Kioti Daedong DK551 Tractor Service Repair Manual

CONTENTS CHAPTER 1 GENERAL ..................................................................................................................... 1-1 1. TRACTOR INDENTIFICATION ....................................................................................................................... 1-3 2. TRACTOR VIEW ............................................................................................................................................... 1-4 3. GENERTAL PRECATIONS 3.1 ASSEMBLY AND DISASSEMBLY ......................................................................................................... 1-5 3.2 ELECTRICAL SYSTEM ......................................................................................................................... 1-6 3.3 TUBE AND RUBBERS .......................................................................................................................... 1-7 3.4 LUBICANT .............................................................................................................................................. 1-7 4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING ................................................... 1-8 5. SPECIFICATION .............................................................................................................................................. 1-9 6. LUBRICANTS,FUEL AND COOLANT ......................................................................................................... 1-10 7. TIGHTENING TORQUE ................................................................................................................................ 1-11 7.1 GENERAL USE SCREW,BOLTS AND NUTS .................................................................................. 1-11 7.2 STUD BOLTS ....................................................................................................................................... 1-11 7.3 AMERICAN STANDARD SCREW,BOLTS AND NUTS WITH UNC OR UNF THREADS ............ 1-12 8. MAINTENANCE CHECK LIST ...................................................................................................................... 1-13 9. CHECK AND MAINTENANCE ...................................................................................................................... 1-15 9.1 DAILY CHECK ...................................................................................................................................... 1-15 9.2 EVERY 50 HOURS .............................................................................................................................. 1-19 9.3 EVERY 100 HOURS ........................................................................................................................... 1-21 9.4 EVERY 200 HOURS ........................................................................................................................... 1-26 9.5 EVERY 400 HOURS ........................................................................................................................... 1-31 9.6 EVERY 600 HOURS ........................................................................................................................... 1-32 9.7 EVERY 800 HOURS ........................................................................................................................... 1-32 9.8 EVERY 1 YEAR .................................................................................................................................... 1-32 9.9 EVERY 2 YEARS ................................................................................................................................. 1-33 9.10 SERVICE AS REQUIRED ................................................................................................................... 1-35 10.TIRES .............................................................................................................................................................. 1-38

CHAPTER 2 ENGINE ........................................................................................................................ 2-1 1. FEATURE .......................................................................................................................................................... 2-3 2. LUBRICATING SYSTEM ................................................................................................................................. 2-4 3. COOLING SYSTEM .......................................................................................................................................... 2-5 4. FUEL SYSTEM ................................................................................................................................................. 2-6 5. TROUBLESHOOTING ..................................................................................................................................... 2-7 6. SERVICING SPECIFICATION ...................................................................................................................... 2-10 6.1 ENGINE BODY .................................................................................................................................... 2-10 6.2 LUBRICATING SYSTEM ..................................................................................................................... 2-13 6.3 COOLING SYSTEM ............................................................................................................................. 2-14

6.4 FUEL SYSTEM ..................................................................................................................................... 2-14 6.5 TIGHTENING TORQUE ...................................................................................................................... 2-15 7. DISASSEMBLING AND MAINTENANCE ..................................................................................................... 2-16 7.1 SEAPRATING THE ENGINE .............................................................................................................. 2-16 7.2 ENGINE DISASSEMBLED VIEW ...................................................................................................... 2-25 7.3 ENGINE BODY .................................................................................................................................... 2-27 7.4 LUBRICATING SYSTEM ..................................................................................................................... 2-50 7.5 COOLING SYSTEM ............................................................................................................................. 2-52 7.6 FUEL SYSTEM ..................................................................................................................................... 2-54

CHAPTER 3 CLUTCH ....................................................................................................................... 3-1 1. FEATURES ........................................................................................................................................................ 3-3 2. TROBLESHOOTING ........................................................................................................................................ 3-4 3. SPECIFICATIONS,TIGHTENING TROQUES AND SPECIAL TOOLS ...................................................... 3-5 3.1 SPECIFICATIONS ................................................................................................................................. 3-5 3.2 TIGHTENING TORQUES ..................................................................................................................... 3-5 3.3 SPECIAL TOOLS ................................................................................................................................... 3-5 4. CHECK, DISASSEMBLYING AND MAINTENANCE ..................................................................................... 3-6 4.1 ADJUSTMENT OF PEDAL .................................................................................................................... 3-6 4.2 DISASSEMBLING AND ASSEMBLY OF CLUTCH ............................................................................. 3-7 4.3 INSPECTION AND REPAIR ............................................................................................................... 3-13

CHAPTER 4 TRANSMISSION SYSTEM ........................................................................................ 4-1 1. STRUCTURE ................................................................................................................................................... 4-3 1.1 POWER TRAIN DIAGRAM .................................................................................................................... 4-3 1.2 POWER TRAIN ...................................................................................................................................... 4-4 1.3 TRANSMISSION SHIFT LINKAGE STRUCTURE ........................................................................... 4-10 2. TROUBLESHOOTING ................................................................................................................................... 4-15 2.1 TROUBLESHOOTING FOR SHUTTLE SHIFT ................................................................................ 4-15 2.2 TROUBLESHOOTING FOR MAIN SHIFTS SECTION IN OPERATION ERROR ........................ 4-15 2.3 TROUBLESHOOTING FOR AUXILIARY AND CREEP SHIFTS IN OPERATION ERROR ......... 4-16 2.4 TROUBLESHOOTING FOR REAR DIFFERENTIAL GEAR IN OPERATION ERROR ............... 4-16 2.5 TROUBLESHOOTING FOR FRONT WHEEL DRIVE IN OPERATION ERROR ......................... 4-17 2.6 TROUBLESHOOTING FOR PTO CLUTCH IN OPERATION ERROR ......................................... 4-17 2.7 TROUBLESHOOTING FOR PTO IN OPERATION ERROR ........................................................... 4-17 2.8 TROUBLESHOOTING FOR PARKING BRAKE IN OPERATION ERROR .................................... 4-17 3. SPECIFICATIONS .......................................................................................................................................... 4-18 3.1 TIGHTENING TORQUES ................................................................................................................... 4-18 4. DISASSEMBLING AND MAINTENANCE ..................................................................................................... 4-19 4.1 DISASSEMBLING TRANSMISSION .................................................................................................. 4-19 4.2 SERVICING .......................................................................................................................................... 4-54

CHAPTER 5 REAR AXLE .................................................................................................................. 5-1 1. STRUCTURE ................................................................................................................................................... 5-3 2. TROUBLESHOOTING ..................................................................................................................................... 5-4 3. TIGHTENING TORQUE .................................................................................................................................. 5-5 4. DISASSEMBLING AND MAINTENANCE ....................................................................................................... 5-6 4.1 DISASSEMBLING REAR AXLE ............................................................................................................ 5-6 4.2 MAINTENANCE .................................................................................................................................... 5-10

CHAPTER 6 BRAKE .......................................................................................................................... 6-1 1. STRUCTURE ................................................................................................................................................... 6-3 2. TROUBLESHOOTING ..................................................................................................................................... 6-5 3. SPECIFICATIONS ............................................................................................................................................ 6-5 4. TIGHTENING TORQUE .................................................................................................................................. 6-6 5. CHECK,DISASSEMBLING AND MAINTENANCE ........................................................................................ 6-7 5.1 ADJUSTMENT OF THE BRAKE .......................................................................................................... 6-7 5.2 DISASSEMBLING AND ASSEMBLY .................................................................................................... 6-8 5.3 SERVICING .......................................................................................................................................... 6-11

CHAPTER 7 FRONT AXLE ............................................................................................................... 7-1 1. STRUCTURE ................................................................................................................................................... 7-3 2. TROUBLESHOOTING ..................................................................................................................................... 7-4 3. SPECIFICATIONS ............................................................................................................................................ 7-5 4. TIGHTENING TORQUE .................................................................................................................................. 7-7 5. CHECK,DISASSEMBLING AND MAINTENANCE ........................................................................................ 7-8 5.1 CHECK AND MAINTENANCE ............................................................................................................. 7-8 5.2 SEPARATING FRONT AXLE ............................................................................................................... 7-10 5.3 DISASSEMBLING THE FRONT AXLE .............................................................................................. 7-12 5.4 SERVICING .......................................................................................................................................... 7-22

CHAPTER 8 STEERING SYSTEM .................................................................................................. 8-1 1. STRUCTURE ................................................................................................................................................... 8-3 1.1 CHARACTERISTICS ............................................................................................................................. 8-3 1.2 HYDRAULIC CIRCUIT OF POWER STEERING SYSTEM .............................................................. 8-4 1.3 GEAR PUMP .......................................................................................................................................... 8-5 1.4 POWER STEERING UNIT .................................................................................................................... 8-6 1.5 STEERING CYLINDER ........................................................................................................................ 8-7 1.6 OIL FLOW ............................................................................................................................................... 8-8 2. TROUBELSHOOTING ................................................................................................................................... 8-10 3. SPECIFICATIONS .......................................................................................................................................... 8-11 4. DISASSEMBLING AND MAINTENANCE ..................................................................................................... 8-12

4.1 SEPARATING THE HYDRAULIC PUMP ........................................................................................... 8-12 4.2 SEPARATING THE STEERING UNIT ............................................................................................... 8-14 4.3 DISASSEMBLING OF THE STEERING CYLINDER ....................................................................... 8-23 4.4 SERVICING .......................................................................................................................................... 8-24

CHAPTER 9 HYDRAULIC SYSTEM ............................................................................................... 9-1 1. STRUCTURE ................................................................................................................................................... 9-3 1.1 HYDRAULIC OIL FLOW SHEMATIC ................................................................................................... 9-3 1.2 HYDRAULIC CIRCUIT SHEMATIC ..................................................................................................... 9-4 1.3 HYDRAULIC FILTER SHEMATIC ........................................................................................................ 9-5 1.4 HYDRAULICPUMP SHEMATIC ........................................................................................................... 9-5 1.5 POWER STEERING SYSTEM ............................................................................................................. 9-6 1.6 PTO CLUTCH VALVE SYSTEM ........................................................................................................... 9-8 1.7 4WD,Q/T AND Q/T (AB) SYSTEM ........................................................................................................ 9-9 1.8 JOYSTICK VALVE ................................................................................................................................ 9-10 1.9 HORIZONTAL CONTROL SYSTEM (ONLY JP) .............................................................................. 9-11 1.10 HYDRAULIC POWER LIFT SYSTEM ................................................................................................ 9-12 1.11 AUXILIARY CONTROL VALVE (IF EQUIPPED) ............................................................................... 9-13 2. TROUBLINGSHOOTING ............................................................................................................................... 9-14 2.1 JOYSTICK VALVE ................................................................................................................................ 9-14 2.2 HYDRAULIC LIFT SYSTEM ............................................................................................................... 9-15 3. CHECKING,DISASSEMBLING AND MAINTENANCE ............................................................................... 9-16 3.1 HYDRAULIC FILTER .......................................................................................................................... 9-16 3.2 HYDRAULIC PUMP ............................................................................................................................. 9-16 3.3 POWER STEERING UNIT .................................................................................................................. 9-18 3.4 PTO CLUTCH VALVE .......................................................................................................................... 9-19 3.5 4WA,Q/T AND Q/T(AB) VALVE ............................................................................................................ 9-23 3.6 JOYSTICK VALV ................................................................................................................................... 9-27 3.7 HORIZONTAL CONTROL VALVE ...................................................................................................... 9-28 3.8 HYDRAULIC LIFT SYSTEM ............................................................................................................... 9-30

CHAPTER 10 CABIN SYSTEM ...................................................................................................... 10-1 1. STRUCTURE ................................................................................................................................................. 10-3 1.1 HEATER ................................................................................................................................................ 10-3 1.2 AIR-CONDITIONER ............................................................................................................................ 10-4 2. TROUBLESHOOTING ................................................................................................................................... 10-6 3. INSPECTION AND ADJUSTMENTS ......................................................................................................... 10-14

CHAPTER11 ELECTRIC SYSTEM .................................................................................................. 11-1 1. HOW TO WIRING DIAGRAM ........................................................................................................................ 11-3 1.1 WIRE CODE ......................................................................................................................................... 11-3 1.2 WIRE SIZEW ........................................................................................................................................ 11-3 1.3 INSTRUMENT PANEL BULBS .......................................................................................................... 11-4 1.4 RELAY AND SWITCH .......................................................................................................................... 11-5 1.5 MULTIPLE SWITCH ............................................................................................................................ 11-5 1.6 RELAY BOX .......................................................................................................................................... 11-6 1.7 FUSE CHECK ...................................................................................................................................... 11-7 1.8 WIRING DIAGRAM .............................................................................................................................. 11-9 2. INSTRMENT PANEL .................................................................................................................................... 11-11 2.1 SYMBOL DESCRIPTION .................................................................................................................. 11-11 2.2 CIRCUIT DIAGRAM OF INSTRUMENT(USA) ............................................................................... 11-14 3. STSRTING SYSTEM .................................................................................................................................... 11-15 3.1 IGNITION CIRCUIT(WITHOUT THE INSTALLATION OF HORIZONTAL CONTROLLER ....... 11-15 3.2 IGNITION CIRCUIT(HORIZONTAL CONTROL INSTALLATION EXPECTATION ONLY JP ..... 11-16 3.3 MAJOR COMPONENTS ................................................................................................................... 11-17 4. CHARGING SYSTEM ................................................................................................................................... 11-22 4.1 CIRCUIT DIAGRAM ........................................................................................................................... 11-22 4.2 AC (ALTERNATING CURRENT)ALTERNATOR ............................................................................ 11-23 5. ENGINE GLOW PLUG SYSTEM ................................................................................................................ 11-25 5.1 CIRCUIT DIAGRAM ........................................................................................................................... 11-25 5.2 MAJOR COMPONENTS ................................................................................................................... 11-26 6. PTO SYSTEM(ONLY USA) .......................................................................................................................... 11-29 6.1 CIRCUIT DIAGRAM ........................................................................................................................... 11-29 6.2 CIRCUIT DESCRIPTION ................................................................................................................. 11-30 6.3 TROUBLESHOOTING ...................................................................................................................... 11-30 7. ROTARY LEVEL CONTROL INSTALLATION(ONLY JP) ......................................................................... 11-31 7.1 SYSTEM COMPOSITION PARTS .................................................................................................... 11-31 7.2 OUTLINE ............................................................................................................................................ 11-32 7.3 LEVEL CONTROL INSTALLATION FUCTION ............................................................................... 11-34 7.4 ELECTRIC CIRCUIT ........................................................................................................................ 11-36 7.5 TERMINAL ARRANGEMENT TABLE ............................................................................................... 11-37 8. QUECK TURN(ONLY JP) ........................................................................................................................... 11-38 8.1 ELECTRIC CIRCUIT ........................................................................................................................ 11-38 8.2 MAIN PARTS COMPOSITION .......................................................................................................... 11-40 8.3 REPAIRS FOR QUECK TURN1 MALFUCTION ............................................................................ 11-42 9. AIR CONDITIONING SYTEM ...................................................................................................................... 11-43 9.1 CIRCUIT DIAGRAM ........................................................................................................................... 11-43 9.2 MAJPR COMPONENTS .................................................................................................................... 11-44 10.HEATER SYSTEM ........................................................................................................................................ 11-46

TO THE READER

TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of KIOTI (DAEDONG) tractors DK50S/55(DK501/551). It is divided into two parts, “Mechanism” and “Servicing”.

MECHANISM Information on the construction and functions are included. The part should be completely understood before proceeding with troubleshooting, disassembling or servicing.

SERVICING In this section you will find general precautions, maintenance and special tools. The are other sections which include troubleshooting, servicing, specifications lists, disassembling, assembling and servicing that explains in detail procedures, precautions, factory specifications and acceptable limits.

This manual contains the latest production information on illustrations and specifications based on the most up to date production information available at the time of publication.

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

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DK50S/55(DK501/551)

SAFETY FIRST This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and the decals on the machine itself to warn of the possibility of personal injury. It is essential that you read the instructions and safety regulations before you attempt to repair or operate this unit. Read these instructions carefully.

DESCRIPTION

SIGNS

DANGER

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

This mark should be indicated for most dangerous situations only.

WARNING

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

CAUTION

This mark indicates potentially hazardous situation which, if not observed, may result in minor or moderate injury. And this mark can be used as a warning against unsafe activities.

IMPORTANT

This mark indicates emphasis on notable characteristics in working procedures or information on working procedures and technology for convenient use.

NOTE

Gives helpful information.

BEFORE SERVICING AND REPAIRING 1. Read all safety instructions in this manual and be aware of the safety decals on your machine itself.

2. Thoroughly clean your work area and the machine.

3. Make sure the machine is on firm and level ground and that the parking brake is set.

4. Lower the implement to the ground.

5. Stop the engine and remove the key.

6. Disconnect the negative battery cable.

7. Place a “DO NOT OPERATE” tag in operator station.

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SAFETY STARTING 1. Always use the safety start switch to start the engine and never by any other means.

2. Do not alter or remove any part of machine safety system.

3. Before starting the engine, make sure that all shift levers are in neutral positions or in the disengaged positions.

4. Never start the engine unless you are in the operator’s seat.

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TO THE READER SAFETY WORKING 1. Do not operate or service the machine while under the influence of alcohol, medication, or other substances.

2. Never wear loose fitting clothing and always use safety equipment appropriate to the job.

3. Never use improvised tools, parts or procedures.

Use only recommended tools appropriate to the work.

4. Be careful to perform all work safely when servicing is done by two or more people.

5. Always support the machine by safety stands. Never work under the machine that is supported solely by a jack.

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6. Do not touch any rotating or hot parts while the engine is running.

7. Never remove the radiator cap while the engine is running, or immediately after stopping. Only remove radiator cap when it is cool enough to touch with bare hands. Slowly loosen the cap to relieve pressure before removing completely.

8. Escaping fluid (fuel or hydraulic oil) under pressure can penetrate the skin causing serious injury.

Relieve pressure before disconnecting hydraulic or fuel lines. Tighten all connections before applying pressure.

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AVOID FIRES 1. Never smoke or allow flames or sparks in your work area, as fuel is extremely flammable and explosive under certain conditions.

2. Always disconnect the negative battery cable first and reconnect it last to avoid sparks from an accidental short circuit.

3. Battery gas will ignite. Keep sparks and open flame away from the top of battery, especially while charging.

4. Be careful not to spill fuel on the engine.

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DK50S/55(DK501/551) VENTILATE WORK AREA 1. Exhaust contains poisonous carbon monoxide, so you should never run the engine in a closed area. If the engine must be running while performing maintenance, make sure the area is well ventilated.

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PREVENT ACID BURNS 1. Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, clothing and cause blindness if splashed into eyes. Keep electrolyte away from eyes, hands and clothing. If you spill electrolyte on yourself, flush with water, and get medical attention immediately.

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DISPOSE OF FLUIDS PROPERLY 1. Observe relevant environmental protection regulations when disposing of oil, fuel, coolant, electrolyte and other harmful waste. Never pour fluids into the ground, down a drain, or into a stream, pond, or lake.

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TO THE READER PREPARE FOR EMERGENCIES 1. Be sure to keep a first aid kit and fire extinguisher handy at all times.

2. Keep emergency numbers for the nearest fire department, hospital, doctor and ambulance service, near your telephone in case of emergency.

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DK50S/55(DK501/551)

SAFETY DECALS z

The following safety decals are installed on the machine.

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

ROPS

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TO THE READER

CABIN

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(1) Parts No. : T4625-52191

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(2) Parts No. : T4837-51181

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DK50S/55(DK501/551) (3) Parts No. : T4685-52311

(4) Parts No. : T4818-52142

(5) Parts No. : T2325-50743

(6) Parts No. : T4625-52351

(7) Parts No. : T4625-52361

(8) Parts No. : T4625-53191

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TO THE READER (9) Parts No. : T2241-50702

(10) Parts No. : T2445-50724

(11) Parts No. : T4837-51093

(12) Parts No. : T2615-54112

(13) Parts No. : T4818-52132

(14) Parts No. : T2615-55112

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DK50S/55(DK501/551) (15) Parts No. : T4817-52201

(16) Parts No. : T2615-53561

CARE OF DANGER, WARNING AND CAUTION LABELS 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.

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CHAPTER 1

GENERAL

GENERAL

1. TRACTOR IDENTIFICATION When contacting your local KIOTI (DAEDONG) distributor, always specify engine serial number, tractor serial number and hour meter reading.

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(1) Statutory Plate

(2) Identification Plate

(3) Engine Serial Number

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(4) Hour Meter

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DK50S/55(DK501/551)

2. TRACTOR VIEW

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GENERAL

3. GENERAL PRECAUTIONS 3.1 ASSEMBLY AND DISASSEMBLY

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(1) Grease

(4) Assemble Towards to be Forced

(2) Snap Ring for Shaft

(5) Reciprocating

(3) Snap Ring for Hole

(6) Rotating

1. Place the tractor on firm and level ground prior to any service or adjustment.

2. Work with the engine stopped whenever possible.

Be careful when doing any testing that requires the engine to be running.

3. Use only KIOTI (DAEDONG) approved special tools.

Servicing dealers may machine tools to KIOTI (DAEDONG) specifications, if the tool will not be used often.

4. Keep your work area and the tractor clean during all phases of the disassembly and reassembly process.

5. After removal, keep parts clean and organized.

Tighten nuts to mating bolts by hand to keep matched sets together.

11. When assembling an outside snap ring, on a shaft, or an inside snap ring, in a hole, assemble with the head in the direction of force. Reference the above figure.

12.When replacing a new part also replace the associated packing (gasket), bearing(s), and o-ring(s).

Apply grease properly for O-rings and oil seals before assembly.

13.Locate the split portion of any spring pin by referencing the direction of force, like the above figure.

14.Replace any split pin with a new one.

IMPORTANT •

Use packing bond, gasket sealer, equivalent to three bond 1208D.

•

Remove all existing sealer before applying new sealer to the part.

7. Use only approved manufactures cleaning agents for parts cleaning. Hydraulic parts should be cleaned with an approved cleaning oil. Diesel fuel should never be used for cleaning.

•

Apply the bond, sealer, in a bead centered on the sealing flange area. If a bolt hole is encountered, continue bead to the center of the inner sealing surface.

8. Remove all oil and contaminates before performing any measurement of parts.

•

Assemble the parts within 10 minutes of bond, sealer, application. Wait 30 minutes before adding oil to the sealed parts, if applicable.

6. Be careful during disassembly, assembly, and storage of hydraulic parts. Dust and metal chips can contaminate the whole hydraulic system. Keep parts covered whenever possible.

9. Disconnect the battery negative (-) cable before removing or installing any live electrical components.

10.Use only KIOTI (DAEDONG) genuine parts to maintain the performance and safety of your KIOTI (DAEDONG) tractor.

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CHAPTER 1

DK50S/55(DK501/551)

3.2 ELECTRICAL SYSTEM 1. Check all electrical connectors daily for any damage or short circuit at their junctions. In addition, annually schedule a complete electrical system inspection with your local KIOTI dealer.

2. Do not modify or reorganize the wiring harness or the electric field parts.

3. When disconnecting battery cables, disconnect the negative cable first. Reinstall the positive cable first when reinstalling.

NOTE: •

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

4. When disconnecting a connector, grasp the plastic section, not the wiring.

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5. When reconnecting the connector, Insert it until it snaps.

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6. When replacing a broken fuse with a new one, be sure to use the fuse with the correct amperage capacity. Use your owner’s manual to establish the correct capacity.

7. Be sure not to drop sensors and relays. They are fragile.

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GENERAL

3.3 TUBES AND RUBBERS Keep the tubes (hoses) and rubber parts free from oil and other petroleum products. This may cause a change in quality in these parts, and may shorten product life.

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3.4 LUBRICANT During assembly and repair, apply designated lubricant where specified in accordance with this repair manual.

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CHAPTER 1

DK50S/55(DK501/551)

4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING To ensure safety and prevent damage to the machine and surrounding equipment, heed the following precautions in handling electrical parts and wiring.

IMPORTANT •

Check electrical wiring for damage and loosened connection every year. To this end, educate the customer to do his or her own check. At the same time recommend that the dealer performs a periodic check during regular maintenance.

•

Do not attempt to modify or remodel any electrical parts and/ or wiring.

• When removing the battery cables, disconnect the negative cable first. When installing the battery cables, connect the positive cable first.

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GENERAL

5. SPECIFICATIONS

Model Model

Engine gross

HP (kW)

P.T.O

HP (kW)

Displacement

cc (cu.in)

Rated revolution

4A 200TA

4A 220T

50 (37.3)

55 (41.0) 38 (28.3)

1,999 (122.0)

2,197 (134.1) 2,600

r.p.m min-1

68 (18.0)

(gal.)

Fuel tank capacity

Dry type single stage

Clutch

Drive train

DK55(DK551)

Liquid-cooled, 4-cylinder diesel

Type Engine

DK50S(DK501)

Transmission

Synchro

Speeds

12F 12R

Differential lock

Standard

Brake

Wet disc type

P.T.O

Trans

Rear

(rpm)

2 speed (540/1000 rpm) Only USA 3 speed (540/750/1000 rpm)

Pump capacity (Max. flow rate)

/min (gpm)

Main pump 37.4 (9.88) Power steering pump 16.4 (4.33)

Hydraulic system

3-point hitch

Cat.I

Maximum lifting capacity

kgf (lbs.)

Hydraulic lift control system

1,204 (2,654) Position, draft and Mixed control

Steering Standard tire size

Hydrostatic

Front Rear (AG, TURF, INDUSTRIAL) Forward (At rated engine rpm)

Traveling speeds

Dimensions

Reverse (At rated engine rpm)

km/h (mph)

km/h (mph)

9.5 - 18, 6PR

9.5 - 20, 6PR

13.6 - 28, 6PR

14.9 - 28, 6PR

0.40 ~ 26.6

0.42 ~ 27.80

(0.25 ~ 16.53)

(0.26 ~ 17.27)

0.3 ~ 22.0

0.34 ~ 23.01

(0.19 ~ 13.67)

(0.21 ~ 14.30)

Overall length (with 3p)

mm (in.)

3,266 (128.6)

3,296 (129.8)

Overall width (minimum tread)

mm (in.)

1,644 (64.7)

1,760 (69.3)

Overall height (Top of Cabin)

mm (in.)

2,453 (96.6)

2,485 (97.86)

Wheel base

mm (in.)

Min. ground clearance

mm (in.)

413 (16.3)

445 (17.5)

Tread

Front

mm (in.)

1,272 (50.1)

1,398 (55.0)

Rear

mm (in.)

1,292 (50.9)

1,352 (53.2)

Min. turning radius (with brake) Weight (with Cabin)

m (Ft.) kgf (lbs.)

1,920 (75.6)

2,780 (109.4) 2,110 (4,652)

2,143 (4,724)

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

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CHAPTER 1

DK50S/55(DK501/551)

6. LUBRICANTS, FUEL AND COOLANT No.

Locations

Capacities

Lubricants No.2-D diesel fuel

1

Fuel

68

(18.0 U.S.gal.)

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

2

Coolant

8.9

(2.35 U.S.gal.)

Fresh clean water with anti-freeze Engine oil: API Service Classification CC or CD Above 25°C (77°F)

3

Engine crankcase

8.5

(2.25 U.S.gal.)

SAE30, SAE10W-30 or 10W-40

0 to 25°C (32 to 77°F) SAE20, SAE10W-30 or 10W-40 Below 0°C (32°F)

SAE10W, SAE10W-30 or 10W-40

Multi-gradetransmission fluid the fluid listed below or equivalent are recommended.

4

5

Transmission case

Front axle case

38.0

8.2

(10.04 U.S.gal)

(2.17 U.S.gal.)

Applying grease Hydraulic control lever shaft section 3 point link section 6

Exxonmobil

Mobilfluid 423 or 424 Exxon hydraul 560

Shell

DONAX-TD/TD Plus

BP

Tractran UTH

SAE 90 gear oil Capacity Small quantity Until grease exits

Type of grease SAE multi-purpose type grease

Brake pedal link section Bracket section in front and rear of the front axle Clutch release hub

1-10

Supply when removed

A13-WOO Dec. 2004

GENERAL

7. TIGHTENING TORQUES 7.1 GENERAL USE SCREWS, BOLTS AND NUTS Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be tightened according to the table below.

Indication on top of bolt

4

Material of bolt

7

No-grade or 4T

SS400, S20C

9

7T

9T

SCr435, SCM435

S43C, S48C

Material of opponent part

Ordinariness

Aluminum

Ordinariness

Aluminum

Ordinariness

Unit Diameter

N·m kgf·m lbf·ft

N·m kgf·m lbf·ft

N·m kgf·m lbf·ft

N·m kgf·m lbf·ft

N·m kgf·m lbf·ft

7.85 M6 ~ (6 mm, 0.24 in.) 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

17.7 M8 ~ (8 mm, 0.31 in.) 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

108 M14 ~ (14 mm, 0.55 in.) 125

11.0 ~ 12.8

79.6 ~ 92.5

124 ~ 147

12.6 ~ 15.0

91.2 ~ 108

167 ~ 196

17.0 ~ 20.0

123 ~ 144

167 M16 ~ (16 mm, 0.63 in.) 191

17.0 ~ 19.5

123 ~ 141

197 ~ 225

20.0 ~ 23.0

145 ~ 166

260 ~ 304

26.5 ~ 31.0

192 ~ 224

246 M18 ~ (18 mm, 0.71 in.) 284

25.0 ~ 29.0

181 ~ 209

275 ~ 318

28.0 ~ 32.5

203 ~ 235

344 ~ 402

35.0 ~ 41.0

254 ~ 296

334 M20 ~ (20 mm, 0.79 in.) 392

34.0 ~ 40.0

246 ~ 289

368 ~ 431

37.5 ~ 44.0

272 ~ 318

491 ~ 568

50.0 ~ 58.0

362 ~ 419

7.2 STUD BOLTS Ordinariness

Material of opponent part Unit

Aluminum

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·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

A13-WOO Dec. 2004

31.4

1-11

CHAPTER 1

DK50S/55(DK501/551)

7.3 AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS SAE GR.5

Grade

SAE GR.8

Unit

Nominal diameter

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·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

1-12

A13-WOO Dec. 2004

GENERAL

8. MAINTENANCE CHECK LIST Period

After Purchase

Indication On Hour Meter

Important

No. 1 2 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1500 3000 year years

Item 1

Engine oil

Change

z

z

2

Engine oil filter

Replace

z

z

z z

z

z z

z

z

3

Transmission oil filter

Replace

z

z

z

z

4

Transmission fluid

Change

5

Front axle case oil

Change

6

Front axle pivot

Adjust

z

7

Engine start system

Check

z z z z z z z z z z z z z z z z

-

z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z

z

z

z

z

z

z

z

z

8

Greasing

9

Wheel bolt torque

Check

10

Battery condition

Check

z

z

z

z

z

z

z

z

Clean

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

11

Air cleaner element

z

Replace Check

12

Fuel filter element

13

Fan belt

Adjust

z

z

z

z

z

z

z

z

14

Clutch

Adjust

z

z

z

z

z

z

z

z

15

Brake

Adjust

z

z

z

z

z

z

z

z

16

Radiator hose and clamp

17

18

Power steering oil line

Check

z

z

z

z

z

z

z

z

z

z

z

z

Replace Check

z

Replace Check

Fuel line

z

Replace

z

z

z

z

z

z z

Replace Check

z

z

z

z

z

z

z

z

19

Intake air line

20

Toe-in

Adjust

21

Engine valve clearance

Adjust

22

Fuel injection nozzle injection pressure

Check

z z

23

Injection pump

Check

z

24

Cooling system

Flush

z

25

Coolant

Change

z

26

Fuel system

27

Fuse

Replace

28

Light bulb

Replace

A13-WOO Dec. 2004

z

Replace

Bleed

z

Service as required

1-13

CHAPTER 1

DK50S/55(DK501/551) Period

After Purchase

Indication On Hour Meter

Important

No. 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1500 3000

Item 29

Air conditioner condenser net

30

Air conditioner belt Replace tension

31

Air conditioner filter

32

1

2

year years

Daily

Clean z

z

z

z

Clean

z

z

z

z

Condensor blocked

Check

z

z

z

z

33

Air conditioner hose and pipe

Check

z

34

Cabin rubber

Check

z

35

Lubrication system

Check

36

Washer liquid

Check

37

Refrigerant capacity

Check

Service as required

IMPORTANT •

The jobs indicated by must be done after the first 50 hours of operation. *1 Air cleaner should be cleaned more often in dusty conditions than in normal conditions. *2 Every year or every 6 times of cleaning. *3 Replace only if necessary. *4 When the battery is used for less than 100 hours per year, check the fluid level annually.

•

The items listed above (@ marked) are registered as emission related critical parts by DAEDONG in the US.EPA 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.

Please see the Warranty Statement in detail.

1-14

A13-WOO Dec. 2004

GENERAL

9. CHECK AND MAINIENANCE 9.1 DAILY CHECK Walk Around Inspection

For your own safety and maximum service life of the machine, make a thorough daily inspection before operating the machine to start the engine.

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

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”.

A. CHECKING AND REFUELING Fuel tank capacity

68 (18.0 U.S.gal.)

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.

A13W112A

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

(1) Fuel Tank Cap

NOTE:

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.

•

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.

•

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

A13-WOO Dec. 2004

1-15

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