Daedong CK22 Workshop Manual Download

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WORKSHOP MANUAL

CK22/CK22H

TRACTORS

Summary of Contents for CK22

Page 1: ...WORKSHOP MANUAL CK22 CK22H TRACTORS...

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Page 3: ...wever DAEDONG has no obligation to modify the contents in this manual especially the contents in the manual which are already distributed or published The modified information is available in DAEDONG...

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Page 5: ...TER 2 CHAPTER 3 CHAPTER 4 CHAPTER 6 CHAPTER 7 CHAPTER 8 CHAPTER 9 CHAPTER 10 CHAPTER 11 CHAPTER 12 CHAPTER 5 SAFETY FIRST GENERAL ENGINE CLUTCH TRANSMISSION HST REAR AXLE BRAKE FRONT AXLE STEERING SYS...

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Page 7: ...area 0 3 2 3 Safety instructions when preparing tractor 0 4 2 4 Fire hazards 0 4 2 5 Cautions when handling the battery 0 5 2 6 Cautions for high pressure hoses 0 6 2 7 Use of appropriate tools and e...

Page 8: ...specting or servicing the tractor without full knowledge of it Read the service manual carefully before starting servicing and follow the instructions for servicing maintenance and inspection to preve...

Page 9: ...accidents that occurred with rotat ing parts are due to this inappropriate manner of wear ing clothes 2 SAFETY TIPS 2 2 WORK PLACE 2 2 1 VENTILATING SYSTEM Service to the tractor should be performed i...

Page 10: ...NERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE T46W009A T46W011A 2 3 SAFETY INSTRUCTIONS WHEN PREPARING TRACTOR T46W010A 2 4 FIRE HAZARDS T46W012A T46W013A T46W014A Lower the implemen...

Page 11: ...S WHEN HANDLING THE BATTERY Always disconnect the negative battery cable first and reconnect it last to avoid sparks from an acci dental short circuit You can get injured or fire may break out Never c...

Page 12: ...er the tractor if the support and the hydraulic jack hoist are not installed When using a hydraulic jack or a hoist do not use it over the limit of the equipment and the lift strap Make sure that the...

Page 13: ...LT Do not put a hand or a foot into the tractor s rotating blade or PTO shaft Do not wear loose clothing Be careful not to get caught by the rotating engine cooling fan You can be seriously injured if...

Page 14: ...XLE REAR AXLE REAR AXLE T46W030A 2 12 CAUTIONS WHEN HANDLING TIRES T46W031A The tire rims can fall out of the tires Therefore stay out of its way when checking or inflating tires Do not weld or apply...

Page 15: ...INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE 1 Parts No T2350 54122 Option...

Page 16: ...NG STEERING STEERING STEERING STEERING BARKE BARKE BARKE BARKE BARKE ELECTRIC ELECTRIC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERA...

Page 17: ...1 14 8 2 Every 50 hours 1 15 8 2 1 Lubricating grease fittings 1 15 8 2 2 Checking wheel bolt torque 1 16 8 3 Every 100 hours 1 17 8 3 1 Changing engine oil 1 17 8 3 2 Checking fuel line 1 17 8 3 3 C...

Page 18: ...e1 29 8 9 4 Replacing HST oil line HST type 1 29 8 9 5 Replacing fuel hose 1 29 8 10 Service as required 1 30 8 10 1 Bleeding fuel system 1 30 8 10 2 Draining clutch housing water 1 30 8 10 3 Replacin...

Page 19: ...TRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK...

Page 20: ...ONT AXLE FRONT AXLE FRONT AXLE FRONT AXLE STEERING STEERING STEERING STEERING STEERING BARKE BARKE BARKE BARKE BARKE ELECTRIC ELECTRIC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULI...

Page 21: ...drostatic 6 12 23 x 8 50 12 23 x 8 50 12 9 5 16 33 x 12 5 x 16 5 12 16 5 2 684 105 7 1 121 44 1 1 970 77 5 1 470 57 9 310 12 2 910 35 8 890 935 35 0 36 8 2 3 7 5 250 551 812 1 790 Model Type Engine gr...

Page 22: ...ion case Front axle case 4WD only Greasing Battery terminal 20 5 28 U S gal 5 7 1 50 U S gal 2 6 0 69 U S gal 3 1 0 82 U S gal No of greasing points 2 4 LUBRICANTS FUEL AND COOLANT Capacity Moderate a...

Page 23: ...25 0 29 0 34 0 40 0 lb ft 5 79 6 87 13 1 15 1 29 0 33 2 46 3 53 5 79 6 92 5 123 141 181 209 246 289 Nm 7 85 8 82 16 7 19 6 31 4 34 3 kgf m 0 80 0 90 1 7 2 0 3 2 3 5 lb ft 5 79 6 50 12 3 14 4 23 2 25 3...

Page 24: ...C GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H Grade Unit Nominal diameter 5 16 3 8 1 2 9 16 5 8 Nm 23 1 27 8 47 5 57 0 108 5 130 2 149 2 179 0...

Page 25: ...2 137 4 144 7 151 9 159 1 166 4 173 6 180 8 Inch 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Length mm 25 4 50 8 76 2 101 6 127 152 4 177 8 203 2 228 6 254 279 4 304 8 330 2 355...

Page 26: ...filter element Fan belt Clutch pedal free play Brake pedal free play Radiator hose and clamp Power steering hose and oil line Fuel line Intake air hose Toe in Engine valve clearance Fuel injection no...

Page 27: ...h build up oil or coolant leaks broken or worn parts NOTE No 2 D is a distillate fuel of lower volatility for en gines in industrial and heavy mobile service SAE J313 JUN 87 Grade of Diesel Fuel Oil A...

Page 28: ...T LEVEL 1 Recovery Tank A FULL B LOW 196W114A 196W115A To avoid personal injury Do not remove radiator cap while coolant is hot When cool slowly rotate cap to the first stop and allow ample time for e...

Page 29: ...SCREEN AND OIL COOLER SCREEN 1 Radiator screen A DETACH HST 1 Radiator screen 2 Oil cooler screen A DETACH 1 Check front grill and side screens to be sure they are free of any debris 2 Detach the scre...

Page 30: ...DRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 8 1 7 CHECKING BRAKE PEDALS AND CLUTCH PEDAL 1 Exam...

Page 31: ...ENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 1 Grease fitting brake lever RH LH 1 Grease fitting rear bracket 1 Battery 2 Battery terminals 196W1...

Page 32: ...DRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 8 2 2 CHECKING WHEEL BOLT TORQUE 1 Bolt 83 Nm 8 5 kgf m 62 lb ft Nut 68...

Page 33: ...W125A 1 Drain plug 1 To drain the used oil remove the drain plug at the bottom of the engine and drain the oil completely into the oil pan All the used oil can be drained out easily when the engine is...

Page 34: ...rge particles of dust and dirt 1 Clutch rod A Free travel 2 Nut 8 3 3 CLEANING AIR CLEANER PRIMARY ELEMENT 1 Remove the air cleaner cover and element 2 Clean the element 1 When dry dust adheres to the...

Page 35: ...ke pedals and measure free travel at top of pedal stroke 3 If adjustment is needed loosen the lock nut and turn the turnbuckle to adjust the rod length within acceptable limits 4 Retighten the lock nu...

Page 36: ...ighest level B Lowest level Never check battery charge by placing a metal object across the posts Use a voltmeter or hydrometer 196W134A 196W135A Mishandling the battery shortens the service life and...

Page 37: ...ed battery it is neces sary to recharge the battery as early as possible Failure to do this will shorten the battery s service life 5 When the specific gravity of electrolyte is between 1 27 and 1 29...

Page 38: ...ormally decreases a little Make sure that the engine oil does not leak through the seal and be sure to check the oil level on the dipstick Then replenish the engine oil up to the prescribed level 196W...

Page 39: ...the engine for a few minutes stop it and check the oil level again add oil to the pre scribed level 8 Make sure that the transmission fluid doesn t leak through the seal 1 Hydraulic oil filter 3 Remo...

Page 40: ...er leaks tighten bands securely 2 Replace hoses and tighten hose clamps securely if radiator hoses are swollen hardened or cracked Replace hoses and hose clamps every 2 years or ear lier if hoses are...

Page 41: ...lat place 2 Turn steering wheel so front wheels are in the straight ahead position 3 Lower the implement lock the park brake and stop the engine 4 Measure distance between tire beads at front of tire...

Page 42: ...range 1 Drain plugs 196W146B 196W147B 196W148A 1 To drain the used oil remove the drain plug at the bottom of the transmission case and drain the oil completely into the oil pan 2 After draining rein...

Page 43: ...t axle pivot pin adjustment is not correct front wheel vibration can occur causing vibration in the steer ing wheel 8 6 2 ADJUSTING PROCEDURE Loosen the lock nut tighten the adjusting screw all the wa...

Page 44: ...l is just below the port Install the coolant up to the FULL mark on the re covery tank 7 Fill with coolant up to the FULL mark on the recov ery tank 8 Start and operate the engine for few minutes 9 St...

Page 45: ...ing agent forming sludge which will affect the engine parts When useing different type of coolant flush the cool ing system thoroughly beforehand 8 9 2 REPLACING RADIATOR HOSE WATER PIPES Replace the...

Page 46: ...en stop the engine 4 Tighten the air vent bolt 1 Fuel cock A Close B Open 1 Split pin plugs 8 10 2 DRAINING CLUTCH HOUSING WATER The tractor is equipped with split pin plug under the clutch housing Af...

Page 47: ...TOP SOLENOID 10A 10A 10A 15A 5A 25A 10A 15A 25A 5A 10A 10A 196W157B PROTECTED CIRCUIT 1 Slow blow fuse Capacity A Protected circuit 1 2 3 4 5 6 20 10 15 15 10 15 Flasher Horn Work light Head lights Ta...

Page 48: ...Tire Sizes 9 5 16 6PR 33 x 12 5 16 5 4PR 12 16 5 6PR 6 12 4PR 23 x 8 50 12 4PR 23 x 8 50 12 6PR Inflation Pressure 207 kPa 2 1 kgf cm 30 psi 207 kPa 2 1 kgf cm 30 psi 276 kPa 2 8 kgf cm 40 psi 193 kPa...

Page 49: ...k mounting bolts 2 Change the position of the rim and or disk right and left to the desired position and then tighten the bolts Models 9 5 16 Farm 33 x 12 5 16 5 Turf 12 16 5 IND 890 mm 35 in 935 mm 3...

Page 50: ...nt of rear ballast should be matched to the job and the ballast should be removed when it is not needed Weight should be added to the tractor in the form of liquid ballast rear wheel weights or a comb...

Page 51: ...NDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 9 4 TRAVELING SPEED At rat...

Page 52: ...MEMO...

Page 53: ...iator 2 11 2 4 13 Thermostat 2 11 2 4 14 Fanbelt 2 11 2 4 15 Tightening torque 2 12 3 OPERATING PRINCIPLE 2 13 3 1 Body and power train 2 13 3 1 1 Cylinder head 2 13 3 1 2 Cylinder block 2 13 3 1 3 Cr...

Page 54: ...ble 2 43 7 1 1 Engine assembly 2 43 7 1 2 Engine stop solenoid 2 43 TABLE OF CONTENTS 7 1 3 Intake manifold and fuel hoses 2 44 7 1 4 Injection nozzle 2 44 7 1 5 Rocker arm and push rods 2 46 7 1 6 Cy...

Page 55: ...RAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CK22 CK22H 1 ENGINE IDENTIFICATION The 3C100A is...

Page 56: ...r example FD4000001 means that this engine is the first manufactured unit 3B183 LXM in 2006 The engine number is necessary information that is requested on the warranty registration form This number s...

Page 57: ...cycle diesel engine 3 75 X 76 mm 1007 cm3 61 45 cu in 22 HP 16 2 kW 2 800 rpm 3 000 rpm 1 000 rpm 63 7 Nm 6 5 kgf m 47 lbs ft 1 900 rpm Spherical type swirl chamber Bosch type K mini pump 5 mm 0 197...

Page 58: ...ELECTRIC ELECTRIC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR...

Page 59: ...LE FRONT AXLE FRONT AXLE STEERING STEERING STEERING STEERING STEERING BARKE BARKE BARKE BARKE BARKE ELECTRIC ELECTRIC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRA...

Page 60: ...cold 2 4 SERVICE SPECIFICATIONS 2 4 1 CYLINDER HEAD 0 05 mm 0 0020 in 100 mm 4 in of cylinder head surface length When tightened 1 15 1 25 mm 0 045 0 049 in 0 7 0 9 mm 0 0275 0 0354 in 58 8 63 7 Nm 6...

Page 61: ...2 in 0 050 0 091 mm 0 0020 0 0036 in 26 75 mm 1 0530 in 26 88 mm 1 0583 in 0 042 0 115 mm 0 0017 0 0045 in 0 15 mm 0 0020 in 0 05 mm 0 0020 in 26 83 mm 1 0563 in 26 88 mm 1 0583 in 0 2 mm 0 0079 in In...

Page 62: ...rings Clearance between crankpins and bearings End play of crankshaft 0 02 mm 0 0008 in 47 934 47 950 mm 1 8872 1 8878 in 48 068 48 138 mm 1 8924 1 8952 in 47 980 48 006 mm 1 8890 1 8900 in 0 118 0 20...

Page 63: ...MPa 210 220 kgf cm2 2 987 3 129 psi 22 Before Top Dead Center Item Reference Value Allowable Limit 30 seconds 5 seconds 2 4 11 OIL PUMP Oil pressure Rotor type End clearance between rotor and cover 24...

Page 64: ...bolt nut Bearing case bolt 1 Bearing case bolt 2 Flywheel bolt Connecting rod bolt Rocker arm bracket sink bolt Idle gear shaft bolt Glow plug no lubrication Waste oil plug Nozzle holder Overflow pip...

Page 65: ...from being heated and expanded by exhaust air The cool high mass suction air has a high large effec tiveness and raises the power of the engine Deforma tion of the cylinder head by heat exhaust air is...

Page 66: ...ar ing cases in which bearings are used Crankshaft bearing 1 at the front end is a wind type bushing Thrust bearing 1 2 of split type are mounted on both sides of the main bearing case at the flywheel...

Page 67: ...ated The fuel camshaft controls the reciprocating movement of the injection pump and is also equipped with a ball to control the governor Fuel camshaft is made of carbon steel and cam sections are cov...

Page 68: ...on pump gear 1 1 Injection pump gear 5 Idle gear 2 Fuel camshaft 6 Crankshaft gear 3 Camshaft gear 7 Crankshaft 4 Camshaft 3 1 10 FLYWHEEL The flywheel is installed on the rear end of the crank shaft...

Page 69: ...CTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 C...

Page 70: ...shaft Rocker arm Valve cam shaft journal Fuel cam shaft Tappet Piston Bore Connectingrod ssmallend No 1Connectingrod ssmallend No 2Connectingrod ssmallend No 3Connectingrod ssmallend journal bearing N...

Page 71: ...ing to the inlet port increases which causes the oil to flow through the inlet port When the rotors rotate to C the port to which the space leads is changed from inlet to outlet At D the space decreas...

Page 72: ...type is bent as far as possible from the center in the opposite direction to rotation the bearing unit prevents cooling water from entering by a special mechanical seal 1 Water pump impeller 3 Water p...

Page 73: ...alve 1 opens to reduce the internal pressure B At low pressure When the water temperature falls and a vacuum is formed in the radiator the vacuum valve 2 opens to allow the air to enter the radiator 3...

Page 74: ...FUEL FILTER A fuel filter is used to prevent dirty fuel from reaching the injection pump and injection nozzles The filter ele ment will require occasional replacement to maintain an adequate flow Thi...

Page 75: ...TAKE STROKE When the diaphragm is pulled down by the spring it builds a vacuum in the chamber 5 causing the ex haust valve 4 to close and the atmospheric pressure in the fuel tank to force the fuel in...

Page 76: ...l rack that rotates the plunger in the cylinder to control the amount of fuel delivered 1 Pump element 5 Control sleeve 2 Cylinder 6 Control groove 3 Plunger 7 Sliding surface 4 Feed hole T46W237A 1 D...

Page 77: ...e the amount of injected fuel in c is larger than the amount of injected fuel in b T46W240A 1 Valve spring 4 Fuel chamber 2 Delivery valve 5 Valve face 3 Valve seal 6 Relief plunger D DELIVERY VALVE T...

Page 78: ...n nozzle is throttle type nozzle It features the low fuel consumption and works well with DAEDONG combustion chamber The nozzle valve opening pressure is about 14 7 MPa 150 kgf cm 2134 psi When the pr...

Page 79: ...REAR AXLE CK22 CK22H 1 Start spring 2 Governor spring 1 3 Governor spring 2 4 Fork lever 1 5 Fork lever 2 196W239B 3 5 GOVERNOR SYSTEM 3 5 1 DISASSEMBLED VIEW The governor keeps the engine speed cons...

Page 80: ...AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 1 Governor spring 1 2 2 Solenoid guide 3 Stop solenoid 4 Pump rack 5 Rack pin T46W246B 6 Steel ball 7 Governor lever 8 Idle spring 9 Start spri...

Page 81: ...ork lever 13 is stopped by the sleeve 11 When the centrifugal force of the steel ball 6 that is proportional to the engine speed is balanced with the tension of the governor spring 1 that is deter min...

Page 82: ...Inlet manifold 5 Exhaust manifold 2 Air cleaner 196W244B 196W245B A Inlet air 1 Outlet port B To inlet manifold 2 Inlet port C Heavier dust 3 Air cleaner element 4 Body 5 Evacuator 3 6 2 AIR CLEANER...

Page 83: ...EAR AXLE REAR AXLE REAR AXLE CK22 CK22H 5 4 3 1 2 10 7 11 9 6 12 8 3 6 4 PCV VALVE A PCV POSITIVE CRANKCASES VENTILATION The PCV system is a system that prevents air pollution by returning the blow by...

Page 84: ...nnection Fuel filter clogged Fuel pump faulty Plunger has worn or seized up Delivery valve spring broken Delivery valve not completely oil tight Needle valve stuck Needle spring broken Injection press...

Page 85: ...roken or loose Air in pump Pump capacity not constant Tappet roller and pin worn Delivery valve not completely oil tight Fuel leaks from nozzle tip Fuel not spraying properly Injection pump or nozzle...

Page 86: ...g worn Excessive gap between cylinder liner and piston Too much oil Injection delayed Compression pressure insufficient Injection too early Injection delayed Plunger does not return completely because...

Page 87: ...ce If the pressure does not reach the allowable limit apply a small amount of oil to the cylinder wall through the nozzle holder hole and measure the pressure again f f f f f JUDGMENT If the pressure...

Page 88: ...1 IN EX cc 196W254B 5 3 VALVE CLEARANCE 1 Remove the cylinder head cover and the timing win dow cover on the flywheel housing and all glow plugs 2 Turn the flywheel and align the 1TC to mark with the...

Page 89: ...ION TIMING MEASURE MENT AND ADJUSTMENT 2 Remove the timing check window cover of the clutch housing 3 Turn the flywheel to find 1 4 FI mark for 4 cylinder engine or 1 FI mark for 3 cylinder engine on...

Page 90: ...e engine slowly 8 When the amount of the fuel in the nozzle holder increases abruptly that moment is the injection timing If the fuel increases too much it means that the injection timing is passed al...

Page 91: ...peed At rated speed Item Factory spec More than 49 kPa 0 5 kgf cm2 7 11 psi 245 441 kPa 2 5 4 5 kgf cm2 36 64 psi Allowable limit 245 kPa 2 5 kgf cm2 36 psi Engine oil pressure Item Oil pressure switc...

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Page 93: ...r 6 Dipstick 7 Cylinder Head 8 Head Bolt 9 Gearcase 10 Oil Filter 11 Mainbearing Case Cover 12 Bearing Case Bolt 1 13 Mainbearing Case 14 Bearing Case Bolt 2 15 Rocker Arm 16 Inlet Exhaust Valve 17 Cy...

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Page 95: ...ightening torque 14 7 19 6 Nm 1 5 2 0 kgf m 10 8 14 4 lb ft 7 SERVICING 7 1 REMOVAL AND REASSEMBLE 7 1 1 ENGINE ASSEMBLY Drain the oil and the water if disassemble the engine body 1 Remove the muffler...

Page 96: ...gs and gaskets by new ones ATTENTION 7 1 4 INJECTION NOZZLE B REMOVING INJECTION PIPES 1 2 AND 3 1 Loosen the screws on the pipe clamps 2 Detach the injection pipes in the order of 1 2 and 3 Note for...

Page 97: ...50 6 lb ft 1 Plus screw driver 2 Nozzle 3 Injection nozzle gasket 4 Heat seal 196W258B D HEAT SEAL ROMOVAL PROCEDURE 1 Drive screw driver lightly into the heat seal hole 2 Turn screw driver three or f...

Page 98: ...arm and shaft assembly When reassembling Rest the end of push rod at the indent of tappet and install the rocker arm assembly Tighten the bolts in several steps and the specified sequence shown in the...

Page 99: ...o tighten 1 to 14 2 Lift up the cylinder head to detach 3 Remove the cylinder head gasket Note for reassembling Tighten the bolts and nuts after applying sufficient oil Tighten the bolts and nuts in d...

Page 100: ...ppets from the crankcase Note for reassembling Visually check the contact between tappets and cams for proper rotation If a defect is found re place tappets Before installing the tappets apply a thin...

Page 101: ...T HST HST HST CK22 CK22H 3 2 1 2 B INJECTION PUMP 1 Remove the injection pipes 1 and the intake mani fold 2 2 Remove the overflow pipe 3 196W269B 1 Fuel feed pump assembly 2 Cover 7 1 7 FUEL FEED PUMP...

Page 102: ...Delivery valve spring 8 Plunger If replacing the pump element the amount of fuel injection should be adjusted on specified bench IMPORTANT Make sure that the lever of the pump control rack is on the...

Page 103: ...L GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE HST HST HST HST HST CK22 CK22H 4 5 196W274B A DETACH THE GOVERNOR SPRING 1 Detach the governor spring 1 2 and speed control plate from gover...

Page 104: ...K22H C REMOVING GEAR CASE 1 Remove the gear case cover 2 Remove the O ring Note for reassembling Apply a thin coat of engine oil to the oil seal and install it noting the lip come off Before installin...

Page 105: ...22H B REMOVING IDLE GEAR 1 Remove the external circle clip 2 Detach the idle gear collar 2 3 Detach the idle gear 4 Detach the idle gear collar 1 Note for reassembling Check to see each gear is aligne...

Page 106: ...AXLE REAR AXLE CK22 CK22H C REMOVING CAMSHAFT STOPPER 1 Align the round hole on the cam gear with the cam shaft stopper mounting bolt position 2 Remove the camshaft stopper mounting bolt 3 Detach the...

Page 107: ...ing bolts Detach the oil pump Note for reassembling Remove the gear with crank gear removal tool or pulley removal tool 1 Oil pump assembly 1 13T gear crank gear 196W288A 196W289A Item Bolts of oil pu...

Page 108: ...ne cradle on its side 2 Remove the eighteen oil pan mounting bolts 3 Detach the oil pan by lightly tapping the groove of the pan with a wooden hammer Note for reassembling Wipe off oil on the oil pan...

Page 109: ...th the grip of a hammer 3 Draw out the other two pistons in the same method as above Note for reassembling Before inserting the pistons into the cylinders ap ply enough engine oil to the pistons 1 Pis...

Page 110: ...efore assembling Heat the piston in approx 80 C 176 F of oil for 10 15 minutes when inserting the piston pin into the piston Install the piston and connecting rod with the mark FW on the piston to the...

Page 111: ...e flywheel Apply oil to flywheel screws To ease alignment of the crankshaft and the flywheel bring the crank of one of the cylinders to TC top dead center Make sure of the flywheel TC align it with th...

Page 112: ...bearing case with their side marks toward the flywheel Be sure to install main bearing 1 with its oil groove facing outward Tighten the bearing case bolts 1 to 20 24 Nm 2 0 2 4 kfg m 15 17 lb ft 1 Ma...

Page 113: ...SURFACE FLATNESS 1 Thoroughly clean the cylinder head surface 2 Place a straightedge on the cylinder head and mea sure the clearance with a feeler gage as shown in the figure 3 If the measurement exce...

Page 114: ...valve guide I D of cylinder head and calculate the clearance 4 If the measurement exceeds the allowable limit replace the valve guide or the valve Reference value Allowable limit 0 035 0 065 mm 0 001...

Page 115: ...with a set of vernier calipers 2 If the measurement exceeds the allowable limit replace B CHECK VALVE SPRING SQUARENESS 1 Put the spring on a surface plate place a square on the side of the spring an...

Page 116: ...HING 1 Measure the rocker arm I D 2 Measure the rocker arm O D 3 If the clearance exceeds the allowable limit replace Reference value Allowable limit 0 02 0 08 mm 0 0008 0 0031 in 0 12 mm 0 0047 in 12...

Page 117: ...ble limit replace B IDLE GEAR SIDE CLEARANCE 1 Pull the idle gear collar 2 1 and push the idle gear 2 to each end 2 Measure the clearance A between the idle gear and the idle gear collar 2 with a feel...

Page 118: ...d the snap ring 2 on the fuel camshaft 3 If the clearance exceeds the allowable limit check the gear the bearing and the key 1 Injection pump gear 2 Snap ring 196W2D2A Item Side clearance A Factory sp...

Page 119: ...ce exceeds the allowable limit replace the shaft H CAMSHAFT ALIGNMENT 1 Support the camshaft with V blocks on the surface plate at both end journals and set a dial indicator with its tip on the interm...

Page 120: ...oil holes of the connecting rod and the bushing IMPORTANT 196W2E0A 7 2 6 CONNECTING ROD AND PISTON A PISTON PIN BORE 1 Measure the I D of piston pin bore in piston lengthwise and widthwise of the pis...

Page 121: ...eds the allowable limit replace the piston ring Top ring 2nd ring Oil ring 196W2E2A Item Factory spec 0 15 0 30 mm 0 0059 0 0118 in 0 30 0 45 mm 0 0118 0 0177 in 0 25 0 35 mm 0 0098 0 0138 in Allowabl...

Page 122: ...AXLE CK22 CK22H F CONNECTING ROD ALIGNMENT 1 Remove the connecting rod bearing and install the bearing cap 2 Install the piston pin in the connecting rod 3 Install the connecting rod on the connectin...

Page 123: ...BEARING 1 OIL CLEARANCE 1 Measure the I D of the crankshaft bearing 1 with an inside micrometer 2 Measure the O D of the crankshaft journal with an outside micrometer 3 If the clearance exceeds the a...

Page 124: ...he specified torque once and remove the cap again 3 Detach the bearing case slowly and measure the depression of the press gauge with a sheet of gauge paper 4 If the clearance exceeds the allowable li...

Page 125: ...AND CONNECTING ROD BEAR ING OIL CLEARANCE 1 Paste a press gauge onto the crank pin bearing with grease 2 Install the connecting rod cap and tighten the screws to the specified torque once and remove t...

Page 126: ...ring free length Factory spec 35 mm 1 38 in Allowable limit 30 mm 1 18 in Item Relief cover screw Tightening torque 32 4 36 3 Nm 3 3 3 7 kgf m 23 9 36 8 lb ft 1 Relief valve ball 2 Relief valve seat 3...

Page 127: ...tween the outer and in ner rotor with a feeler gauge 2 Measure the clearance between the outer and the housing with a feeler gauge 3 If the clearance exceeds the allowable limit replace the pump D ROT...

Page 128: ...olts and nuts and relo cate the alternator to adjust 3 If the belt is damaged or worn See figure replace the belt f Radiator Water Tightness 1 Fill the radiator with water to the specified amount and...

Page 129: ...pulley 1 2 Remove the water pump body from gear case cover 3 Remove the water pump flange 2 4 Remove the impeller and water pump shaft 3 5 Remove the impeller from the water pump shaft 6 Remove the m...

Page 130: ...A Item Fuel injection pressure Standards Factory spec 21 57 MPa 220 kgf cm2 3 129 psi 10 sec Allowable limit 20 59 MPa 210 kgf cm2 2 987 psi 5 sec Item Fuel injection pressure Factory spec 13 73 14 71...

Page 131: ...AXLE REAR AXLE REAR AXLE HST HST HST HST HST CK22 CK22H C FUEL TIGHTNESS OF NEEDLE VALVE SEAT TIGHTNESS 1 Set the injection nozzle to the nozzle tester 2 Apply a pressure 130 kgf cm 12 75 MPa 1 849 ps...

Page 132: ...MEMO...

Page 133: ...assembling 3 6 5 1 1 Draining the transmission fluid 3 6 5 1 2 Bonnet 3 7 5 1 3 Instrument panel 3 7 5 1 4 Power steering unit 3 7 5 1 5 Propeller shaft 3 8 5 1 6 Step 3 8 5 1 7 Hydraulic pipes 3 9 5...

Page 134: ...RAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 200 mm 7 87 in 205 7 226 mm 8 1 8 9 in 0 5 mm 0 020 in 2 0 mm 0 079 in 2 0 mm 0 079 in 0 5 mm 0 0197 in 0 3 mm 0 0118 in 20 30 mm 0 79...

Page 135: ...pressure plate 2 Clutch disc 3 Flywheel 4 Clutch release bearing 5 Hub 196W301A The clutch pedal assembly 1 is connected by an ad justable rod 2 to a clutch rod pin 3 and clutch rod 4 on which a fork...

Page 136: ...r improperly adjusted Clutch disc excessively worn Grease or oil on clutch disc facing Clutch disc or pressure plate warped Clutch spring weaken or broken Grease or oil on clutch disc facing Clutch di...

Page 137: ...od 2 length 3 Retighten the lock nut 3 4 1 Clutch pedal 2 Clutch rod 3 Lock nut 4 Lock nut 4 2 ADJUSTMENT OF CLUTCH PEDAL STOPPER BOLT 1 When working clutch pedal and clutch disconnected adjust bolt s...

Page 138: ...ange 1 Drain plugs 196W320A 196W147B 196W322A 1 To drain the used oil remove the drain plug at the bottom of the transmission case and drain the oil completely into the oil pan 2 After draining reinst...

Page 139: ...rease to it 196W306A 196W307B 1 Bonnet 3 Side cover 2 Connector 4 Battery terminal 1 Steering wheel 2 Parking brake lever grip 3 Speed set lever grip 4 Transmission cover 5 Instrument panel cover 6 In...

Page 140: ...the spring pin 8 and then slide the cou pling 2 to the rear When reassembling Apply grease to the splines of the propeller shaft 1 Propeller shaft 2 Coupling 3 Cir Clip 4 Propeller shaft cover 1 5 Pro...

Page 141: ...en remove the engine by pulling it slowly When reassembling Apply grease to the splines Apply liquid gasket Three Bond 1 208D or equivalent to joint face of the engine and clutch housing Item Engine a...

Page 142: ...W314A NOTE Do not allow grease and oil on the clutch disc facing Item Clutch mounting screws Tightening torque 23 5 27 5 Nm 2 4 2 8 kgf m 17 4 20 3 lb ft 5 1 9 REMOVING CLUTCH 1 Remove the clutch from...

Page 143: ...limit re place it 5 2 2 CLUTCH DISC WEAR 1 Measure the depth from clutch disc surface to the top of rivet at least 10 points with a depth gauge 2 If the depth is less than the allowable limit replace...

Page 144: ...ENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 5 2 4 THRUST BALL BEARING 1 Check the contact area for excessive wear 2 With inner wheel seized and outer wh...

Page 145: ...ERVICING 4 21 4 1 Draining the transmission fluid 4 21 4 2 Bonnet 4 22 4 3 Instrument panel 4 22 4 4 Power steering unit 4 23 4 5 Propeller shaft 4 23 4 6 Step 4 24 4 7 Separating rops and tires 4 24...

Page 146: ...AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H Spiral bevel gear pinion turning torque PTO shaft lock nut tightening torque Backlash between Spiral bevel gear turning torque Adjusting shims thickness B...

Page 147: ...ECTRIC ELECTRIC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AX...

Page 148: ...ARKE BARKE BARKE BARKE BARKE ELECTRIC ELECTRIC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR A...

Page 149: ...power is transmitted from engine to gear shaft through a tie Clutch can be changed three ways by the main shift lever and transmits to the counter shaft 1 Main shaft 2 22T gear 3 34T gear 4 24T gear 5...

Page 150: ...nd synchro hub 1 rotates in a body f f f f f INTERMEDIATE STAGE When synchronizer key 2 is not slipping any longer by synchronizer ring 5 it will be fallen from shift 3 and key entered groove of synch...

Page 151: ...L GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 2 2 2 REVERSE SHIFT CK22 1 Main Shaft 2 22T gear 3 34T gear The standard 6 x 2 gear transmission 1 consists of two forwar...

Page 152: ...NERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 2 2 3 HIGH LOW SHIFT 1 Counter shaft 2 14T gear CK22 23T gear CK22H 3 42T gear CK22 33T gear CK22H With high...

Page 153: ...IC ELECTRIC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE R...

Page 154: ...17T gear 3 42T gear 4 37T gear 5 23T gear 6 Mid PTO shaft 7 1 PTO drive shaft 2 5 37T gear 2 PTO drive shaft 3 6 23T gear 3 17T gear 7 Mid PTO shaft 4 42T gear B REAR PTO The rear power take off is av...

Page 155: ...2 15 slides to the right side to engage with spline Boss f f f f f FRONT WHEEL DRIVE ENGAGEMENT HST output shaft 1 Spline boss 2 19T gear 3 23 gear 4 spline boss 5 Range shaft 6 23T 36T gear 7 20 33T...

Page 156: ...SHIFT CK22 A MAIN GEAR SHIFT 1ST 2ND 3RD 1 Main shift arm 2 Main shift fork 1 3 Shifter 4 37T gear The transmission shift lever is located in left of driver s seat and connected to main shift arm 1 m...

Page 157: ...TRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 2 3 2...

Page 158: ...IC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 2 3 3 HIGH LOW RANGE SHIFT 1 High Low shift lever 2 Connecting plate 3 High Low shift...

Page 159: ...er 2 Rear PTO lever 3 Mid PTO rod 4 Rear connecting rod A MID PTO The mid PTO lever 1 is located at left side of driver s seat and connected to mid PTO rod 3 mid PTO lever 1 5 mid PTO shift arm 7 and...

Page 160: ...ERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 2 3 5 FRONT WHEEL DRIVE SHIFT 1 Front wheel drive lever 2 Front wheel rod 3 Front wheel drive arm 2 4 Front wheel drive shaft...

Page 161: ...22 CK22H 2 4 DIFFERENTIAL GEAR 2 4 1 STRUCTURE 1 11 gear shaft RH 2 Spiral bevel pinion 3 Differential bearing case RH 4 Spiral bevel gear 5 Rear differential case 6 11 gear shaft LH 7 Differential be...

Page 162: ...tial pinions 3 start rotating on their axes The other differential side gear is increased in speed by the increment of the differential pinions 3 This means that rotation of one rear axle is slowed do...

Page 163: ...t When the differential lock pedal is stepped on it causes the differential lock fork 10 and differential lock clutch 7 are moved toward the spiral bevel gear 1 The differential lock clutch 7 is engag...

Page 164: ...ut of mesh Differential lock cannot be set Differential lock pedal does not return Probable Cause Transmission oil insufficient Gear worn or broken Improper backlash between ring gear and spiral bevel...

Page 165: ...n plugs 196W4C3B 196W4C4B 196W4C5A 1 To drain the used oil remove the drain plug at the bottom of the transmission case and drain the oil completely into the oil pan 2 After draining reinstall the dra...

Page 166: ...nd the bonnet 2 Remove the side cover LH RH 3 3 Disconnect the battery terminal 4 For assembly When connect the battery terminal apply a little of grease to it 196W4C6A 196W4C7B 4 3 INSTRUMENT PANEL 1...

Page 167: ...ease to the splines of the propeller shaft 1 Propeller shaft 6 O ring 2 Coupling 7 O ring 3 Cir clip 8 Spring pin 4 Propeller shaft cover 1 9 O ring 5 Propeller shaft cover 2 10 Bolt 4 4 POWER STEERIN...

Page 168: ...D TIRES 1 Remove the lynch pin 2 and the lock pin 1 from the ROPS frame 2 Loosen the bolt 3 and remove the pin 4 3 Place to fix the jack to the bottom of the rear axle 4 Remove the nuts bolts from the...

Page 169: ...1 1 Remove the sprit pin 1 plain washer 2 and joint pin 3 2 Loosen the lock nut a of the parking brake wire 4 on the parking brake bracket 1 7 3 Remove the grommet 5 parking brake wire 1 8 and parking...

Page 170: ...uel filter 1 5 Remove the nuts 2 6 Remove the fuel tank assembly 3 the socket fixture 4 12 FRONT WHEEL DRIVING LEVER 1 Remove the snap pin and plain washer and then remove the lever rod 1 2 Remove the...

Page 171: ...n remove the engine by pulling it slowly When reassembling Apply grease to the splines Apply liquid gasket Three Bond 1 208D or equivalent to joint face of the engine and clutch housing 4 13 HYDRAULIC...

Page 172: ...C ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H...

Page 173: ...3 Plain washer 4 Damper cylinder 5 Spacer 6 Spacer 4 17 FRAME 1 Remove the bonnet wire harness 2 1 2 Disconnect the acceleration wiring 2 3 Remove the brake rods LH RH 3 4 Remove the clutch rod 4 5 Re...

Page 174: ...olt 7 Nut 4 Bolt 196W451A Item Clutch housing and mid case mounting screws Clutch housing and mid case mounting nuts Clutch housing and mid case mounting stud bolts Tightening torque 77 5 90 2 Nm 7 9...

Page 175: ...ISASSEMBLING THE HST ASSEMBLY CK22H 1 Remove the bolts 1 2 Disconnect the front axle case 3 from HST case 2 as a unit 3 Remove the bolt and the joint 4 4 Remove the volts and HST case 2 5 Remove the b...

Page 176: ...h bearings 4 7 5 Remove the oil seal 3 1 Bolt 2 Front wheel drive case 3 Oil seal 4 Ball bearing 5 Front wheel drive shaft 2 6 Front wheel drive shifter 7 Ball bearing 8 Ball 9 Spring 10 Ball bearing...

Page 177: ...ont wheel drive stopper 7 front wheel drive shaft 2 and O ring 4 3 Tap out the spring pin 3 and remove the front wheel drive arm 1 1 Front wheel drive arm 2 Front wheel drive shaft 3 Spring pin 4 O ri...

Page 178: ...t 2 and spring washer 3 2 Tap out the middle case assembly to the front side 1 Bolt 3 Spring washer 2 Nut 196W463A B DISSEMBLING THE HST OUTPUT SHAFT 1 Tap out the 19 gear spline boss 3 to the front s...

Page 179: ...Cir clip 9 ball bearing 10 to the rear side 1 PTO drive shaft 1 8 Cir clip 2 Spacer 1 9 Cir clip 3 O ring 10 Ball bearing 4 Oil seal 11 Bolt 5 Cir clip 12 Bearing case 6 Ball bearing 13 Bolt 7 22T gea...

Page 180: ...XLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 1 Remove the coupling 24 bolt 25 bolt 23 and stopper 22 2 Remove the bearing case 26 3 Remove the Cir clip 27 4 Draw out the front wheel drive sh...

Page 181: ...ERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 4 23 DISASSEMBLING SPIRAL BEVEL GEAR 1 Tap out the spring pin 1 and remove the differen tial lock arm...

Page 182: ...AXLE REAR AXLE CK22 CK22H 8 Remove the range shift arm 8 Separate it from inside of gear case 196W476A 8 Range shift arm CK22 5 Straighten locking tab of lock nut 1 and remove the nut 1 6 Tap out the...

Page 183: ...EAR AXLE REAR AXLE REAR AXLE CK22 CK22H 4 24 PTO LEVER AND MID PTO LEVER 1 Tap out the spring pin 18 2 Remove the mid PTO lever 1 17 3 Remove the nut 5 screw 4 4 Remove the items 13 16 5 Remove the PT...

Page 184: ...49T gear 3 Ball bearing 16 Ball bearing 4 PTO drive shaft 3 17 PTO change shifter 5 17T gear 18 Snap ring 6 Ball bearing 19 Snap ring 7 Snap ring 20 Ball bearing 8 Nut 21 Spline boss 9 Oil seal 22 42T...

Page 185: ...plug 2 Support the mid PTO assembly remove the bolts 1 and remove the assembly 3 Remove the O ring 3 spring pin 4 mid PTO counter shaft 5 ball bearings 6 7 snap ring 8 and 37T gear 9 4 Remove the oil...

Page 186: ...MEMO...

Page 187: ...ans mission 5 6 2 3 Functions of each component 5 7 2 3 1 Hydraulic pump 5 7 2 3 2 Hydraulic motor 5 7 2 3 3 Charge pump 5 8 2 3 4 Check valve and high pressure relief valve 5 8 2 3 5 Neutral valve 5...

Page 188: ...pm Maximum output torque theoretical Theoretical corner output Charge relief pressure Spiral bevel gear pinion turning torque PTO shaft lock nut tightening torque Backlash between Spiral bevel gear tu...

Page 189: ...RKE BARKE BARKE ELECTRIC ELECTRIC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE...

Page 190: ......

Page 191: ...nnected to closed circuit one fixed type pis ton motor oil filter charge pump charge relief valve check valve high pressure relief valve and neutral valve 2 2 2 APPEARANCE OF HYDRAULIC TRANSMISSION AN...

Page 192: ...BARKE BARKE BARKE BARKE BARKE ELECTRIC ELECTRIC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR...

Page 193: ...nd outlet port in valve plate at every 180 By adjusting the angle of the swash plate with trunnion shaft the amount of displacement can be changed In addition the displacement direction can be changed...

Page 194: ...d circuit The trochoid pump is installed as a charge pump to compensate the leaks The oil filter is installed at outlet side of the pump The displaced oil from charge pump flows into main circuit thro...

Page 195: ...tion during starting When the swash plate s angle and discharge volume become smaller the motor does not rotate because the oil flows into the inner passage of case passage B drain circuit via orifice...

Page 196: ...OP When the swash plate control lever is at neutral position the sliding surface of the swash plate will have vertical position against piston Then the cylinder block rotates with input shaft but the...

Page 197: ...l comes in through piston port and continues to rotate the oil will be dis charged through pump port B When the oil is supplied to motor port B oil pressur izes the piston by increasing the pressure T...

Page 198: ...mes in through piston port And continues to rotate the oil will be dis charged through pump port A When the oil is supplied to motor port A oil pressur izes the piston by increasing the pressure The p...

Page 199: ...to neutral holder Check input shaft Check charge pressure case pressure Check oil lever turn good good good Repair or replace Fill to proper level Repair or replace Change oil to specified oil not tur...

Page 200: ...E REAR AXLE REAR AXLE REAR AXLE CK22 CK22H CONTINUED Reset correctly High above maximum allowable limit 280 kg cm2 3982 5 PSI Oil heat over Inspect radiator net and oil cooler Check charge pressure ca...

Page 201: ...IC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H CONTINUED Inspect neutral valve Check linkage speed control pedal speed to neutral hol...

Page 202: ......

Page 203: ...g snap 6 Pin 7 Shaft motor 15 Plate swash motor 16 Plate shoe 17 Block cylinder 18 Seat spring 19 Spring 20 Ring snap 21 Pin space 22 Guide ball 23 Plate set 24 Piston ass y 25 Cover rear 26 Pin 27 Ch...

Page 204: ......

Page 205: ...r cover 25 then remove them Keep the valve plates 45 46 separate for cor rect assembly IMPORTANT NOTE Replace the oil seal and O ring with new ones when installing For assembly lubricate new O rings s...

Page 206: ...64 up to the shoulder of the shaft 7 Install the shaft 7 with the bearing 64 to the housing 15 Swash plate 64 Bearing 4 3 ASSEMBLY 1 Install the swash plate 8 into the housing 2 Using bushing bearing...

Page 207: ...nap ring 33 32 Oil seal 33 Snap ring 51 Charge pump casing 12 Install items 50 and 53 and new O ring into the charge pump casing 51 and install items 51 54 55 56 onto the housing and tighten 55 to a t...

Page 208: ...or lever 2 11 Lock arm 12 Connector plate 13 Lock shoe 14 Lock shaft 15 Connector 16 Damper cylinder assembly 196W486A 1 Lift rod 1 to take up the free play adjust nuts until distance A is 152 mm 5 98...

Page 209: ...r train 6 3 2 2 Principle of differential system 6 4 2 3 Differential lock system 6 6 3 TROUBLESHOOTING 6 7 4 SERVICING 6 8 4 1 Draining the transmission fluid 6 8 4 2 Hand brake EU 6 9 4 3 Separating...

Page 210: ...IC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 0 060 0 102 mm 0 0023 0 0040 in 0 15 0 20 mm 0 0059 0 0079 in 1 5 mm 0 0059 in 1 6 mm...

Page 211: ...ssion to the rear wheels The shaft speed controlled by the transmission is further reduced to approx 1 6 16 6T 37T by the spiral bevel pinion 1 and spiral bevel gear 2 and then reduced to 1 6 54 11T 7...

Page 212: ...otates as shown in the figure C The rack with a weight keeps its position and the other rack without a weight rises in the amount of the height that the pinion moves and the pinion pushes up the rack...

Page 213: ...RAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H However if the wheels on one side are on the slippery road the load difference between both differential side gears rem...

Page 214: ...e differential fork 2 moves to lock the differential system The differential lock is designed to operate the differ ential lock shift pin 3 to lock the differential case 4 and one differential side ge...

Page 215: ...er backlash between 7T spiral bevel pinion and bevel gear Improper backlash between differential pinion and differential side gear Bearings worn Insufficient or improper type or transmission fluid use...

Page 216: ...s 196W502A 196W147B 196W512A 1 To drain the used oil remove the drain plug at the bottom of the transmission case and drain the oil completely into the oil pan 2 After draining reinstall the drain plu...

Page 217: ...1 Remove the split pin 1 plain washer 2 and joint pin 3 2 Loosen the lock nut a of the parking brake wire 4 on the parking brake bracket 1 7 3 Remove the grommet 5 parking brake wire 1 8 and parking...

Page 218: ...f the rear axle 4 Remove the nuts bolts from the wheel 196W503A 1 Lock pin 3 Bolt 2 Lynch pin 4 Pin 4 4 FENDER 1 Remove the joystick mounting bolts and disconnect the cover 1 2 Remove the frame 2 3 Rm...

Page 219: ...ENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 4 6 REAR AXLE CASE 1 Loosen and remove the rear axle case mounting screws 1 3 2 Support the rear axle with n...

Page 220: ...AULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 1 Bolt 2 Spring washer 3 Bolt 4 Cir clip 5 Ball bearing 196W510A 6 72T bear 7 Spacer 8 Collar...

Page 221: ...6 4 1 Disassembling and assembling 7 6 4 1 1 Draining the transmission fluid 7 6 4 1 2 Hand brake CK22 EU 7 7 4 1 3 Separating rops and tires 7 8 4 1 4 Fender 7 8 4 1 5 Disassembling and assembling 7...

Page 222: ...BARKE ELECTRIC ELECTRIC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXL...

Page 223: ...fferential gear shaft When the brake pedal is pressed the force causes the brake cam shaft lever 2 to move via the brake rod 1 Brake case 5 Brake case cover 2 Cam lever 6 Brake plate 3 Cam plate 7 Bra...

Page 224: ...ET DISC BRAKES A REDUCED DISC WEAR Although wet discs are worn by approximately several tens of microns depending on the initial contact in ini tial period 50 hours or so of use almost no wear occurs...

Page 225: ...IC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H Brake pedal play unevenly adjusted Brake disc worn Cam plate warpe...

Page 226: ...ange 1 Drain plugs 196W604A 196W147B 196W619A 1 To drain the used oil remove the drain plug at the bottom of the transmission case and drain the oil completely into the oil pan 2 After draining reinst...

Page 227: ...ket 1 1 Remove the sprit pin 1 plain washer 2 and joint pin 3 2 Loosen the lock nut a of the parking brake wire 4 on the parking brake bracket 1 7 3 Remove the grommet 5 parking brake wire 1 8 and par...

Page 228: ...tom of the rear axle 4 Remove the nuts bolts from the wheel 196W620A 1 Lock pin 3 Bolt 2 Lynch pin 4 Pin 196W621A Item Fender support bolt ROPS support bolt Tightening torque 77 5 90 1 Nm 7 9 9 2 kgf...

Page 229: ...1 2 Remove the mounting bolts and remove the brake assembly 2 When reassembling When assembling note left or right positions 196W607A Item Brake assembly mounting bolt Tightening torque 24 5 29 4 Nm...

Page 230: ...in 4 2 INSPECTION FOR OVERHAUL 4 2 1 CHECKING DISASSEMBLING AND SERVICING A BRAKE PEDAL FREE PLAY 1 Press the center of the pedal with a force of ap proximately 39 59 N 4 6 kgf 9 13 lbs and measure th...

Page 231: ...gear case 8 13 5 1 7 Disassembling bevel gear case front differential case and 40 bevel gear 8 14 5 1 8 Disassembling bevel gear case gears 8 15 5 1 9 Disassembling axle 8 15 5 1 10 Disassembling spir...

Page 232: ...R AXLE CK22 CK22H 1 SPECIFICATIONS 1 1 GENERAL SPECIFICATIONS 1 Fluid SAE 90 gear oil or transmission fluid Transmission fluid specification DAEDONG TF65 Exxon Mobilfluid 423 or 424 BP Tractran UTH Sh...

Page 233: ...ntial case Differential case cover bore Differential side gear Pinion shaft to differential pinion Pinion shaft Differential pinion Differential pinion to differential side gear Shim Toe in Axial sway...

Page 234: ...REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 98 1 117 7 N 10 12 kgf 22 0 26 5 lbs 0 2 0 3 mm 0 0078 0 0118 in 0 15 0 35 mm 0 0059 0 0138 in 0 1 mm 0 0039 in 0 2 mm 0 0078 in 0 4 mm 0...

Page 235: ...rential cover 8 Front axle 9 Spiral bevel pinion shaft 10 Spiral bevel gear 11 Pinion shaft 12 Differential gear shaft 13 Bevel gear 14 Bevel gear 15 Bevel gear shaft 16 Bevel gear 17 Bevel gear The f...

Page 236: ...E REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 2 2 WHEEL ALIGNMENT To improve control and safety running front wheel is applied with adequate inclination in the direction of left right and forward 1 Cambe...

Page 237: ...LE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 4 The front wheels tend to roll outward due to the camber but toe in offsets it and ensures parallel rolling of the front wheels Another purpose of toe in i...

Page 238: ...d Replace Replace Replace Replace Reassemble Adjust or replace Replenish Replace Replace Adjust Symptom Front wheels wander to right or left Front wheel can not be driven Noise Provable Causes Tire pr...

Page 239: ...ir pressure as specified to tires 2 Measure the front width A and the rear width b between the front wheels while straightened to ob tain the difference toe in 3 For other than specified loosen the ti...

Page 240: ...If the runout exceeds the factory specifications check the bearing rim and front wheel hub 196W709A 196W710A 4 4 FRONT WHEEL STEERING ANGLE 1 Inflate the tires to the specified pressure 2 Loosen the...

Page 241: ...n reassembling 1 Steering hose L 2 Steering hose R 5 1 DISASSEMBLING AND ASSEM BLING 5 1 1 DRAINING FRONT AXLE CASE OIL 1 Place oil pans underneath the front axle case 2 Remove the drain plug 3 both s...

Page 242: ...G PROPELLER SHAFT 1 Slide the propeller shaft cover 5 4 after remov ing the bolts 10 2 Tap out the spring pin 8 and then slide the cou pling 2 to the rear When reassembling Apply grease to the splines...

Page 243: ...t axle from the front support 4 Remove the front wheels 5 1 6 DISSEMBLING BEVEL GEAR CASE AND FRONT GEAR CASE 1 Remove the bevel gear case mounting bolts 2 Remove the bevel gear case 3 and front gear...

Page 244: ...3 and shim 2 3 Remove the 40T bevel gear 1 4 Tap out the bevel gear 7 and ball bearing 5 Draw out the bevel gear shaft 8 6 Remove the external snap ring 5 7 Tap the bevel gear case 9 and separate it f...

Page 245: ...3 1 5 1 8 DISASSEMBLING BEVEL GEAR CASE GEARS 1 Remove the internal snap ring 1 2 Take out the bevel gears 5 7 with ball bearings 4 6 collar 2 and shims 3 When reassembling Install the same shims 3 be...

Page 246: ...bear ing and shim 14 from right side of front axle case 1 5 Remove the stake of lock nut 10 and then remove the lock nut 10 6 Remove the taper roller bearings 8 When reassembling Replace the lock nut...

Page 247: ...ernal snap ring 8 and then remove the ball bearing 6 and spiral bevel gear 7 as a unit with a puller 3 Remove the straight pin 13 4 Pull out the pinion shaft 10 and take out the differ ential pinions...

Page 248: ...erential case cover and differential side gear Allowable limit 0 35 mm 0 0138 in Factory spec 0 040 0 074 mm 0 00167 0 00291 in Item Differential case bore I D Differential case cover bore I D Differe...

Page 249: ...0 024 in 0 8 mm 0 031 in 1 0 mm 0 039 in 1 2 mm 0 047 in Tooth contact More than 35 Center of tooth contact 1 3 to 1 2 of the entire width from the small end 5 2 4 TURNING FORCE OF SPIRAL BEVEL PINION...

Page 250: ...BETWEEN SPIRAL BEVEL PINION SHAFT AND SPIRAL BEVEL GEAR 1 Set a dial gauge lever type with its finger on the spline of spiral bevel pinion shaft 2 Measure the backlash by moving the spiral bevel pinio...

Page 251: ...the backlash is not within the factory specifications adjust with shim 3 Reference Thickness of adjusting shims 3 0 8 mm 0 031 in 1 2 mm 0 047 in 1 0 mm 0 039 in Tooth contact More than 35 1 16T beve...

Page 252: ...exceeds the allowable limit replace the front axle case A PRESS FITTING BUSHING When press fitting a new bushing observe the di mension described in the figure NOTE After replacing the bushing be sur...

Page 253: ...g control motor 9 8 2 5 Steering cylinder 9 9 2 6 Gear pump 9 10 3 TROUBLESHOOTING 9 11 4 SERVICING 9 12 4 1 Hydraulic pump 9 12 4 1 1 Bonnet 9 12 4 1 2 Disassembly the hydraulic pump ass y 9 12 4 1 3...

Page 254: ...YDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H Gear 29 min 7 66 GPM 1 0 8056 40 cc rev 110 kgf cm2 10 8 MPa...

Page 255: ...optimally and results in a high front wheel steering angle and small turning radius The steering power of the steering wheel is transmit ted to the front wheel through the power steering motor hydraul...

Page 256: ...L GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 2 2 HYDRAULIC CIRCUIT DIAGRAM 1 Oil tank transmission case 2 Oil filter 3 Gear pump With engine started the hydra...

Page 257: ...and L will be shut off at control valve Steering cylinder will not move and keeps front wheel straight or at given angle without motion 1 Steering controller 4 Centering spring 2 Steering wheel 5 Ger...

Page 258: ...AXLE REAR AXLE REAR AXLE CK22 CK22H 2 3 3 TURNING TO LEFT The operation for the left turn is same as that of right turn except for the oil flow direction 1 Steering controller 4 Centering spring 2 Ste...

Page 259: ...ENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 2 4 OPERATING OF STEERING UNIT 1 Steering case assembly 2 Dust seal 3 Retainer ring 4 Seal gland bushing 5 O ring 6...

Page 260: ...n the pin and the holes on the spool Therefore when the shaft and sleeve rotate the spool rotates with approx 10 of clearance At this moment a fluid passage is formed between the spool and the sleeve...

Page 261: ...C ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE C...

Page 262: ...steering hydraulic pumps have superior volume efficiency and mechanical efficiency and extracts power from the engine right cam shaft gear B PUMP PERFORMANCE Type Single Gear Ratio 1 0 805 Rotation D...

Page 263: ...nt Oil leak from tube joint Hydraulic pump malfunctioning Relief valve malfunctioning Air in the hydraulic tube Low operating pressure Hydraulic pump malfunctioning Improper relief valve adjustment Co...

Page 264: ...3 4 1 HYDRAULIC PUMP 4 1 1 BONNET 1 After opening the bonnet 1 disconnect the con nector 2 remove the bolts and the bonnet 2 Remove the side cover LH RH 3 3 Disconnect the negative battery terminal 4...

Page 265: ...GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 3 Remove the thrust plate 6 1 Loosen the bolts 12 and remove the cover 2 2 Remove the cover 2 and formed seal gasket When r...

Page 266: ...EX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 4 Remove the drive gear 4 and the driven...

Page 267: ...STRUMENT PANEL 1 Remove the steering wheel 1 2 Remove the parking brake lever grip 2 and the speed set lever grip 3 3 Remove the transmission cover 4 CK22H 4 Remove the instrument panel cover down 5 5...

Page 268: ...ding the power steering motor up under the steering shaft while turning the steering wheel slightly to engage the splines of the steering shaft and motor Push the power steering motor up completely on...

Page 269: ...and stator 2 from the spacer plate 5 Remove the large O ring which fits between the stator 2 and stator plate and the smaller O ring and seal ring 1 which fits between the rotor 4 and cap NOTE The inn...

Page 270: ...DEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 6 Using a screwdriver remove the...

Page 271: ...spool 2 assembly 11 Push the spool upward out of the sleeve slightly and pull the centering springs 1 outward Then remove the spool from the bottom side of the sleeve 196W831A 196W832A 1 Sleeve 3 Pin...

Page 272: ...OR pump stator and rotor for wear Make certain the rotor turns within the stator 5 Inspect the drive shaft for wear or damage 6 Inspect the thrust bearing for wear or damage 7 Inspect the centering sp...

Page 273: ...rizontal to the bench and carefully insert the as sembly into the bottom of the steering motor hous ing 1 Rotate the assembly slightly while inserting it to ease installation Position the spool and sl...

Page 274: ...in the gland bushing then insert the bushing into the hous ing while rotating it 9 Install the retaining ring in the housing groove 196W738A 10 Position the steering motor housing in a vise with the b...

Page 275: ...gages the pin in the spool and sleeve Mark a line 2 on the face of the drive shaft that is parallel to the pin and to the port face of the steering motor housing 3 15 Coat a new O ring 2 and seal ring...

Page 276: ...o of the valleys of the rotor NOTE A sign that the rotor is positioned correctly is that the tip of one rotor lobe is resting halfway between the valleys 1 in the stator directly above the port face s...

Page 277: ...ELECTRIC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REA...

Page 278: ...1 2 2 Pull out the split pin 5 and remove the nut 6 3 With tapping the end of support pin using a plastics hammer pull out support pin from the front axle case 4 Remove the bolt 3 and pull out the cyl...

Page 279: ...engine speed at approx 2 800 rpm 2 Set a spring balance to the steering wheel to mea sure the operating force 3 If the measurement exceeds the factory specification check the performance of hydraulic...

Page 280: ...MEMO...

Page 281: ...low control valve 10 28 4 1 1 Bonnet 10 28 4 1 2 Flow control valve 10 28 4 1 3 Relief valve assembly 10 29 4 1 4 Flow divider assembly 10 29 4 1 5 Directional valve 10 29 4 2 Joy stick valve disassem...

Page 282: ......

Page 283: ...ission Oil filter not built in Required degree of filtering 20 25 m Oil temperature 80 C Reference Dimension Gear 29 min 7 66 gpm 1 0 805 Max Pore Dia 110 8 Min Pore Dia 92 4 2 772 cm 429 7 in Max Por...

Page 284: ...p oil filter oil cooler CK22H HST CK22H priority valve Joy stick valve control valve and lift links The rear axle and transmission case serve as a com mon hydraulic fluid tank and supply fluid to the...

Page 285: ...FRONT AXLE FRONT AXLE STEERING STEERING STEERING STEERING STEERING BARKE BARKE BARKE BARKE BARKE ELECTRIC ELECTRIC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAUL...

Page 286: ......

Page 287: ...mination B OPERATION PRINCIPLE The filtering system is composed of filter bracket and element ass y The filter used for CK series tractors is applicable to both hydraulic lift and steering control cir...

Page 288: ...XLE CK22 CK22H 2 4 HYDRAULIC BLOCK When implement is not attached When implement is attached This hydraulic block type outlet is provided to send hydraulic fluid out from the tractor to operate the hy...

Page 289: ...fed to the EF port The PF port is connected to the power steering The EF port is connected to joy stick v v or remote hyd v v Vibration is caused by a change in the oil flow when the engine speed is...

Page 290: ...ect the implement s inlet line to port A The outlet line to the port B then turn the directional valve coun terclockwise to the end The oil pressure fed from the hydraulic pump enters into the P port...

Page 291: ...INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 2 5 JOYSTICK VALVE...

Page 292: ...control valve contains check valves located in the valve spool passages The check valves function to hold the loader lift and bucket cylin ders in a fixed position while the valve is being initially...

Page 293: ...ULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H A DUMP POSITION 1 Lift control valve spool 2 Bucket control spool 3 Control lever 4 Bucket cyl...

Page 294: ...DRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H B ROLL BACK POSITION 1 Lift control valve spool 2 Bucket control spool 3 Control...

Page 295: ...R AXLE CK22 CK22H C RAISING POSITION 1 Lift control valve spool 2 Bucket control spool 3 Control lever 4 Bucket cylinder 5 Lift cylinder When the control lever 3 is moved to the raising posi tion the...

Page 296: ...IC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H D LOWERING POSITION 1 Lift control valve spool 2 Bucket control spool 3 Control lever...

Page 297: ...GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H E FLOATING POSITION 1 Lift control valve spool 2 Bucket control spool 3 Control lever 4 Bucket cylinder 5 Lift cylinder When the li...

Page 298: ...valve 2 Nut 5 Screw 8 Spool 3 Screw 6 Cover 9 Articulation 704W918B A double acting detent type control valve is used When the control valve operating lever is moved to the imple ment cylinder actuat...

Page 299: ...RKE BARKE ELECTRIC ELECTRIC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR...

Page 300: ...ulic lift cylinder remains by the check valve 3 Therefore the 3 point hitch can maintain its position even when the load is applied to it The hydraulic fluid is supplied to the b port and its pressure...

Page 301: ...drawn through the b port passes the spool and then joins the fluid drawn through the a port Meanwhile the oil from the a port is supplied to the top of the pilot valve 5 and the bottom of the regulato...

Page 302: ...id from the top of the discharge valve when the exhaust valve is closed again The fluid on the top of the discharge valve is drained through this hole and the fluid passage h Lowering speed adjust val...

Page 303: ...es the arms of the Rockshaft With the raising movement the crank 7 with its pin 8 rotate anticlockwise and by means of lever 9 they ro tate the balance lever 10 in the same direction The lever 10 with...

Page 304: ...strument posi tioned on the end of the lifting arm rotate clockwise the screw B for 1 2 3 4 of a turn max And block the position with the self locking nut A In this way the Control Valve is sensitivit...

Page 305: ...DRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H This is an important measurement of the good func tioning of the rocksh...

Page 306: ...ve safety valve protecting the cylinder Faulty adjustment of the max Upper position of lift arms Symptom The rockshaft lifts jerkily Rockshaft does not operate The rockshaft does not descend over its...

Page 307: ...rnal leakage control kit or opposite side Excessive internal leakage on A and B ports Dropping load during transition while raising Inability to build pressure on A and B ports 3 2 JOYSTICK VALVE Prov...

Page 308: ...r open the bonnet 1 and disconnect the connector remove the bolt 2 and the bonnet 2 Remove the side cover LH RH 3 3 Disconnect the negative battery terminal 4 For assembly When connect the battery ter...

Page 309: ...assembling Install the flow divider assembly 2 to the outlet using care not to damage the O ring 4 1 5 DIRECTIONAL VALVE 1 Remove the external snap ring 2 2 Remove the directional valve 3 When reassem...

Page 310: ...ECTION AND ASSEMBLY 4 2 1 JOY STICK VALVE REMOVAL 1 Remove the step mat 1 2 Loosen the joy stick bolts and remove the cover 2 3 Remove the frame 3 and push the joy stick down 4 Remove the parking brak...

Page 311: ...0 End cap 21 Spool control kit 22 Plug 4 2 2 JOY STICK VALVE DISASSEMBLY 5 Disassemble the spool 25 in the same manner as the float spool using step through 4 6 Remove the load check plugs 17 with O r...

Page 312: ...E REAR AXLE CK22 CK22H 2 Install the load check poppets with O rings springs and check plugs 17 Item Blocking plug Tightening torque 42 Nm 4 3 kgf m 31 lb ft 4 2 3 JOY STICK VALVE ASSEMBLY 1 Install t...

Page 313: ...CTRIC ELECTRIC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXL...

Page 314: ...Gauge A Oil level is acceptable within this range 196W502A 196W511A 1 To drain the used oil remove the drain plug at the bottom of the transmission case and drain the oil completely into the oil pan...

Page 315: ...IRES 1 Remove the lynch pin 2 and the lock pin 1 from the ROPS frame 2 Loosen the lock nuts 3 and remove the pin 4 3 Remove ROPS 4 Place a jack securely to the bottom of the rear axle 5 Remove the nut...

Page 316: ...rs to the rear combi lamp turn sigal lamp and working lamp 2 Remove the ROPS mounting bracket 1 3 Remove the grip 2 from the levers and then re move the lever guide 3 4 Remove the fender support 5 5 R...

Page 317: ...the position lever 1 2 Remove the joint bolt and the hydraulic tube a 2 b 3 3 Remove the double acting valve 4 the lever 5 4 Remove the hydraulic tube p 6 5 Remove the PTO lever 7 6 Remove the oil fi...

Page 318: ...for ease of reassembly 4 Use soft face hammer to tap inside of lift arm to remove lift arm from splined shaft Installation 1 Align marks on splined shaft and lift arm and slide lift arms onto splines...

Page 319: ...E REAR AXLE REAR AXLE CK22 CK22H 4 Hold cylinder with large opening down and remove piston from bore 5 Inspect cylinder bore piston and piston seal for damage Replace as necessary 6 Replace O ring and...

Page 320: ...end of eccentric actuator 196W965A Do not force components during disassembly or assembly Clearances are tight and components must be free to move for depth control mecha nism to function correctly IM...

Page 321: ...19 mm 0 748 in from spring set 196W970A 1 Stop rod 2 Spring set A 19 mm 0 748 in 11 Remove push rod assembly from lever by removing plug 10 from either side of lever 12 Remove stop rod from spring set...

Page 322: ...KE BARKE BARKE ELECTRIC ELECTRIC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE...

Page 323: ...Be sure to pay attention to orientation of components when assembling 196W976A 1 Cir clip 6 Link 2 Cir clip 7 Cir clip 3 Support pin 8 Roller 4 Arm 9 Plain washer 5 Seal washer 19 Measure shaft 1 out...

Page 324: ...plines 2 Arm 3 Set screw A Direction of shaft movement Rockshaft can only be removed from one side of housing due to stepped bearing surfaces Be sure to determine correct orientation of rockshaft be f...

Page 325: ...GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 1 1 Shaft to busing clearance Shaft right O D Shaft left O D Factory specification 0 075 0 114 mm 0 0030 0 0045 in...

Page 326: ...new O rings on body of MLS valve if required 2 Orient MLS valve so that the mounting holes line up with the appropriate holes in the housing with the MLS towards the bottom of the housing See re mova...

Page 327: ...E BARKE BARKE ELECTRIC ELECTRIC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE R...

Page 328: ...GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H HYDRAULIC SYSTME SERVICING T46WAD3A T46WAD4A 5 Unscrew the socket head bolt 1 and remove the end pl...

Page 329: ...AR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H HYDRAULIC SYSTME SERVICING T46WAD5A T46WAD6A B REASSEMBLY Apply sufficient amount of oil to each part to prevent any damage when installing t...

Page 330: ...IC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 4 Insta...

Page 331: ...INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H HYDRAULIC SYSTME SERVICING T46WAE2A T46WAE3...

Page 332: ...MEMO...

Page 333: ...11 18 3 4 Trouble shooting fuel level circuit 11 19 3 5 Trouble shooting oil pressure circuit 11 19 3 6 Trouble shooting coolant temp circuit 11 19 3 7 Trouble shooting enigne tachometer circuit 11 19...

Page 334: ......

Page 335: ...R 10A 10A 10A 15A WORKING LAMP Holding COMBIMETER PREHEAT PLUG RELAY PREHEAT SW CLUCH Pull in PUSH 0 77A 32A 5 6 7 5 9 10 8 5 6 7 23 23 P2 11 3 23 8 8 7 6 9 10 9 10 P1 3 11 8 7 P2 10 6 P1 12 12 3 R 5...

Page 336: ...anel 17 Diode 16 Horn 32 Head Lamp 12 Turn signal lamp LH 27 Turn signal lamp RH 6 Oil pressure switch 3 Alternator 33 Diode 2 Coolant temperature sensor 4 Slow blow fuse 5 Starter Motor 10 Pull coil...

Page 337: ...ENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CK22 CK22H Description Symbol Description Symbol Fuse Slow blow fuse Motor Switch Normally Open Type...

Page 338: ...EAR AXLE CK22 CK22H 196WA55A 1 3 2 WIRING COLOR IDENTIFICATION Color Black Blue White Brown Green Red Black White Black Red Yellow Green Yellow Brown Brown Red Red White Yellow Red Yellow White White...

Page 339: ...f wire 0 85 mm2 G Base color of insulating cover R Stripe color on the base color ELECTRIC SYSTEM CIRCUIT AND COMPONENT LOCATION If the wire color is striped the base color is given first followed by...

Page 340: ...he ON position after starting the engine the preheat controller operates the preheat relay again for 20 sec onds for after heating This is to optimize fuel combus tion in the engine after starting If...

Page 341: ...LENOID PULL COIL RELAY ENGINE STOP SOLENOID 25A 10A UNITS HOLD COIL PREHEAT CONT TIMER RELAY SIGNAL LAMP GND 1Hz ON ST Holding COMBIMETER PREHEAT PLUG RELAY PREHEAT SW CLUCH Pull in 0 77A 32A P2 11 3...

Page 342: ...rning lamp However this voltage is blocked by the diode and the lamp goes out due to a loss of ground If the alternator is in a normal charge condition but the charge warning lamp does not go off afte...

Page 343: ...COMBINATION SWITCH IS INSTALLED ON THE LEFT SIDE OF THE DASHBOARD Six switch positions OFF Tail Headlamp low beam Tail Headlamp high beam Turn signal lamp LH Turn signal lamp RH Horn 196WA03B 196WA04...

Page 344: ...DRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 196WA57A 2 4 3 FLASHER UNIT The flasher unit controls the flashing of the hazard lights Thi...

Page 345: ...L REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CK22 CK22H 1 3 2 C TAIL LIGHT ONLY CK22 USA The tail lights only operate while the main light switch is ON B BRAK...

Page 346: ...BARKE ELECTRIC ELECTRIC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXL...

Page 347: ...rn signal indicator LH 6 Turn signal indicator RH 7 Parking brake operation indicator 8 Engine oil low pressure warning lamp 9 Battery discharging warning lamp 10 Pre heat operation indicator 11 High...

Page 348: ...gine coolant When the gauge enters the red zone please shut tractor OFF immediately Never operate the tractor while the gauge is in the red zone D HOUR METER 1 Hz signal 1 wave for 1 second is sent to...

Page 349: ...BRAKE SWITCH AM ACC OFF ACC ON GL ST ON GL ST 5A CONNECTOR CUSTOMER USE 10A 10A UNITS HOLD COIL PREHEAT CONT TIMER RELAY ON SIGNAL LAMP GND 1Hz ON ST COMBIMETER PREHEAT PLUG RELAY PREHEAT SW CLUCH P2...

Page 350: ...w plug will not heat Glow plug indicator light not functioning properly Continuously discharge battery Remedy Recharge or replace the battery Replace the 60 amp fuse Test the switch and replace if nec...

Page 351: ...d replace if necessary 3 5 TROUBLE SHOOTING OIL PRESSURE CIRCUIT ELECTRIC SYSTEM TROUBLESHOOTING Possible Cause Blown 5 amp fuse Malfunctioning temp sensor Improper ground circuit Malfunctioning temp...

Page 352: ...ive cord of the battery 2 Connect the Ampere meter like figure 3 Operates all electrical system like head lights Sect Current Voltage Engine rpm Rated spec 50 A 14 15 V 2 800 rpm To avoid accidental s...

Page 353: ...e latch release to the right and lifting the hood to its fully raised position 2 Disconnect the negative battery cable 3 3 Disconnect the positive battery cable 2 4 Remove the battery hold down hardwa...

Page 354: ...to test the switch With the key in the OFF position continuity will not exist between any of the terminals not shown With the key in the ACCESSORY position there will be continuity between the AM BATT...

Page 355: ...test a relay disconnect it from the circuit Use an ohmmeter to verify non energized conditions Connect the ohmmeter leads to terminals 87 and 30 There will be no continuity between terminals 87 and 3...

Page 356: ...2 1 3 196WA23B 4 2 3 ENGINE STOP SOLENOID The Engine Stop Solenoid Is Installed On The Engine Gear Case The resistance of the engine stop solenoid should be measured when the wiring connector is disc...

Page 357: ...low plugs operate A PRE HEAT CONTROLLER TESTING NOTES Always verify polarity of the battery before testing A 12 volt battery voltmeter a switch and jumper wires are needed to test the pre heat control...

Page 358: ...starter motor from the engine 3 Connect a battery positive cable at least 20sq to starter motor B terminal and battery positive terminal Connect the negative battery cable to the starter body 4 Conne...

Page 359: ...ct Battery positive terminal to S terminal with a switch placed in the circuit 4 Switch ON the pinion will moves 5 If the pinion does not move change the magnetic switch NOTES Operating for more than...

Page 360: ...nd position the headlamps high beam and tail lamps are turned on When the switch is in headlamp high position the high beam indicator blue lamp illuminates on the in strument panel 4 3 2 TURN SIGNAL S...

Page 361: ...ens 2 and 3 2 Push in on the bulb 6 and 9 and rotate counter clockwise in the socket to remove the old bulb 3 Insert a new bulb into the socket and turn the bulb clockwise until tightened 4 3 6 BRAKE...

Page 362: ...X HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE CK22 CK22H 4 3 7 HEADLIGHTS To replace a failed head light...

Page 363: ...AXLE REAR AXLE REAR AXLE REAR AXLE CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CK22 CK22H 196WA67A 4 3 8 BRAKE AND TAIL LIGHTS INSIDE BRAKE LIGHT OUTSIDE TAIL LIGHT CK22 USA To replace a faulty taillight bulb...

Page 364: ...ASS Y COMBI METER TEMP SENSOR FUEL GAUGE SENSOR ENGINE OIL SWITCH PARKING BRAKE SWITCH 5A 3 A 11 8 7 P2 10 6 P1 12 0 85 GW 0 5 B 0 5 R 0 5 R 0 5 B 0 5 PB 0 5 Gr 0 85 B 0 85 B 0 85 B 0 85 Y 0 5 WB 0 5...

Page 365: ...loses when oil pressure is low 0 5 0 1 kgf cm to complete the ground circuit of the oil pressure warning light When the ground circuit is completed the oil pressure warning light illuminates on the in...

Page 366: ...f f FUEL LEVEL SENSOR TESTING Use an ohmmeter to test the fuel level sensor Re move the sensor from the fuel tank Attach one of the meter leads to the wire yellow brown color of the sensor Attach the...

Page 367: ...2 12 CAUTIONS WHEN HANDLING TIRES 0 8 3 SAFETY DECALS 0 9 3 1 LOCATION OF DECALS 0 9 CHAPTER 1 GENERAL 1 1 1 TRACTOR IDENTIFICATION 1 3 2 DIMENSIONS 1 4 3 SPECIFICATIONS 1 5 4 LUBRICANTS FUEL AND COO...

Page 368: ...EM 2 17 3 3 COOLING SYSTEM 2 20 3 4 FUEL SYSTEM 2 22 3 5 GOVERNOR SYSTEM 2 27 3 6 INTAKE AND EXHAUST SYSTEM 2 30 4 TROUBLESHOOTING 2 32 5 MEASUREMENT AND ADJUSTMENT 2 35 5 1 FAN BELT 2 35 5 2 COMPRESS...

Page 369: ...4 23 4 6 STEP 4 24 4 7 SEPARATING ROPS AND TIRES 4 24 4 8 SEAT 4 24 4 9 HAND BRAKE CK22 EU 4 25 4 10 FENDER 4 26 4 11 FUEL TANK 4 26 4 12 FRONT WHEEL DRIVING LEVER 4 26 4 13 HYDRAULIC TUBES 4 27 4 14...

Page 370: ...IONS 6 2 2 OPERATING PRINCIPLE 6 3 2 1 POWER TRAIN 6 3 2 2 PRINCIPLE OF DIFFERENTIAL SYSTEM 6 4 2 3 DIFFERENTIAL LOCK SYSTEM 6 6 3 TROUBLESHOOTING 6 7 4 SERVICING 6 8 4 1 DRAINING THE TRANSMISSION FLU...

Page 371: ...9 STEERING SYSYTEM 9 1 1 SPECIFICATIONS 9 2 2 OPERATING PRINCIPLE 9 3 2 1 HYDRAULIC SCHEMATIC 9 3 2 2 HYDRAULIC CIRCUIT DIAGRAM 9 4 2 3 OPERATION 9 5 2 4 OPERATING OF STEERING UNIT 9 7 2 5 STEERING C...

Page 372: ...GEND FOR CIRCUIT DIAGRAM 11 5 2 OPERATION PRINCIPLE 11 8 2 1 PREHEATING 11 8 2 2 STARTING 11 9 2 3 CHARGING 11 10 2 4 LIGHTING 11 11 2 5 INSTRUMENT CLUSTER 11 15 3 TROUBLESHOOTING 11 18 3 1 TRUOUBLE S...

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Daedong CK22, Workshop Manual

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