLING AND ASSEMBLING

4.1 SEPARATING PANEL FRAME ASSEMBLY

PREP ARA TION 1

1. Removing the following parts.

• Bonnet

• Side Cover (RH, LH)

• Side Skirt (RH, LH)

• Battery Negative Code

CLUTCH

569W303A

PREP ARA TION 2

1. Disconnect the brake rods (4), (10).

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. Remove the shuttle shaft lever (5) after disconnecting

limit switch wire harness.

7. Disconnect the 2P connector of alternator (1), jumper

for fuel level sensor (3) and starter (9).

8. Disconnect the meter cable (13) at the engine side.

(1) 2P Connector for Alternator (2) Clutch Rod (3) Jumper Lead For Fuel Level Sensor (4) Brake Rod (LH) (5) Shuttle Shift Lever (6) Connectors (7) Panel Frame Cover (8) Jumper Lead For Oil Switch (9) Jumper Lead For Starter

(10) Brake Rod (RH)

(11) Food Accelerator Rod

(12) Accelerator Cable

(13) Meter Cable

(1) Side Cover (RH, LH) (4) Side Skirt (RH, LH) (2) Bonnet (5) Battery Negative Code (3) Front Grille

569W305A

569W306A

D569-W02 May-2003

3-7

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

Turning delivery

hose retaining

nut

46.6 ~ 50.9 N·m

4.8 ~ 5.2 kgf·m

34.4 ~ 37.6 lbf·ft

24.5 ~ 29.4 N·m

2.5 ~ 3.0 kgf·m

18.1 ~ 21.7 lbf·ft

PANEL FRAME AND STEERING ASSEMBLY

1. Remove the panel frame mounting crews (Two screws a upper part. Seven screws at lower part).

2. Take out the panel frame and steering assembly as a unit.

(When reassembling)

• Do not get in the wiring harness between panel frame and platform.

569W307A

(1) Steering Hose P (3) Steering Hose R (2) Steering Hose T (4) Steering Hose L

569W308A

3-8

D569-W02 May-2003

4.2 SEPARATING ENGINE AND

CLUTCH HOUSING CASE

PROPELLER SHAFT

1. Slide the propeller shaft covers (4), (5) after remov-

ing to bolt (9).

2. Tap out the spring pin (10), and then slide the cou-

pling (2) the front.

(When reassembling)

• Apply grease to the splines of the propeller shaft.

CLUTCH

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. Remove the brake rod (4) and suction pipe (3).

2. Remove the rubber hose (2).

3. Slide the return hose (1).

(When reassembling)

• Reinstall the pipe clamp securely.

Tightening torque

Joint bolt for

delivery pipe (3)

and hydraulic

block

Joint bolt for

delivery pipe (2)

49.0 ~ 58.8 N·m

5.0 ~ 6.0 kgf·m

36.2 ~ 43.4 lbf·ft

34.3 ~ 39.2 N·m

3.5 ~ 4.0 kgf·m

25.3 ~ 28.9 lbf·ft

569W311A

(1) Return hose (3) Suction Pipe

(2) Rubber Hose (4) Brake Rod

D569-W02 May-2003

3-9

CHAPTER 3 8454

SEP ARA TION 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.

569W312A

Tightening torque

Engine and clutch

housing

mounting

screws, nuts

Engine and clutch

housing mounting stud bolts

77.5 ~ 90.2 N·m

7.9 ~ 9.2 kgf·m

57.1 ~ 66.5 lbf·ft

39.2 ~ 49.0 N·m

4.0 ~ 5.0 kgf·m

28.9 ~ 36.2 lbf·ft

4.3 DISASSEMBLY

A. Insert clutch center guide (1) up to the spline hub

and fix it not to be come off even though clutch inlet bolt (2) is removed.

B. Remove clutch inlet bolts (2) and separate clutch

cover assembly (4).

• When attaching or detaching clutch,

slowly remove and slowly tighten the clutch inlet bolts diagonally to secure

CAUTION

ASSEMBLY

A. Thoroughly remove worn dust attached on clutch

cover (4), clutch disc (5) and flywheel (3).

B. Insert clutch center guide (1) into the flywheel and

then fix.

C. When assembling clutch disc, face the shorter

spline boss toward flywheel side.

D. Tighten the clutch cover with bolts after confirming

the locations of lock pin holes (2 places).

operational safety and to prevent deformation of the clutch cover and clutch pressure plate.

569W320A

Tightening torque

(1) Clutch Center Guide (4) Clutch Cover (2) Bolt (5) Clutch Disc (3) Flywheel ( 6) Straight Pin

Clutch cover

assembling

bolts

23.5 ~ 27.5 N·m

2.4 ~ 2.8 kgf·m

17.4 ~ 20.3 lbf·ft

3-10

569W313A

D569-W02 May-2003

Cub Cadet 8454 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual