Daedong DSC48 Workshop Manual Download Page 78 | Manualshive

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Daedong DSC48 Workshop Manual Download Page 78

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Apr. 2007

DSC48

1.1 APPEARANCE

417W201A

The KIOTI engine is a vertical, water-cooled, 4-cycle, and
four-cylinder diesel engine. It integrates KIOTI's foremost
technologies. With swirl combustion chamber, BOSCH K
type fuel injection pump, and well-balanced designs, this
engine features great power, low fuel consumption, and
less vibration and noise.

1. GENERAL

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Summary of Contents for DSC48

Page 1: ...DSC48 COMBINE HARVESTER WORKSHOP MANUAL...

Page 2: ......

Page 3: ...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 KIOTI has a principle to app...

Page 4: ......

Page 5: ...TABLE OF CONTENTS CHAPTER 1 GENERAL CHAPTER 2 ENGINE CHAPTER 3 REAPING UNIT CHAPTER 4 THRESHING UNIT CHAPTER 5 DRIVING CHAPTER 6 HYDRAULIC CHAPTER 7 ELECTRICAL CHAPTER INDEX CHAPTER 0 SAFETY FIRST...

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Page 7: ...Driving 0 10 3 2 1 Driving on a road 0 10 3 2 2 Driving on a narrow rural path bumpy road or slope 0 10 3 2 3 Stopping and parking 0 10 3 2 4 Loading and unloading the combine harvester to the transpo...

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Page 9: ...n your knowledge with additionally supplied service information for optimal service IMPORTANT This mark indicates emphasis on information which can be confused when servicing If this information is no...

Page 10: ...FETY EQUIPMENT Be sure to keep a first aid kit and fire extinguisher handy at all times 2 2 5 CLEAN WORKING AREA Keep the working area clean before and during work If any oil or fuel is spilled it sho...

Page 11: ...sary 2 4 AVOID FIRES Never smoke or allow flames in your work area when servicing the fuel system T46W010A T46W011A T46W012A Keep flames or sparks away from the spray paint or fuel containers and be c...

Page 12: ...arks 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 ca bles with metal for test Use only tester when...

Page 13: ...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 d...

Page 14: ...old turbocharger etc only when they are not hot Do not open the radiator cap when the radiator is hot Hot coolant or steam can be surged leading to a seri ous scald 2 10 PREVENTION OF SCALD T46W027A T...

Page 15: ...ing the engine When starting the engine in an enclosed space venti late the area by opening doors or windows Apply the parking brake on safe and level ground and stop the engine If a safety label on t...

Page 16: ...RAL PATH BUMPY ROAD OR SLOPE Remain at a low speed when driving on a narrow rural or bumpy road Do not get too close to the edge of a road to avoid ve hicles coming in the opposite direction Do not dr...

Page 17: ...e driving 3 3 3 STORAGE AFTER DAILY WORK IS COMPLETED Apply the parking brake on level ground and stop the engine Let the engine cool down before inspecting parts around the engine 3 4 AFTER COMPLETIN...

Page 18: ...ch operation Repair it immediately as nec essary Check and repair the combine harvester every season An unexpected accident may happen due to the poor servicing 417W111A Never let any passenger ride m...

Page 19: ...fuel hose or leakage If there is any leak on the hose replace it with a new one Replace the fuel hose every 2 years Keep the area around the battery clean It can catch fire 417W115A Do not open the ra...

Page 20: ...cover and other parts removed for inspection and repair should be installed again after the work is done You can be trapped or entangled into the engine system and get injured 417W119A Avoid abrupt tu...

Page 21: ...he engine before opening the body cutter binder dust proof cover and grain tank Park the combine harvester on level ground before opening any cover Engage the prop after opening body cutter and binder...

Page 22: ...curred when not followed Do not allow anyone especially children to come near the combine harvester before starting the engine If anyone including a child approaches the combine har vester an accident...

Page 23: ...cornering Drive off at a low speed 2 000 rpm When turning move the main shift lever to the low speed position The combine harvester can roll over 417W126A Follow the traffic rules when driving on a r...

Page 24: ...at night If it is inevitable turn on the headlamps and work lamp It can cause an accident overturn or fall resulting in an injury or even death 417W129A If the hopper is used an assistance should use...

Page 25: ...rection Do not drive on a soft edge of a road or a grass covered shoulder Drive at a low speed with care when it is raining or after rain The edges can collapse and the combine harvester can roll over...

Page 26: ...he hooks on the ramps are securely engaged The combine harvester can lose balance and overturn 417W135A Drive the combine harvester backward to load it up to the transporting vehicle Move forward to u...

Page 27: ...the combine harvester is secured on the deck The combine harvester may abruptly move and cause an injury or accident 417W139A Secure all covers when loading the combine harvester onto the transportin...

Page 28: ...catch fire 417W142A Lay a cover on the combine harvester after the muffler and engine cool down It can catch fire 417W143A Do not open the radiator cap if the radiator is hot Stop the engine and let...

Page 29: ...t proof cover and grain tank with the prop when they are open You can be trapped into the rotating part and get injured 417W146A Do not run the engine with the body cutter binder dust proof cover and...

Page 30: ...e engine apply the parking brake and remove the ignition key Replenish each part with fuel oil and fluid for long term storage Children may climb up to the combine harvester which can lead to an accid...

Page 31: ...location are as follows Part numbers appear at the bottom of decals 12 1 LOCATION OF DECALS 417O121A 1 Label muffler warning 2 Label radiator 3 Label caution fan 4 Label muffler 5 Label fuel warning 6...

Page 32: ...mbine Caution C7610 62181 Under this cover there is a spinning part that can cause serious injuries Do not put your hand under this cover when operating the combine Before performing any inspection ad...

Page 33: ...xiliary acceleration lever into any position except the neutral position When the auxiliary accelerator lever engages into the neutral position the HST hydraulic value does not work Therefore if the p...

Page 34: ...el C7331 64221 For the LOCK position secure fasten the plate FASTENING Unlock Operation Up Down Lock Adjustment C7341 55131 Before adjusting or cleaning up the cutter shut off the engine first Do not...

Page 35: ...perate slowly Do not operate the main shift lever on the ramp To change direction return to the ground or the truck first Only use standard ramp that is 4 times the length of the machine and equipped...

Page 36: ...ir it may slip suddenly and cause casualty Secure the safety locating device on the lifting oil tank Put chocks like wood under the header to prevent it from slipping before carrying out inspection an...

Page 37: ...ce Install in sequence according to the order 7 6 5 4 3 2 1 mentioned above Caution C7343 51741 Fire extinguisher G Fire extinguisher must be available during operation User Guide for the Dry Powder F...

Page 38: ...MEMO...

Page 39: ...bolts and nuts 1 14 1 7 2 Stud bolts 1 14 1 7 3 American standard screws bolts and nuts with UNC or UNF threads 1 15 1 8 Unit conversion table 1 16 1 9 Check and maintenance 1 17 1 9 1 Check before s...

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Page 41: ...IDENTIFICATION 3 Chassis Number 1 Manufacturing Label 2 Engine Serial Number When contacting your local KIOTI distributor always specify its model number serial number engine model and manufac turing...

Page 42: ...ing speed m s Forward 195 Reverse Low speed 0 0 86 Average 0 1 22 Drive 0 1 65 Reaping unit Reaping width mm 1 450 Reaping rows 4 Stripper harvester with lifting device Hydraulic model Reaping height...

Page 43: ...ximum harvesting speed No weeds above the cutting line All crops must be in upright position Natural height must be between 650 1300 mm Spike length must not be greater than 250 mm Water content of gr...

Page 44: ...r U U U Every 100 hr Check Every 300 hr Change Fan belt z U z U U Every 100 hr Check Every 500 hr Change Run hour meter cable Every 200 hr Check Every 800 hr Change Accelerator wire Every 100 hr Check...

Page 45: ...100 hr Check Every 400 hr Change Pick up chain z U z U z Every 100 hr Check Every 400 hr Change Cutter blade U U U U U Every 100 hr Check Every 200 hr Change Cutter blade axle slave wheel bearing bear...

Page 46: ...assembling Threshing Unit Threshing roter belt z U z U Every 100 hr Check Every 500 hr Change Drive belts z U z U Every 100 hr Check Every 500 hr Change Threshing chain z U z U Every 100 hr Check Ever...

Page 47: ...essing cable U Every 500 hr Check Every 1000 hr Change Threshing chain guide Every 500 hr Check Every 1000 hr Change Rail deck combination Every 1000 hr Change Threshing rotor left plank Every 1000 hr...

Page 48: ...aner element Driving unit Transmission case oil U U U U Amount of oil in oil tank Hydrostatic transmission U U U U Grease in the threshing cam clutch Re grease when disassembled Reaping unit Oil in th...

Page 49: ...EA Tightening nuts of rocker shaft 1 2 and 3 M8 7T Threshing unit tension arm shaft Threshing cylinder tension arm shaft Driving unit Hex captive bolts of flywheel coupling 4EA Electronic pick up sens...

Page 50: ...e case gasket Transmission case gasket Vehicle speed sensor gasket Rubber cap and oil seal of reaping drive pulley Seal plug on the end of No 1 shaft of the transmission case LH Rubber caps on front a...

Page 51: ...gine oil 15 C or higher 30 or 15W 40 for the diesel engine oil 8 0 Below 15 C 15W 40 for the diesel engine oil Transmission oil Daedong TF65 7 1 Hydrostatic transmission oil Daedong TF65 or Shell DoNA...

Page 52: ...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 M12 12 mm 0 47 in 62 8 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...

Page 53: ...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 16 27 110 0 13...

Page 54: ...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...

Page 55: ...nge Radiator capacity 8 1 Auxiliary coolant tank capacity 1 0 Temperature Type of oil Capacity 15 C or above Diesel oil 30 or 15W 40 8 0 Below 15 C 15W 40 for diesel engine If it is difficult to purch...

Page 56: ...7 B66 8 Blower 9 B108 10 Separator drum 11 Dust discharge fan 12 B55 13 Cutter 14 Rocker 15 B42 16 B101 17 Counter 18 C145 19 B38 A 193 mm B 160 mm C 165 mm D 396 mm E 165 mm F 286 mm G 145 mm No Bel...

Page 57: ...engine run it for approx 2 minutes and stop it Then check the oil level again B CHANGING TRANSMISSION FLUID 1 Remove the drain plug and drain the fluid completely 2 Remove the HST filter and hydrauli...

Page 58: ...its surface is worn or stuck into the belt groove replace it 417W149A 1 Fan drive belt A Pull 2 Mounting bolt B Deflection C REPLACING HYDRAULIC OIL HST FILTER AND TANK FILTER 1 Remove the drain plug...

Page 59: ...the tension bolt to loose the tension of the crawler 2 Unscrew the crawler mounting nut and tighten the ten sility bolt 3 Adjust the distance between the crawler and the 2nd front wheel to be 13 18 mm...

Page 60: ...procket due to deflection or cannot be corrected with the adjusting bolt 417W154A 1 Stem side chain RH A 168 172 mm 6 614 6 772 in H ADJUSTING STEM SIDE FEEDING CHAIN Check and adjustment Check whethe...

Page 61: ...t 417W159A 1 Feeding chain A 150 155 mm 5 906 6 102 in I ADJUSTING FEEDING DEPTH CONTROL CHAIN Check and adjustment Check whether the chain is deflected or the roller is broken or worn Replacement If...

Page 62: ...lutch lever s correct movement without deflection to the upright position from the Disengage position The spring length should be 102 mm when the clutch is in the Engage position 417W161A 1 Turnbuckle...

Page 63: ...compressed air from the inside to the upper and lower sides to remove the dust 2 When carbon or oil is stuck to the element use deter gent to remove them 3 The element should be checked every day 417W...

Page 64: ...BRAKE CABLE Check Check if the cable is deflected or damaged Replacement If it is malfunctioning Adjustment Adjust the power brake cable with the adjusting nut so that the clearance A between the bra...

Page 65: ...A Adjustable hole should not be visible C ADJUSTING STEM SIDE CHAIN LH see page 1 22 D ADJUSTING STEM SIDE FEEDING CHAIN see page 1 22 E ADJUSTING FEEDING DEPTH CONTROL CHAIN see page 1 23 F ADJUSTING...

Page 66: ...re properly engaged during operation Replacement If the blade is worn 1 mm or more diameter 2 mm 417W172A A New blade 170 mm L CHECKING CUTTING BLADE 1 Remove the side covers LH RH 2 Remove the drive...

Page 67: ...t If oil definitely or probably leaks 417W175A 1 Band 2 Engine oil drain hose 1 9 7 EVERY 200 HOURS A CHECKING GRAIN SIDE CHAIN LH Check and adjustment Check if the grain side tension slides properly...

Page 68: ...pin and remove the bolt 3 Open the threshing cylinder Be careful with your safety when attaching or detaching the blade support CAUTION 417W179A 1 Threshing chamber cover 2 Blade support mounting plat...

Page 69: ...it is worn and the liner steel plates are at proper interval Replacement If the blade edge is worn or tilted 417W181A E CHECKING COOLANT PIPE Check and adjustment Check if coolant leaks due to breaks...

Page 70: ...TANK FILTER see page 1 20 D REPLACING HST FILTER see page 1 20 E REPLACING CUTTING BLADE CRANK PIN AND ROLLER Check Check if it is worn or improperly installed Replacement If it is worn 2 mm or more A...

Page 71: ...Wear M REPLACING OIL DRAIN HOSE see page 1 29 N REPLACING ELEVATOR CHAIN CUSHION RUBBER Check Check if it is cracked or worn Replacement If it is severely damaged or worn K CHECKING FRONT COVER Check...

Page 72: ...Adjustable space 417W189A A Replace if it is tilted back 19 mm or more B CHECKING CONVEYOR RAKE STRAW DIS CHARGE CHAIN GRAIN SIDE Check Check if it is worn or deformed Replacement If it is excessively...

Page 73: ...ar A Collapse B Replace if it goes down 2 6 mm or less B REPLACING ELEVATOR TENSION SPROCKET see page 3 11 C REPLACING GRAIN SIDE CHAIN LH see page 3 14 D REPLACING STRAW SIDE CHAIN LH see page 3 14 E...

Page 74: ...ess new one 2 6 mm 417W193A 1 No 1 auger discharge blade 2 No 1 auger discharge blade 3 I CHECKING NO 1 AUGER DISCHARGE BLADE Check Check if it is worn or not properly installed Replacement If the bla...

Page 75: ...4 mm No 1 vertical auger shaft B REPLACING PACKER Check Check if the packers are not at the same level or they are abnormally worn or damaged Replacement If it is abnormally worn or damaged C REPLACIN...

Page 76: ...FRAME LH AND COVER UPPER AND LOWER see page 3 14 F REPLACING ELEVATOR FRAME AND COVER see page 3 11 G REPLACING STRAW SIDE RAIL LH see page 3 14 H REPLACING STRAW SIDE GUIDE PLATE RH see page 3 13 I...

Page 77: ...g water 2 11 2 3 2 Water pump 2 11 2 3 3 Radiator 2 12 2 3 4 Radiator cap 2 12 2 4 Fuel system 2 13 2 4 1 Flow of fuel 2 13 2 4 2 Fuel feed pump 2 13 2 4 3 Fuel injection pump 2 14 2 4 5 Fuel injectio...

Page 78: ...ter cooled 4 cycle and four cylinder diesel engine It integrates KIOTI s foremost technologies With swirl combustion chamber BOSCH K type fuel injection pump and well balanced designs this engine feat...

Page 79: ...chamber Swirl chamber Power NET 48 2 800 HP rpm Max idling speed without load 3 000 rpm Min idling speed without load 1 000 rpm Order of ignition 1 3 4 2 Rotating direction Counterclockwise viewed fr...

Page 80: ...e on the new O ring and oil seal when reassembling When replacing parts use only genuine KIOTI parts to maintain engine performance and safety To prevent oil and water leakage apply non drying ad hesi...

Page 81: ...being heated and expanded by heated exhausted air The KIOTI swirl type combustion chamber is designed for high efficiency combustion and reducing fuel consumption The glow plugs assures easy engine st...

Page 82: ...le journal is supported by a split type bearing The rear journal is supported by split type and thrust type bearings The crankshaft and crank pin bearing have oil holes for lubricant flow 2 1 4 PISTON...

Page 83: ...mshaft 2 Injection pump gear 2 1 7 FUEL CAMSHAFT The fuel camshaft is made of forged steel Its cams are hardened and tempered to increase wear resistance The cams on the fuel camshaft 1 drive the inje...

Page 84: ...mark FI shows the fuel injection timing when they are aligned with the mark of the window on the clutch housing Injection sequence 1 3 4 2 2 1 9 INTAKE AND EXHAUST VALVES The valve and its guide of th...

Page 85: ...cates other parts such as the push rods 11 tappets 12 piston pins and timing gears 2 2 2 OIL PUMP The oil pump is a gear type whose rotors have trochoid lobes The inner rotor 3 has 4 lobes while the o...

Page 86: ...the contacts of the oil switch close to turn on the warning lamp 1 A At low oil pressure 49 kPa 0 5 kgf cm2 7 psi or less B At proper oil pressure 2 2 3 OIL FILTER AND RELIEF VALVE The engine oil forc...

Page 87: ...ore The water pump receives water from the radiator and forces it into the cylinder block The thermostat opens or closes according to the water temperature When the wa ter temperature is high the ther...

Page 88: ...ap is installed on the radiator and pre vents the radiator from being deformed because of the pressure difference between the inside and outside of the radiator A At high pressure over 88 kPa 0 9 kgf...

Page 89: ...in the fuel overflow pipes and returns to the fuel tank 417W226A 1 Inlet valve 6 Diaphragm 2 Push rod 7 Fuel camshaft 3 Tappet a From fuel filter 4 Outlet valve b To injection pump 5 Chamber 2 4 2 FUE...

Page 90: ...er 3 fits in the control sleeve 5 at the driving surface 7 The sleeve is engaged with the control rack which rotates the plunger in the cylin der to control the amount of fuel delivery 417W227A 2 4 3...

Page 91: ...amber from the delivery chamber through the control groove and feed hole 417W230A 1 Slot 4 Delivery chamber 2 Plunger 5 Feed hole 3 Control rack 6 Control groove C AMOUNT OF FUEL DELIVERED A No fuel d...

Page 92: ...pring the nozzle valve is instantly pushed up Then the fuel is injected in a proper quantity into the swirling air in the combustion chamber for combustion Addition or reduction of adjusting shims can...

Page 93: ...engine speeds B OPERATION OF GOVERNOR AT START The steel balls 13 have no centrifugal force As the fork lever 1 4 is pulled by the start spring 1 the control rack pin 14 moves to the maximum injection...

Page 94: ...limit spring are balanced providing stable idling 1 Start spring 14 Control rack 2 Governor spring 1 15 Speed control lever 2 Governor spring 2 16 Idle adjusting spring 4 Fork lever 1 20 Idle adjusti...

Page 95: ...k lever 1 19 Stop lever 14 Control rack TO STOP ENGINE When the stop lever is moved to the STOP position the fork lever 1 4 is moved to the left and the control rack 14 is moved to the non injection p...

Page 96: ...arried to the evacuator 10 where the dust exits the port The fine dust in the air is filtered with the air cleaner element 8 The filtered air flows to the outlet port 6 2 5 3 MUFFLER The exhaust noise...

Page 97: ...ce Repair or replace Replace head gasket tighten cylinder head bolt repair or replace glow plug or nozzle holder Repair or replace Correct or replace timing gear Replace Adjust Starter does not run Ba...

Page 98: ...t Weak or broken relief valve spring Excessive oil clearance of crankshaft bearing Excessive oil clearance of crank pin bearing Excessive oil clearance of rocker arm bushings Oil passage clogged Impro...

Page 99: ...MPa 33 38 kgf cm2 469 540 psi 2 55 MPa 26 kgf cm2 370 psi Item Factory specification Allowable limit Valve clearance cold IN 0 25 mm 0 010 in EX 0 30 mm 0 012 in Valve seat angle IN 1 047 rad 60 EX 0...

Page 100: ...Rocker arm bracket I D 19 0 19 035 mm 0 74803 0 74941 in G TAPPET Item Factory specification Allowable limit Clearance between tappet and guide 0 020 0 062 mm 0 00079 0 00244 in 0 07 mm 0 0028 in Tapp...

Page 101: ...ation Allowable limit Piston pin bore I D 25 000 25 006 mm 0 98425 0 98448 in 25 03 mm 0 9854 in Clearance between 2nd ring and ring groove 0 04 0 08 mm 0 00157 0 00315 in 0 15 mm 0 00591 in 2nd ring...

Page 102: ...g 1 0 040 0 118 mm 0 00157 0 00465 in 0 20 mm 0 0079 in Crankshaft journal O D 51 921 51 940 mm 2 04414 2 04489 in Crankshaft bearing 1 I D 51 980 52 039 mm 2 04646 2 04878 in Clearance between cranks...

Page 103: ...0 0 16 mm 0 0039 0 0063 in 0 2 mm 0 00787 in Clearance between outer rotor and pump housing 0 11 0 19 mm 0 0043 0 0078 in 0 25 mm 0 0098 in Clearance between inner rotor and cover 0 105 0 150 mm 0 004...

Page 104: ...107 9 10 5 11 0 75 9 79 6 Head cover nuts M10 x 1 25 8 8 10 8 0 9 1 1 6 5 8 0 Bearing case bolt 1 M9 x 1 25 46 1 51 0 4 7 5 2 34 0 37 6 Bearing case bolt 2 M10 x 1 25 69 7 73 6 7 0 7 5 50 6 54 2 Flyw...

Page 105: ...earing case cover 18 Engine installation plate 19 Flywheel 20 Speed control plate 21 Stop lever 22 Fan pulley 23 Fork lever assembly 24 Injection pump gear 25 Idle gear 26 Cam gear 27 Tappet 28 Push r...

Page 106: ......

Page 107: ...ridge with a filter wrench Adjust the fan belt tension 3 3 2 EXTERNAL COMPONENTS A CHECKING AND ADJUSTING FAN BELT 1 Measure the deflection by depressing the belt halfway between the fan drive pulley...

Page 108: ...lve clearance for proper air in taking CAUTION Compression pressure Factory spec 33 38 kgf cm2 Allowable limit 26 kgf cm2 Difference be tween cylinders Allowable limit Within 10 417W245A 417W244A VALV...

Page 109: ...ile turning the screwdriver slowly pull the heat seal and nozzle gasket If the heat seal drops repeat the above procedure 4 The heat seal and nozzle gasket should be replaced when the nozzle is remove...

Page 110: ...ve 4 Valve spring 2 Valve spring collet 5 Valve stem seal 3 Valve spring retainer Mark the cylinder number to the tappets to prevent interchanging CAUTION When reassembling Apply a liquid gasket to bo...

Page 111: ...shaft of the en gine stop lever 2 at the right side of the protrusion of the fork lever 1 1 GOVERNOR SPRINGS AND SPEED CONTROL PLATE 1 Separate the governor springs 1 1 and 2 2 from the governor lever...

Page 112: ...ling Apply grease to the crankshaft oil seal lip on the gear case and take care not to damage it when installing Apply a liquid gasket to both sides of the gear case gasket Tightening torque of cranks...

Page 113: ...gn the alignment marks referring to the figure IMPORTANT When removing the oil pump loosen the pump gear nut if the oil pump gear 7 and crank gear 2 do not move CAUTION When reassembling Heat the cran...

Page 114: ...Apply oil to the connecting rod big end bearing cylinder wall and connecting rod cap bolt Insert the rod and piston assembly with the mark on the side of the piston facing the injection pump using a p...

Page 115: ...ston and the mark on the con necting rod to face the injection pump Install the piston rings with their manufacturer s mark facing upward Install the expander in the oil ring with its gap opposite to...

Page 116: ...CASE COVER 1 Loosen the bolt on the inside and then the bolt on the outside Lift both sides of the cover with a screwdriver When reassembling Apply grease to the oil seal lip Be careful not to scratch...

Page 117: ...e bearing case to prevent interchanging IMPORTANT When reassembling Clean the oil passage and parts of the bearing case Apply oil to the journal bearing inserts and bearing case bolts Install the thru...

Page 118: ...quid A 4 Wash away the red permeative liquid on the cylinder head surface with the detergent B after ten minutes 5 Spray the white developer C on the cylinder head sur face 6 If any flaw is found such...

Page 119: ...its seat and hold it with the valve flap per 5 Lap the value seat by turning and flapping its valve back and forth or up and down on the valve seat 6 Remove the compound and clean the valve and its se...

Page 120: ...ker arm I D with an inside micrometer 2 Measure the rocker arm shaft O D with an outside mi crometer 3 If the measurement exceeds the allowable limit replace the rocker arm 4 If the clearance still ex...

Page 121: ...to its ends 2 Measure the clearance A between the cam gear 2 and camshaft stopper 3 3 If the clearance exceeds the allowable limit replace the camshaft stopper 3 1 Camshaft 3 Stopper 2 Cam gear IDLE G...

Page 122: ...an outside mi crometer 2 Measure the idle gear bushings I D with an inside mi crometer 3 If the measurement exceeds the allowable limit replace the bushing REPLACING IDLE GEAR BUSHINGS 1 Press out the...

Page 123: ...otate the camshaft on the V block and get the eccen tricity half of the measurement 3 If the eccentricity exceeds the allowable limit replace the camshaft CAM HEIGHT 1 Measure the height of the camsha...

Page 124: ...ace the bushing 4 If the clearance still exceeds the allowable limit after replacing the bushing replace the piston pin REPLACING CONNECTING ROD SMALL END BUSHING 1 Press out the bushing using a conne...

Page 125: ...CONNECTING ROD ALIGNMENT 1 Remove the crank pin bearing and install the connect ing rod cap 2 Install the piston pin in the connecting rod small end 3 Install the connecting rod on the connecting rod...

Page 126: ...at table And set a dial indicator with its tip on the intermediate journal 2 Rotate the crank shaft on the V block and get the ec centricity half of the measurement 3 If the misalignment exceeds the a...

Page 127: ...bearing 1 to the cylinder block so that its seam faces the exhaust manifold side 1 Seam a 4 2 4 5 mm 417W2A2A OIL CLEARANCE BETWEEN CRANKSHAFT JOURNAL AND BEARING 2 1 Put a plastigage lengthwise in th...

Page 128: ...2 52 Apr 2007 DSC48 417W2A4A 417W2A5A E CYLINDER BORE CYLINDER BORE 1 Measure the cylinder I D at six positions shown in the figure to find the maximum wear Cylinder I D 87 0 0 022 mm 0 0 001 in...

Page 129: ...il passage and oil clearance Reference OIL FILTER AND RELIEF VALVE 1 Drain the engine oil and remove the oil filter to check it 2 Check the condition of the relief valve the seat 2 and ball 1 for dama...

Page 130: ...OR AND LOBE CLEARANCE 1 Measure the clearance between the outer and inner ro tors with a feeler gauge 2 Measure the clearance between the outer rotor and housing with a feeler gauge 3 If the clearance...

Page 131: ...the specified level and warm up the engine 2 Set a radiator tester and raise the water pressure to the specified pressure 3 Check the radiator for water leaks 4 If water leaks from the pin hole repai...

Page 132: ...SEMBLY AND ASSEMBLY WATER PUMP 1 Remove the cooling fan and fan pulley 2 Remove the water pump assembly from the gear case 3 Remove the water pump flange 1 4 Pull out the impeller and water pump beari...

Page 133: ...the shim and retards by adding the shim One shim 0 15 mm corresponds to approx 1 5 of crank angle 2 Delivery valve fuel tightness 1 Remove the injection pipes glow plugs and inlet mani fold And insta...

Page 134: ...essure 3 If the measurement is not within the factory specifica tions adjust the pressure by removing the nozzle and replacing the adjusting washer 1 CAUTION NOTE Pressure variation within 0 1 mm diff...

Page 135: ...the amount of fuel injection should be adjusted with the specified tool CAUTION INJECTION NOZZLE 1 Nozzle holder 1 Secure the nozzle nut 7 with a vise 2 Remove the nozzle holder 1 and take out the in...

Page 136: ...MEMO...

Page 137: ...Adjustment and replacement of stem side chain RH 3 13 1 5 3 Adjustment and replacement of stem side chain LH 3 14 1 5 4 Adjustment and replacement of grain side chain LH 3 14 1 5 5 Adjustment and repl...

Page 138: ......

Page 139: ...2 7 sprocket feeding chain 33 15 sprocket grain side chain RH 34 Feeding propeller shaft 35 47 bevel gear 36 22 bevel gear 37 14 bevel gear 1 38 18 bevel gear 27 39 Blade connecting shaft 40 16 bevel...

Page 140: ......

Page 141: ...tachment work should follow the detachment proce dures in the reverse order 1 Reaping unit stand 2 Reaping unit mounting pin 3 Reaping unit connecting wiring cable 4 Reaping unit mounting bolts 4 EA 5...

Page 142: ...Never touch the blade It may operate abruptly and lead to an accident When removing the cutting blade unit always wear protective gloves The unit should be removed by two persons from the machine by...

Page 143: ...to overlap with the bade blade 2 Loosen two mounting nuts LH RH on the crank rod 3 Rotate the crank rod and adjust the distance between the two crank rod mounting nuts to be within the speci fied valu...

Page 144: ...lied and the crank stop bolt 5 Remove the cutting blade crank 4 from the shaft 7 Remove the oil seal B REPLACEMENT OF CRANK PIN AND ROLLER EVERY 500 HOURS 1 Unscrew the crank pin threaded nut 2 Remove...

Page 145: ...CASE When installing the drive case assembly make sure to align the mating surface of the bearing holder Align with the spline boss in the case 417W312A 1 Cutting blade drive case 2 Cutting blade driv...

Page 146: ...ator tension hook and pulling nut 2 If the measure clearance is not within 0 5 2 5 mm adjust the clearance with the pulling bolt 3 If the chain is loose remove the chain 2 link When assembling Install...

Page 147: ...9 11 1 4 4 ELEVATOR DRIVE 14 SPROCKET SHAFT BEARING 12 SPROCKET 1 Loosen two nuts 1 of the pulling bolt Then remove the tension hook 2 and tension spring 2 Remove the elevator chain 4 3 Remove the sna...

Page 148: ...3 12 Apr 2007 DSC48 1 2 1 4 5 ELEVATOR SHIFT CASE 1 Apply grease on the gear and the shaft 2 When installing the shift plug apply LOCTITE on it 417W321A 1 Elevator shift case 2 Shift plug...

Page 149: ...B REPLACEMENT 1 Loosen the tension nut Do not remove it 2 Remove the split pin from the chain engaged section and remove the chain Make sure to remove the chain to its rotating direction To rotate th...

Page 150: ...grain side frame to remove the grain side frame LH 3 Remove the grain side chain LH by removing its clip 1 Cover 4 Grain side frame LH 2 Bolt 5 Grain side chain LH 3 Conveyor guide 1 Stem side chain...

Page 151: ...f the chain is stretched and the stopper s hole is visible move the stopper so that the shaft contacts the hole If the chain is excessively stretched and cannot be adjusted itself remove the chain 2 l...

Page 152: ...STEM SIDE FEEDING CHAIN A ADJUSTMENT 1 Stem side feeding chain A 162 168 mm 417W332A 1 Stem side feeding chain 2 Adjustment nut A Rotating direction B Direction of split pin B REPLACEMENT 1 Loosen the...

Page 153: ...is broken or worn 1 Lock nut 2 Adjusting bolt A Interval 1 2 mm 417W334A B REPLACEMENT 1 Replace the chain when the chain is visibly worn or damaged sits on the drive sprocket due to its deflec tion...

Page 154: ...ng the mounting bolts for the packer use plain washers 1 Packer 417W336A 1 Mid packer shaft 2 Dust proof cover 1 Cutting blade crank cover The packer shaft has the dust proof cover Apply grease before...

Page 155: ...rank roller to the cutting blade head 1 Bearing holder 2 Stop bolt LOCTITE applied 3 Cutting blade crank 4 Packer shaft mount ing bolts 5 Nut applied with LOCTITE 1 5 9 INSTALLATION OF STEM SIDE CONVE...

Page 156: ...11 INSTALLATION OF CHAIN LOCK PLATE 417W341A 1 Anti chain lock plate 2 Feeding guide 3 Feeding chain A 2 8 3 2 mm 1 5 12 INSTALLATION OF STEM SIDE PROP A 26 34 mm 1 Stem side prop 2 Feeding chain A Fi...

Page 157: ...h control chain A Deflection of feeding depth control chain B 7 13 mm parallel C 2 6 7 6 mm 1 5 13 INSTALLATION OF FEEDING GUIDE 417W344A 1 Feeding chain 2 Feeding guide A Minimum Clearance 4 7 mm Adj...

Page 158: ...B 1 5 16 VERTICAL ADJUSTMENT OF FEEDING DEPTH CONTROL CHAIN 417W347A 1 Prop 2 Chain plate A 6 9 mm B Adjust with the turnbuckle C Clearance between the prop and chain plate when the feeding depth cont...

Page 159: ...on surface 13 Feeding depth control stop switch 14 Reaping clutch lever point shaft grease applied 417W351A 1 Reaping unit shaft case 1 2 Reaping unit shaft case 2 3 Bolt LOCTITE applied 4 Feeding dep...

Page 160: ...MEMO...

Page 161: ...r 4 15 1 6 Vertical auger and No 1 auger 4 16 1 6 1 Removal and installation of vertical au ger and No 1 auger 4 16 1 7 No 2 auger 4 18 1 7 1 Removal and installation of No 2 au ger 4 18 1 8 Separator...

Page 162: ......

Page 163: ...eve case 6 Reprocessing cylinder 7 Separator drum 8 Grain sieve 9 Straw rack 10 Blower manually adjusted 11 Chaff manually adjusted 12 No 1 screw 13 No 2 screw 14 No 2 thrower 15 Outlet pipe 5 Threshi...

Page 164: ...07 DSC48 417W403A 1 Tension pulley 2 115 V pulley 3 No 2 auger 4 No 2 thrower 5 No 2 rotation sensor 6 No 1 rotation sensor 7 Vertical auger 8 14T bevel gear 9 15T bevel gear 10 No 1 auger 11 No 1 dri...

Page 165: ...shaft 1 10 Rocker shaft 3 11 Attachment metal 12 Mounting Bolt 13 Separator drum 14 200 V pulley 15 Bearing holder LH 16 Cover 17 Separator drum shaft 18 Sprocket driving con veyor chain 19 38 Gear 20...

Page 166: ...ine belt 1 2 1 FRONT SECTION OF THRESHING CYLINDER 1 2 2 REAR SECTION OF THRESHING CYLINDER 1 Threshing drive belt 2 Threshing cylinder 3 Counter 417W406A 417W405A Belt Belt specification Quantity Spe...

Page 167: ...g unit pulley 4 Transmission drive belt 5 Threshing drive belt 6 Engine pulley A 141 145 mm 417W409A 1 2 4 LH ON THRESHING UNIT 1 Blower drive belt 2 Counter 3 No 1 drive belt 4 Blower 5 No 2 drive be...

Page 168: ...500 hours 1 3 1 ADJUSTMENT AND REPLACEMENT OF FEEDING CHAIN A ADJUSTMENT 417W410A 1 Feeding chain A 150 155 mm Standard spring length installed 150 155 mm B REPLACEMENT 1 Loosen the tension and remove...

Page 169: ...both ends CAUTION 1 Open the threshing chamber cover 2 Disengage the blade lock pin and remove the bolt 417W177A 417W178A 1 Threshing chamber cover 2 Blade support mounting plate 3 Bolt 4 Blade suppor...

Page 170: ...s 3 FR RR and pull out the blade support mounting plate 2 3 Open the threshing cylinder 4 Remove the blade support 4 5 Remove the concave 5 by rotating it Work safely when attaching or detaching the b...

Page 171: ...shing knives 2 EA supplementary teeth plate 4 EA Threshing knives plate 2 EA common knives 88 EA No 1 supplementary teeth 4 EA feeding teeth plate 64 EA No 2 supplementary teeth 4 EA threshing cylinde...

Page 172: ...et plate 2 3 Front cover 1 Nut 2 Belt tension rod 3 Belt 4 Pulley 4 Remove the belt tension spring and then remove the belt from the pulley rear 5 Remove the pulley mounting nut front 6 Remove the bel...

Page 173: ...with a urethane hammer to insert it After installation rotate the threshing cylinder several times and check whether or not the threshing cylinder stops at the same position after each rotation Weight...

Page 174: ...48 1 2 3 1 4 5 INSTALLATION OF FRONT COVER 1 Install the front covers in the correct order 1 3 2 as shown in the figure Be careful with the overlapped sec tions 1 Front cover 1 2 Front cover 2 3 Front...

Page 175: ...ring and then the belt 3 Remove the shift pulley 4 Remove the key and then the shift pulley 2 5 Remove the mounting bolt from the blower shaft sup port Remove the blower shaft and blade together When...

Page 176: ...ension arm 3 No 1 pulley 417W429A 4 Remove the mounting bolts from the vertical auger pipe Remove two bolts on top and four bolts at the bottom to remove the vertical auger pipe 1 Vertical auger pipe...

Page 177: ...rear direc tion 417W433A 1 No 1 blade shaft 2 No 1 auger blade end 3 Horizontal auger top end 417W434A 1 Horizontal auger shaft 2 Horizontal auger case 3 No 1 bevel case 4 Horizontal auger top end 5 N...

Page 178: ...1 No 1 drive belt 4 No 2 pulley 2 No 2 drive belt 5 No 2 tension arm 3 No 1 pulley 3 Remove the wing bolt from the No 2 case cover 4 Remove the No 2 auger shaft chain case assembly and No 2 case cover...

Page 179: ...NDER 1 Remove the cover 1 Cover 1 Belt 3 Nut 2 Pulley 417W438A 2 Before removing the belt loosen the pulley mounting bolt and boss mounting nut 3 Loosen the tension and remove the belt 4 Remove the pu...

Page 180: ...L AND INSTALLATION OF SIEVE CASE A REMOVAL PROCEDURE 1 Push up the tension lever and remove the rocker belt When removing the rocker shaft components loosen the nut and bolt of the pulley before remov...

Page 181: ...threshing cyl inder concave Install the front cover The sieve guide 1 should be behind the cover 6 and the cover 2 should be between the cover and the right plate as shown in the fig ure Correctly in...

Page 182: ...1 Straw sieve 2 Chaff sieve 417W450A 1 Straw rack 2 Rack frame 5 Pull out the straw rack and remove the chaff sieve as sembly 6 Remove the split pin and pull out the chaff link support 1 LH and suppor...

Page 183: ...ieve as sembly 417W452A 1 9 3 REMOVAL OF COMPONENTS RELATED TO ROCKER SHAFT 1 Unscrew the mounting bolts on both sides of the rocker arm and remove the components of the rocker shaft 2 Unscrew four bo...

Page 184: ...a puller 5 Remove the mounting nut and the washer from the rocker shaft 2 417W456A 6 Install the nut to the threaded section of the rocker shaft 1 to be protruded a little or just to contact with Inse...

Page 185: ...TENSION OF STRAW DISCHARGING CHAIN STEM SIDE 1 Measure the protrusion of the spacer 1 and 2 at the tension bracket 2 If its length is out of the standard adjust it by the nut C CLEARANCE BETWEEN STRA...

Page 186: ...or support 2 press con tacts with the cover 1 417W461A 1 Cover 1 2 Straw discharging sensor 3 Straw discharging sensor support 2 F CLEARANCE BETWEEN STEM SIDE PRESS AND STRAW DISCHARGING SUPPORT COVER...

Page 187: ...on the up per frame 2 and grain side conveyor case 1 Tension arm 3 Bolt 2 Belt 417W464A 1 Upper cover 1 417W465A B UPPER COVER 1 1 Open the cutter 2 Disconnect the connector from the upper cover 1 3 R...

Page 188: ...and remove the grain side conveyor case 2 2 Undo the chain connection and remove the 20T sprock et 1 When assembling the chain connection compress the straw discharging roller grain side 4 and ten sio...

Page 189: ...re the inner length between the tension spring hooks of the cutter drive belt 2 If its length is out of the standard adjust it by the ten sion bolt 417W467A 1 Cutter drive belt B DIMENSION OF OPEN SEL...

Page 190: ...widen the gap B Right turn to shorten the gap Unscrew the bolt with a spanner from the cutter shaft side CAUTION D CUTTER DISC 1 Adjust the gap between the base disc and cutting disc as follows The i...

Page 191: ...ulley When assembling Apply LOCTITE to the M10 bolt 1 Cutter drive belt 3 M10 bolt 2 180 pulley Wear protective gloves during work Be careful not to touch the cutter blade when removing or installing...

Page 192: ...length of the cutter installed section on the cutter shaft is 849 mm Adjust the gap between the cutter discs after installing the cutter shaft 7 Replace the cutter discs 417W479A 1 Cutter shaft assem...

Page 193: ...sembling The protrusion on the spring washer 20 should face the left side of the hex nut Make sure to install the discs in correct direction and order Refer to the diagram below 417W481A 1 Pulling bla...

Page 194: ...ing 417W484A 1 Scraper guide 1 Hex nut RH 3 38T gear 2 Nut 2 3 3 38T GEAR 1 Set a spanner 26 mm to the hex nut RH to stop ro tation Unscrew the mounting nut of the 38T gear 2 Undo three bolts and remo...

Page 195: ...the discharge wing 1 417W487A 5 Scraper 7 Discharge wing 1 6 Spring washer 16 8 Support washer 3 1 Hex nut RH 3 Feed loader 160 2 Base disc 160 4 Base shaft When assembling Install the scraper guide t...

Page 196: ...MEMO...

Page 197: ...l and filters 5 4 1 2 2 Transmission drive belt 5 5 1 2 3 Power brake cable 5 5 1 2 4 Cam clutch of reaping drive pulley 5 6 1 2 5 Crawler 5 6 1 2 6 Track roller idle roller and rocker roller 5 7 1 2...

Page 198: ......

Page 199: ...1 BRAKE TURN RIGHT TURN 417W501A 1 HST output shaft 4 No 1 shaft 2 Transmission case LH 5 101 pulley reaping 3 Transmission case RH 6 No 2 shaft 7 Side clutch shaft 10 Axle shaft RH 8 Pressure plate 1...

Page 200: ...heck bolt and check whether the oil comes out Transmission fluid type 417W503A 1 Oil Inlet 4 Hydraulic Oil Filter 2 Level check bolt 5 Drain Plug 3 Oil tank Replacement of HST oil filter 1 Remove the...

Page 201: ...sion 417W506A 417W507A 1 2 3 POWER BRAKE CABLE 1 Check the clearance A between the brake arm 3 and the variable relief valve rod 4 Also check the play B of the brake arm on the power brake cable 2 sid...

Page 202: ...ULLEY 1 Remove the seal plug 6 and shaft snap ring 8 2 Remove the reaping drive pulley 5 by turning it clock wise from the seal plug side and pulling it out When assembling 1 Apply grease to the gap b...

Page 203: ...l seal 11 Bolt 6 Bearing unit 12 Cap 1 2 6 TRACK ROLLER IDLE ROLLER AND ROCKER ROLLER A TRACK ROLLER SHAFT 1 Remove the cap 12 and bolt 11 2 Remove the plain washer 10 to take out the 160 roller 7 fro...

Page 204: ...the rear wheel shaft in the following order When assembling Apply grease to the oil seal 3 before installing it to the wheel tension 1 Apply LOCTITE to the bolt 9 before installing it 417W514A 1 Plug...

Page 205: ...ght side clutch lever 417W518A 1 2 7 REMOVAL OF TRANSMISSION CASE A DETACHMENT OF REAPING UNIT see page 3 5 B REMOVAL OF CRAWLER see page 5 6 C TRANSMISSION FLUID DRAIN 1 Open the fluid inlet cover an...

Page 206: ...4 132 pulley When assembling Adjust the belt s tension after installation Check the distance between the center of the spring holder bolt s hole and the spring s end to adjust the belt tension 417W52...

Page 207: ...cam clutch while turning it coun terclockwise 417W522A Apply grease to the rubber cap before installing it Apply liquid gasket Three Bond 1215 or equivalent to the rubber cap Do not tap the pulley to...

Page 208: ...pacer 4 to the correct posi tion of the No 2 shaft When installing the 23516 gear 6 to the No 2 shaft make sure that it points the correct direction Install the spacer 9 large inner I D and the spacer...

Page 209: ...RAKE CABLE Depress the brake pedal 5 times Adjust the parking brake pedal free play so that its depressed point is 0 mm to 5 mm from the top position Then adjust the brake cable so that the left and r...

Page 210: ...to damage the pan with a screwdriver A damaged fan can result in poor cooling 417W531A 1 Radiator B ENGINE OIL Change after the initial 50 hours of operation Then check every 50 hours and change ever...

Page 211: ...417W534A 1 Engine oil filter D RADIATOR COOLANT Check every 50 hours and replace every 2 years Check whether the coolant level in the reservoir is between the LOW and FULL marks Factory specification...

Page 212: ...17W537A 1 Battery 3 Positive cable 2 Negative cable G AIR CLEANER ELEMENT Check every 50 hours and replace every 300 hours Before daily operation remove any dust by blowing air from the inside of elem...

Page 213: ...e nut of the adjusting metal 417W542A 1 Adjusting metal 3 Lever 2 Stop screw I HOUR METER CABLE Check at every 200 hours replace at every 800 hours 1 Clamp the hour meter cable 2 to the suction hose 1...

Page 214: ...is not aged or the hose clamp is not loose 1 Water pipe 1 3 Water pipe 3 2 Water pipe 2 M HYDRAULIC HOSE Check every 200 hours and replace every 500 hours Make sure that the hose is not aged or the h...

Page 215: ...nd adjustment 6 13 1 6 1 Check for pressure of low pressure relief valve 6 13 1 6 2 Check for pressure of high pressure relief valve 6 14 1 7 Removal and installation 6 15 1 7 1 Removal of valve unit...

Page 216: ......

Page 217: ...valve unit is composed of the solenoid valve and hy draulic block DH as one unit It also protects the hydraulic system by controlling the max pressure in the system with the low pressure relief valve...

Page 218: ...ting reaping unit C Left turn D Right turn 1 2 1 LIFTING AND LOWERING REAPING UNIT A LIFTING 1 When the lever is pushed to the lifting direction the le ver and its lever point move around from the piv...

Page 219: ...ve unit is turned to the left by the inner cable and pushes in the variable relief valve Therefore the oil pressure in the right steering clutch cylinder rises and powerfully pushes its piston 7 After...

Page 220: ...ing unit height check valves 417W606A 1 Direction port LH DL 2 Steering control solenoid valve 3 Direction pump port P D 4 Variable Relief Valve 5 Tank port T 6 Brake port B 7 Hydraulic block DH 8 Dir...

Page 221: ...block B port from the steering clutch cylinder As the rod is pressed down the pressure increases However the maxi mum pressure is limited by the low pressure relief valve This valve is operated throu...

Page 222: ...f direction control solenoid valve C To oil tank C LOW PRESSURE RELIEF VALVE It limits the maximum oil pressure from the hydraulic pump D of the hydraulic circuit operating the right and left steer in...

Page 223: ...id a 4 Spool 5 Reaping unit lifting solenoid valve 6 Reaping unit lowering solenoid valve 1 3 2 REAPING UNIT LIFTING SOLENOID VALVE The threshing controller sends electric current to the reap ing unit...

Page 224: ...ed Also when the piston is pushed out approx 16 mm 1st stroke the oil will be sent to the variable relief valve from the brake port The hydraulic pressure to the variable relief valve rises as the pow...

Page 225: ...utch cylinder RH operation Pressing A LH operation Pressing B Reaping unit Lifting Pressing E Lowering high speed Pressing D 1 Valve 2 Reaping unit lowering solenoid valve 3 Steering control solenoid...

Page 226: ...brake cable Abnormal low pressure relief valve Abnormal steering control solenoid valve Abnormal steering cylinder Worn or damaged cylinder damaged O ring Adjust Repair Replace Replace The reaping uni...

Page 227: ...ngine When the engine speed reaches ap prox 2 800 rpm maintain that speed 3 Push the power steering lever to the left or right as far as possible to measure the low pressure relief valve s pressure 4...

Page 228: ...When the engine speed reaches ap prox 2 800 rpm maintain that speed 3 Push the power steering lever to the left or right as far as possible to measure the high pressure relief valve s pressure 4 When...

Page 229: ...oid valve 4 Power brake cable When assembling Engage the connectors to the connectors with the same colored tapes Cellophane tape color of connectors Steering control solenoid valve 2 No tape Reaping...

Page 230: ...artridge 10 for the inlets of the charge pump and vari able capacity pump To prevent the rise of the oil tempera ture the oil cooler is also installed to the drain line The power is transferred to the...

Page 231: ...iable capacity pump 8 Charge relief valve 9 Port block 10 Valve plate P 11 Charge pump 12 Cylinder block P 13 Valve plate M 14 Fixed capacity motor 15 Fixed swash plate 16 Thrust plate 17 Piston 18 Dr...

Page 232: ...W625A 1 Variable swash plate 5 Swash plate shaft 2 Piston 6 Swash plate shaft cover 3 Pump side 7 Cylinder block P 4 Thrust plate 2 2 2 VARIABLE SWASH PLATE When the main shift lever is moved its move...

Page 233: ...gf cm2 417W627A 1 Spring 2 Poppet A CHECK HIGH PRESSURE RELIEF VALVE There is only one type of check high pressure relief valve It can be used both for forward and reverse driving When driving forward...

Page 234: ...ter 4 Use the pressure gauge with the capacity of over 400 kg cm2 There is only one type of high pressure relief valve It can be used both for forward and reverse driving The pressure of the high pres...

Page 235: ...on pipe Warm up engine Service charge pipe Replace filter Replace high pressure relief valve Tighten suction hose and plug Check oil for specification and change to specified oil Clean seats replace v...

Page 236: ...Clean drain circuit Replace seal installation Corresponding part Adjustable Charge circuit pressure Oil is leaked Restricted oil cooler Restricted drain circuit Malfunctioning pump or motor Clean oil...

Page 237: ...cosity Defective suction pipe Clean strainer Change oil Repair and service suction pipe Charge pump inlet pressure Defective pipe Defective low pressure relief valve Defective HST inner part Repair bo...

Page 238: ...rge relief valve s pressure 4 If the measured value is out of the specified range check the oil level HST oil filter HST suction filter for clogging and charge pump for wear and damage 417W633A B PRES...

Page 239: ...the footstep 4 Remove the HST rod 5 5 Remove the range shift rod neutral rod and neutral plate for easier removal 6 Remove the brake pedal and parking brake lever 7 Disconnect the suction hose 7 and d...

Page 240: ...5 Disconnect the suction hose 2 and drain hose Clamp them to prevent oil leakage 6 Unscrew three bolts 3 and four nuts and remove the HST assembly When assembling Apply Three Bond to both sides of the...

Page 241: ...2 11 Oil lamp instrument panel 7 10 2 2 12 Ignition switch 7 10 2 3 Wiring diagram 7 11 2 4 Checking normal operation 7 12 2 5 Troubleshooting 7 13 2 5 1 Straw discharge alarm 7 13 2 5 2 Grain alarm 7...

Page 242: ...Checking starter 7 33 7 1 3 Checking feeding depth control motor 7 33 7 1 4 Checking engine stop motor 7 34 7 1 5 Checking fuel gauge unit 7 34 7 1 6 Flasher unit resistance S 7 34 7 1 7 Checking vehi...

Page 243: ...UMENT PANEL The lamps are checked by the MICOM When the MICOM is malfunctioning only the charge lamp oil lamp and check lamp come on and h is displayed on the LED of the MICOM unit CAUTION 1 2 CHECK F...

Page 244: ...no relay sound from the MICOM unit Power is not supplied to the MICOM unit The ground wire of the MICOM unit is faulty Power to the MICOM unit Ground wire of the MICOM unit Only the charge lamp oil l...

Page 245: ...t temperature alarm are con trolled by the MICOM unit However the threshing unit controller determines whether to send electric signal and turn on the coolant temperature warning lamp The MICOM unit o...

Page 246: ...threshing clutch is OFF threshing unit switch OFF the buzzer stops and the lamp goes out However the buzzer and the lamp output do not stop even though the sensor becomes OFF if the threshing clutch i...

Page 247: ...hop per s grain sensor is ON When the grain sensor is OFF or the threshing clutch is disengaged threshing unit switch OFF the buzzer stops and the grain alarm lamp goes out Stopping buzzer with horn...

Page 248: ...r ON Threshing clutch engaged threshing unit switch ON Neutral switch OFF Reverse switch OFF Engine rpm over specified rpm Vehicle speed Over the specified speed The current engine rpm is newly stored...

Page 249: ...w side is OFF and the grain sensor S2 grain side is ON That means the error type 1 occurs during self diagnosis In this case the front buzzer sounds at short intervals Also the LED of the MICOM unit d...

Page 250: ...engine stop sole noid for 5 seconds and the automatic engine stop function operates If turning the ignition switch to the START posi tion while the straw discharge alarm is activated electric power i...

Page 251: ...Apr 2007 7 11 DSC48 2 3 WIRING DIAGRAM 417W717A...

Page 252: ...grain lamp blinks When the grain sensor is OFF the front buzzer and the grain lamp output stop 3 When the grain alarm is activated with the grain sen sor ON the front buzzer can be stopped by pressing...

Page 253: ...to the front buzzer Faulty front buzzer Power Replace No lamp comes on Power is not supplied to the instrument panel Blown lamp bulb Power Replace After engaging the threshing clutch the automatic eng...

Page 254: ...low Faulty input signal from the No 2 rotation sensor Input signal wire The No 1 or No 2 alarm operate when the engine speed is high Faulty input signals from the No 1 or No 2 rotation sensor open ci...

Page 255: ...does not come on nor blink Faulty input signal sent to the MICOM unit from the electronic pick up sensor Input signal wire 2 5 6 CHARGE LAMP Symptom Cause Action The charge lamp does not come on afte...

Page 256: ...not supplied to the automatic engine stop relay and engine stop motor Faulty components related to the above relay and motor Power to MICOM unit Ground of MICOM unit Power Replace The engine does not...

Page 257: ...e difference between the speed without load and the current speed decreases The max engine speed with load when starting reaping is detected by the electronic pick up device when the thresh ing clutch...

Page 258: ...g unit switch ON 4 Maintain the specified engine speed 5 Move the shift lever to the Forward position 6 Increase and decrease the engine rpm with the ac celerator lever to check if the load level is d...

Page 259: ...eeding depth control lever Also the feeding depth of the grain sensor can be adjusted in three stages standard shallow and deep at a certain position with the feeding depth selection switch 417W720A 1...

Page 260: ...t the grain is close to the grain sensor S2 4 2 3 DELAY OF SHALLOW AND DEEP FEEDING OUTPUT There is delay until the feeding depth control motor actu ally operates after the both grain sensors S1 and S...

Page 261: ...st or deepest feeding position the limit switch turns OFF normally ON and stops the relay which cuts power to the feeding depth control relay Then power will not be supplied to the feed ing depth cont...

Page 262: ...7 22 Apr 2007 DSC48 4 3 WIRING DIAGRAM 417W723A...

Page 263: ...ever is moved to the Forward posi tion reverse switch OFF neutral switch OFF and nothing contacts with the grain sensor S1 and S2 S1 S2 OFF the feeding chain moves to the deep feed ing position 7 When...

Page 264: ...ective limit switch manual operation unavailable as well There is relay sound from the threshing controller when either the deep and shallow control is engaged Faulty feeding depth control motor to po...

Page 265: ...control motor with the split section of the feeding depth adjustment drive arm A in figure Also connect the protrusion on the limit switch depth stop switch shaft to the protrusion on the feeding dep...

Page 266: ...lutch disengaged or the brake operated Also the amount of applied power to the steering lever can adjust the level of braking and allow the combine harvester to make a wide or sharp corner turn By pus...

Page 267: ...1 When the lever is pushed to the lowering direction forward the reaping unit height control lever switch moves to the right and the switch for lowering comes on 2 The reaping unit lowering relay in t...

Page 268: ...RH 5 At the same time the brake arm LH is pressed to the left side and the outer power brake cable is pulled as the C section of the lever pin moves The inner cable is fixed to the brake arm RH 6 The...

Page 269: ...ower steering lever to the left the piston LH of the direction control cylinder operates 4 When moving the power steering lever rearward lifting position the reaping unit is lifted 5 When moving the p...

Page 270: ...id and reaping unit lowering solenoid The reaping unit cannot be lifted Malfunction in the lifting position of the reaping unit height control lever switch Power is not supplied to the reaping unit li...

Page 271: ...wiring connector of the threshing controller Direction control lever switch Threshing controller The direction control cylinder LH or RH operates even with the power steering lever is kept in the neut...

Page 272: ...S1 straw side is OFF and the S2 grain side is ON during the automatic depth control LED display E and 1 Automatic feeding depth control lamp Blinking Front buzzer 5 sec Error 2 Defective grain sensor...

Page 273: ...3 Connect the B and S terminals with a screwdriver or equivalent 4 If the pinion driver gear is popped out the starter is nor mal If the starter is normal check the wiring 417W735A 1 S terminal 2 B te...

Page 274: ...417W738A 7 1 6 FLASHER UNIT RESISTANCE S 417W739A If the measured resistance of the fuel gauge unit is same to the above values check the connector and wiring IMPORTANT Approx 100 If the measured resi...

Page 275: ...nnector and wiring CAUTION 7 1 7 CHECKING VEHICLE SPEED ROTARY SENSOR 1 Remove the vehicle speed sensor from the combine harvester 2 With the connector connected install the measuring terminal of the...

Page 276: ...be performed with a digital tester If the sensor is normal check the connector and wir ing 417W744A 1 Sensor side 7 1 12 CHECKING SHIFT LEVER SWITCH If the above operation occurs the switch is normal...

Page 277: ...the connector and wiring 1 Switch side 1 Switch side 2 1 4 3 7 1 15 CHECKING SAFETY SWITCH N O normally open type 417W748A 1 Switch side If the above operation occurs it is normal If the sensor is no...

Page 278: ...the negative terminal to the body ground 3 Set the tester to the DCV range 4 Turn the ignition switch to the ON position 5 If the measured voltage reads approx DC 12 V the wiring is normal replace th...

Page 279: ...ITCH 417W753A 1 Switch side 7 1 20 CHECKING SLOW BLOW FUSE It is normal if there is continuity between the terminals Fuse blink If heat generates after starting the engine replace it 417W754A If the a...

Page 280: ...l 417W757A Set the tester to the resistance range and contact each ter minal in each range If the tester pointer indicates 0 it is normal 1 Lever switch neutral mark 1 2 3 4 5 6 3 2 1 3 2 1 31 32 Ligh...

Page 281: ...417W758B B ON GND B GND 7 2 CIRCUIT DIAGRAM Apr 2007 7 41 DSC48...

Page 282: ......

Page 283: ...switch THE REAPING UNIT LIFTING LOWERING SO LENOID DOES NOT OPERATE 1 Fuse in the fuse box 2 Lever switch 3 Threshing controller 4 Reaping unit lifting lowering solenoid THE COMBINE HARVESTER CANNOT...

Page 284: ...ENGINE STOP LAMP BUZZER 1 Straw discharging sensor 2 MICOM 3 Automatic engine stop relay 4 Engine stop motor OIL LAMP 1 Oil switch 2 Instrument panel FUEL GAUGE 1 Fuel gauge 2 Instrument panel COOLANT...

Page 285: ...DSC48 INDEX...

Page 286: ...ping drive pulley 5 6 Camshaft 2 7 Cautions for high pressure hoses 0 6 Cautions when handling the battery 0 6 Charge lamp instrument panel 7 10 Charge lamp 7 15 Charge pump 6 18 Charge relief valve 6...

Page 287: ...er 4 9 Conditions for automatic control function 7 19 Connecting rod 2 6 Control for self diagnosis 7 32 Control function 7 19 Conveyor 3 13 Coolant temperature alarm alarm buzzer and in strument pane...

Page 288: ...h control motor out put 7 19 H Handling of hazardous materials 0 7 Handling of rotating blade shaft and driving belt 0 7 Harvesting 0 11 HST Hydrostatic Transmission 6 16 HST hose diagram and pressure...

Page 289: ...self diagnosis 7 32 Overview 1 3 P Piston and piston ring 2 6 Power brake cable 5 5 Power steering 6 4 Power steering function 7 26 Preparation and inspection 0 9 Pressure check 6 20 Prevention of sca...

Page 290: ...lts 1 14 T Table for changing of oil coolant 1 10 Tension plate 4 34 Threshing unit 4 3 Tightening torque for service 2 28 Tightening torque 1 14 Timing gear 2 8 Track roller idle roller and rocker ro...

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