Kioti Daedong CK25 Tractor Service Repair Manual 1

CK25/27/30/35 (CK25H/27H/30H/35H)

This manual is to provide servicing personnel with information on the general specifications, service, operating principle, troubleshooting, exploded view including part name, removing and installing procedures for CK25/27/30/ 35 and CK25H/27H/30H/35H tractors with high-end technology.

All information in this manual is based on the latest product information available at the time of publication.

Therefore, some of the information in this manual may differ from the machine you have.

DAEDONG has a principle to apply update to the next edition of the manual if there is any. However, DAEDONG has no obligation to modify the contents in this manual, especially the contents in the manual which is already distributed or published.

The modified information is available in DAEDONG’s online electronic manual system (DEMSS).

This manual is ultimately to satisfy customers with best performance of tractor. If there is any typo, wrong information or question for this manual, feel free to contact DAEDONG.

2008. 06 Overseas service team DAEDONG INDUSTRIAL Co., Ltd.

IMPORTANT • Using unspecified parts, fuel and lubricants other than DAEDONG’s genuine parts can damage the tractor and such damage will not be covered by warranty.

REMARK • We reserve the right to make changes throughout the entire manual at any time without notice.

SAFETY FIRST

GENERAL

ENGINE

CLUTCH

TRANSMISSION

HST

REAR AXLE

BRAKE

FRONT AXLE

STEERING SYSTEM

HYDRAULIC SYSTEM

ELECTRIC SYSTEM

INDEX

CK25/27/30/35

SAFETY FIRST TABLE OF CONTENTS 1. FOR SAFETY .......................................................................... 0-2 1.1 Alert symbols .................................................................. 0-2 2. SAFETY TIPS ......................................................................... 0-3 2.1 Safety gear ...................................................................... 0-3 2.2 Work place ....................................................................... 0-3 2.2.1 Ventilating system ................................................ 0-3 2.2.2 Safe working place ............................................... 0-3 2.2.3 Illumination ............................................................ 0-3 2.2.4 Safety equipment .................................................. 0-3 2.2.5 Clean working area ............................................... 0-3 2.3 Safety instructions when preparing tractor .................. 0-4 2.4 Avoid fires ........................................................................ 0-4 2.5 Cautions when handling the battery .............................. 0-5 2.6 Cautions for high pressure hoses .................................. 0-6 2.7 Use of appropriate tools and equipment ....................... 0-6 2.8 Handling of hazardous materials ................................... 0-6 2.9 Handling of rotating blade, shaft and driving belt ......... 0-7 2.10 Prevention of scald .......................................................... 0-7 2.11 Disposal of environmental waste ................................... 0-8 2.12 Cautions when handling tires ......................................... 0-8 3. SAFETY DECALS ................................................................... 0-9

SAFETY FIRST - FOR SAFETY

1. FOR SAFETY •

Most accidents can be avoided if basic safety instructions and regulations are followed. Always follow the safety regulations and avoid any dangerous situation to prevent an accident.

•

You can be unexpectedly injured if inspecting or servicing the tractor without full knowledge of it.

Read the service manual carefully before starting servicing and follow the instructions for servicing, maintenance and inspection to prevent any injury.

HST

TRANSMISSION

CLUTCH

ENGINE

GENERAL

CK25/27/30/35

READ MANUAL! ᴯᖿ⤇#╤ⴋ#$ T46W001A

1.1 ALERT SYMBOLS In this manual, the following safety-alert symbols are used. Their meanings are as follows:

B. CAUTION

FRONTAXLE

BARKE

REARAXLE

A. REMARK

CAUTION ⱇ#⪣

REMARK T46W002A

•

Broaden your knowledge with additionally supplied service information for optimal service.

•

This mark indicates potentially hazardous situation which, if not observed, may result in serious injury.

D. WARNING

WARNING T46W003A

•

This mark indicates emphasis on information which can be confused when servicing. If this information is not carefully read and observed, the tractor cannot fully function or may be damaged.

T46W005A

•

This mark indicates hazardous situation which, if not observed, may result in death or injury.

INDEX

ELECTRIC

HYDRAULIC

STEERING

C. IMPORTANT

T46W004A

2

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Jun. 2008

CK25/27/30/35 GENERAL

2. SAFETY TIPS 2.1 SAFETY GEAR

CLUTCH

ENGINE

When working on the tractor, wear safety gloves, safety shoes, ear plugs, safety goggles, safety helmet, working clothes, etc. appropriate for your working environment. Never wear loose fitting clothing or a tie which can be caught to the rotating part. According to the statistics, most accidents that occurred with rotating parts are due to this inappropriate manner of wearing clothes.

T46W006A

HST

2.2 WORK PLACE

TRANSMISSION

SAFETY FIRST - SAFETY TIPS

2.2.1 VENTILATING SYSTEM REARAXLE

The service should be performed in well-ventilated area. If the engine should be started in an enclosed place, the exhaust gas pipe should be installed.

WARNING •

California Proposition 65 Warning BARKE

Inhaling exhaust gas can cause cancer or damage the generative function leading to infertility.

The work should be done in a wide, level and safe place to prevent slip and fall accident.

T46W007A

2.2.3 ILLUMINATION

STEERING

The work place should be well illuminated. If working in a dark place or under the tractor, use the work lamp.

The work lamp should be covered by the safety cover.

The bulb can cause fire due to leaked fuel if it is broken.

FRONTAXLE

2.2.2 SAFE WORKING PLACE

Be sure to keep a first aid kit and fire extinguisher handy at all times.

2.2.5 CLEAN WORKING AREA T46W008A

INDEX

Keep the working area clean before and during work. If any oil or fuel is spilled, it should be cleaned up immediately.

ELECTRIC

HYDRAULIC

2.2.4 SAFETY EQUIPMENT

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3

SAFETY FIRST - SAFETY TIPS

2.3 SAFETY INSTRUCTIONS WHEN PREPARING TRACTOR

2.4 AVOID FIRES

CLUTCH

ENGINE

GENERAL

CK25/27/30/35

T46W011A

•

•

Lower the implement on to the ground.

Never smoke or allow flames in your work area when servicing the fuel system.

T46W012A T46W010A

•

Stop the engine and remove the key.

•

Put “Do not operate” label on the tractor if necessary.

•

Keep flames or sparks away from the spray paint or fuel containers and be careful of leak.

STEERING

FRONTAXLE

BARKE

REARAXLE

HST

TRANSMISSION

T46W009A

•

Always disconnect the battery cable before servicing.

•

Be extra cautious of fire when welding.

INDEX

ELECTRIC

HYDRAULIC

T46W013A

T46W014A

•

4

Always keep a fire extinguisher in workshop.

D704-W01

Jun. 2008

SAFETY FIRST - SAFETY TIPS

CK25/27/30/35

CLUTCH

ENGINE

GENERAL

2.5 CAUTIONS WHEN HANDLING THE BATTERY

Always disconnect the negative battery cable first and reconnect it last to avoid sparks from an accidental short circuit. You can get injured or fire may break out.

•

The battery contains the acid that can burn you.

When it contacts with your eyes, you may lose your sight.

REARAXLE

HST

•

T46W018A

TRANSMISSION

T46W015A

Do not charge the frozen battery. Charging the frozen battery can cause explosion. Let the battery warmed up to ambient temperature (16°C, 60°F) before charging.

HYDRAULIC

STEERING

FRONTAXLE

•

BARKE

T46W016A

Keep sparks and flames (match, lighter) away from the battery. The battery can explode due to the battery fluid.

•

Never connect the battery’s negative and positive cables with metal for test. Use only tester when checking the battery voltage.

INDEX

•

ELECTRIC

T46W017A

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5

SAFETY FIRST - SAFETY TIPS

2.6 CAUTIONS FOR HIGH PRESSURE HOSES

2.7 USE OF APPROPRIATE TOOLS AND EQUIPMENT

CLUTCH

ENGINE

GENERAL

CK25/27/30/35

T46W022A

The hydraulic fluid leaked from high pressure hoses or pipes can penetrate your skin.

•

Use the appropriate tools in proper size. If an inappropriate tool is used, it can be slipped which can damage parts or injure you.

Do not confuse units (mm, inch, etc.).

•

Use the air impact wrench only when unscrewing the bolts or nuts. Such wrench should not be used when assembly precisely machined parts which its tightening torque should be strictly observed. It can cause malfunction.

•

Be careful of a socket popped out due to the turning force when using the air impact wrench. Especially, be extra cautious when working on connection or socket with joint.

•

When lifting the tractor with hoist, fix it firmly and install Never work under the tractor hydraulic jack (hoist) are not

•

When using a hydraulic jack or a hoist, do not use it over the limit of the equipment and the conveying belt.

•

Make sure that the hydraulic lock operates properly before using the hydraulic jack. Improper use of lock can cause a serious accident.

•

Check the buttons and operating direction of the hoist before using it. Improper operation can cause a serious accident.

•

Do not use wooden blocks or bricks as support under the tractor. As the tractor’s weight is continuously applied to them, they can be broken or collapsed.

2.8 HANDLING OF HAZARDOUS MATERIALS

T46W020A

•

Before connecting a high pressure hose or pipe, stop the engine and depressurize it by valve.

•

Check the bolts for tightness before starting the engine after servicing the hydraulic system.

•

Use a cardboard or plank when checking leakage.

FRONTAXLE

BARKE

REARAXLE

HST

•

STEERING

•

HYDRAULIC

TRANSMISSION

T46W019A

T46W021A

ELECTRIC

•

Never weld the high pressure pipe or the surrounding area. The pipe or hose can be heated and explode which can lead to fire or burn.

•

a hydraulic jack or a the auxiliary support. if the support and the installed.

Do not use pressurized air to blow out hazardous materials, such as clutch dust, with compressed air. Inhaling such hazardous materials can damage your health.

INDEX

NOTE:

6

•

All DAEDONG’s genuine parts contain no asbetos.

•

These materials should be rinsed or wiped away after spraying oil.

D704-W01

Jun. 2008

SAFETY FIRST - SAFETY TIPS

GENERAL

2.10 PREVENTION OF SCALD

CLUTCH

ENGINE

2.9 HANDLING OF ROTATING BLADE, SHAFT AND DRIVING BELT

CK25/27/30/35

T46W027A

Do not open the radiator cap when the radiator is hot. Hot coolant or steam can be surged leading to a serious scald.

HST

•

T46W024A

Be extra careful when you are in loose clothes.

T46W028A

Be careful not to get caught by the rotating engine cooling fan.

•

Perform any service on the engine parts (muffler, exhaust manifold, turbocharger, etc.) only when they are not hot.

ELECTRIC

HYDRAULIC

•

Check the surface temperature of the container before draining the engine oil, transmission fluid, coolant, etc. If it is hot, let it cool down before draining it. There is danger of burning.

STEERING

T46W025A

•

BARKE

REARAXLE

Do not set a hand or a foot into the tractor’s rotating blade or PTO shaft.

FRONTAXLE

•

TRANSMISSION

T46W023A

T46W026A

You can be seriously injured if your hand or clothes is caught by the rotating fan belt or A/C belt.

D704-W01

Jun. 2008

INDEX

•

7

SAFETY FIRST - SAFETY TIPS

2.11 DISPOSAL OF ENVIRONMENTAL WASTE

2.12 CAUTIONS WHEN HANDLING TIRES

T46W029A

•

Observe all relevant environmental protection regulations when disposing used oil, transmission fluid, coolant, oil filter, etc. Otherwise, they can pollute the environment seriously and you can be charged in violation of regulations.

T46W030A

•

The tire rims can fall out of the tires. Therefore, stay out of its way when checking or inflating tires.

BARKE

REARAXLE

HST

TRANSMISSION

CLUTCH

ENGINE

GENERAL

CK25/27/30/35

•

Do not weld or apply heat to the tire rim or disc. The tire can explode due to the rapidly increased pressure in the tire.

•

Check tires for inflation pressure, damage, deformation, extended wear on lug and damage of rim and disc. Also check if wheel bolts, rim bolts and nuts are loose.

INDEX

ELECTRIC

HYDRAULIC

STEERING

FRONTAXLE

T46W031A

8

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Jun. 2008

SAFETY FIRST - SAFETY DECALS

CK25/27/30/35

GENERAL

3. SAFETY DECALS The following safety decals are installed on the machine.

BARKE

REARAXLE

HST

TRANSMISSION

CLUTCH

ENGINE

If a decal becomes damaged, illegible or is not on the machine, replace it. The decal part number is listed in the parts list.

(2) Parts No. : T4625-52351

(3) Parts No. : T4625-52361

INDEX

ELECTRIC

HYDRAULIC

STEERING

(1) Parts No. : T2181-54121 (Optional)

FRONTAXLE

704W010A

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9

CK25/27/30/35

SAFETY FIRST - SAFETY DECALS (5) Parts No. : T2325-50512

(6) Parts No. : T2445-50724

(7) Parts No. : T2615-55111

(8) Parts No. : T2350-54141

BARKE

REARAXLE

HST

TRANSMISSION

CLUTCH

ENGINE

GENERAL

(4) Parts No. : T2325-50743

FRONTAXLE

(10) Parts No. : T2615-53561

HYDRAULIC

STEERING

(9) Parts No. : T2615-54112

CARE OF DANGER, WARNING AND CAUTION LABELS

INDEX

ELECTRIC

1. Keep danger, warning and caution labels clean and free from obstructing material.

2. Clean danger, warning and caution labels with soap and water, dry with a soft cloth.

3. Replace damaged or missing danger, warning and caution labels with new labels.

4. If a component with danger, warning or caution label(s) is replaced, make sure new label(s) is (are) attached in the same locations(s) as the replaced component.

5. Mount new labels by applying on a clean dry surface and pressing any bubbles to outside edge.

10

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CK25/27/30/35

GENERAL TABLE OF CONTENTS 1. TRACTOR IDENTIFICATION .................... 1-3

8.2 Every 50 hours .................................. 1-15

2. DIMENSIONS .............................................. 1-4

8.2.1 Lubricating grease fittings .... 1-15

3. SPECIFICATIONS ...................................... 1-5 4. LUBRICANTS, FUEL AND COOLANT ... 1-7

8.2.2 Checking wheel bolt torque .. 1-16 8.3 Every 100 hours ............................... 1-17 8.3.1 Changing engine oil .............. 1-17

5. TIGHTENING TORQUES .......................... 1-8 5.1 General use screws, bolts and nuts . 1-8 5.2 Stud bolts ............................................. 1-8

8.3.2 Checking fuel line .................. 1-17 8.3.3 Cleaning air cleaner primary element .................................... 1-18

5.3 American standard screws, bolts and nuts with unc or unf threads ....................... 1-9

8.3.4 Evacuator valve ..................... 1-18

6. UNIT CONVERSION TABLE .................. 1-10

8.3.6 Adjusting brake pedal ........... 1-19

7. MAINTENANCE SCHEDULE CHART ... 1-11

8.3.7 Cleaning fuel filter ................. 1-19

8. CHECK AND MAINTENANCE ............... 1-12

8.3.8 Adjusting fan belt tension ..... 1-20

8.1 Daily check ........................................ 1-12

8.3.9 Battery ..................................... 1-20

8.1.1 Checking and refueling ......... 1-12

8.4 Every 200 hours ............................... 1-22

8.1.2 Checking engine oil level ..... 1-13

8.4.1 Replacing fuel filter ............... 1-22

8.1.3 Checking coolant level .......... 1-13

8.4.2 Replacing engine oil filter ..... 1-22

8.1.4 Checking head light, hazard light, etc. ........................................... 1-14

8.4.3 Replacing hydraulic oil filter & transmission oil filter (HST type) ................................................. 1-23

8.1.5 Checking seat belt and rops 1-14

8.3.5 Adjusting clutch pedal ........... 1-18

8.1.6 Cleaning grill, radiator screen and oil cooler screen .................... 1-14

8.4.4 Checking radiator hose and clamp ................................................. 1-24

8.1.7 Checking brake pedals and clutch pedal ........................................ 1-14

8.4.5 Adjusting toe-in ...................... 1-25

8.1.8 Checking gauges, meter and easy checker .......................... 1-14

8.5 Every 400 hours ............................... 1-26 8.5.1 Changing transmission fluid . 1-26 8.5.2 Replacing fuel filter element 1-26 8.5.3 Changing front axle case oil 1-26

TABLE OF CONTENTS 8.6 Every 600 hours ............................... 1-27

8.10.4 Replacing fuse ...................... 1-31

8.6.1 Adjusting front axle pivot ...... 1-27

9. TIRES ........................................................ 1-32

8.6.2 Adjusting procedure .............. 1-27

9.1 Inflation pressure ............................. 1-32

8.7 Every 800 hours ............................... 1-27

9.2 Tread .................................................. 1-33

8.7.1 Adjusting engine valve clearance ................................................. 1-27

9.2.1 Front wheels ........................... 1-33

8.8 Every 1 year ...................................... 1-27 8.8.1 Replacing air cleaner element ................................................. 1-27

9.2.2 Rear wheels ............................ 1-34 9.3 Ballast ................................................ 1-35 9.3.1 Front ballast............................ 1-35

8.9 Every 2 years .................................... 1-28

9.3.2 Rear ballast ............................ 1-35

8.9.1 Flushing cooling system and changing coolant .................... 1-28

9.4 Traveling speed ................................ 1-36

8.9.2 Replacing radiator hose (water tubes) ...................................... 1-29 8.9.3 Replacing power steering hose ................................................. 1-29 8.9.4 Replacing HST oil line (HST type) ................................................. 1-29 8.9.5 Replacing fuel hose ............... 1-29 8.10 Service as required .......................... 1-30 8.10.1 Bleeding fuel system ........... 1-30 8.10.2 Draining clutch housing water . 130 8.10.3 Replacing light bulb ............. 1-30

CK25/27/30/35

1. TRACTOR IDENTIFICATION

704W101A

(1) Statutory Plate

(2) Identification NO(EU)

(3) Engine Serial Number (5) Transmission Serial Number(MANUAL TYPE) HST

(4) Transmission Serial Number(HST TYPE)

TRANSMISSION

CLUTCH

ENGINE

When contacting your local DAEDONG distributor, always specify engine serial number, tractor serial number and hour meter reading.

GENERAL

GENERAL - TRACTOR IDENTIFICATION

CK35

704W103A

(6) Hour Meter

INDEX

ELECTRIC

HYDRAULIC

STEERING

(6) Hour Meter

704W165A

FRONT AXLE

BARKE

REAR AXLE

CK25/27/30

D704-W01 Jun. 2008

1-3

INDEX

ELECTRIC

HYDRAULIC

STEERING

FRONT AXLE

BARKE

REAR AXLE

HST

TRANSMISSION

CLUTCH

ENGINE

GENERAL

CK25/27/30/35

1-4

GENERAL - DIMENSIONS

2. DIMENSIONS mm (in.)

704W102B

D704-W01 Jun. 2008

GENERAL - SPECIFICATIONS

CK25/27/30/35 GENERAL

3. SPECIFICATIONS MODEL:CK25/CK27 CK25

Forward(At rated engine rpm) km/h (mph) Reverse(At rated engine rpm) km/h (mph) Overall length (includes 3p) mm (in.)

Overall width (minimum tread) mm (in.)

Overall height (from top of ROPS) mm (in.)

Wheel base mm (in.)

Min. ground clearance mm (in.)

Tread Front mm (in.)

Rear mm (in.)

Min. turning radius (without brake) m (Ft.) Weight (with rops) kg (lbs.)

Max. Drawbar load kg (lbs.)

Max. Trailer loading weight kg (lbs.)

NOTE)

ENGINE CLUTCH HST

Cat.I 800 (1,764)

1.5-22.9 (0.93-14.22) 1.32-20.18 (0.82-12.53)

0-21.1 (0-13.11) 0-14.0 (0-8.69)

1.5-22.9 (0.93-14.22) 1.32-20.18 (0.82-12.53) 3,103 (122.2)

REAR AXLE

Position control (Option : Draft, Mixed control) Hydrostatic Power Steering 6-14, 6PR (25 x 8.50-14, 25 x 8.50-14) [Only USA : 7-14 (4PR), 27 x 8.50-15 (4PR), 25 x 8.50-14 (6PR) 9.5-24, 4PR (13.6-16, 15-19.5) [Only USA : 11.2-24 (4PR), 41 x 14.0-20 (4PR), 15 x 19.5 (6PR) 0-21.1 (0-13.11) 0-14.0 (0-8.69)

BARKE

Rear AG.(TURF,INDUSTRIAL)

Live

50.1 (13.24) / 1st : 32.9 (8.7), 2nd : 17.2 (4.54)

/min (gpm) 3-point hitch Maximum lifting capacity (24in. aft of hitch) kg (lbs) Hydraulic lift control system Steering Front AG.(TURF,INDUSTRIAL)

Live Transmission 540 rpm at 2,520 engine rpm / (Option 1,000 rpm) (Option 2,000 rpm at 2,499 engine rpm) Gear (Tandem)

TRANSMISSION

Transmission (rpm) (rpm)

FRONT AXLE

Differential lock Brake P.T.O Rear Mid Pump Pump capacity

HST HST MANUAL TD1300LXE 3A139LWH 3A139LWM Vertical, water-cooled, 3-cylinder diesel 25 (18.7) 28 (20.7) 19 (14.2) 18 (13.4) 20.5 (15.3) 21.7 (16.2) 1,299 (79.3) 1,393 (85.0) 2,600 30 (7.9) Dry dual Dry single Dry dual Dry single Synchro shuttle Hydrostatic Drive Synchro shuttle Hydrostatic Drive 8F 8R 8F 8R INF.3 INF.3 (EU-option:16F16R) (EU-option:16F16R) Standard Wet disc type

1,387 (54.6) 2,460 (96.8) 1,680 (66.1) 351 (13.82) 1,105 (43.5) 970-1,302 (38.2-51.3) 2.9 (9.5) 1,380 (3,042)

1,386 (3,055) 1,380 (3,042) 500 (1,102)

1,000 (2,204)

1,386 (3,055)

STEERING

Model Type Engine gross HP (kW) P.T.O HP (kW) Displacement cc (cu.in) Rated revolution r.p.m min-1 Fuel tank capacity (gal.)

Clutch Transmission Speeds

CK27

MANUAL TD1300LXA

HYDRAULIC

Other spec.

Dimensions Traveling speeds

Standard tire size

Hydraulic system

Drive train

Engine

Model

1,000 (2,204)

1. USA-only USA, EU-only Europe, AU-Australia, New zealand, etc.

INDEX

ELECTRIC

2. The specifications are subject to change for the purpose of improvement without any notice.

D704-W01 Jun. 2008

1-5

GENERAL - SPECIFICATIONS

3. SPECIFICATIONS MODEL:CK30/CK35 CK30

Dimensions Traveling speeds

Standard tire size

Hydraulic system

Drive train

Engine

Model

Other spec.

HYDRAULIC

STEERING

FRONT AXLE

BARKE

REAR AXLE

HST

TRANSMISSION

CLUTCH

ENGINE

GENERAL

CK25/27/30/35

Model Type Engine gross HP (kW) P.T.O HP (kW) Displacement cc (cu.in) Rated revolution r.p.m min-1 Fuel tank capacity (gal.)

Clutch Transmission Speeds Differential lock Brake P.T.O Rear Mid Pump Pump capacity

Transmission (rpm) (rpm)

Live

Cat.I

3-point hitch Maximum lifting capacity (24in. aft of hitch) kg (lbs) Hydraulic lift control system Steering Front AG.(TURF,INDUSTRIAL)

800 (1,764) Position control (Option : Draft, Mixed control) Hydrostatic Power Steering 7-14 (4PR), (27 x 8.50-15, 25 x 8.50-14

Rear AG.(TURF,INDUSTRIAL)

NOTE)

Live Transmission 540 rpm at 2,520 engine rpm / (Option 1,000 rpm) (Option 2,000 rpm at 2,499 engine rpm) Gear (Tandem) 50.1 (13.24) / 1st : 32.9 (8.7), 2nd : 17.2 (4.54)

/min (gpm)

Forward(At rated engine rpm) km/h (mph) Reverse(At rated engine rpm) km/h (mph) Overall length (includes 3p) mm (in.)

Overall width (minimum tread) mm (in.)

Overall height (from top of ROPS) mm (in.)

Wheel base mm (in.)

Min. ground clearance mm (in.)

Tread Front mm (in.)

Rear mm (in.)

Min. turning radius (without brake) m (Ft.) Weight (with rops) kg (lbs.)

Max. Drawbar load kg (lbs.)

Max. Trailer loading weight kg (lbs.)

CK35

HST HST MANUAL 3A150LWH 3A165LWH 3A165LWM Vertical, water-cooled, 3-cylinder diesel 30 (22.4) 34 (25.4) 22 (16.4) 26.5 (19.8) 23 (17.2) 27.6 (20.6) 1,500 (91.5) 1,467 (100.5) 2,600 30 (7.9) Dry single Dry dual Dry dual Dry single Synchro shuttle Hydrostatic Drive Synchro shuttle Hydrostatic Drive 8F 8R 8F 8R INF.3 INF.3 (EU-option:16F16R) (EU-option:16F16R) Standard Wet disc type MANUAL 3A150LWM

11.2-24, 4PR, (41 x 14.0-20, 15 x 19.5) 1.5-22.9 (0.93-14.22) 1.32-20.18 (0.82-12.53)

0-21.1 (0-13.11) 0-14.0 (0-8.69)

1.5-22.9 (0.93-14.22) 1.32-20.18 (0.82-12.53) 3,103 (122.2)

0-21.1 (0-13.11) 0-14.0 (0-8.69)

1,387 (54.6) 2,460 (96.8) 1,680 (66.1) 351 (13.82) 1,105 (43.5) 1,054-1,302 (41.5-51.3) 2.9 (9.5) 1,380 (3,042)

1,386 (3,055) 1,380 (3,042) 500 (1,102)

1,500 (3,306)

1,386 (3,055)

1,500 (3,306)

1. USA-only USA, EU-only Europe, AU-Australia, New zealand, etc.

INDEX

ELECTRIC

2. The specifications are subject to change for the purpose of improvement without any notice.

1-6

D704-W01 Jun. 2008

GENERAL - LUBRICANTS, FUEL AND COOLANT

CK25/27/30/35 GENERAL

4. LUBRICANTS, FUEL AND COOLANT To prevent serious equipment damage, use only genuine DAEDONG fluids, oils and greases, or equivalents.

1

Locations

Capacities MANUAL

Fuel

Lubricants

HST

30 (7.9 U.S.gal.)

ENGINE

No.

No.2-D diesel fuel No.1-D diesel fuel if temperature is below -10°C (14°F)

2

Coolant

3

Engine crankcase

CK25/CK27/CK35 : 7.4 (2.0 U.S.gal.) Fresh clean water with anti-freeze

Front axle case

6

Greasing Battery terminal

SAE20, SAE10W-30 or 10W-40

Below 0°C (32°F)

SAE10W, SAE10W-30 or 10W-40

(7.93 U.S.gal.)

4.5 (1.19 U.S.gal.)

TRANSMISSION

SAE30, SAE10W-30 or 10W-40

0 to 25°C (32 to 77°F)

30

27 (7.13 U.S.gal.)

5

Above 25°C (77°F)

Mobilfluid 423 or 424 Exxonmobil

Exxon Hydraul 560

Shell

DONAX-TD/TD Plus

BP

Tractran UTH

SAE 90 gear oil or transmission case oil

No. of greasing points

Capacity

Type of grease

2

Moderate amount

Multipurpose type grease

HST

Transmission case

Engine oil: API Service Classification CC or CD

REAR AXLE

4

5.8 (1.53 U.S.gal.)

CLUTCH

CK30 : 7.8 (2.1 U.S.gal.)

WARNING

BARKE

Check the oil level regularly.

Correct the oil level, if needed, before operating.

Always check and add oil with the tractor on a flat, level surface.

To prevent personal injury, always stop the engine and set the parking brake before performing any kind of service.

INDEX

ELECTRIC

HYDRAULIC

STEERING

FRONT AXLE

D704-W01 Jun. 2008

1-7

GENERAL - TIGHTENING TORQUES

5. TIGHTENING TORQUES 5.1 GENERAL USE SCREWS, BOLTS AND NUTS If the tightening torques are not specified for some screws, bolts and nuts in this manual, tighten them according to the table below.

Indication on top of bolt

4

Material of bolt Material of opponent part Unit

No-grade or 4T

7

SS400, S20C Ordinariness

7T

9

9T

SCr435, SCM435

S43C, S48C

Ordinariness

Aluminum

Ordinariness

Aluminum

Nm kgf-m lb-ft

Nm kgf-m lb-ft

Nm

kgf-m lb-ft

Nm

kgf-m lb-ft

Nm

kgf-m lb-ft

M6 (6 mm, 0.24 in.)

7.85 ~ 9.31

0.80 ~ 0.95

5.79 ~ 6.87

7.85 ~ 8.82

0.80 ~ 0.90

5.79 ~ 6.50

9.81 ~ 11.2

1.00 ~ 1.15

7.24 ~ 8.31

7.85 ~ 8.82

0.80 ~ 0.90

5.79 ~ 6.50

12.3 ~ 14.2

1.25 ~ 1.45

9.05 ~ 10.4

M8 (8 mm, 0.31 in.)

17.7 ~ 20.5

1.8 ~ 2.1

13.1 ~ 15.1

16.7 ~ 19.6

1.7 ~ 2.0

12.3 ~ 14.4

23.6 ~ 27.4

2.4 ~ 2.8

17.4 ~ 20.2

17.7 ~ 20.5

1.8 ~ 2.1

13.1 ~ 15.1

29.5 ~ 34.3

3.0 ~ 3.5

21.7 ~ 25.3

39.3 M10 ~ (10 mm, 0.39 in.) 45.1

4.0 ~ 4.6

29.0 ~ 33.2

31.4 ~ 34.3

3.2 ~ 3.5

23.2 ~ 25.3

48.1 ~ 55.8

4.9 ~ 5.7

35.5 ~ 41.2

39.3 ~ 44.1

4.0 ~ 4.5

29.0 ~ 32.5

60.9 ~ 70.6

6.2 ~ 7.2

44.9 ~ 52.0

62.8 M12 ~ (12 mm, 0.47 in.) 72.5

6.4 ~ 7.4

46.3 ~ 53.5

77.5 ~ 90.2

7.9 ~ 9.2

57.2 ~ 66.5

62.8 ~ 72.5

6.4 ~ 7.4

46.3 ~ 53.5

103 ~ 117

10.5 ~ 12.0

76.0 ~ 86.7

M14 (14 mm, 0.55 in.)

108 ~ 125

11.0 ~ 12.8

79.6 ~ 92.5

124 ~ 147

12.6 ~ 15.0

91.2 ~ 108

167 ~ 704

17.0 ~ 20.0

123 ~ 144

M16 (16 mm, 0.63 in.)

167 ~ 191

17.0 ~ 19.5

123 ~ 141

197 ~ 225

20.0 ~ 23.0

145 ~ 166

260 ~ 304

26.5 ~ 31.0

192 ~ 224

M18 (18 mm, 0.71 in.)

246 ~ 284

25.0 ~ 29.0

181 ~ 209

275 ~ 318

28.0 ~ 32.5

203 ~ 235

344 ~ 402

35.0 ~ 41.0

254 ~ 296

M20 (20 mm, 0.79 in.)

334 ~ 392

34.0 ~ 40.0

246 ~ 289

368 ~ 431

37.5 ~ 44.0

272 ~ 318

491 ~ 568

50.0 ~ 58.0

362 ~ 419

Diameter

5.2 STUD BOLTS Material of opponent part Unit

Ordinariness

Aluminum

Nm

kgf-m

lb-ft

Nm

kgf-m

lb-ft

M8 (8 mm, 0.31 in.)

11.8 ~ 15.6

1.2 ~ 1.6

8.68 ~ 11.5

8.82 ~ 11.8

0.90 ~ 1.2

6.51 ~ 8.67

M10 (10 mm, 0.39 in.)

24.6 ~ 31.3

2.5 ~ 3.2

18.1 ~ 23.1 19.7 ~ 25.4

2.0 ~ 2.6

14.5 ~ 18.8

M12 (12 mm, 0.47 in.)

29.5 ~ 49.0

3.0 ~ 5.0

21.7 ~ 36.1

3.2

23.1

Diameter

31.4

INDEX

ELECTRIC

HYDRAULIC

STEERING

FRONT AXLE

BARKE

REAR AXLE

HST

TRANSMISSION

CLUTCH

ENGINE

GENERAL

CK25/27/30/35

1-8

D704-W01 Jun. 2008

GENERAL - TIGHTENING TORQUES

CK25/27/30/35

SAE GR.5

SAE GR.8

Nominal diameter

kgf-m

lb-ft

Nm

kgf-m

lb-ft

5/16

23.1 ~ 27.8

2.35 ~ 2.84

17.0 ~ 20.5

32.5 ~ 39.3

3.31 ~ 4.01

24.0 ~ 29.0

3/8

47.5 ~ 57.0

4.84 ~ 5.82

35.0 ~ 42.0

61.0 ~ 73.2

6.22 ~ 7.47

45.0 ~ 54.0

1/2

108.5 ~ 130.2

11.07 ~ 13.29

80.0 ~ 96.0

149.2 ~ 179.0

15.22 ~ 18.27

110.0 ~ 132.0

9/16

149.2 ~ 179.0

15.22 ~ 18.27

110.0 ~ 132.0

217.0 ~ 260.4

22.14 ~ 26.57

160.0 ~192.0

5/8

203.4 ~ 244.1

20.75 ~ 24.91

150.0 ~ 180.0

298.3 ~ 358.0

30.44 ~ 36.53

220.0 ~ 264.0

INDEX

ELECTRIC

HYDRAULIC

STEERING

FRONT AXLE

BARKE

REAR AXLE

HST

Nm

TRANSMISSION

Unit

CLUTCH

ENGINE

Grade

GENERAL

5.3 AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS

D704-W01 Jun. 2008

1-9

GENERAL - UNIT CONVERSION TABLE

GENERAL

CK25/27/30/35

6. UNIT CONVERSION TABLE

BARKE

REAR AXLE

HST

TRANSMISSION

CLUTCH

ENGINE

Kgf-m

Nm

lb-ft

Inch

mm

Volume

Pressure

U.S.gal kgf/cm

2

Temperature

kPa

PSI

°C

°F

1

9.8

7.2

1

25.4

1

0.26418

1

98

14.22

-20

-4

2

19.6

14.5

2

50.8

2

0.5

10

980

142.2

-15

5

3

29.4

21.7

3

76.2

4

1.1

20

1960

284.4

-10

14

4

39.2

28.9

4

101.6

6

1.6

30

2940

426.6

-5

23

5

49

36.2

5

127

8

2.1

40

3920

568.8

0

32

6

58.8

43.4

6

152.4

10

2.6

50

4900

711

5

41

7

68.6

50.6

7

177.8

12

3.2

60

5880

853.2

10

50

8

78.4

57.9

8

203.2

14

3.7

70

6860

995.4

15

59

9

88.2

65.1

9

228.6

16

4.2

80

7840

1137.6

20

68

10

98

72.3

10

254

18

4.8

90

8820

1279.8

25

77

11

107.8

79.6

11

279.4

20

5.3

100

9800

1422

30

86

12

117.6

86.8

12

304.8

22

5.8

110

10780

1564.2

35

95

13

127.4

94.0

13

330.2

24

6.3

120

11760

1706.4

40

104

14

137.2

101.3

14

355.6

26

6.9

130

12740

1848.6

45

113

15

147

108.5

15

381

28

7.4

160

15680

2275.2

50

122

16

156.8

115.7

16

406.4

30

7.9

170

16660

2417.4

55

131

17

166.6

123.0

17

431.8

32

8.5

180

17640

2559.6

60

140

18

176.4

130.2

18

457.2

34

9.0

190

18620

2701.8

65

149

19

186.2

137.4

19

482.6

36

9.5

200

19600

2844

70

158

20

196

144.7

20

508

38

10.0

225

22050

3199.5

75

167

21

205.8

151.9

21

533.4

40

10.6

250

24500

3555

80

176

22

215.6

159.1

22

558.8

42

11.1

275

26950

3910.5

85

185

23

225.4

166.4

23

584.2

44

11.6

300

29400

4266

90

194

24

235.2

173.6

24

609.6

46

12.2

325

31850

4621.5

95

203

25

245

180.8

25

635

48

12.7

350

34300

4977

100

212

INDEX

ELECTRIC

HYDRAULIC

STEERING

FRONT AXLE

Length

Torque

1-10

D704-W01 Jun. 2008

GENERAL - MAINTENANCE SCHEDULE CHART

7. MAINTENANCE SCHEDULE CHART Run hour 100

200

400

Engine oil

Change

2

Engine oil filter

Replace

3

Transmission oil filter

Replace

4

HST oil filter

Replace

5

Transmission fluid

Change

6

Front axle oil

Change

7

Front axle pivot

Adjust

8

Engine start system

Check

Run age 800 1500 3000

9

Greasing

Apply

Wheel bolt torque

Check

11

Battery condition

Check

12

Air cleaner element

Clean

*1

Adjust

Brake pedal free play

Adjust

17

Radiator hose and clamp

Check

Replace 18

Check

Power steering hose and oil line

Replace 19

Check

Fuel line

#

Replace Check

20

Intake air hose

21

Toe-in

22

Engine valve clearance

Adjust

23

Fuel injection nozzle injection pressure

Check

24

Injection pump

Check

25

Cooling system

26

Coolant

27

Fuel system

Check

*3

28

Fuse

Replace

*3

29

Light bulb

Replace

*3

30

Tire pressure

Check

*3

Replace Adjust

HST

Clutch pedal free play

16

*3

REAR AXLE

15

#

BARKE

Adjust

Replace

*3

# #

Clean

Replace

IMPORTANT FOR INTERVAL •

FRONT AXLE

Fan belt

#

*2

STEERING

14

Remarks

*3

Replace Fuel filter element

2 year

10

13

1 year

ENGINE

1

600

CLUTCH

50

TRANSMISSION

Maintenance interval Item

HYDRAULIC

No.

GENERAL

CK25/27/30/35

must be performed after the initial 50 hours of operation.

*2 Every year or every 5 times of cleaning. *3 Replace only if necessary.

The items listed above (# marked) are registered as emission related critical parts by DAEDONG in the U. S.EPA exhaust emission standards non-road emission regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the above instruction.

INDEX

•

ELECTRIC

*1 The air cleaner should be cleaned more frequently a in dusty condition than in a normal condition.

D704-W01 Jun. 2008

1-11

ENGINE

GENERAL

CK25/27/30/35

GENERAL - CHECK AND MAINTENANCE

8. CHECK AND MAINTENANCE 8.1 DAILY CHECK For your own safety and maximum service life of the machine, make a thorough daily inspection before operating the machine to start the engine.

A. WALK AROUND INSPECTION Look around and under the tractor for such items as loose bolts, trash build-up, oil or coolant leaks, broken or worn parts.

BARKE

REAR AXLE

HST

TRANSMISSION

CLUTCH

CAUTION To avoid personal injury: • Be sure to check and service the tractor on a flat place with the engine shut off and the parking brake “ON”.

8.1.1 CHECKING AND REFUELING 30 (7.9 U.S.gal.)

Fuel tank capacity

CAUTION To avoid personal injury: • Do not smoke while refueling.

• Be sure to stop the engine before refueling.

1. Turn the key switch to “ON”, check the amount of fuel showing on the fuel gauge.

2. Fill fuel tank when the fuel gauge shows 1/4 or less fuel in the tank.

704W110A

(1) Fuel Tank Cap

3. Use No.2-Diesel fuel at all temperatures above -10°C (14°F).

NOTE:

FRONT AXLE

•

Be careful not to spill during refueling. If a spill should occur, wipe it off at once. Fuel on the tractor may cause a fire.

•

To prevent condensation( water) accumulation in the fuel tank, fill the tank before parking the tractor overnight.

INDEX

ELECTRIC

HYDRAULIC

•

STEERING

IMPORTANT

•

Do not permit dirt or trash to get into the fuel system.

Be careful not to let the fuel tank become empty, otherwise air will enter the fuel system, requiring the fuel system to be bled before next engine start.

•

No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE J313 JUN 87)

•

Grade of Diesel Fuel Oil According to ASTM D975

Flash Point °C (°F)

Water and Sediment, Volume %

Carbon Residue On, 10 Percent Residuum, %

Ash, Weight %

Min

Max

Max

Max

52 (125)

0.05

0.35

0.01

Distillation Temperatures, °C (°F) 90% Point

Viscosity Kinematic cSt or mm²/s at 40°C

Viscosity Saybolt, SUS at 100°F

Sulfur, Weight %

Copper Strip Corrosion

Cetane Number

Min

Max

Min

Max

Min

Max

Max

Max

Min

282 (540)

338 (640)

1.9

4.1

32.6

40.1

0.50

No.3

40

1-12

D704-W01 Jun. 2008

GENERAL - CHECK AND MAINTENANCE

CK25/27/30/35 GENERAL

8.1.2 CHECKING ENGINE OIL LEVEL

When using an oil of different maker or viscosity from the previous one, remove all of the old oil.

Never mix two different types of oil.

•

Never run engine is the oil level is low.

ENGINE

IMPORTANT •

CAUTION Be sure to stop the engine before checking the oil level.

704W155B

3. To check the oil level, draw out the dipstick, wipe it clean, replace it, and draw it out again. Check to see that the oil level is between the two notches. If the level is too low, add new oil to the prescribed level at the oil inlet.

(1) Oil Inlet TRANSMISSION

2. Check the engine oil before starting the engine or 5 minutes or more after the engine has stopped.

(2) Dipstick (A) Oil Level is Acceptable Within this Range

HST

1. Park the machine on a flat surface.

(See “LUBRICANTS” in Maintenance Section)

REAR AXLE

8.1.3 CHECKING COOLANT LEVEL CAUTION To avoid personal injury: Do not remove the radiator cap while coolant is hot. When cool, slowly rotate cap to the first stop and allow ample time for excess pressure to escape before removing the cap completely.

BARKE

•

1. Make sure to see that the coolant level is between the “FULL” and “LOW” marks of recovery tank.

2. When the coolant level drops due to evaporation, add water only up to the full level.

(See “Flush Cooling System and Changing Coolant” in every 2 yours maintenance.)

704W112A

(1) Recovery Tank

(A) FULL (B) LOW

STEERING

In case of leakage, add anti-freeze and water in the specified mixing ration up to the full level.

•

Use clean, fresh water and anti-freeze to fill the recovery tank.

•

If water should leak, consult your local DAEDONG Dealer.

INDEX

ELECTRIC

If the radiator cap has to be removed, follow the caution above and securely retighten the cap.

HYDRAULIC

IMPORTANT •

FRONT AXLE

•

CLUTCH

To avoid personal injury:

D704-W01 Jun. 2008

1-13

TRANSMISSION

CLUTCH

ENGINE

GENERAL

CK25/27/30/35

8.1.4 CHECKING HEAD LIGHT, HAZARD LIGHT, ETC. 1. Inspect the lights for broken bulbs and lenses.

2. Replace if broken.

8.1.5 CHECKING SEAT BELT AND ROPS 1. Always check condition of seat belt and ROPS attaching hardware before operating tractor.

2. Replace if damaged.

8.1.6 CLEANING GRILL, RADIATOR SCREEN AND OIL COOLER SCREEN

CAUTION To avoid personal injury:

HYDRAULIC

STEERING

FRONT AXLE

BARKE

REAR AXLE

HST

•

Be sure to stop the engine before removing the screen.

1. Check the front grill and the side screens to be sure they are clean of any debris.

2. Detach the screen and eliminate all the foreign material.

IMPORTANT •

Grill and screen must be clean from debris to keep the engine from overheating and to allow good air intake to the air cleaner.

704W113A

(1) Radiator Screen (2) Oil Cooler Screen (A) DETACH

8.1.7 CHECKING BRAKE PEDALS AND CLUTCH PEDAL 1. Examine the brake and clutch pedals for free travel, and smooth operation.

2. Adjust if free travel is not within specifications: (See “Adjusting Clutch and Brake Pedal” in every 100 hours maintenance.)

NOTE: Brake pedals should be equal when depressed.

8.1.8 CHECKING GAUGES, METER AND EASY CHECKER 1. Examine the instrument panel for broken gauge(s), meter(s) and Easy Checker lamps.

2. Replace if broken.

INDEX

ELECTRIC

GENERAL - CHECK AND MAINTENANCE

1-14

D704-W01 Jun. 2008

GENERAL - CHECK AND MAINTENANCE

CK25/27/30/35 GENERAL

8.2 EVERY 50 HOURS 8.2.1 LUBRICATING GREASE FITTINGS Apply a small amount of multipurpose grease to the following points every 50 hours:

704W117A

704W114A

(1) Grease Fitting (Power Steering Cylinder) (RH, LH) HST

(1) Grease Fitting (Power Steering Cylinder) (RH, LH)

TRANSMISSION

CLUTCH

ENGINE

If you operated the machine in extremely wet and muddy conditions, lubricate grease fittings more often.

704W115 A

704W118A

(1) Grease Fitting (Rear Bracket)

704W116A

(1) Grease Fitting (Top Link)

704W119A

(1) Hydraulic Cylinder

(3) Lift Rod

ELECTRIC

HYDRAULIC

STEERING

(1) Grease Fitting (Brake Lever) (RH, LH)

FRONT AXLE

BARKE

REAR AXLE

(2) Grease Fitting (Front Bracket)

INDEX

(2) Hydraulic Cylinder Support

D704-W01 Jun. 2008

1-15

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