Cub Cadet 8454 User Manual
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.
1-4
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,
4
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
1-8
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.)
40
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.)
3
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
4
87.0 x 92.4 (3.43 x 3.64)
2,197(134.1
)
vortex chamber
43/2,700 (30.9/2,700)
2,900
850 ~ 900
1-3-4-2
Counterclockwise
(viewed from flywheel side)
Bosch K TYPE mini pump
140 ~ 150 kgf/cm
2
(13.73 ~ 14.71 MPa, 1991 ~ 2133 psi)
18°
22 : 1
Diesel fuel
Engine oil SAE 15W-40
817.3 x 488.1 x 735.8
(32.2 x 19.2 x 29.0)
207 (456)
4A200T
Vertical, water-cooled,
4-cycle diesel engine (Turbo)
4
83.0 x 92.4 (3.27 x 3.64)
1,999(122.0)
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
2
(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
A
697.3 (27.45)
697.3 (27.45)
G
736 (28.98)
736 (28.98)
B
817.3 (32.18)
817.3 (32.18)
H
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.)
C
I
D
φ
400 (15.75)
φ
400 (15.75)
J
φ
321 (12.64)
φ
321 (12.64)
E
502.6 (19.79)
519 (20.43)
K
104.5 (4.11)
104 (4.09)
F
262.5 (10.33)
282.4 (11.12)
L
-
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
Loading...