DAEDONG WORKSHOP MANUAL INDUSTRIAL DIESEL ENGINES

Transcription

1 DAEDONG WORKSHOP MANUAL INDUSTRIAL DIESEL S

2 Contents 1. 3C Series Workshop Manual 2. 3A Series Workshop Manual 3. 4A, 3B, 4B Series Workshop Manual

3 1. 3C Series Workshop Manual

4 CK20S/CK20S(H) 1. IDENTIFICATION 1.1 FEATURES The 3C100A is a vertical, watercooled, 4cycle diesel engine. They are incorporated with DAEDONG s leading technologies. They feature greater power, lower fuel consumption, and little vibration and quiet operation due to the DAEDONG s circular combustion chamber, wellknown Bosch K type injection pump and wellbalanced designs. IDENTIFICATION 196W207B INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

5 IDENTIFICATION CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH 1.2 EPA DECAL This aluminum decal is riveted on the engine cylinder head cover. This provides the information such as model number, displacement, rated output, valve clearance, injection timing, etc. This decal represents that this engine is in compliance with the U.S.EPA and California (CARB) exhaust emission regulation. 1.3 BAR CODE FOR NUMBER The bar code for the DAEDONG engine number is located on the intake manifold. 1.4 NUMBER ASSIGNMENT STANDARD The engine number is also stamped near the fuel injection pump on the cylinder block, in case the bar code is not available due to damage. IMPORTANT The engine number is necessary information that is requested on the warranty registration form. This number should be on the form as well as the tractor serial number and the amount of time used. For example, FD means that this engine is the first manufactured unit, 3B183 LXM, in IMPORTANT INFORMATION Engine Family: 5DCLL02.2D87 Injection Timing: 18 DEG BTDC Engine Type: Displacement: L Advertised Power: 33.6 kw a 2600 RPM Idle Min: 850 RPM Valve Clearance(mm): Inlet 0.25 Exhaust 0.3 e11*97/68da*2002/88*0182*03 Adjustments should be made when the engine is at normal operating temperature with transmission in neutral. This engine conforms to 2005 U.S EPA andcalifornia regulations for offroad compressionignition engines. This engine is certified to operate on commercially available diesel fuel. Refer to owner's manual for maintemance specifications and adjustmints. E F D Engine model Serial number 3B183LXM 3B183LXH 4A200LXM 4A200LXH 4A220LXM 4A220LXH 4B243LXM 4B243LXH Year of manufacturing D E F G... D40 D41 D22 D23 D24 D25 D38 D T46W202A 24 SS30W00 May. 2007

6 CK20S/CK20S(H) 2. SPECIFICATIONS 2.1 SPECIFICATIONS Item Model Type Number of cylinders Bore stroke Total displacement Engine gross power Maximum idle speed Minimum idle speed Maximum torque Combustion chamber Fuel injection pump Plunger bore Governor Injection type Injection timing Injection pressure Compression ratio Lubricating system Lubricating oil filter Oil relief pressure Lubricating oil capacity Engine oil specification Cooling system Coolant capacity Antifreeze Starting system Battery Starting support device Dynamo for charging Fuel Weight (Dry) Injection order Direction of rotation SPECIFICATIONS Factory Specification 3C100A Vertical, watercooled 4 cycle diesel engine 3 75 X 76 mm 1007 cm 3, cu.in. 22 HP (16.2 kw) / 2,800 rpm. 3,000 rpm 1,000 rpm 63.7 Nm, 6.5 kgfm, 47 lbsft/1,900 rpm Spherical type, swirl chamber Bosch type K mini pump 5 mm, in. Centrifugal ball mechanical governor Indirect injection with pre combination chamber 18 before top dead center 14.2 MPa, 145 kgf/cm 2, 2,062 psi 21.5 : 1 Forced lubrication by rotortype pump Full flow paper filter (cartridge type) 4.5 ~ 5.4 kgf/cm 2 (64 ~ 76 psi) 3.2 (0.84 U.S.gal.) SAE 15W40, CD or high or of API grode Pressurized radiator, forced circulation (with pump) 4.6 (1.21 U.S.gal.) Ethylene glycol 50% with anti corrosive agent Electric starting with start motor 12 V, 80AH, Equivalent (CCA, 630AH) By glow plug in combustion chamber 12 V, 240 W Diesel fuel No.2D (ASTM D975) 98 kg, 216 lbs Counterclockwise (wiewed from flywheel side) The engine gross output is measured with the cooling fan removed. The cylinder number for ignition sequence is given from the cylinder on the engine cooling fan side. If the coolant level drops due to its evaporation, add only water. If the coolant level drops due to the leakage, add coolant mixed with antifreeze. The freezing point of the coolant mixture is 37 C (34 F) in a normal condition. When replacing the coolant with a different type of coolant, flush the cooling system thoroughly beforehand. INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

7 SPECIFICATIONS CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH 2.2 PERFORMANCE CURVE NOTE: Performance curve, obtained in accordance with SAE J SFC (Specific Fuel Consumption) According to the curve, 197g/Hphr at 2,800 rpm 197g/Hphr X 22 HP = 4,334 kg/hr 4,334 kg/hr 0.81 kg/ = 5.35 /hr 1 of diesel fuel is 0.81 kg 196W203B 26 SS30W00 May. 2007

8 CK20S/CK20S(H) SPECIFICATIONS 2.3 DIMENSIONS 502 (19.7) 494 (19.4) (24.7) mm (in.) 196W204B INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

9 SPECIFICATIONS CK20S/CK20S(H) 2.4 SERVICE SPECIFICATIONS INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH CYLINDER HEAD Item Distortion of cylinder head surface length. Thickness of gasket Top clearance Tightness of head bolts VALVES Valve seat width Valve seat angle (intake, exhaust) O.D. of valve stems (intake, exhaust) I.D. of valve guides (intake, exhaust) Clearance between valve stems and guides Valve recessing Valve clearance (intake, exhaust) cold Free length Fitted length Load to compress to fitted length Squareness Item VALVE SPRINGS Item Reference Value 0.05 mm ( in.) / 100 mm (4 in.) of cylinder head surface length. When tightened 1.15 ~ 1.25 mm (0.045 ~ in.) 0.7 ~ 0.9 mm ( ~ in.) 58.8 ~ 63.7 Nm 6.0 ~ 6.5 kgfm (43.4 ~ 47.0 lbft) Reference Value 2.1 mm in , rad. 60, ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in mm in Reference Value 35.1 ~ 35.6 mm ~ in mm in. 74 N / 31 mm 7.5 kgf / 31 mm, 16.5 lbs / 1.22 in. 1.3 mm in. Allowable Limit Allowable Limit 0.1 mm in. 1.3 mm in. Allowable Limit 34.8 mm 1.37 in. 63 N / 31 mm 6.4 kgf / 31 mm, 14.1 lbs / 1.22 in. 28 SS30W00 May. 2007

10 CK20S/CK20S(H) SPECIFICATIONS VALVE ROCKER ARMS CAMSHAFT O.D. of camshaft bearing journal I.D. of camshaft bearing Clearance between camshaft bearing journals and bearings Alignment of camshaft Cam height Gear backlash PISTON RINGS Ring gap Side clearance of ring in groove Item O.D. of rocker arm shafts I.D. of rocker arm bushings Clearance between rocker arm shafts and bushings Adjustment of compression release Item Item Intake Exhaust Top ring 2nd ring Oil ring Top ring 2nd ring Oil ring Reference Value ~ mm ~ in ~ mm ~ in ~ 0.07 mm ~ in ~ mm ~ in. Reference Value ~ mm ~ in ~ mm ~ in ~ mm ~ in mm in mm in ~ mm ~ in. Reference Value 0.15 ~ 0.30 mm ~ in ~ 0.45 mm ~ in ~ 0.35 mm ~ in ~ 0.08 mm ~ in ~ 0.06 mm ~ in. Allowable Limit 0.12 mm in. Allowable Limit 0.15 mm in mm in mm in mm in. 0.2 mm in. Allowable Limit 1.25 mm in mm in mm in. INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

11 SPECIFICATIONS CK20S/CK20S(H) PISTONS INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH I.D. of piston bosses O.D. of piston pin CRANKSHAFT Crankshaft alignment O.D. of crankshaft journals I.D. of crankshaft bearing 1 I.D. of crankshaft bearing 2 Clearance between crankshaft journals and bearing 1 Clearance between crankshaft journals and bearing 2 O.D. of crankpins I.D. of crankpin bearings Clearance between crankpins and bearings End play of crankshaft FUEL INJECTION NOZZLES Opening pressure Item I.D. of connecting rod small end bushings (fitted) Clearance between piston pin and small end bushings Connecting rod alignment Item Item Fuel tightness of nozzle valve seat Reference Value ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in mm in. Reference Value 0.02 mm in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ 0.31 mm ~ in. Reference Value 14.2 ~ 15.2 MPa 145 ~ 155 kgf/cm², 2,062 ~ 2,204 psi. Dry nozzle at 12.7 MPa 130 kgf/cm², 1,848.6 psi. Allowable Limit mm in mm in mm in. Allowable Limit 0.08 mm in mm in mm in mm in. 0.5 mm in. Allowable Limit 210 SS30W00 May. 2007

12 CK20S/CK20S(H) SPECIFICATIONS INJECTION PUMP Item Reference Value Allowable Limit Tightness of plunger Tightness of delivery valve Injection timing More than 60 seconds; initial pressure from ~ MPa 350 ~ 400 kgf/cm 2, 4,978 ~ 5,689 psi. More than 10 seconds; initial pressure from ~ MPa 210 ~ 220 kgf/cm 2, 2,987 ~ 3,129 psi 22 Before Top Dead Center 30 seconds 5 seconds OIL PUMP Oil pressure Rotor type End clearance between rotor and cover RADIATOR THERMOSTAT Item Reference Value Allowable Limit At rated speed At idle speed Opening pressure of cap Test pressure Rotor lobe clearance Radial clearance between outer rotor and pump body Item Opening temperature cap Distance of lift FANBELT Item Belt sag under load of 78.5 N (8 kgf, 17.6 lbs.) 245 ~ 441 kpa 2.5 ~ 4.5 kgf/cm 2, 36 ~ 64 psi. More than 49 kpa 0.5 kgf/cm 2, 7.11 psi ~ 0.15 mm ~ in ~ 0.15 mm ~ in ~ 0.13 mm ~ in. 245 kpa 2.5 kgf/cm 2, 36 psi 0.20 mm in mm in. 0.2 mm in. Allowable Limit Item Reference Value Allowable Limit Beginning Fullopen Reference Value 88.3 kpa 0.9 kgf/cm 2, 12.8 psi kpa 0.9 kgf/cm 2, 12.8 psi C ~ 83.5 C F ~ F 95 C 203 F 8 mm in. Reference Value 8 mm (0.32 in.) Allowable Limit INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

13 SPECIFICATIONS CK20S/CK20S(H) TIGHTENING TORQUE INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH Indicate the bolts with mark and manually tighten first. Item Nm Head 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 pipe nut Oil switch Bis 58.8 ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ 1.9 Taper screw 14.7 ~ 19.6 Fuel supply limit cap nut Idle limit fixing nut Injection pipe nut Crankshaft nut 27.5 ~ ~ ~ ~ kgfm 6.0 ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ 16 lbft 43.4 ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ SS30W00 May. 2007

14 CK20S/CK20S(H) 3. OPERATING PRINCIPLE 3.1 BODY AND POWER TRAIN CYLINDER HEAD The cylinder head has openings on both sides that allow crossflow type inlet/exhaust ports to the engine. Because the inlet/exhaust ports overlap and are smaller than other ports, the suction air can be protected from being heated and expanded by exhaust air. The cool, high mass suction air has a high large effectiveness and raises the power of the engine. Deformation of the cylinder head by heat exhaust air is reduced because inlet ports are arranged alternately. The combustion chamber is of DAEDONG s select circular combustion chamber type. Suction air is combustion and reduces fuel consumption. Throttle type injection nozzles and rapid heating enclosed glow plugs are installed in the combustion. This glow plug assures easier engine starts even at a temperature of 15 C (5 F) CYLINDER BLOCK The engine features a high resilience tunneltype cylinder block. Pressurefitted cylinders allow effective cooling, less distortion, higher wearresistance qualities and each cylinder having its own chamber helps to minimize noise. OPERATING PRINCIPLE 196W208A 196W209B (1) Combustion chamber (4) Nozzle assembly (2) Inlet port (5) Glow plug (3) Exhaust port (6) Cylinder head 196W210B INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

15 OPERATING PRINCIPLE CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH CRANKSHAFT The crankshaft drives the pistons and connecting rods, and transfers its reciprocating movement to a circular camshaft. Six counterweights are integrated into one unit to minimize bearing wear and lubricating oil temperature rise. Seal sliding sections are inductionhardened to raise wear resistance quality. Crankshaft journals are supported by the main bearing 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 side. Crankshaft bearing and thrust bearings are plated with special raised alloy wear resistance PISTON AND PISTON RINGS Piston circumference has special elliptic shape in consideration of expansion due to heat. The piston head is flat formed and ribbed to reduce distortion and to help heat radiation. Pistons are made of special aluminum alloy of low thermal expansion and high temperature resistance. The key stone type top ring is well fitted to the wall and plated with hard chrome. Second ring type is effective in preventing oil rising. The oil ring is effective because it is closely fitted to the cylinder wall by a coil so oil can be scraped from the upper and lower ends of its sliding cylinder walls. A portion of the scraped oil is forced inside the piston through escape holes of the. rings and pistons. The oil ring is plated with hard chrome to raise the wear resistance quality CONNECTING RODS The connecting rod is used to connect the piston with the crankshaft. The big end of this rod has crankpin bearings (split type) and the small end has a bushing (solid type). (1) Crankshaft (5) Crankshaft bearing 2 (2) Piston (6) Thrust bearing (3) Connecting rod (7) Counterweight (4) Crankshaft bearing 1 (8) Main bearing case (1) Rib (4) Hard chrome (2) Top ring (5) 2nd ring (3) Surface (6) Coil expander ring (1) Connecting rod (3) Bushing (2) Crankpin bearing 196W211B 196W212A 196W213A 214 SS30W00 May. 2007

16 CK20S/CK20S(H) OPERATING PRINCIPLE CAMSHAFT AND FUEL CAMSHAFT The camshaft is made of special cast iron; the journal and cam sections are chromed to resist wear. The journal sections are forcelubricated. 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 covered and tempered to provide greater wear resistance ROCKER ARM ASSEMBLY The rocker arm assembly includes the rocker arms, arm brackets and arm shafts and converts the movement of the push rods to open/close of the inlet and exhaust valves. Valve controlled timing must be adjusted with screws on the rocker arms. Lubrication oil is pressurized through arm bearings and the entire system is lubricated. 196W214A 196W215A (1) Tappet (7) Governor ball case (2) Push rod (8) Circlip (3) Camshaft (9) Circlip (4) Camshaft gear (10) Fuel camshaft (5) Injection pump gear (11) Ball (6) Governor sleeve (12) Ball bearing (1) Rocker arm (4) Valve (2) Rocker arm shaft (5) Push rod (3) Rocker arm bracket 196W216B INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

17 OPERATING PRINCIPLE CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH INLET AND EXHAUST VALVES The inlet and exhaust valves and their guides are different from each other. Other parts, such as valve springs, spring retainers, valve spring collets, valve stem seals, and valves all contact or sliding parts, which are covered and tempered to resist, wear TIMING GEARS The crankshaft drives the oil pump and the idle gear engages the fuel camshaft and camshaft. The timings for opening and closing the valve are extremely important to achieve effective air intake and sufficient gas exhaust. The appropriate timing can be obtained when assembling by aligning the mark on the crankshaft gear either with (6) the one on the idle gear or (5), the idle gear with camshaft gear (3), idle gear (5) or with injection pump gear (1) FLYWHEEL The flywheel is installed on the rear end of the crankshaft and keeps the flywheel turning at a constant speed. While the crankshaft tends to speed up during the power stroke it slows down during other strokes. The flywheel has a ring gear (1), which meshes with the drive pinion of the starter. The flywheel has marks TC and FI on its outer rim. The mark TC shows the piston s top dead center and the mark FI shows the fuel injection timing, when they are aligned with the mark of window on the clutch housing. Injection sequence Three cylinders: (1) Valve spring retainer (5) Valve guide (2) Valve spring collets (6) Intel valve (3) Valve spring (7) Exhaust valve (4) Valve stem seal (1) Injection pump gear (5) Idle gear (2) Fuel camshaft (6) Crankshaft gear (3) Camshaft gear (7) Crankshaft (4) Camshaft (1) Ring gear (3) Crankshaft (2) Flywheel 196W217A 196W218A 196W219B 216 SS30W00 May. 2007

18 CK20S/CK20S(H) OPERATING PRINCIPLE 3.2 LUBRICATION SYSTEM A. Oil filter 1 B. Oil pump 1. Inlet hole 2. Outlet hole C. Oil filter cartridge and relief valve 3. To rocker arm shaft and camshaft 4. To crankshaft 5. Relief valve 6. From pump 196W200B D. Camshaft E. Rocker arm rocker arm shaft F. Piston G. Crankpin bearing H. Oil switch I. Idle gear INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

19 OPERATING PRINCIPLE CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH OIL FLOW Valve cam shaft gear Fuel cam shaft gear Idle gear Valve cam shaft journal Fuel cam shaft Bore Crank shaft gear Pressurized Splash, flow Piston Connecting rod's small end Rocker arm Tappet Rocker arm shaft No.1 Connecting rod's small end No.2 Connecting rod's small end No.3 Connecting rod's small end journal bearing Valve cam shaft Valve cam shaft journal Bore Piston Connecting rod's small end No.1 main bearing Rocker arm Rocker arm Engine oil pressure sensor Main oil gallery Oil pump gear Oil pump gerotor Relief valve Oil fiter Oil pan Valve cam shaft Tappet Valve cam shaft journal Strainer Bore Valve cam shaft Tappet Piston Connecting rod's small end No.2 main bearing Valve cam shaft journal No.3 main bearing T46W223A 218 SS30W00 May. 2007

20 CK20S/CK20S(H) OPERATING PRINCIPLE RELIEF VALVE The relief valve prevents damage to the lubrication system due to high oil pressure. Control range of the relief valve is 196 to 441 Kpa (2.0 to 4.5 kgh/cm², 28 to 64 psi) BYPASS VALVE Oil filter cartridge has a bypass valve inside, to prevent the lack of lubrication oil in the engine, If the oil filter element is clogged the bypass valve opens and lets the oil pass to each part of the engine without passing through the filter OIL PRESSURE SWITCH The oil pressure switch is installed on the cylinder block and leads to the oil passage of the lubricating oil. When the oil pressure falls below the specified value, the contacts of the oil pressure switch closes to turn on the warning lamp (1). (A) At lower oil pressure (49 kpa (0.5 kgf/cm 2, 7 psi) or less) (B) At proper oil pressure OIL PUMP The oil pump is a gear pump, whose rotors have trochoid lobes. The inner rotor (3) has 4 lobes and the outer rotor (4) has 5 lobes, and they are eccentrically engaged with each other. The inner rotor, which is driven by the crankshaft through the gears, rotates the outer rotor in the same direction, varying the space between the lobes. While the rotors rotate from (A) to (B), the space leading 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 decreases and sucked oil is discharged from the outlet port. (1) Relief valve (4) From pump (2) Bypass valve (5) To crankshaft (3) To rocker arm shaft and camshaft (1) Warning lamp (5) Contact (2) Battery (6) Oil passage (3) Rubber gasket (7) Cylinder block (4) Contact rivet (8) Oil (1) Inlet (3) Inner rotor (2) Outlet (4) Out rotor 196W222A 196W223B 196W224A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

21 OPERATING PRINCIPLE CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH 3.3 COOLING SYSTEM The cooling system consists of a radiator, centrifugal water pump, suction fan and thermostat. The water is cooled through the radiator core, and the fan set behind the radiator pulls cooling air through the core to improve cooling. The pump sucks the cooled water, forces it into the cylinder block and draw out the hot water. Then the cooling is repeated. Furthermore, to control temperature of water, a thermostat is provided on the way. When the thermostat opens, the water moves directly to radiator, but when it closes, the water moves toward the water pump through the bypass between thermostat and water pump. The opening temperature of thermostat is about 83 C (180 F) WATER PUMP 35 /min. (7.7 lmp.gals/min, 9.2 U.S gals/min) of water is forced into the crankcase and cylinder head to cool them. The impeller, of backward 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) Radiator (4) Cylinder block (2) Suction fan (5) Cylinder head (3) Water pump (6) Thermostat 196W225B 196W226A (1) Water pump impeller (3) Water pump body (2) Mechanical seal (4) Bearing unit 220 SS30W00 May. 2007

22 CK20S/CK20S(H) OPERATING PRINCIPLE THERMOSTAT The thermostat is wax pellet type, which controls the flow of the cooling water to the radiator to keep the proper temperature. The case has a seat (1) and the pellet has a valve (2). The spindle attached to the case is inserted into the synthetic rubber in the pellet. The pellet is charged with wax. (A) At low temperature (lower than 71 C (160 F)) The valve (2) is seated by the spring (7) and the cooling water circulates in the engine through the water return pipe but does not engine the radiator. (B) At high temperature (higher then 71 C (160 F)) As the water temperature rises, the wax in the pellet (3) melts expands, repelling the spindle. The pellet lowers and the valve (2) opens to send the cooling water to the radiator RADIATOR The radiator core consists of water carrying tubes (2) with fins (3) at a right angle to it. The air flowing through between the tube wall and the fin cools the water in the radiator RADIATOR CAP The pressure type cap is installed on the radiator, which prevents the pressure difference between the inside and the outside of the radiator from deforming the radiator. (A) At high pressure(higher than 88 kpa (0.9 kgf/cm², 13 psi)) When the water temperature rises and the pressure in the radiator increase above the specified pressure, the pressure valve (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. (1) Seat (6) Wax (solid) (2) Valve (7) Spring (3) Pellet (8) Leak hole (4) Spindle (9) Wax (liquid) (5) Synthetic rubber (1) Cooling air (3) Fin (2) Tube (1) Pressure valve (2) Vacuum valve 196W227A 196W228A 196W229A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

23 OPERATING PRINCIPLE CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH 3.4 FUEL SYSTEM FLOW OF FUEL The fuel is feed from the fuel tank (1) through the fuel filter (2) to the injection pump (4) by the fuel feed pump (3). The injection pump forcefeeds the fuel through the injection nozzles (6), which inject the fuel into the cylinders for combustion. Any excessive fuel from the injection pump to the injection nozzles is collected in the fuel overflow pipes (7) and returns to the fuel tank FUEL FILTER A fuel filter is used to prevent dirty fuel from reaching the injection pump and injection nozzles. The filter element will require occasional replacement to maintain an adequate flow. This flow will vary according to the cleanliness of available fuel and the care used in storage. The fuel filter between the tank and pump to eliminate foreign matter and protect injection pump and nozzles filters fuel pumped by the fuel pump from the fuel tank. When fuel enters the filter, it passes through the filter element s circumference toward the center for filtering. The maximum filtrated granular size of this element is 48 µm (0.048 mm, in.) and general size is form 10 to 20 µm (0.01 to 0.02 mm, to in.) AIR BLEED BOLT 1. Check the fuel level in the fuel tank and fill the tank with fuel if necessary. 2. Check the fuel level in the fuel filter is 2/3 or higher. If not, loosen the air bleed bolt (8) and crank the engine to bleed the system. 3. When air stops bleeding, tighten the air bleed bolt and crank the engine. 4. If the engine still fails to start, loosen the nozzle holder nut (9) or injection nozzle nut (6) and crank the engine to bleed the system. 5. Tighten the loosened nut and start the engine. (1) Fuel tank (6) Injection nozzle (2) Fuel filter (7) Fuel overflow pipe (3) Fuel feed pump (8) Air bleed bolt (4) Injection pump (9) Nozzle holder nut (5) Injection pipe (1) Cock body (3) Element (2) Retainer ring (4) Filter cup W230B 196W231A 222 SS30W00 May. 2007

24 CK20S/CK20S(H) OPERATING PRINCIPLE FUEL FEED PUMP The diaphragm (6) is linked to the tappet (3) with the push rod (2). The tappet is reciprocated by the eccentric cam on the fuel camshaft (7). A. INTAKE STROKE When the diaphragm is pulled down by the spring, it builds a vacuum in the chamber (5) causing the exhaust valve (4) to close and the atmospheric pressure in the fuel tank to force the fuel into the chamber, opening the intake valve (1). B. SCAVENGING STROKE When the diaphragm is pushed up by the cam, the pressure in the chamber causes the intake valve to close and forces out the fuel, opening the exhaust valve FUEL INJECTION PUMP This fuel injection pump is Bosch K type fuel injection pump. It features a compact and light weight design. (A) From fuel tank (B) To fuel filter T46W235B (1) Intake valve (5) Chamber (2) Push rod (6) Diaphragm (3) Tappet (7) Fuel camshaft (4) Exhaust valve a 1 b (a) To injection nozzle (b) From fuel filter (1) Delivery valve holder (5) Plunger (2) Delivery valve spring (6) Control rack (3) Delivery valve (7) Plunger spring (4) Cylinder (8) Tappet T46W236A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

25 OPERATING PRINCIPLE CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH A. PUMP ELEMENT The pump element (1) consists of a plunger (3) and cylinder (2) which their sliding surfaces are finely machined to maintain the fuel tightness. The plunger (3) is installed in the control sleeve (5) and the sleeve is engaged with the control rack that rotates the plunger in the cylinder to control the amount of fuel delivered. B. OPERATION OF PUMP ELEMENT a. Before delivery As the plunger (2) lowers, fuel is drawn into the delivery chamber (1) through the feed hole (4) from the fuel chamber (5). b. Beginning of delivery When the plunger is pushed up by the cam and the head of the plunger closes the feed hole (4), the pressure in the delivery chamber (1) rises to push the delivery valve (3) open. c. Delivery While the plunger (2) is rising, delivery of fuel continues. d. End of delivery When the plunger rises further and the control groove (6) on its periphery meets the feed hole, the injection stops because the pressure in the delivery chamber (1) is reduced to the opening pressure (1) Pump element (5) Control sleeve (2) Cylinder (6) Control groove (3) Plunger (7) Sliding surface (4) Feed hole (1) Delivery chamber (4) Feed hole (2) Plunger (5) Fuel chamber (3) Delivery valve (6) Control T46W237A T46W238A 224 SS30W00 May. 2007

26 CK20S/CK20S(H) OPERATING PRINCIPLE C. AMOUNT OF FUEL DELIVERY a. No fuel delivery When the control rack (3) is at the engine stop position, the lengthwise slot (1) on the plunger (2) aligns with the feed hole (5). The pressure in the delivery chamber does not build up and no fuel is forced to the injection nozzle since the delivery chamber (4) is opened to the feed hole during the entire stroke of the plunger. b. Fuel delivery The plunger is rotated by the control rack and the feed hole is not aligned with the lengthwise slot. When the plunger is pushed up, the feed hole is closed by the plunger. The pressure in the delivery chamber builds up and forces the fuel to the injection nozzle until the control groove (6) meets the feed hole. The amount of the fuel to be forced into the nozzle corresponds to distance A. In the above figure, the amount of injected fuel in (c) is larger than the amount of injected fuel in (b). D. DELIVERY VALVE The delivery valve (2) prevents the fuel in the injection pipe from flowing back into the delivery chamber and the fuel in the injection nozzle from dribbling after injection. The relief plunger (6) sucks the fuel back from the injection pipe to prevent the leakage dribbling and unnecessary subsequent injection after the major injection. The stroke of A corresponds to the amount of fuel sucked back (35 mm 3 ). SS30W00 May (1) Slot (4) Delivery chamber (2) Plunger (5) Feed hole (3) Control rack (6) Control groove Location of fuel supply hole Stop 6 (1) Valve spring (4) Fuel chamber (2) Delivery valve (5) Valve face (3) Valve seal (6) Relief plunger 1 Low speed T46W239A High speed 3 4 T46W240A T46W241A 225 INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH

27 OPERATING PRINCIPLE CK20S/CK20S(H) E. INJECTION NOZZLE INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH (1) Nozzle holder assembly (2) Adjusting washer (3) Nozzle spring (4) Push rod (5) Lock nut (6) Nozzle body This injection 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/cm², 2134 psi). When the pressure overcomes the counterforce of nozzle valve spring (3), the pressure pushes up the needle valve (7) constantly and then the proper amount of fuel is injected into the swirling air inside the combustion chamber for combustion. The opening pressure can be adjusted by adding or reducing the washer (2). A washer of 0.1 mm corresponds to 980 kpa (10 kgf/cm², 142 psi) change in opening pressure. The heat seal (8) is adopted to improve the durability and reliability of the nozzle. 9 8 Supplied fuel 1 Excessive fuel (7) Needle valve (8) Heat seal (9) Packing T46W242A 226 SS30W00 May. 2007

28 CK20S/CK20S(H) OPERATING PRINCIPLE 3.5 GOVERNOR SYSTEM DISASSEMBLED VIEW (1) Start spring (2) Governor spring 1 (3) Governor spring 2 (4) Fork lever 1 (5) Fork lever 2 (6) Fork lever shaft (7) Fork lever holder (8) Governor lever (9) Fuel injection camshaft (10) Governor ball case The governor keeps the engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in the load. The engine employs an allspeed governor, which controls centrifugal force of the steel ball (13) weight, produced by rotation of the fuel camshaft (9), and tension of the governor spring 1 (2) and 2 (3) are balanced. (11) Steel ball (12) Governor sleeve (13) Steel ball (14) Fork lever pin 196W239B INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

29 OPERATING PRINCIPLE CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH BASIC PRINCIPLE OF GOVERNOR SYSTEM (1) Governor spring 1, 2 (2) Solenoid guide (3) Stop solenoid (4) Pump rack (5) Rack pin 8 (6) Steel ball (7) Governor lever (8) Idle spring (9) Start spring (10) Idle shaft As shown in the above figure, the steel ball (6) in the fuel camshaft gear is supported by the governor sleeve (11) to prevent from coming out. The sleeve pushes the fork lever 1 (13) to transfer the power to the fuel injection pump pin (5) Torque Spring 12 2 Torque control screw (11) Governor sleeve (12) Fork lever 2 (13) Fork lever 1 (14) Fuel limit bolt (15) Torque spring T46W246B 228 SS30W00 May. 2007

30 CK20S/CK20S(H) OPERATING PRINCIPLE OPERATION OF GOVERNOR A. WHEN STOPPED The fuel is blocked since the solenoid (3) pushes the speed control rack (4) to the left. B. WHEN TURNING THE KEY SWITCH ON When the electromagnet in the stop solenoid operates and the pin is retracted, the speed rack (4) of the fuel injection pump is pushed to the right by the start spring (9) and the start shaft (10) to supply the sufficient amount of fuel to start the engine. C. WHEN STARTING THE AND RUN NING THE AT LOW IDLE SPEED When the engine is started, the steel ball (6) pushes the sleeve (11) to the left as the centrifugal force of the steel ball increases. Therefore, the governor fork lever 1 (13) pushes the speed rack (4) of the pump to the left to reduce the amount of fuel supplied. As the speed rack is stopped by the idle spring (8), it keeps the balance with the centrifugal force of the steel ball so that at least minimum amount of fuel is delivered for stable engine running at idle speed. D. ACCELERATION AND DECELERATION When depressing the accelerator pedal, the governor spring (1) pulls the fork lever 2 (12) to the right and then pushes the fork lever 1 (13) to the right. The fork 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 determined by the driver, the stable speed is maintained. E. LOAD INCREASE AT HIGH SPEED T46W247B When a load is applied to the engine running at a high speed, the centrifugal force of steel ball (6) decreases as the engine speed drops. Also, the fork lever 2 (12) is pulled to the right by the governor spring until it contacts the fuel limit bolt (14). Until then, the amount of injected fuel per one stroke of the injector plunger and the torque increase. This range (a) is between the max. speed point with no load and the max. power point of the torque curve. When the fork lever 2 is blocked by the fuel limit bolt (14) and does not move any more and the load is increased, the centrifugal force of steel ball drops further and the torque spring (15) compressed between the fork lever 1 and 2 is loosened. Then, the fork lever 2 moves to the right until the torque spring is free, and the amount of fuel supplied and the torque increase simultaneously. This range (b) is between the max. power and the max. torque point in the torque curve. IMPORTANT The fuel limit bolt (14), idle spring (9) and max. rpm setting bolt are set at factory. Unauthorized adjustment of such components can negatively effect the performance of the engine. Therefore, never adjust them without permission from DAEDONG. Such action violates the EPA regulation and also can void the warranty. F. WHEN STOPPED When the key switch is moved to the OFF position, the stop solenoid power is cut off to release the electromagnet. Therefore, the stop pin comes off by the return force of the spring and pushes the solenoid guide (2) and fuel injection pump rack to the stop position to stop the engine. Torque Curve INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

31 OPERATING PRINCIPLE CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH 3.6 INTAKE AND EXHAUST SYSTEM FLOW OF INTAKE AIR AND EXHAUST GAS AIR CLEANER The air cleaner is drycyclone type and easy to maintain. The air from the inlet port (2) circulated along the fin (3) and around the air cleaner element (4) and the heavier dust is carried to the evacuator (6), where the dusts exhaust port. The fine dust in the air is filtered with the air cleaner element (4), and the filtered air flows to the outlet port (1) MUFFLER The exhaust noises are absorbed and dumped, while the gas pass through a series of holes on the inner tube and fiberglass wool of muffler. 196W244B (A) Inlet air (3) Cylinder head (B) Exhaust gas (4) Muffler (1) Inlet manifold (5) Exhaust manifold (2) Air cleaner 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 196W246A 230 SS30W00 May. 2007

32 CK20S/CK20S(H) OPERATING PRINCIPLE PCV VALVE A. PCV (POSITIVE CRANKCASES VENTILATION) The PCV system is a system that prevents air pollution by returning the blowby gas to the intake manifold through the bleeding pipe of the cylinder head cover for recirculation of the gas. (However, the turbo charged engine has the open crankcase type that discharges the blowby gas to the air.) (1) Head cover bolt (2) Oil filler flange (3) Oil baffle plate (4) Head cover gasket (5) Cylinder head cover (6) Intake manifold T46W248A T46W249A (7) Bleeding pipe (8) Intake valve (9) Cylinder head (10) Cylinder head cover (11) Oil baffle plate (12) Bleeding pipe connection INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

33 INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH 4. TROUBLESHOOTING DOES NOT START. Crankshaft does not turn Crankshaft turns No or small fuel injection sounds. Regular fuel injection sounds. TROUBLESHOOTING Frictional resistance of moving parts is too much Fuel supply to injection pump is insufficient. Injection pump does not send on fuel. Fuel does not inject through injection nozzle. Injection mistimed. Compressed air leaks. Valve action timing out of adjustment. CK20S/CK20S(H) Crankshaft and camshaft have seized up. Piston and cylinder liner have seized up. Bearings are oilstuck. Lubrication system not working property. Starter faulty. Battery capacity is low or terminal loose. Fuel pipe broken. Air enters fuel pipe through connection. Fuel filter clogged. Fuel pump faulty. Plunger has worn or seized up. Delivery valve spring broken. Delivery valve not completely oiltight. Needle valve stuck. Needle spring broken. Injection pressure misadjusted. Injection pipe mounting nut loose. Injection timing misadjusted. Contact between intake/exhaust valve and seat not tight. Intake/exhaust valve spring broken. Intake/exhaust valve stuck. Gasket faulty. Tightness torque of cylinder head not enough. Piston ring stuck. Piston ring worn. Cylinder liner worn. Tightness torque of injection nozzle and glow plug not enough. Valve clearance excessive. 232 SS30W00 May. 2007

34 CK20S/CK20S(H) TROUBLESHOOTING Engine does not turn normally. Irregular Revolution Engine output insufficient. Slow engine revolutions. Revolution is not smooth at high speeds. Idling not smooth. Injection pump wrong. Injection nozzle faulty. Governor not functioning normally. Idling misadjusted. Fuel supply insufficient. Compression pressure not enough. Fuel filter clogged. Fuel pipes broken or loose. Air in pump. Pump capacity not constant. Tappet roller and pin worn. Delivery valve not completely oiltight. Fuel leaks from nozzle tip. Fuel not spraying properly. Governor spring deformed. Valve clearance incorrect. Injection pump or nozzle not functioning normally. Compression pressure is different among cylinders. Governor sleeve not sliding property. Fork lever not functioning normally. Start spring deformed. Control rack not sliding property. Idling regulator misadjusted. Accelerator rod misadjusted. Main moving parts have almost seized up. Engine overheated. Injection mistimed. Governor not functioning normally. Filter clogged. Fuel pipe broken or loose. Injection pump s capacity not enough. Nozzle needle valve worn. Air leaking. Air cleaner clogged. INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

35 TROUBLESHOOTING CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH Color of exhaust fumes not normal. Excessive lubricant consumption. Lubricant increasing. White or blue smoke. Black or dark gray smoke. Fuel mixed with oil. Injection mistimed. Water mixed with oil. Lubricant rises through piston gap. Fuel pump s injecting capacity varies. Nozzle does not inject fuel properly. Gear oil mixed with oil. Piston ring stuck. Piston ring 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 spring is stuck or broken. Plunger worn. Needle valve stuck. Nozzle spring broken. Too much carbon sticks to nozzle tip. Injection pressure too low. Compressed air leaks. Not enough air. Excessive gap between piston and liner. Piston ring stuck. Piston ring worn. Excessive gap between intake/exhaust valve and valve stem. Valve stem seal broken. Oil leaks from defective seals. Injection pump plunger leaking. Fuel pump leaking. Head gasket seal faulty. Crankcase cracked. Hydraulic pump s oil seal broken. 234 SS30W00 May. 2007

36 CK20S/CK20S(H) 5. MEASUREMENT AND ADJUSTMENT 5.1 FAN BELT 1. Measure the deflection, depressing the belt halfway between the fan drive pulley and the alternator pulley at 78.5 N (8 kgf, 17.6 lbs) of force. 2. If the deflection is not between the factory specifications, loosen the bolts and nuts, and relocate the alternator to adjust. 3. Replace the belt if damaged or worn Item Belt tension (deflection) 5.2 COMPRESSION PRESSURE 1. Run the engine until warm. 2. Stop the engine and remove the air cleaner, the muffler and all nozzle holders. 3. Set a compression tester to the adaptor installed in the nozzle holder hole and fixed with the locating screw. 4. Pull the stop lever to cut the fuel and run the engine with the starter at 200 to 300 rpm for 5 to 10 seconds. Measure the maximum pressure while running, several times For the test, use a fully charged battery and the specified valve clearance. 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. JUDGMENT If the pressure raises after applying oil, check the cylinder wall and piston rings. If the pressure still low, check the top clearance, valve clearance and cylinder head. If the compression differs more than 10% among the cylinders, trace the cause of pressure variation and take corrective measures. Item Compression pressure Difference between two cylinders Factory spec. 2.8 ~ 3.2 Mpa 29 ~ 33 kgf/cm ~ 269 psi. Allowable limit 2.32 Mpa 23.7 kgf/cm psi. 10 % NOTE: Check the compression pressure with the specified valve clearance for proper air intake. MEASUREMENT AND ADJUSTMENT Factory spec. 8 mm(0.32 in.) at 78.5 N (8 kgf, 17.6 lbs) of force 196W248A 196W252B INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

37 MEASUREMENT AND ADJUSTMENT CK20S/CK20S(H) 5.3 VALVE CLEARANCE INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH 1. Remove the cylinder head cover and the timing window cover on the flywheel housing and all glow plugs. 2. Turn the flywheel and align the 1TC to mark with the timing mark of window on the flywheel housing to position the 1st cylinder valves at the top dead center during compression. 3. Measure the clearance at the valves marked with in the table below with a feeler gauge. 4. If the clearance is not within the factory specifications, turn the adjusting screw to adjust. 5. Turn the flywheel just one turn to position the 1st cylinder valves at the top dead center during overlap. 6. Measure the clearance at the valves marked with in the table below with a feeler gauge. 7. If the clearance is not within the factory specifications, adjust. Item Valve clearance Cylinder No. Valve Checking 1 IN. EX. Factory spec mm in. 2 IN. EX. 3 IN. EX. (A) Gear case 196W253B 196W254B 236 SS30W00 May. 2007

38 CK20S/CK20S(H) MEASUREMENT AND ADJUSTMENT 5.4 INJECTION TIMING MEASURE MENT AND ADJUSTMENT NOTE: Perform the work with the engine installed in the tractor. 1. Remove the engine stop solenoid. 2. Remove the timing check window cover of the clutch housing. 3. Turn the flywheel to find 1, 4 FI mark for 4cylinder engine or 1 FI mark for 3cylinder engine on the flywheel. 4. When the mark is found, turn the crankshaft counterclockwise approx. 30 (when looking at the front of the engine). 1, 4 FI means the injection timing of the No. 1 or 4 cylinders. When turning the crankshaft, use a socket for turning the crankshaft. NOTE: How to use the crankshaft turning socket You can use DAEDONG special tool kit (part No.: G0611B0010) for spline socket. T46W259A T46W256B T46W257A T46W258A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

39 MEASUREMENT AND ADJUSTMENT CK20S/CK20S(H) 4. Remove the No. 1 high pressure pipe. INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH 5. Unscrew the nozzle holder (1) slightly and tighten it when it is filled with fuel. 6. Remove the fuel in the nozzle holder with clean cloth and leave only small amount of fuel. 7. Observe the fuel of the nozzle holder while turning the crankshaft clockwise (when looking at the front of the 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 already. Repeat the above process to identify the moment when the amount of fuel starts to increase. If the fuel does not increase, it means that it is the exhaust cycle. Therefore, turn the crankshaft 360 to find the compression cycle and repeat the above procedures. 9. Mark the measured injection timing on the flywheel through the timing window and measure the distance between the 1, 4 FI or 1 FI and the mark you made. 10.To advance the injection timing, reduce the amount of shims. To delay the injection timing, increase the amount of shims(2). Model CK20 CK20S/ 22 Injection timing BTDC 22 BTDC 18 Diameter of flywheel 270 mm (10.6 in.) 270 mm (10.6 in.) Flywheel circumference for mm (0.093 in.) 2.35 mm (0.093 in.) BTDC: Before top dead center Amount of shims to adjust mm (0.004 in.) 0.1 mm (0.004 in.) fuel 2 T46W260C T46W261A T46W2I1B 238 SS30W00 May. 2007

40 CK20S/CK20S(H) MEASUREMENT AND ADJUSTMENT 5.5 OIL PRESSURE 1. Remove the oil pressure switch and install adaptors and pressure tester. 2. Start the engine and run it until it is warmed up, and measure the oil pressure both at idling and rated speed. 3. If the oil pressure is less than the allowable limit, check the amount of oil, oil filter, oil pump relief valve, oil passages and oil clearances. (When reassembling) Supply the specified amount of recommended oil. The oil filter must not be clogged or broken. Engine oil pressure Item (Reference) At idle speed At rated speed Item Oil pressure switch Factory spec. Allowable limit More than 49 kpa 0.5 kgf/cm psi. 245 ~ 441 kpa 245 kpa 2.5 ~ 4.5 kgf/cm kgf/cm 2 36 ~ 64 psi. 36 psi. Tightening torque 14.7 ~ 19.6 Nm 1.5 ~ 2.0 kgfm 10.8 ~ 14.5 lbft 196W2F4B INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

41

42 CK20S/CK20S(H) 6. EXPLODED VIEW (CK20S/CK22) 49 (1) Cylinder Block (2) Oil Pressure Switch (3) Oil Pump (4) Oil Pan (5) Oil Strainer (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) Cylinder Hear Cover SS30W00 May EXPLODED VIEW (CK20S/CK22) 48 (18) Push Rod (19) Tappet (20) Camshaft (21) Camshaft Gear (22) Idle Gear (23) Piston (24) Connecting Rod (25) Crankshaft (26) Flywheel (27) Rear End Plate (28) Starter (29) Injection Pipe (30) Glow Plug (31) Nozzle (32) Fuel Injection Pump (33) Fuel Feed Pump (34) Fuel Camshaft (35) Fuel Camshaft Gear 39 (36) Engine Stop Solenoid (37) Manual Stop Lever (38) Fork Lever (Governor) (39) Water Pump (40) Thermostat (41) Alternator (42) Fan Drive Pulley (43) Cooling Fan (44) Inlet Manifold (45) Exhaust Manifold 47 9 (46) Idle Limit System (47) Speed Control (48) PCV V/v (49) Fuel Control Limit 196W247B 241 INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH

43

44 CK20S/CK20S(H) 7. SERVICING 7.1 REMOVAL AND REASSEMBLE ASSEMBLY Drain the oil and the water, if disassemble the engine body. 1. Remove the muffler and exhaust manifold (7). 2. Remove the oil pressure switch (8). 3. Pull out the dipstick (6). 4. Remove the alternator (5) and the belt (2). 5. Loosen the oil filter cartridge (3) with the filter wrench and remove it and the flange (4). (When reassembling) Apply liquid gasket (Three bond 1215 or equivalent) on the thread of the oil pressure switch. Apply liquid gasket to the both sides of the hour meter gasket. Apply oil to the Oring and tighten the oil filter cartridge not with wrench but by hands Adjust the fan belt tension. (See Fan Belt) Item Oil pressure switch Tightening torque 14.7 ~ 19.6 Nm 1.5 ~ 2.0 kgfm 10.8 ~ 14.4 lbft STOP SOLENOID 1. Disconnect the wire connector of solenoid (1). 2. Remove the nut (2). 3. Remove the stop solenoid (1). SERVICING 196W249B (1) Cooling fan (5) Alternator (2) Fan belt (6) Dipstick (3) Oil filter cartridge (7) Exhaust manifold (4) Filter flange (8) Oil pressure switch (1) Engine stop solenoid (2) Nut 2 196W250B INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

45 SERVICING CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH INTAKE MANIFOLD AND FUEL HOSES 1. Disconnect the fuel hose (3). 2. Loosen the injection pipe fittings with two wrenches and remove the injection pipes (2). 3. Remove the inlet manifold (1) and the fuel feed pump (4). IMPORTANT Tighten or loosen injection pipe fittings using the onehand twowrench squeeze method. Cap the nozzle inlet to prevent entrance of foreign materials. Item Injection pipe nut 19 mm (0.75 in.) across flats INJECTION NOZZLE ATTENTION When reassembling, replace all the Orings and gaskets by new ones. A. REMOVING HEAD COVER 1. Remove the head cover bolts. 2. Remove the head cover. (Note for reassembling) Check to see if the cover gasket is not defective. To prevent valve stem seizure, apply enough engine oil to the valve guide and valve stem. Item Nut x 2, Bolt x 5 (10 mm) 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 reassembling) Send compressed air, into the pipes to blow out dust. Then reassemble the pipes in the reverse order. Item Injecion pipe nuts Pipe clamp Feed pipe (17 mm) Injection pipe Tightening torque 14.7 ~ 24.5 Nm 1.5 ~ 2.5 kgfm 10.8 ~ 18.1 lbft Tightening torque 48.1 ~ 55.8 Nm 4.9 ~ 5.7 kgfm 35.5 ~ 41.2 lbft Tightening torque 24.5 ~ 34.3 Nm 2.5 ~ 3.5 kgfm 18.1 ~ 25.3 lbft (1) Intake manifold (3) Fuel hose (2) Injection pipe (4) Fuel feed pump (1) Head cover 196W251B 196W255B 196W256B (1) Injection pipe 1 (3) Injection pipe 3 (2) Injection pipe SS30W00 May. 2007

46 CK20S/CK20S(H) SERVICING C. REMOVING NOZZLE HOLDER ASSEMBLIES 1. Remove the pipe clips holding the fuel overflow pipes, and detach the pipes. 2. Detach the nozzle holders using a 27 mm ( in.) nozzle holder socket wrench, after loosening the lock nuts. 3. Detach the copper gaskets on the seats on which the nozzles are to be installed. (Note for reassembling) Return the nozzle holders after confirming that there are no metallic particles or foreign matter on the surface on which the nozzles are to be installed. Item Nozzle holder ass y Tightening torque 49.0 ~ 68.6 Nm 5.0 ~ 7.0 kgfm 36.1 ~ 50.6 lbft D. HEAT SEAL ROMOVAL PROCEDURE 1. Drive screw driver lightly into the heat seal hole. 2. Turn screw driver three or four times each way. 3. While turning the screw driver, slowly pull the heat seal put together with the injection nozzle gasket. If the heat seal drops, repeat the above procedure. 4. Heat seal and injection nozzle gasket must be changed when the injection nozzle is removed for cleaning or for service. NOTE: Use a plus screw driver that has a diameter which is bigger than the geat seal hole 1/4 in (approx. 6 mm) E. NOZZLE HOLDER DISASSEMBLING NOZZLE HOLDER 1. Secure the retaining nut with a vise. 2. Remove the nut, the over flow pipe Ass y and the plain washer. 3. Remove the nozzle holder body and take out parts inside. (Note for reassembling) When disassembling and reassembling the nozzle piece dip it in clean fuel. Install the push rod, noting its direction(upside down). Do not tighten it too much, or the needle valve will not slide easily and the injection performance will be decreased. Item Retaining nut Tightening torque 29.4 ~ 49.0 Nm 3 ~ 5 kgfm 21.7 ~ 36.1 lbft (1) Nozzle holder socket wrench (2) Lock nut (1) Plus screw driver (2) Nozzle (3) Injection nozzle gasket (4) Heat seal 196W257B 196W258B 196W268A (1) Retaining nut (6) Adjusting washer (2) Nozzle holder body (7) Nozzle spring (3) Nut (8) Push rod (4) Over flow pipe ass y (9) Distance piece (5) Gasket (10) Nozzle piece INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

47 SERVICING CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH ROCKER ARM AND PUSHRODS A. ROCKER ARM ASSEMBLY 1. Loosen the nuts in several steps and the specified sequence shown in the figure and remove them. To loosen (3) to (1). To tighten (1) to (3). 2. Remove the rocker 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 figure to the specified torque. Adjust the valve clearance after assembling the rocker arm assembly. IMPORTANT When assembling the rocker arm assembly, locate groove of rocker arm shaft on stud bolt. Item Rocker arm shaft on stud bolt B. REMOVING PUSHRODS 1. Remove the six pushrods. Tightening torque 16.7 ~ 20.6 Nm 1.7 ~ 2.1 kgfm 12.3 ~ 15.2 lbft (Note for reassembling) Before inserting the push rods into the tappets, check to see if their ends are properly engaged with the grooves. If a push rod is roughly inserted, it may hit the shoulder of the tappet and be damaged. 196W260B 196W261B (1) Rocker arm shaft (3) Rocker arm bracket (2) Rocker arm (4) Bolt 196W262B (1) Pushrod (2) Glow plug cable 246 SS30W00 May. 2007

48 CK20S/CK20S(H) SERVICING CYLINDER HEADS AND VALVES A. REMOVING CYLINDER HEADS AND GASKET. 1. Remove the fourteen cylinder head set bolts and two nuts. To loosen (14) to (1) To 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 diagonal sequence starting from the center. Tighten them uniformly, or the head may deform in the long run. Before installing the gasket, check to see there is no foreign matter on the cylinder head and the cylinder. IMPORTANT When overhauling the engine, replace the gasket with a new one without confusing its front and back. Retighten the cylinder head after running the engine for 30 minutes. Tighten the cylinder head bolts and nuts to: Item Cylinder head bolts Tightening torque 58.8 ~ 63.7 Nm 6.0 ~ 6.5 kgfm 43.4 ~ 47.0 lbft (A) Gear case side (1) Cylinder head gasket (B) Flywheel side 196W263B 196W264A 196W265B INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

49 SERVICING CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH B. REMOVING TAPPETS 1. Remove the six tappets from the crankcase. (Note for reassembling) Visually check the contact between tappets and cams for proper rotation. If a defect is found, replace tappets. Before installing the tappets, apply a thin coat of oil around them. C. VALVES 1. Compress the valve spring with a valve spring replacer and remove the collet (2). 2. Remove the valve spring retainer (3), valve spring (4), valve stem seal (5) and the valve (1). IMPORTANT Do not interchange valves and valve parts. Mark the cylinder number on the valve and the parts to prevent interchanging. (When reassembling) Apply oil to the stem of valve and install in the cylinder head. Lubricate the valve and the parts after reassembling. (1) Tappets 196W266B 196W267B (1) Valve (4) Valve spring (2) Collet (5) Valve stem seal (3) Retainer 248 SS30W00 May. 2007

50 CK20S/CK20S(H) SERVICING FUEL FEED PUMP AND INJECTION PUMP A. FUEL FEED PUMP REMOVING FUEL FEED PUMP 1. Remove the two fuel feed pump mounting nuts. 2. Detach the fuel feed pump. 3. Remove the injection pump cover(2). (Note for assembling) Be careful the install the fuel feed pump in the right direction. Install the fuel feed pump gasket after applying nondrying adhesive to it. B. INJECTION PUMP 1. Remove the injection pipes (1) and the intake manifold (2). 2. Remove the overflow pipe (3). 3. Remove the stop solenoid (1) with guide (2). (1) Fuel feed pump assembly (2) Cover (1) Injection pipes (2) Intake manifold (3) Overflow pipe 2 (1) Stop solenoid (2) Stop solenoid guide 2 196W269B T46W298B T46W299A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

51 SERVICING CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH 4. Remove the idle limit system (3). 5. Remove the injection pump mounting bolts and nuts (A). 6. Align the control rack pin (4) with the slot (5) on the cylinder and remove the injection pump. 7. The injection pump should not be disassembled. (Note for reassembling) Install the injection pump by aligning the control rack with the indicated position. Addition or reduction of one shim (0.1 mm) delays or advances the injection timing by rad. (1 ). IMPORTANT Make sure that the lever of the pump control rack is on the outer side from the fork lever 1 when installing the pump. Otherwise, the engine can be damaged by over speed or cannot be started. C. INJECTION PUMP IMPORTANT If replacing the pump element, the amount of fuel injection should be adjusted on specified bench. A (1) Pump body (5) Delivery valve (2) Control rack (6) Tappet roller (3) Delivery valve holder (7) Cylinder (4) Delivery valve spring (8) Plunger W272B T46W294A 196W2H2A 250 SS30W00 May. 2007

52 CK20S/CK20S(H) SERVICING CRANK CASE A. DETACH THE GOVERNOR SPRING 1. Detach the governor spring 1, 2 and speed control plate from governor lever. 2. Remove the manual stop lever plate (4). (Note for reassembling) Be careful not to drop the governor spring 1, 2 in the gear case. Fix the governor spring 1, 2 to the fork lever and pull the spring, hook on the governor lever. 3. Detach governor spring on the side of fork lever if needed W274B (1) Speed control plate (3) Governor lever (2) Governor spring 1, 2 (4) Manual stop lever 5 (5) Governor springs 196W277B 196W275B INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

53 SERVICING CK20S/CK20S(H) B. REMOVING FAN DRIVE PULLEY INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH 1. Flatten the crankshaft washer. 2. Loosen and remove the crankshaft nut. 3. Draw out the pulley with a puller. (Note for reassembling) Bend the crankshaft washer against one side of the nut. Item Crankshaft nut C. REMOVING GEAR CASE 1. Remove the gear case cover. 2. Remove the Oring. Tightening torque ~ Nm 14 ~ 16 kgfm ~ lbft (Note for reassembling) Apply a thin coat of engine oil to the oil seal, and install it, noting the lip come off. Before installing the gear case gasket, apply a non drying adhesive. Tighten the oil filter cartridge by hand. Stick the Oring to the gear case with thin grease to prevent from coming off during reassembling. (1) Oring 196W278B 196W279B 252 SS30W00 May. 2007

54 CK20S/CK20S(H) SERVICING TIMING GEARS, CAM SHAFTS AND OIL PUMP A. REMOVING CRANKSHAFT OIL SLINGER 1. Remove the crankshaft collar. 2. Remove the Oring. 3. Detach the crankshaft oil slinger. B. REMOVING IDLE GEAR 1. Remove the external circle clip. 2. Detach the idle gear collar Detach the idle gear. 4. Detach the idle gear collar 1. (Note for reassembling) Check to see each gear is aligned with its aligning mark: 1) Idle gear and crank gear 2) Idle gear and camshaft gear 3) Idle gear and injection pump gear Item Idle gear shaft mounting bole torque Tightening torque 7.8 ~ 9.8 Nm 0.8 ~ 1.0 kgfm 5.7 ~ 7.2 lbft (1) Crankshaft oil slinger (2) Oring (3) Crankshaft collar (1) External circle clip (2) Gear collar 2 (3) Idle gear 196W280A 196W281A 196W282A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

55 SERVICING CK20S/CK20S(H) C. REMOVING CAMSHAFT STOPPER INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH 1. Align the round hole on the cam gear with the camshaft stopper mounting bolt position. 2. Remove the camshaft stopper mounting bolt. 3. Detach the camshaft stopper. D. REMOVING GEAR AND CAMSHAFT Draw the camshaft and the cam gear. (Note for reassembling) Apply a thin coat of engine oil to the camshaft before installation. E. REMOVING FORK LEVER ASSEMBLY AND FUEL INJECTION CAMSHAFT 1. Remove the fuel injection camshaft stopper. 2. Remove the two fork lever holder mounting bolts. 3. Detach the fork lever assembly and fuel camshaft. (1) Camshaft stopper (1) Camshaft assembly (1) Fork lever assembly (2) Fuel camshaft assembly 196W283A 196W284A 196W285B 254 SS30W00 May. 2007

56 CK20S/CK20S(H) SERVICING F. REMOVING OIL PUMP DRIVE GEAR 1. Remove the nut from oil pump. 2. Draw out the oil pump drive gear with gear puller. (Note for reassembling) Ensure there is a feather key. G. REMOVING OIL PUMP Remove the four oil pump mounting bolts. Detach the oil pump. (Note for reassembling) Remove the gear with crank gear removal tool or pulley removal tool. Item Bolts of oil pump Tightening torque 9.8 ~ 11.8 Nm 1.0 ~ 1.2 kgfm 7.2 ~ 8.7 lbft H. REMOVING CRANK GEAR Remove the gear with crank gear removal tool or pulley removal tool. (Note for reassembling) Check to see that the key is on the crankshaft. Heat the crank gear to about 80 C (176 F), and fit on the crankshaft. If there is fear of the shaft being damaged, heat the gear more and fit. (1) Crank gear (2) Oil pump drive gear (1) Oil pump assembly (1) 13T gear (crank gear) 196W287A 196W288A 196W289A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

57 SERVICING CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH PISTON A. REMOVING OIL PAN 1. Lay the engine on the engine 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 mounting surface, apply a nondrying adhesive, and install the oil pan. To avoid uneven tightening, tighten mounting bolts in diagonal order from the center. Ensure that the drain plug is tight. B. REMOVING OIL STRAINER 1. Remove the mounting bolt of oil strainer. 2. Detach oil strainer, being careful of the Oring. (Note for reassembling) After cleaning the oil strainer, check to see that the strainer mesh is clean, and install it. Visually check the Oring, apply engine oil, and install it. After checking to see that the Oring is securely installed, attach the oil strainer. C. REMOVING CONNECTING ROD CAP 1. Remove the connecting rod bolts from connecting rod cap. 2. Detach the connecting rod caps. IMPORTANT Apply engine oil to the connecting rod bolt. Align the marks with each other. Face the marks toward the injection pump. Item Connecting Rod Tightening torque 26 ~ 30 Nm 2.7 ~ 3.1 kgfm 20 ~ 22 lbft (1) Oil pan (1) Oil strainer 196W290B 196W291A 196W292A (1) Connecting rod cap (a) Align the marks with each other (b) Face the marks toward the injection pump 256 SS30W00 May. 2007

58 CK20S/CK20S(H) SERVICING D. REMOVING PISTONS 1. Turn the crankshaft and bring the piston to top dead center. 2. Draw out the piston upward by lightly tapping it from the bottom of the crankcase with 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, apply enough engine oil to the pistons. IMPORTANT Install the piston rings with their end gaps making an angle of 120 (2.09 rad) or 180 (3.14 rad) to each other. (Place the top ring with their gaps on the opposite side of the combustion chamber.) Attach a ring to the pistons securely with a piston ring compressor, and set them to the cylinder, being careful about the cylinder number and the position of the connecting rod (Connecting rods must be installed with their ends bearing the number toward the fuel injection pump). Carefully insert the pistons. Otherwise, their chrome plated section may be scratched, causing trouble inside the liner. Set the gap of top ring toward the opposite direction of combustion chamber. (1) Piston 196W294A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

59 SERVICING CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH E. PISTON RING AND PISTON PIN 1. Remove the piston rings with a piston ring replacing tool. 2. Remove the piston pin. (When reassembling) Clean all the parts before 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 flywheel and the mark on the connecting rod to the injection pump. Install the piston rings with their manufacturer s mark to the top of piston. Install the top ring with its gap at 90 (1.57 rad) from piston pin to the exhaust port. Install the second ring and oil ring with their gap at every 120 (2.09 rad) or 180 (3.14 rad). Install the expander in the oil ring with its gap opposite to the gap of oil ring. 196W295B 196W296A 196W297A (1) Piston pin (9) Mark (2) Piston (10) Casting mark (3) Piston pin snap ring (11) Expander joint (4) Top ring (12) Oil ring gap (5) Second ring (13) Manufacturer s mark (6) Oil ring (14) Top ring (7) Connecting rod (15) Second ring (8) Connecting rod cap (16) Oil ring gap 258 SS30W00 May. 2007

60 CK20S/CK20S(H) SERVICING FLYWHEEL AND MAIN BEARING CASE COVER A. FLYWHEEL AND REAR PLATE 1. Loosen the flywheel bolt and remove the flywheel. 2. Loosen the bolt and remove the rear plate. (When reassembling) Check the end of crankshaft any uneven wear, lack or crack of teeth. Clean the end of crankshaft and the mating surface of the 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 the punch mark of the rear and plate, and set the flywheel. Tighten the flywheel bolts to in diagonal order. NOTE: Screw longer screws to the flywheel to carry it, if needed. Item Flywheel screw B. BEARING CASE COVER Loosen the screws first inside and next outside, and lift the cover (1) by screwing two screws gradually and evenly, referring to the photo. (When reassembling) Apply grease to the oil seal lip and take care that it is not rolled when installing. Item Bearing case cover screw NOTE: Tightening torque 54 ~ 59 Nm 5.5 ~ 6.0 kgfm 40 ~ 43 lbft Tightening torque 12.7 ~ 15.7 Nm 1.3 ~ 1.6 kgfm 9.8 ~ 11.2 lbft When installing the main bearing case cover, the UP mark on it should be at the highest position so that its holes are aligned with the holes of the cylinder block. (1) Rear plate (1) Bearing case cover up 196W298A 196W299A T46W2D3B INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

61 SERVICING CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH CRANKSHAFT AND JOURNAL BEARING A. REMOVING BEARING CASE BOLT 2 Detach the bearing case bolts. (Note for reassembling) When tightening the main bearing case bolts, align the direction of the holes so that the crankshaft can be easily installed. Apply oil to the bearing case screw. Item Main bearing case screw 2 B. REMOVING CRANKSHAFT Tightening torque 30 ~ 34 Nm 3.0 ~ 3.5 kgfm 22 ~ 25 lbft Pull the crankshaft from the back of the cylinder block by lightly tapping it with a brass hammer. (Note for reassembling) Before installing the crankshaft, clean the oil holes in the crankshaft with compressed air. C. REMOVING MAIN BEARING CASE 1. Remove the two mounting bolts for main bearing case assembly Detach the main bearing case, being careful with the side and crankshaft bearing. 3. Detach the other bearing cases 2 and 3 in the same method. Be careful not to mix them up. (Note for reassembling) Clean the oil holes in the main bearing case. Install the main 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 kfgm, 15 ~ 17 lbft). Item Bearing case bolts Tightening torque 30 ~ 34 Nm 3.0 ~ 3.5 kgfm 22 ~ 25 lbft (1) Bearing case bolt 2 (1) Main bearing case assembly 1 (2) Main bearing case assembly 2 (3) Main bearing case assembly 3 (4) Bearing case bolt 1 (5) Thrust bearing (6) Alignment mark 196W2A1A 196W2A2A 196W2A3B 260 SS30W00 May. 2007

62 CK20S/CK20S(H) SERVICING 7.2 INSPECTION FOR OVERHAUL CYLINDER HEAD A. CYLINDER HEAD SURFACE FLATNESS 1. Thoroughly clean the cylinder head surface. 2. Place a straightedge on the cylinder head and measure the clearance with a feeler gage as shown in the figure. 3. If the measurement exceeds the allowable limit, replace the cylinder head. IMPORTANT Do not place the straight edge on the combustion chamber. Flatness Item Allowable limit 0.05 mm in. B. CYLINDER HEAD SURFACE FLAW 1. Clean the cylinder head surface with the detergent (B). 2. Spray the cylinder head surface with the red permeative liquid (A). 3. Wash away the red permeative liquid on the cylinder head surface with the detergent (B) after ten minutes. 4 Spray the cylinder head surface with the white developer (C). 5. If any flaw is found such as a red mark, replace the cylinder head. 196W2A9A 196W2B0A 196W2B1A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

63 SERVICING CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH C. VALVE STEM CLEARANCE 1. Remove the carbon from the valve guide. 2. Measure the valve stem O.D. with an outside micrometer. 3. Measure the 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. IMPORTANT When changing the valve guide, be sure to ream as the figure indicates after inserting the valve guide. Reference value Allowable limit Item Valve recessing Factory spec. 0.9 ~ 1.1 mm ~ in ~ mm ~ in. 0.1 mm in. D. VALVE RECESSING 1. Clean the cylinder head, the valve face and the seat. 2. Insert the valve in the guide. 3. Measure the valve recessing with a depth gauge. 4. If the recessing exceeds the allowable limit, replace the valve and check the valve seating. Allowable limit 1.3 mm in. (A) Finishing size of inlet valve guide (B) Finishing size of exhaust valve guide (1) ~ mm ~ in. (2) ~ mm ~ in. 196W2B2B 196W2B3B 196W2B4A 262 SS30W00 May. 2007

64 CK20S/CK20S(H) SERVICING VALVE SPRING A. CHECKING VALVE SPRING FREE LENGTH 1. Measure the spring with a set of vernier calipers. 2. If the measurement exceeds the allowable limit, replace. Reference value Allowable limit 35.1 ~ 35.6 mm ~ in mm 1.37 in. B. CHECK VALVE SPRING SQUARENESS 1. Put the spring on a surface plate, place a square on the side of the spring, and check to see if the entire side is in contact with the square. 2. Rotate the spring and measure the maximum A. 3 If the measurement exceeds the allowable limit, replace. The flat surface at the end of the spring coil must exceed the full circumference by twothirds. Check the entire surface of the spring for scratches. Allowable limit 1.3 mm in. C. CHECKING VALVE SPRING TENSION 1. Place the spring on a tester and compress it to the same degree that it is actually compressed in the engine. (31 mm, 12 in.) 2. Read the compression load on the gauge. Reference value Allowable limit 74 N / 31 mm 7.5 kgf / 31 mm 16.5 lbs / 1.22 in. 63 N / 31 mm 6.4 kgf / 31 mm 14.1 lbs / 1.22 in. 196W2B9A 196W2C0A 196W2C2A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

65 SERVICING CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH CHECKING OIL CLEARANCE BE TWEEN ROCKER ARM SHAFT AND BUSHING 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 Rocker arm shaft O.D. Rocker arm bushing I.D ~ 0.08 mm ~ in mm in ~ mm ~ in ~ mm ~ in CHECKING TOP CLEARANCE 1. Remove the nozzle holder. 2. Lover the piston in the cylinder to be measured. 3. Insert a highquality fuse from the nozzle holder hole. Be careful not to let the fuse touch the valve surface. 4. Rotate the engine with your hand. 5. Take the fuse out carefully. 6. Measure the place where the fuse was crushed with vernier calipers. Reference value Thickness of gasket when tightened 0.7 ~ 0.9 mm ~ in ~ 1.26 mm ~ in W2C3A 196W2C4B 264 SS30W00 May. 2007

66 CK20S/CK20S(H) SERVICING TIMING GEARS AND CAMSHAFTS A. TIMING GEAR BACKLASH 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Clamp one gear, rotate the other and measure the backlash. 3. If the backlash exceeds the allowable limit, replace. Item Reference value Allowable limit 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 feeler gauge. 3. If the clearance exceeds the allowable limit, replace the idle gear collar 1 (3). Item Side clearance (A) C. CAM GEAR SIDE CLEARANCE 1. Pull the cam gear (2) with the camshaft (1) to its end. 2. Measure the clearance A between the cam gear (2) and the camshaft stopper (3). 3. It the clearance exceeds the allowable limit, replace the camshaft stopper (3). Item Side clearance (A) Factory spec ~ 0.51mm ~ in. Factory spec ~ 0.22 mm ~ in. Allowable limit ~ mm ~ in. 0.2 mm in. Allowable limit 0.9 mm in. Allowable limit 0.3 mm in. 196W2C9A 196W2D0A (1) Idle gear collar 2 (3) Idle gear collar 1 (2) Idle gear snap ring (4) Idle gear (1) Camshaft (3) Stopper (2) Cam gear 196W2D1A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

67 SERVICING CK20S/CK20S(H) D. INJECTION PUMP GEAR SIDE CLEARANCE INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH 1. Pull the fuel camshaft and pull the injection pump gear (1) to each end. 2. Measure the clearance A between the injection pump gear (1) and the snap ring (2) on the fuel camshaft. 3. If the clearance exceeds the allowable limit, check the gear, the bearing and the key. Item Side clearance (A) Factory spec ~ 0.57 mm ~ in. Allowable limit 0.9 mm in. E. IDLE GEAR OIL CLEARANCE 1. Measure the idle gear shaft O.D. with an outside micrometer. 2. Measure the idle gear bushings I.D. with an inside micrometer. 3. If the clearance exceeds the allowable limit, replace the bushing Item Oil clearance Shaft O.D Bushing I.D Factory spec ~ mm ~ in ~ mm ~ in ~ mm ~ in. Allowable limit 0.1 mm in. F. REPLACING IDLE GEAR BUSHINGS 1. Press out the bushings using an idle gear bushing replacing tool. 2. Clean the bushings and the bore, and apply oil to them. 3. Press in the bushing using the replacing tool. (1) Injection pump gear (2) Snap ring 196W2D2A 196W2D3A 196W2D4A 266 SS30W00 May. 2007

68 CK20S/CK20S(H) SERVICING G. CAMSHAFT OIL CLEARANCE 1. Measure the I.D. of the camshaft bore on the crankcase with an inside micrometer. 2. Measure the O.D. of the camshaft journal with an outside micrometer. 3. If the clearance exceeds the allowable limit, replace the shaft. Item Oil clearance Journal O.D. Bore I.D Factory spec ~ mm ~ in ~ mm ~ in ~ mm ~ in. Allowable limit 0.15 mm in. 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 intermediate journal. 2. Rotate the camshaft in the V block and get the eccentricity (half of the measurement). 3. If the eccentricity exceeds the allowable limit, replace the camshaft. Item Eccentricity Allowable limit 0.08 mm in. I. CAM HEIGHT 1. Measure the height of the camshaft lobes at their largest O.D. with an outside micrometer. 2. If the measurement is less than the allowable limit, replace the camshaft. Item Reference value Allowable limit Allowable limit mm in mm in. 196W2D5A 196W2D6A 196W2D7A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

69 SERVICING CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH CONNECTING ROD AND PISTON A. PISTON PIN BORE 1. Measure the I.D. of piston pin bore in piston (lengthwise and widthwise of the piston) with a cylinder gauge. 2. If the measurement exceeds the allowable limit, replace the piston. Item Piston pin bore I.D. Factory spec ~ mm ~ in. B. PISTON PIN AND BUSHING CLEARANCE 1. Measure the piston pin O.D. with an outside micrometer. 2. Measure the piston pin busing I.D. with an inside micrometer. 3. Of the clearance exceeds the allowable limit, replace the bushing. 4. If the clearance still exceeds the allowable limit with new bushing, replace the piston pin. C. REPLACING PISTON PIN BUSHING Allowable limit mm in. Item Piston pin and bushing clearance Factory spec ~ mm ~ in. Allowable limit 0.15 mm in. Bushing I.D ~ mm ~ in. Piston pin ~ mm O.D ~ in. 1. Press out the bushing, using a piston pin bushing replacing tool. 2. Clean the new bushing and the bore and apply oil to them. 3. Press in the bushing, using the replacing tool. IMPORTANT Align the oil holes of the connecting rod and the bushing. 196W2D9A 196W2E0A 196W2E1A 268 SS30W00 May. 2007

70 CK20S/CK20S(H) SERVICING D. PISTON RING GAP 1. Push down the ring into the cylinder to the lower limit of ring travel in the assembled engine with a piston. 2. Measure the ring gap with a feeler gauge. 3. If the gap exceeds the allowable limit, replace the piston ring. Item Piston Top ring ring gap 2nd ring Oil ring Factory spec ~ 0.30 mm ~ in ~ 0.45 mm ~ in ~ 0.35 mm ~ in. Allowable limit 1.25 mm in mm in mm in. IMPORTANT Measure The piston ring gap at the point of the minimum inside diameter of the cylinder liner. E. PISTON RING CLEARANCE 1. Clean the rings and the ring grooves, and install each ring in its groove. 2. Measure the clearance between the ring and the groove with a feeler gauge. 3. If the clearance exceeds the allowable limit, replace the piston ring. 4. If the clearance still exceeds the allowable limit with new ring, replace the piston. NOTE: As the top ring is a keystone type, it cannot be measured by this method. Item Second ring Oil ring Reference value ~ mm ~ in ~ mm ~ in. 196W2E2A 196W2E3A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

71 SERVICING CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH 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 connecting rod alignment tool. 4. Put a gauge over the piston pin and move it against the face plate. 5. If the gauge does not fit squarely against the faceplate, measure the space between the pin of the gauge and the faceplate. 6. If the measurement exceeds the allowable limit, replace the connecting rod. Reference value Allowable limit 0.02 mm in mm in. IMPORTANT Because the I.D. of the connecting rod small end bushing is used as the basis for this check, check it is not worn beforehand. 196W2E4A 270 SS30W00 May. 2007

72 CK20S/CK20S(H) SERVICING CRANKSHAFT A. FLYWHEEL DEFLECTION AND CRANK SHAFT END PLAY 1. Set a dial indicator with its tip on the rear friction face of the flywheel near the edge. 2. Turn the flywheel and measure the deflection or the uneven wear. 3. If the measurement exceeds the allowable limit, remove the flywheel and check the mating faces of the crankshaft and flywheel. 4. If scored or worn excessively, regrind or replace the flywheel. 5. Move the crankshaft with flywheel back and forth to each end and measure the end play. 6. If the play exceeds the allowable limit, replace the side bearing. Item Deflection End play B. CRANKSHAFT ALIGNMENT 1. Support the crankshaft with V blocks on the surface plate at its front and rear journals and set a dial indicator with its tip on the intermediate journal. 2. Rotate the crankshaft in the V blocks and get the misalignment (half of the measurement) 3. If the misalignment exceeds the allowable limit, replace the crankshaft. Item Misalignment Factory spec mm in. Allowable limit 0.08 mm in. C. CRANKSHAFT JOURNAL AND 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 allowable limit, replace the bearing replacing to Replacing Crankshaft Bearing 1. Item Oil clearance Journal O.D. Bearing 1 I.D. Factory spec ~ 0.31 mm ~ in. Factory spec ~ mm ~ in ~ mm ~ in ~ mm ~ in. Allowable limit 0.05 mm in. 0.5 mm in. Allowable limit 0.20 mm in. 196W2E5B 196W2E6A 196W2E7A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

73 SERVICING CK20S/CK20S(H) D. REPLACING CRANKSHAFT BEARING 1 INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH 1. Press out the bearing 1 with crankshaft replacing tool. 2. Clean a new bearing 1 and bore, and apply engine oil to them. 3. Press fit a new bearing 1 using a inserting tool, taking due care to see that the seam of bearing 1 faces the exhaust manifold side. Item Depressed depth of bush at block E. CRANKSHAFT JOURNAL AND BEARING 2 OIL CLEARANCE 1. Paste a press gauge with grease on the crankshaft bearing 2. Install the bearing cap and tighten the screws to the 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 limit, replace the bearing. Item Bearing cap Reference value Allowable limit Crankshaft journal O.D. Crankshaft bearing 2 I.D. Factory spec. 4.2 ~ 4.5 mm ~ in. Tightening torque 20 ~ 24 Nm 2.0 ~ 2.4 kgfm 15 ~ 17 lbft ~ mm ~ in mm in ~ mm ~ in ~ mm ~ in. (1) Seam 196W2E8A 196W2E9A 272 SS30W00 May. 2007

74 CK20S/CK20S(H) SERVICING F. CRANKPIN 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 the cap again. 3. Remove the connecting rod gently, and measure the depression of the press gauge with a sheet of gauge (paper). 4. If the clearance exceeds the allowable limit, replace the bearing. Item Connecting rod cap Reference value Allowable limit Tightening torque 26.5 ~ 30.4 Nm 2.7 ~ 3.1 kgfm ~ lbft ~ mm ~ in mm in. (Note for measuring) Fasten the crankshaft so that it does not turn. Do not insert the press gauge into the crank pin hole. Crankpin bearing measuring points are shown below. 196W2F0A 196W2F1A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

75 SERVICING CK20S/CK20S(H) LUBRICATING SYSTEM INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH A. OIL PRESSURE 1. Remove the oil pressure switch and install adaptors and pressure tester. 2. Start the engine and run it until it is warmed up, and measure the oil pressure both at idling and rated speed. 3. If the oil pressure is less than the allowable limit, check the amount of oil, oil filter, oil pump relief valve, oil passages and oil clearances. (When reassembling) Supply the specified amount of recommended oil. The oil filter must not be clogged or broken. Engine oil pressure Item (Reference) B. RELIEF VALVE 1. Remove the relief valve. 2. Check the relief valve for dirt, and the seat (2) and ball (1) for damage. 3. If damaged, replace. 4. Check the free length of spring (3). 5. If less than the allowable limit, replace. Item Spring free length At idle speed At rated speed Item Oil pressure switch Factory spec. 35 mm 1.38 in. Allowable limit 30 mm 1.18 in. NOTE: Install the relief valve cover with the mark up. Item Relief cover screw Factory spec. Allowable limit More than 49 kpa 0.5 kgf/cm psi. 245 ~ 441 kpa 245 kpa 2.5 ~ 4.5 kgf/cm kgf/cm 2 36 ~ 64 psi. 36 psi. Tightening torque 14.7 ~ 19.6 Nm 1.5 ~ 2.0 kgfm 10.8 ~ 14.5 lbft Tightening torque 32.4 ~ 36.3 Nm 3.3 ~ 3.7 kgfm 23.9 ~ 36.8 lbft (1) Relief valve ball (2) Relief valve seat (3) Relief valve spring 196W2F4B 196W2F5A 274 SS30W00 May. 2007

76 CK20S/CK20S(H) SERVICING C. ROTOR AND LOBE CLEARANCE OF OIL PUMP 1. Measure the clearance between the outer and inner 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. Item Outer and inner rotor clearance Outer rotor and housing clearance Factory spec ~ 0.15 mm ~ in ~ 0.15 mm ~ in. Allowable limit 0.20 mm in mm in. D. ROTOR END CLEARANCE OF OIL PUMP 1. Put a strip of Plastic gauge on the rotor and assemble the pump. 2. Disassemble the pump and measure the amount of the flattening with the scale to get the clearance. 3. If the clearance exceeds the allowable limit, replace the pump. Item End clearance Factory spec ~ 0.13 mm ~ in. Allowable limit 0.20 mm in. 196W2F6A 196W2F7A 196W2F8A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

77 SERVICING CK20S/CK20S(H) INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH COOLING SYSTEM A. CHECKING AND ADJUSTING Fan Belt 1. Measure the deflection, depressing the belt halfway between the fan drive pulley and the alternator pulley at 78.5 N (8 kgf, 17.6 lbs.) of force. 2. If the deflection is not between the factory specifications, loosen the bolts and nuts, and relocate the alternator to adjust. 3. If the belt is damaged or worn (See figure), replace the belt. Item Belt tension (deflection) Factory spec. 8 mm(0.32 in.) at 78.5 N (8 kgf, 17.6 lbs.) of force Radiator Water Tightness 1. Fill the radiator with water to the specified amount 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. For water leak from the pin holes, repair with the radiator cement, and for other leaks, replace the radiator. Item Radiator water tightness Factory spec. No leaks at 137 kpa (1.4 kgf/cm², 20 psi) Radiator Cap Tightness 1. Set a radiator tester on the radiator cap. 2. Apply 88 kpa (0.9 kgf/cm², 13 psi) of pressure and measure the pressure for 10 seconds. 3. If the pressure falls below 59 kpa (0.6 kgf/cm², psi), replace the radiator cap. Item Radiator cap tightness Factory spec. More than 10 seconds for pressure fall from 88 ~ 59 kpa (0.9 ~ 0.6 kgf/cm 2, 13 ~ 9 psi). 196W2F9A 196W2G0A 196W2G1A 276 SS30W00 May. 2007

78 CK20S/CK20S(H) SERVICING B. DISASSEMBLING AND ASSEMBLING THERMOSTAT 1. Remove the thermostat cover (2). 2. Take out the thermostat (1). (When reassembling) Apply liquid gasket (Three Bond 1,215 or equivalent) to the gasket. WATER PUMP 1. Remove the fan and fan 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 mechanical seal (5). (When reassembling) Replace the mechanical seal (5) with new one. If changing the water pump, change the whole one. If disassembling the water pump, check to see the clearance between the water pump impeller and body. C. THERMOSTAT 1. Suspend the thermostat in the water by a string with its end inserted between the valve and seat. 2. Heating the water gradually, read the temperatures when the valve open and leave the string and when the valve opens approx. 8 mm (0.315 in.) 3. If the measurements are not within the factory specification, replace the thermostat. Item Opening temperature Factory spec. 82 ± 1.5 C (180 ± 3 F) at beginning lower than 95 C (203 F) at 8 mm (0.315 in.) of opening. 196W2G2A (1) Thermostat (2) Thermostat Cover 196W2G3B (1) Fan pullry (4) Water pump body (2) Flange (5) Mechanical seal (3) Pump shaft (6) Impeller 196W2G4A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

79 SERVICING CK20S/CK20S(H) FUEL SYSTEM INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH A. DELIVERY VALVES FUEL TIGHTNESS 1. Remove the injection pipes, glow plugs and the inlet manifold, and install the pressure tester. 2. With the speed control lever at the fuel injection position, turn the crankshaft counterclockwise (facing the flywheel) until the pressure build up to the fuel injection pressure. 3. Release the pressure in the delivery chamber by moving down the plunger to bottom dead center (turn the crankshaft clockwise approx rad (90 ) from the F1 timing). 4. If the pressure drop for 5 seconds exceeds the allowable limit, replace the delivery valve or pump assembly. 5. If the pressure does not built up, replace the pump element with new one and test again. Item Fuel injection pressure Standards Factory spec MPa 220 kgf/cm 2 3,129 psi 10 sec Allowable limit MPa 210 kgf/cm 2 2,987 psi. 5 sec CAUTION Never contact with spraying diesel fuel under pressure, which can have sufficient force to penetrate the skin, causing serious personal injury. Be sure nobody is in the direction of the spray. B. FUEL LECTION PRESSURE 1. Set the injection nozzle to the nozzle tester. 2. Measure the injection pressure. 3. If the measurement is not within the factory specification, adjust with the adjustment washer (1) inside the nozzle holder. (Reference) Pressure variation with 0.1 mm (0.004 in.) difference of adjusting washer thickness is approx. 10 kgf/cm². Fuel injection pressure Item Fuel injection pressure Factory spec ~ MPa 140~ 150 kgf/cm² 1,991 ~ 2,133 psi. (1) Pump element (3) Plunger (2) Cylinder 196W2G7B 196W2G8A 196W2G9A 278 SS30W00 May. 2007

80 CK20S/CK20S(H) SERVICING C. FUEL TIGHTNESS OF NEEDLE VALVE SEAT TIGHTNESS 1. Set the injection nozzle to the nozzle tester. 2. Apply a pressure 130 kgf/cm² (12.75 MPa, 1,849 psi). After keeping the nozzle under this pressure for 10 seconds. Check to see if fuel leaks from the nozzle. 3. If the should leak, replace the nozzle. D. INJECTION NOZZLE Nozzle holder 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1), and take out parts inside. (When reassembling) Assemble the nozzle in clean fuel oil. Install the push rod (4), noting its direction. (1) Nozzle holder (3) Nozzle spring (2) Adjusting washer (4) Push rod 196W2H1A 196W2H3A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH SS30W00 May

81 MEMO

82 2. 3A Series Workshop Manual

83 1. SPECIFICATIONS 1.1 TD1300 SPECIFICATIONS (CK25) BODY A. CYLINDER HEAD Item Cylinder head surface flatness Top clearance Thickness of gasketfree Compression pressure (when cranking with starting motor) Factory Specification 0.7 ~ 0.9 mm ~ in. When tightened 1.18 ~ 1.28 mm ~ in ~ 3.73 MPa 33 ~ 38 kgf/cm ~ 540 psi * Variance of compression pressure among cylinders should be 10% or less. B. VALVES CK25/27/30/ mm / 100 mm in. / 3.94 in MPa 26 kgf/cm psi Item Factory Specification Allowable Limit Valve clearance (cold) Valve seat angle Valve face angle IN. IN. IN. 0.1 mm in rad rad. 60 EX. EX. EX. 0.1 mm in rad rad. 60 Valve recessing 1.1 ~ 1.3 mm ~ in. 1.6 mm in. Clearance between valve stem and valve guide ~ mm 0.10 mm ~ in in. Valve stem O.D ~ mm ~ in. Valve stem I.D 8.0 ~ mm ~ in. C. VALVE TIMING Inlet valve Exhaust valve SPECIFICATIONS Allowable Limit Item Factory Specification Allowable Limit Open 0.349rad 20 before T.D.C Close 0.785rad 45 after B.D.C Open 0.873rad 50 before B.D.C Close 0.262rad 15 after T.D.C INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

84 CK25/27/30/35 SPECIFICATIONS INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D. CYLINDER BORE Item Factory Specification Allowable Limit Cylinder bore inner diameter ~ mm ~ in mm in. E. VALVE SPRING Item Factory Specification Allowable Limit Free length Assembling load / Assembling length 41.7 ~ 42.2 mm ~ in kgf / mm 26.5 lbs / in mm in kgf / mm 22.5 lbs / in. Squareness 1.0 mm in. F. ROCKER ARM Item Factory Specification Allowable Limit Rocker arm shaft O.D ~ mm ~ in. Rocker arm bushing I.D ~ mm ~ in. G. TAPPET Item Factory Specification Allowable Limit Clearance between tappet and guide ~ mm ~ in mm in. Tappet O.D ~ mm ~ in. Tappet guide I.D ~ mm ~ in. H. CAMSHAFT Item Factory Specification Allowable Limit Camshaft alignment Cam height IN. EX mm in ~ 33.6 mm ~ in ~ 33.6 mm ~ in mm in mm in mm in. Clearance between camshaft Camshaft journal O.D ~ mm ~ in ~ mm ~ in mm in mm in. Camshaft counter bore I.D ~ mm ~ in. 24 D704W01 Jun. 2008

85 SPECIFICATIONS CK25/27/30/35 I. TIMING GEAR Timing gear backlash Idle gear side clearance Clearance between J. PISTON RING Piston pinbore I.D Clearance between Clearance between Top ring, oil ring end gap 2nd ring end gap K. CONNECTING ROD Item Factory Specification Allowable Limit Idle gear shaft and idle gear bushing Idle gear shaft O.D Idle gear bushing I.D 0.04 ~ 0.11 mm ~ in ~ 0.51 mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ 5.03 mm ~ in ~ 4.99 mm ~ in ~ mm ~ in ~ mm ~ in ~ 1.99 mm ~ in ~ 0.40 mm ~ in ~ 0.40 mm ~ in mm in. 0.9 mm in. 0.1 mm in. Item Factory Specification Allowable Limit Oil ring and ring groove Oil ring groove width Oil ring width 2nd ring and ring groove 2nd ring groove width 2nd ring width mm in mm in mm in mm in mm in. Item Factory Specification Allowable Limit Connecting rod alignment 0.05 mm in. Clearance between Piston and small end ~ mm 0.15 mm bushing ~ in in. Piston pin O.D ~ mm ~ in. Small end bushing I.D ~ mm ~ in. INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

86 CK25/27/30/35 SPECIFICATIONS INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH L. CRANKSHAFT Item Factory Specification Allowable Limit Crankshaft alignment 0.08 mm in. Clearance between Crankshaft and crankshaft bearing ~ mm ~ in mm in. Crankshaft O.D ~ mm ~ in. Crankshaft bearing 1 I.D ~ mm ~ in. Clearance between Crankshaft and crankshaft bearing ~ mm ~ in mm in. Crankshaft O.D ~ mm ~ in. Crankshaft bearing 2 I.D ~ mm ~ in. Clearance between Crank pin and crank pin bearing ~ mm ~ in mm in. Crank pin O.D ~ mm ~ in. Crank pin bearing I.D ~ mm ~ in. Crankshaft side clearance 0.15 ~ 0.31 mm ~ in. 0.5 mm in LUBRICATING SYSTEM A. OIL PUMP Item Factory Specification Allowable Limit Engine oil pressure At idle speed more than 68.6 kpa (oil temp. 85 ~ 95 C, 185 ~ 203 F) 0.7 kgf/cm psi At rated speed Clearance between inner rotor and outer rotor Radial clearance between outer rotor and pump End clearance between inner rotor and cover ~ 441 kpa 3.0 ~ 4.5 kgf/cm ~ 64.0 psi 0.10 ~ 0.16 mm ~ in ~ 0.19 mm ~ in ~ mm ~ in kpa 3.0 kgf/cm psi 0.2 mm in mm in. 0.2 mm in. 26 D704W01 Jun. 2008

87 SPECIFICATIONS CK25/27/30/ COOLING SYSTEM A. THERMOSTAT Valve opening temperature at beginning Opened completely (height 8 mm in.) B. RADIATOR Radiator tightness Radiator cap tightness Fan belt tension [deflection at 78 N (8 kgf, 18 lbs) of force] FUEL SYSTEM A. INJECT PUMP B. INJECTION NOZZLE Fuel injection pressure Fuel tightness of nozzle valve seat NOTE: Injection Sequence Three Cylinders: (The cylinder number is given in order from the gear case end.) 69.5 ~ 72.5 C (157.1 ~ F) 85 C (185 F) No leak at 137 kpa, 1.4 kgf/cm 2, 20 psi 10 seconds or more for pressure falling from 88 ~ 59 kpa from 0.9 ~ 0.6 kgf/cm 2 from 13 ~ 9 psi 7 ~ 9 mm 0.28 ~ 0.35 in. Injection timing (BTDC) MPa 150 kgf/cm 2 2,134 psi No fuel leak for 5 sec. at pressure MPa 130 kgf/cm 2 1,849 psi INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

88 CK25/27/30/35 SPECIFICATIONS INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH TIGHTENING TORQUES Item Cylinder head screws Head cover bolts * Bearing case screw 1 * Bearing case screw 2 * Flywheel screw * Connecting rod screws Rocker arm support bolts Drain plug Glow plugs Oil switch Nozzle locating screws Injection pipe nuts Size x Pitch M11 x 1.25 M6 x 1.0 M9 x 1.25 M10 x 1.25 M12 x 1.25 M8 x 1.0 M10 x 1.25 M12 x 1.25 M10 x 1.25 PT1/8 M20 x 1.5 M12 x 1.5 NOTE: For *marked screw, bolts and nuts on the table, apply engine oil to their threads and seats before tightening. The letter M in Size x Pitch means that the screw, bolt or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between two threads. Nm ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ 34.3 kgfm 10.5 ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ 3.5 lbft 75.9 ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ D704W01 Jun. 2008

89 SPECIFICATIONS CK25/27/30/ A139(CK27) / 3A150 (CK30) / 3A165 (CK35) BODY A. CYLINDER HEAD Item Factory Specification Allowable Limit Cylinder head surface flatness 0.05 mm / 100 mm in. / 3.94 in. Top clearance ~ 0.9 mm ~ in. Thickness of gasketfree (MSL Gasket) Compression pressure (when cranking with starting motor) When tightened 1.21 mm in ~ 3.73 MPa 33 ~ 38 kgf/cm ~ 540 psi 2.55 MPa 26 kgf/cm psi * Variance of compression pressure among cylinders should be 10% or less. B. VALVES Valve clearance (cold) Valve seat angle Valve face angle Valve recessing IN. EX. IN. EX. IN. EX. Clearance between valve stem and valve guide Valve stem O.D Valve stem I.D C. VALVE TIMING Inlet valve Exhaust valve Item Factory Specification Allowable Limit 0.25 mm in mm in rad rad rad rad ~ 0.5 mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in. 0.05mm 0.8 mm in mm in. Item Factory Specification Allowable Limit Open 0.14rad 8 before T.D.C Close 0.611rad 35 after B.D.C Open 0.785rad 45 before B.D.C Close 0.140rad 8 after T.D.C INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

90 CK25/27/30/35 SPECIFICATIONS INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D. CYLINDER BORE Cylinder bore inner diameter E. VALVE SPRING ~ mm ~ in ~ mm ~ in ~ mm ~ in mm in. Item Factory Specification Allowable Limit Free length Assembling load / Assembling length Squareness 41.7 ~ 42.2 mm ~ in kgf / mm 26.5 lbs / in mm in kgf / mm 22.5 lbs / in. 1.0 mm in. F. ROCKER ARM Rocker arm shaft O.D Rocker arm bushing I.D G. TAPPET Item Factory Specification Allowable Limit 3A139 3A165 3A150 Item Factory Specification Allowable Limit ~ mm ~ in ~ mm ~ in. Item Factory Specification Allowable Limit Clearance between tappet and guide ~ mm ~ in mm in. Tappet O.D ~ mm ~ in. Tappet guide I.D ~ mm ~ in. H. CAMSHAFT Camshaft alignment Cam height Clearance between camshaft Camshaft journal O.D Camshaft counter bore I.D Item Factory Specification Allowable Limit IN. EX mm in mm in mm in ~ mm ~ in ~ mm ~ in ~ mm ~ in mm in mm in mm in mm in mm in. 210 D704W01 Jun. 2008

91 SPECIFICATIONS CK25/27/30/35 I. TIMING GEAR Timing gear backlash Idle gear side clearance Clearance between J. PISTON RING Piston pinbore I.D Clearance between Clearance between Top ring, oil ring end gap 2nd ring end gap K. CONNECTING ROD Item Factory Specification Allowable Limit Idle gear shaft and idle gear bushing Idle gear shaft O.D Idle gear bushing I.D 0.04 ~ 0.11 mm ~ in ~ 0.51 mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ 3.03 mm ~ in ~ 2.99 mm ~ in ~ 0.08 mm ~ in ~ 2.05 mm ~ in ~ 1.99 mm ~ in ~ 0.40 mm ~ in ~ 0.40 mm ~ in ~ 0.70 mm ~ in mm in. 0.9 mm in. 0.1 mm in. Item Factory Specification Allowable Limit Oil ring and ring groove Oil ring groove width Oil ring width 2nd ring and ring groove 2nd ring groove width 2nd ring width 3A150 Model Oil ring end gap 3A150 Model Top ring and gap 3A165/3A139 Model mm in mm in mm in mm in mm in. Item Factory Specification Allowable Limit Connecting rod alignment 0.05 mm in. Clearance between Piston and small end bushing ~ mm ~ in mm in. Piston pin O.D ~ mm ~ in. Small end bushing I.D ~ mm ~ in. INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

92 CK25/27/30/35 SPECIFICATIONS INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH L. CRANKSHAFT Crankshaft alignment Clearance between Clearance between Clearance between Item Factory Specification Allowable Limit Crankshaft and crankshaft bearing 1 Crankshaft O.D Crankshaft bearing 1 I.D Crankshaft and crankshaft bearing 2 Crankshaft O.D Crankshaft bearing 2 I.D Crank pin and crank pin bearing 2 Crank pin O.D Crank pin bearing I.D Crankshaft side clearance LUBRICATING SYSTEM A. OIL PUMP Engine oil pressure (oil temp. 85 ~ 95 C, 185 ~ 203 F) Clearance between inner rotor and outer rotor ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ 0.31 mm ~ in mm in mm in mm in mm in. 0.5 mm in. Item Factory Specification Allowable Limit At idle speed At rated speed more than 68.6 kpa 0.7 kgf/cm psi ~ kpa 2.5 ~ 4.5 kgf/cm kpa 2.5 kgf/cm 2 Radial clearance between outer rotor and pump End clearance between inner rotor and cover 35.5 ~ 64.0 psi 0.10 ~ 0.16 mm ~ in ~ 0.19 mm ~ in ~ mm ~ in psi 0.2 mm in mm in. 0.2 mm in. 212 D704W01 Jun. 2008

93 SPECIFICATIONS CK25/27/30/ COOLING SYSTEM A. THERMOSTAT Valve opening temperature at beginning Opened completely (height 8 mm in.) B. RADIATOR Radiator tightness Radiator cap tightness Fan belt tension [deflection at 78 N (8 kgf, 18 lbs) of force] FUEL SYSTEM A. INJECT PUMP B. INJECTION NOZZLE Fuel injection pressure Fuel tightness of nozzle valve seat 69.5 ~ 72.5 C (157.1 ~ F) 85 C (185 F) No leak at 137 kpa, 1.4 kgf/cm 2, 20 psi 10 seconds or more for pressure falling from kpa from kgf/cm 2 from 13 9 psi 7 ~ 9 mm 0.28 ~ 0.35 in. Injection timing (BTDC) 18 NOTE: Injection Sequence Three Cylinders: (The cylinder number is given in order from the gear case end.) MPa 150~160 kgf/cm 2 2,134~2,276 psi No fuel leak for 5 sec. at pressure MPa 130 kgf/cm 2 1,849 psi INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

94 CK25/27/30/35 SPECIFICATIONS INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH TIGHTENING TORQUES Item Cylinder head screws Head cover bolts * Bearing case screw 1 * Bearing case screw 2 * Flywheel screw * Connecting rod screws Rocker arm support bolts Drain plug Glow plugs Oil switch Nozzle locating screws Injection pipe nuts Size x Pitch M11 x 1.25 M6 x 1.0 M9 x 1.25 M10 x 1.25 M12 x 1.25 M8 x 1.0 M10 x 1.25 M12 x 1.25 M10 x 1.25 PT1/8 M20 x 1.5 M12 x 1.5 NOTE: For *marked screw, bolts and nuts on the table, apply engine oil to their threads and seats before tightening. The letter M in Size x Pitch means that the screw, bolt or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between two threads. Nm ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ 34.3 kgfm 10.5 ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ 3.5 lbft 75.9 ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ D704W01 Jun. 2008

95 2. OPERATING PRINCIPLE 2.1 LUBRICATING SYSTEM The lubricating oil is forced to each journal through the oil passages of the cylinder block, cylinder head and shafts. The oil, splashed by the crankshaft or thrown off from the bearings, lubricates other engine parts such as the push rods (11), tappets (12), camshaft (14), and crankshaft (15). OPERATING PRINCIPLE CK25/27/30/35 (1) Piston (5) Strainer (9) Rocker Arm Shaft (13) Oil Pressure Switch (2) Idle Gear (6) Oil Filter Element (10) Rocker Arm (14) Camshaft (3) Oil Pump (7) Bypass Valve (11) Push Rod (15) Crankshaft (4) Relief Valve (8) Oil Pan (12) Tappet 704W217A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

96 CK25/27/30/35 OPERATING PRINCIPLE INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH 2.2 COOLING SYSTEM (1) Water Return Pipe (2) Thermostat (3) Cylinder Head Water Jacket (4) Cylinder Block Water Jacket The cooling system consists of a radiator (5), a centrifugal water pump (7), a cooling fan (6) and a thermostat (2). The water is cooled as it flows through the radiator core, and the fan behind the radiator pulls the cooling air through the radiator core. The water pump receives water from the radiator or from the cylinder head and forces it into cylinder block. The thermostat open or closes according to the water temperature. When the (5) Radiator (6) Cooling Fan (7) Water Pump 704W221B water temperature is high, the thermostat opens to allow the water to flow from the cylinder block to the radiator. When the water temperature is low, the thermostat closes and the flow stays within the block. The opening temperature of the thermostat is approx. 71 C (160 F). 216 D704W01 Jun. 2008

97 OPERATING PRINCIPLE CK25/27/30/ FUEL SYSTEM FUEL FLOW ROUTE (1) Fuel Tank (2) Fuel Filter (3) Fuel Injection Pump The fuel in the fuel tank (1) is drawn to the fuel feed pump (7) and then is supplied to the fuel injection pump (3) passed through the fuel filter (2). Then, the fuel injection pump feeds the fuel to the injection nozzles (5) which then inject the fuel into the cylinders for combustion. The excessive fuel from the fuel injection pump to the injection nozzles is collected in the fuel overflow pipes (6) and returns to the fuel tank. NOTE: For air bleeding, see the next page (4) Injection Pipe (5) Injection Nozzle (6) Fuel Overflow Pipe (Hose) (7) Fuel Feed Pump (8) Bleeding Bolt (9) Bleeding Hose T46W233B INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

98 CK25/27/30/35 OPERATING PRINCIPLE INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH FUEL FILTER The fuel from fuel feed pump enters into the filter port through the (b) port and passes through the filter paper. Then, it is drained through the (c) port and supplied to the fuel injection pump. The filter paper collects the particles bigger than 90 microns ( in.) at 20 kpa (0.2 kgf/cm², 3 psi) BLEEDING THE FUEL SYSTEM 1. Make sure that the amount of fuel in the fuel tank is sufficient. 2. If there is air in the fuel filter, turn the filter cock (5), shown in the figure, to the air side and crank the engine. Then, the air in the filter port is discharged through the bleeding hose (1) shown in the figure. CAUTION Do not crank for over 5 seconds. Crank the engine for several times while keeping the cranking time below 5 seconds. 3. When the amount of fuel in the fuel filter port goes over 3/4 level, stop cranking the engine and turn the cock (5) of the figure to the ON position. NOTES: The bleeding process could be skipped if installing the fuel port after filling the bowl with fuel. 4. Loosen the bleeding bolt (2) in the figure and crank the engine to bleed air. Then tighten the bolt again. 5. If the engine still cannot be started, loosen 1 or 2 nozzle holders (3) and crank the engine to bleed air. 6. When the air bubble is not seen anymore in the bleeding fuel, tighten the loose parts and start the engine. 2 1 a b c T46W234A (a) To fuel tank (c) To fuel injection pump (b) From fuel feed pump (1) Cock (4) Retainer ring (2) Air vent (5) Port (3) Filter body (6) Filter element W2C6B 218 D704W01 Jun. 2008

99 OPERATING PRINCIPLE CK25/27/30/ FUEL FEED PUMP The diaphragm (6) is linked to the tappet (3) with the push rod (2). The tappet is reciprocated by the eccentric cam on the fuel camshaft (7). A. INTAKE STROKE When the diaphragm is pulled down by the spring, vacuum in the chamber (5) causes the exhaust valve (4) to close and the atmospheric pressure in the fuel tank to force the fuel into the chamber, opening the intake valve (1). B. SCAVENGING STROKE When the diaphragm is pushed up by the cam, the pressure in the chamber causes the intake valve to close and forces out the fuel, opening the exhaust valve FUEL INJECTION PUMP This fuel injection pump is Bosch K type fuel injection pump. It features a compact and light weight design. (A) From fuel tank (B) To fuel filter T46W235B (1) Intake valve (5) Chamber (2) Push rod (6) Diaphragm (3) Tappet (7) Fuel camshaft (4) Exhaust Valve a b (a) To injection nozzle (b) From fuel filter (1) Delivery valve holder (5) Plunger (2) Delivery valve spring (6) Control rack (3) Delivery valve (7) Plunger spring (4) Cylinder (8) Tappet T46W236A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

100 CK25/27/30/35 OPERATING PRINCIPLE INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH A. PUMP ELEMENT The pump element (1) consists of a plunger (3) and cylinder (2) which their sliding surfaces are finely machined to maintain the fuel tightness. The plunger (3) is installed in the control sleeve (5) and the sleeve is engaged with the control rack that rotates the plunger in the cylinder to control the amount of fuel delivered. B. OPERATION OF PUMP ELEMENT a. Before delivery As the plunger (2) lowers, fuel is drawn into the delivery chamber (1) through the feed hole (4) from the fuel chamber (5). b. Beginning of delivery When the plunger is pushed up by the cam and the head of the plunger closes the feed hole (4), the pressure in the delivery chamber (1) rises to push the delivery valve (3) open. c. Delivery While the plunger (2) is rising, delivery of fuel continues. d. End of delivery When the plunger rises further and the control groove (6) on its periphery meets the feed hole, the injection stops because the pressure in the delivery chamber (1) is reduced to the opening pressure T46W237A (1) Pump element (5) Control sleeve (2) Cylinder (6) Control groove (3) Plunger (7) Sliding surface (4) Feed hole T46W238A (1) Delivery chamber (4) Feed hole (2) Plunger (5) Fuel chamber (3) Delivery valve (6) Control 220 D704W01 Jun. 2008

101 OPERATING PRINCIPLE CK25/27/30/35 C. AMOUNT OF FUEL DELIVERY a. No fuel delivery When the control rack (3) is at the engine stop position, the lengthwise slot (1) on the plunger (2) aligns with the feed hole (5). The pressure in the delivery chamber does not build up and no fuel is forced to the injection nozzle since the delivery chamber (4) is opened to the feed hole during the entire stroke of the plunger. b. Fuel delivery The plunger is rotated by the control rack and the feed hole is not aligned with the lengthwise slot. When the plunger is pushed up, the feed hole is closed by the plunger. The pressure in the delivery chamber builds up and forces the fuel to the injection nozzle until the control groove (6) meets the feed hole. The amount of the fuel to be forced into the nozzle corresponds to distance A. In the above figure, the amount of injected fuel in (c) is larger than the amount of injected fuel in (b). D. DELIVERY VALVE The delivery valve (2) prevents the fuel in the injection pipe from flowing back into the delivery chamber and the fuel in the injection nozzle from dribbling after injection. The relief plunger (6) sucks the fuel back from the injection pipe to prevent the leakage dribbling and unnecessary subsequent injection after the major injection. The stroke of A corresponds to the amount of fuel sucked back (35 mm 3 ). D704W01 Jun (1) Slot (4) Delivery chamber (2) Plunger (5) Feed hole (3) Control rack (6) Control groove Location of fuel supply hole Stop 6 (1) Valve spring (4) Fuel chamber (2) Delivery valve (5) Valve face (3) Valve seal (6) Relief plunger 1 Low speed T46W239A High speed 3 T46W240A 4 T46W241A 221 INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH

102 CK25/27/30/35 OPERATING PRINCIPLE INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH E. INJECTION NOZZLE (1) Nozzle holder assembly (2) Adjusting washer (3) Nozzle spring (4) Push rod (5) Lock nut (6) Nozzle body This injection 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/cm², 2134 psi). When the pressure overcomes the counterforce of nozzle valve spring (3), the pressure pushes up the needle valve (7) constantly and then the proper amount of fuel is injected into the swirling air in the combustion chamber for combustion. The opening pressure can be adjusted by adding or reducing the washer (2). A washer of 0.1 mm corresponds to 980 kpa (10 kgf/cm², 142 psi) change in opening pressure. The heat seal (8) is adopted to improve the durability and reliability of the nozzle. 9 8 Supplied fuel 1 Excessive fuel (7) Needle valve (8) Heat seal (9) Packing T46W242A 222 D704W01 Jun. 2008

103 OPERATING PRINCIPLE CK25/27/30/ GOVERNOR SYSTEM BASIC PRINCIPLE OF GOVERNOR SYSTEM 8 Tip (1) Governor Spring 1, 2 (2) Solenoid Guide (3) Stop Solenoid (4) Pump Rack (5) Rack Pin Torque spring (6) Steel Ball (7) Governor Lever (8) Idle Spring (9) Start Spring (10) Idle Shaft As shown in the above figure, the steel ball (6) in the fuel camshaft gear is supported by the governor sleeve (11) to prevent from coming out. The sleeve pushes the fork lever 1 (13) to transfer the power to the fuel injection pump pin (5) Torque control screw 13 6 (11) Governor Sleeve (12) Fork Lever 2 (13) Fork Lever 1 (14) Fuel Limit Bolt (15) Torque Spring T46W246A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

104 CK25/27/30/35 OPERATING PRINCIPLE INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH OPERATION OF GOVERNOR A. WHEN STOPPED The fuel is blocked since the solenoid (3) pushes the speed control rack (4) to the left. B. WHEN TURNING THE KEY SWITCH ON When the electromagnet in the stop solenoid operates and the pin is retracted, the speed rack (4) of the fuel injection pump is pushed to the right by the start spring (9) and the start shaft (10) to supply the sufficient amount of fuel to start the engine. C. WHEN STARTING THE AND RUN NING THE AT LOW IDLE SPEED When the engine is started, the steel ball (6) pushes the sleeve (11) to the left as the centrifugal force of the steel ball increases. Therefore, the governor fork lever 1 (13) pushes the speed rack (4) of the pump to the left to reduce the amount of fuel supplied. As the speed rack is stopped by the idle spring (8), it keeps the balance with the centrifugal force of the steel ball so that at least minimum amount of fuel is delivered for stable engine running at idle speed. D. ACCELERATION AND DECELERATION When depressing the accelerator pedal, the governor spring (1) pulls the fork lever 2 (12) to the right and then pushes the fork lever 1 (13) to the right. The fork 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 determined by the driver, the stable speed is maintained. E. LOAD INCREASE AT HIGH SPEED Torque curve T46W247A When a load is applied to the engine running at a high speed, the centrifugal force of steel ball (6) decreases as the engine speed drops. Also, the fork lever 2 (12) is pulled to the right by the governor spring until it contacts the fuel limit bolt (14). Until then, the amount of injected fuel per one stroke of the injector plunger and the torque increase. This range (a) is between the max. speed point with no load and the max. power point of the torque curve. When the fork lever 2 is blocked by the fuel limit bolt (14) and does not move any more and the load is increased, the centrifugal force of steel ball drops further and the torque spring (15) compressed between the fork lever 1 and 2 is loosened. Then, the fork lever 2 moves to the right until the torque spring is free, and the amount of fuel supplied and the torque increase simultaneously. This range (b) is between the max. power and the max. torque point in the torque curve. IMPORTANT The fuel limit bolt (14), idle spring (9) and max. rpm setting bolt are set at factory. Unauthorized adjustment of such components can negatively effect the performance of the engine. Therefore, never adjust them without permission from DAEDONG. Such action violates the EPA regulation and also can void the warranty. F. WHEN STOPPED When the key switch is moved to the OFF position, the stop solenoid power is cut off to release the electromagnet. Therefore, the stop pin comes off by the return force of the spring and pushes the solenoid guide (2) and fuel injection pump rack to the stop position to stop the engine. 224 D704W01 Jun. 2008

105 OPERATING PRINCIPLE CK25/27/30/ PCV VALVE PCV (POSITIVE CRANKCASES VENTILATION) The PCV system is a system that prevents air pollution by returning the blowby gas to the intake manifold through the bleeding pipe of the cylinder head cover for recirculation of the gas. (However, the turbo charged engine has the open crankcase type that discharges the blowby gas to the air.) (1) Head Cover Bolt (2) Oil Filler Cap (3) Oil Baffle Plate (4) Head Cover Gasket (5) Cylinder Head Cover (6) Intake Manifold (7) Bleeding Pipe (8) Intake Valve (9) Cylinder Head (10) Cylinder Head Cover (11) Oil Baffle Plate (12) Bleeding Pipe Connection T46W248B 10 T46W249A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

106 INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH CK25/27/30/35 3. TROUBLESHOOTING DOES NOT START. Crankshaft does not turn Crankshaft turns No or small fuel injection sounds. Regular fuel injection sounds. TROUBLESHOOTING Frictional resistance of moving parts is too much Fuel supply to injection pump is insufficient. Injection pump does not send on fuel. Fuel does not inject through injection nozzle. Injection mistimed. Compressed air leaks. Valve action timing improper. Crankshaft and camshaft have seized up. Piston and cylinder liner have seized up. Bearings are oilstuck. Lubrication system not working property. Starter faulty. Battery capacity is low or terminal loose. Fuel pipe broken. Air enters fuel pipe through connection. Fuel filter clogged. Fuel pump faulty. Plunger has worn or seized up. Delivery valve spring broken. Delivery valve not completely oiltight. Needle valve stuck. Needle spring broken. Injection pressure maladjusted. Injection pipe mounting nut loose. Injection timing maladjusted. Contact between intake/exhaust valve and seat not tight. Intake/exhaust valve spring broken. Intake/exhaust valve stuck. Gasket faulty. Tightness torque of cylinder head not enough. Piston ring stuck. Piston ring worn. Cylinder liner worn. Tightness torque of injection nozzle and glow plug not enough. Valve clearance excessive. 226 D704W01 Jun. 2008

107 TROUBLESHOOTING CK25/27/30/35 Engine does not turn normally. Irregular Revolution Engine output insufficient. Slow engine revolutions. Revolution is not smooth at high speeds. Idling not smooth. Injection pump wrong. Injection nozzle faulty. Governor not functioning normally. Idling maladjusted. Fuel supply insufficient. Compression pressure not enough. Fuel filter clogged. Fuel pipes broken or loose. Air in pump. Pump capacity not constant. Tappet roller and pin worn. Delivery valve not completely oiltight. Fuel leaks from nozzle tip. Fuel not spraying properly. Governor spring deformed. Valve clearance incorrect. Injection pump or nozzle not functioning normally. Compression pressure is different among cylinders. Governor sleeve not sliding property. Fork lever not functioning normally. Start spring deformed. Control rack not sliding property. Idling regulator maladjusted. Accelerator rod maladjusted. Main moving parts have almost seized up. Engine overheated. Injection mistimed. Governor not functioning normally. Filter clogged. Fuel pipe broken or loose. Injection pump s capacity not enough. Nozzle needle valve worn. Air leaking. Air cleaner clogged. INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

108 CK25/27/30/35 TROUBLESHOOTING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH Color of exhaust fumes not normal. Excessive lubricant consumption. Lubricant increasing. White or blue exhaust fumes. Black or dark gray exhaust fumes. Fuel mixed with oil. Injection mistimed. Water mixed with oil. Lubricant rises through piston gap. Fuel pump s injecting capacity varies. Nozzle does not inject fuel properly. Gear oil mixed with oil. Piston ring stuck. Piston ring 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 spring is stuck or broken. Plunger worn. Needle valve stuck. Nozzle spring broken. Too much carbon sticks to nozzle tip. Injection pressure too low. Compressed air leaks. Not enough air. Excessive gap between piston and liner. Piston ring stuck. Piston ring worn. Excessive gap between intake/exhaust valve and valve stem. Valve stem seal broken. Oil leaks from defective packings. Injection pump plunger leaks much fuel. Fuel pump leaks much fuel. Head gasket packing faulty. Crankcase cracked. Hydraulic pump s oil seal broken. 228 D704W01 Jun. 2008

109 4. MEASUREMENT AND ADJUSTMENT 4.1 FAN BELT 1. Measure the deflection, depressing the belt halfway between the fan drive pulley and the alternator pulley at 78 N (8 kgf, 18 lbs) of force. 2. If the deflection is not between the factory specifications, loosen the bolts and nuts, and relocate the alternator to adjust. 3. If the belt is damaged or worn (See figure), replace the belt. Belt tension (direction) Factory spec 4.2 BODY 7 ~ 9 mm 0.28 ~ 0.35 in. at 78 N (8 kgf, 18 lbs) of force CHECKING AND ADJUSTING A. COMPRESSION PRESSURE 1. Run the engine until warmed up. 2. Stop the engine and remove the air cleaner, the muffler and all nozzle holders. 3. Connect a compression tester to the nozzle holder hole. 4. Pull the stop lever to cut the fuel and run the engine with the starter at 250 ~ 350 rpm for 5 ~ 10 seconds. 5. Measure the maximum pressure while running, several times. 6. 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 check the pressure again. 7. If the pressure raises after oil is apply, check the cylinder wall and piston ring. 8. If the pressure is still low, check the top clearance, valve clearance and cylinder head. Compression pressure Difference between two cylinders Factory spec. Allowable limit Allowable limit 3.24 ~ 3.73 MPa 33 ~ 38 kgf/cm ~ 541 psi 2.55 MPa 26 kgf/cm psi 10 % NOTE: Check the compression pressure with the specified valve clearance for proper air in taking. MEASUREMENT AND ADJUSTMENT CK25/27/30/35 704W2B5A 704W248B INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

110 CK25/27/30/35 MEASUREMENT AND ADJUSTMENT INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH 4.3 VALVE CLEARANCE 1. Remove the cylinder head cover and the timing window cover on the flywheel housing and all glow plugs. 2. Turn the flywheel and align the 1 TC mark mark with the timing mark of window on the flywheel housing. This will position the 1st cylinder valves at the top dead center during compression stroke. 3. Measure the clearance at the valves marked with in the table below with a feeler gauge. 4. If the clearance is not within the factory specifications, turn the adjusting screw to adjust. 5. Turn the flywheel just one turn to position the 1st cylinder valves at the top head center during overlap. 6. Measure the clearance at the valves marked with in the table below with a feeler gauge. 7. If the clearance is not within spec. ; adjust. See above. Factory spec. 3A139/ 3A150 3A165 TD1300 Cylinder NO. Valve Checking 1 IN. EX. In. : 0.25 mm in. Ex. : 0.30 mm in. In. : 0.1 mm in. Ex. : 0.1 mm in. 2 IN. EX. 3 IN. EX. (A) Gear Case 704W249A 704W250A 230 D704W01 Jun. 2008

111 MEASUREMENT AND ADJUSTMENT CK25/27/30/ INJECTION TIMING MEASURE MENT AND ADJUSTMENT NOTE: Perform the work with the engine installed in the tractor. 1. Remove the engine stop solenoid. 2. Remove the timing check window cover of the flywheel housing. 3. Turn the flywheel to find 1 FI mark for 3cylinder engine on the flywheel. 4. When the mark was found, turn the crankshaft counterclockwise approx. 30 (when looking at the front of the engine). When turning the crankshaft, use a special service tool (socket) for turning the crankshaft by engaging it with the socket wrench. NOTE: How to make the crankshaft turning socket T46W259A a. Cut the coupler (DAEDONG part No.: ) in half. b. Weld the 1/2 socket to the coupler. c. You can use DAEDONG speical tool kit (part No.: G0611B0010). 704W2D4B 704W2D3B T46W258A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

112 CK25/27/30/35 MEASUREMENT AND ADJUSTMENT INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH 5. Remove the No. 1 high pressure pipe. 6. Unscrew the nozzle holder (1) slightly and tighten it when it is filled with fuel. 7. Remove the fuel in the nozzle holder with clean cloth and leave only small amount of fuel. 8. Observe the fuel of the nozzle holder while turning the crankshaft clockwise (when looking at the front of the engine) slowly. 9. 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 already. Repeat the above process to identify the moment when the amount of fuel starts to increase. If the fuel does not increase, it means that it is the exhaust cycle. Therefore, turn the crankshaft 360 to find the compression cycle and repeat the above procedures. 10. Mark the measured injection timing on the flywheel through the timing window and measure the distance between the 1 FI and the mark you made. 11. To advance the injection timing, reduce the amount of shims. To delay the injection timing, increase the amount of shims(2). Model CK25 CK27 CK30 CK35 Injection timing BTDC 18 Diameter of flywheel 282 mm (11.1 in.) Flywheel circumference for mm (0.097 in.) * BTDC: Before top dead center Amount of shims to adjust mm (0.004 in.) Example) For 3A150 / 3A165, if the measured injection timing is on the 2.74 mm above the FI mark, it means that the injection timing is 1 advanced. Therefore, the measured injection timing is BTDC 19. In this case, the injection is adjusted to 18 if adding 0.1 mm of shim under the fuel injection pump. Fuel 2 T46W260B T46W261A T46W2I1B 232 D704W01 Jun. 2008

113 MEASUREMENT AND ADJUSTMENT CK25/27/30/ OIL PRESSURE 1. Remove the oil pressure switch. Install the adapter and pressure tester in its place. 2. Start the engine and run it until it is warmed up. Measure the oil pressure at both idling and rated speed. 3. If the oil pressure is less than the allowable limit, check the oil level, oil filter, oil pump relief valve, oil passages and oil clearance. Engine oil pressure (Reference) Tightening torque At idle speed At rated speed Oil pressure switch Factory spec. 3A139 3A150 3A165 TD1300 Factory spec. Allowable limit Factory spec. Allowable limit more than 49.0 kpa 0.5 kgf/cm² 7.11 psi 245 ~ 441 kpa 2.5 ~ 4.5 kgf/cm² 35.6 ~ 64.0 psi 245 kpa 2.5 kgf/cm² 35.6 psi 245 ~ 441 kpa 2.5 ~ 4.5 kgf/cm² 35.6 ~ 64.0 psi 245 kpa 2.5 kgf/cm² 35.6 psi 14.7 ~ 19.6 Nm 1.5 ~ 2.0 kgfm 10.8 ~ 14.5 lbft T46W262A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

114

115 EXPLODED VIEW (CK25/27/30/35) CK25/27/30/ EXPLODED VIEW (CK25/27/30/35) 26 CLUTCH TRANSMISSION REARAXLE 37 HST BARKE FRONTAXLE STEERING (8) Head Bolt (14) Bearing Case Bolt 2 (21) Camshaft Gear (27) Flywheel Housing (33) Fuel Feed Pump (2) Oil Pressure Switch (9) Gearcase (15) Rocker Arm (22) Idle Gear (28) Starter (34) Fuel Camshaft (35) Fuel Camshaft Gear (39) Water pump (40) Thermostat (36) Engine Stop Sole(41) Alternator noid (3) Oil Pump (10) Oil Filter (16) Inlet, Exhaust Valve (23) Piston (29) Injection Pipe (4) Oil Pan (11) Mainbearing Case Cover (17) Cylinder Hear Cover (24) Connecting Rod (30) Glow Plug (25) Crankshaft (31) Nozzle (26) Flywheel (32) Fuel Injection Pump (37) Manual Stop Lever (5) Oil Strainer (6) Oil Gauge (7) Cylinder Head D704W01 Jun (18) Push Rod (12) Bearing Case Bolt 1 (19) Tappet (13) Mainbearing Case (20) Camshaft (38) Fork Lever (Governor) (42) Fan Drive Pulley (43) Cooling Fan (49) Air Cleaner (44) Radiator (50) PCV V/v (45) Reserve Tank Ass y (51) Idle Limit System (46) Inlet Manifold (52) Oil Filter (47) Muffler (53) Speed Control (48) Exhaust Manifold (54) Fuel Control Limit INDEX (1) Cylinder Block ELECTRIC 704W243C HYDRAULIC

116

117 6. SERVICING 6.1 REMOVAL AND REASSEMBLY DRAINING THE COOLANT CAUTION Never open radiator cap when the coolant s temprature reaches boiling point. Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop. Relieve any excess pressure before removing cap completely. 1. Stop the engine and let it cool down. 2. After open the bonnet 3. To drain the coolant, open the radiator drain plug and remove radiator cap. The radiator cap must be removed to completely drain the coolant. 4. After all coolant is drained, close the drain plug. (Filling) Fill water up the point between Full and Low mark on the recovery water tank. Coolant capacity CK25/27/35 CK (2.0 U.S.gal.) 7.8 (2.1 U.S.gal.) SERVICING (1) Drain Plug (1) Radiator Cap (A) FULL (2) Recovery Tank (B) LOW CK25/27/30/35 704W143B 704W144A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

118 CK25/27/30/35 SERVICING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH DRAINING THE OIL CAUTION To avoid personal injury: Be sure to stop the engine before changing the oil. Allow engine to cool down sufficiently, oil can be hot and can burn. 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 still warm. 2. After draining reinstall the drain plug. 3. Fill with the new oil up to the upper notch on the dipstick. Oil capacity with filter 5.8 (1.53 U.S.gal.) A 704W2C5A (1) Oil Inlet (2) Dipstick (A) Oil Level is Acceptable Within this Range 704W307A (1) Drain Plug 238 D704W01 Jun. 2008

119 SERVICING CK25/27/30/ BONNET 1. Open the bonnet (1) and disconnect the electronic connector (2). 2. Remove the aircylinder (3). 3. Remove the snappin, jointpin and bonnet(1). 4. Remove the side cover (LH/RH) (4). 5. Disconnect the battery terminal () (5). NOTE: When disconnecting the battery cords, disconnect the () cord first. Connecting, (+) cable first. (For assembly) After connecting the battery terminal (), apply a little grease to it HYDRAULIC PIPE AND ELECTRIC WIRING 1. Remove the steering hoses(r, P, T).(2, 3, 4). 2. Remove the accelerator wires (hand, pedal).(5, 6) 3. Disconnect the bonnet wire harness 2 Assy. 4. Remove the rubber pipe 1 (7) out of suction pipe 3 (8). 5. Remove the hydraulic pipe (B1).(9) 6. Remove the cooling pipe 3 (HST type) 7. Remove the steering hose (L).(10) 8. Remove the cooling pipe 4 (HST type) 9. Disconnect the bonnet wire harness 1 Assy.(11) (When reassembling) A hose classification Steering hose P : A red tag attachment Steering hose R : A white tag attachment Steering hose L : A yellow tag attachment Steering hose T : No tag Item Steering hose P, R, L Pipe bed D704W01 Jun Tightening torque 9.8 Nm 1.0 kgfm 7.2 lbft 9.8 Nm 1.0 kgfm 7.2 lbft (3) Aircylinder W308A (1) Bonnet (4) Side Cover (2) Connector (5) Battery Terminal () 704W309B 704W310B (1) Steering Hose (R) (2) Steering Hose (P) (3) Steering Hose (T) (4) Accelerator Wire (Hand) (5) Accelerator Wire (Pedal) (6) Rubber Pipe (7) Suction Pipe 3 (8) Hydraulic Pipe (B1) (9) Steering Hose (L) (10) Bonnet Wire Harness 1 Assy 239 INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH

120 CK25/27/30/35 SERVICING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH PROPELLER SHAFT 1. Remove the bolts and slide the propeller shaft cover. 2. Tap out the spring pin (8), and then slide the coupling (2) to the rear. 3. Romove the propeller shaft and cover. (When reassembling) Apply grease to the splines of the propeller shaft SEPARATING & CLUTCH HOUSING 1. Place the jacket to the bottom of the clutch housing and engine. 2. Remove the mounting bolts for the fuel tank support. 3. Separate engine and clutch housing. (When reassembling) Apply grease to the spline of main shaft. Apply liquid gasket (Three Bond 1,211 or equivalent) to the joint face of the flywheel housing and clutch housing. Item Bolts, nuts Stud bolts Tightening torque 48.1 ~ 55.9 Nm 4.9 ~ 5.7 kgfm ~ lbft 24.5 ~ 31.4 Nm 2.5 ~ 3.2 kgfm ~ lbft (1) Propeller Shaft (2) Coupling (3) CirClip (4) Propeller Shaft Cover 1 (5) Propeller Shaft Cover 2 704W311A (6) Oring (7) Oring (8) Spring Pin (9) Oring (10) Bolt 704W312A 240 D704W01 Jun. 2008

121 SERVICING CK25/27/30/ REMOVING CLUTCH 1. Put alignment marks on the clutch cover and fly wheel. (CK25/27/30/35) 2. Insert the clutch center tool. 3. Remove the clutch assembly SEPARATING THE FUEL TANK 1. Remove the bonnet wireharness1 (1). 2. Remove the air cleaner (2). 3. Remove the reovery tank (3). 4. Loosen bolts and remove the fuel tank (4). 5. Remove the muftler (5). 6. Remove the bonnet wire harness2 (6). 7. Remove the water pipe (7, 8) (1) Bonnet Wire Harness 1 (2) Air Cleaner (3) Recovery Tank (4) Fuel Tank (5) Muftler (6) Bonnet Wire Harness2 (7) Water Pipe (Upper) (8) Water Pipe (Lower) 704W313A 704W314A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

122 CK25/27/30/35 SERVICING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH DISASSEMBLING FRONT AXLE FRAME 1. Lift engine with chain hook and support it. 2. Loosen bolts and remove the engine from the front axle frame. Item M10 Bolt (Only CK30) M12 Bolts Tightening torque 60.9 ~ 70.6 Nm 6.2 ~ 7.2 kgfm 44.9 ~ 52.0 lbft 103 ~ 117 Nm 10.5 ~ 12.0 kgfm 76.0 ~ 86.7 lbft DISASSEMBLING OTHER PARTS. 1. Remove the gear pump assy (1) and pump holder. 2. Remove the fan belt (2), cooling fan (3) and fan pulley. 3. Remove the dynamo assy (4). 4. Remove the start motor (5). (1) Gear Pump (4) Dynamo Assy (2) Fan Belt (5) Starter Motor (3) Cooling Fan 704W313A 704W312C 242 D704W01 Jun. 2008

123 SERVICING CK25/27/30/ CYLINDER HEAD COVER, GLOW PLUGS AND FUEL OVERFLOW PIPES 1. Remove the injection pipes and over flow pipe. 2. Remove the glow plugs. 3. Remove the injection nozzles, gaskets, and heat seals. 4. Remove the cylinder head cover. (When reassembling) Check that the cylinder head cover gasket is not defective. Tighten the cylinder head cover cap nuts in several steps HEAT SEAL REMOVAL PROCEDURE 1. Drive screw driver lightly into the heat seal hole. 2. Turn screw driver three or four times each way. 3. While turning the screw driver, slowly pull the heat seal and the injection nozzle gasket. If the heat seal drops, repeat the above procedure. 4. The heat seal and injection nozzle gasket must be changed when the injection nozzle is removed for cleaning or for service. NOTE: Use a philips screw driver that has a diameter which is bigger than the heat seal hole 1/4 in. (approx. φ 6 mm). (1) Injection Nozzle (3) Heat Seal (2) Gasket (1) Philips Screw Driver (2) Nozzle (3) Injection Nozzle Gasket (4) Heat Seal 704W251A 704W252A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

124 CK25/27/30/35 SERVICING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH ROCKER ARM ASSEMBLY 1. Loosen the bolts in several steps and the specified sequence shown in the figure and remove them. To loosen (3) to (1) To tighten (1) to (3) 2. Remove the rocker arm assembly and the push rod. (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 in the specified sequence to the specified torque. Refer to the figure. Adjust the valve clearance after assembling the rocker arm assembly. Tightening torque 3A139 3A150 3A165 TD ~ 70.6 Nm 6.2 ~ 7.2 kgfm 44.8 ~ 52.1 lbft 29.4 ~ 34.3 Nm 3.0 ~ 3.5 kgfm 21.7 ~ 25.3 lbft (A) Gear Case 704W253A 704W254A (1) Rocker Arm Shaft (3) Rocker Arm Bracket (2) Rocker Arm (4) Bolt 244 D704W01 Jun. 2008

125 SERVICING CK25/27/30/ CYLINDER HEAD 1. Remove the screw in the specified sequence shown in the figure and remove the cylinder head (1) and head gasket. To loosen (14) to (1) To tighter (1) to (14) 2. Remove the water flange (2). 3. Take out the tappets from the cylinder block. NOTE: Mark the cylinder number to the tappets to prevent interchanging. (When reassembling) Apply liquid gasket (Three bond 1215 or equivalent) on the both sides of the water flange gasket. Replace the head gasket with a new one and place on the cylinder block, be careful of its direction and side. When using the head gasket shim, install the shim on the cylinder head prior to the gasket. Before installing the tappets apply engine oil around them. IMPORTANT Apply oil to the thread of screws and tighten in several steps and the specified sequence shown in the figure to the specified torque. Check the torque after 30 minutes operation of the assembled engine, and adjust valve clearance. Tightening torque VALVE 1. Compress the valve spring and remove the collect (2). 2. Remove the retainer (3), valve spring (4), valve stem seal (5) and the valve (1). IMPORTANT 3A139 3A150 3A165 TD ~ Nm 10.5 ~ 11.0 kgfm 75.9 ~ 79.6 lbft 78.5 ~ 83.4 Nm 8.0 ~ 8.5 kgfm 57.9 ~ 61.5 lbft Do not interchange valves and valve parts. Mark the cylinder number on the valve and the parts to prevent interchanging. (When reassembling) Apply oil to the stem of valve and install in the cylinder head. Lubricate the valve and the parts after reassembling. 2 1 (1) Cylinder Head (2) Water Flange (A) Gear Caser 704W255A 704W256B 704W257A (1) Valve (4) Valve Spring (2) Collect (5) Valve Stem Seal (3) Retainer INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

126 CK25/27/30/35 SERVICING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH INJECTION PUMP A. INJECTION PUMP REMOVAL 1. Remove the injection pipes (1) and the intake manifold (2). 2. Remove the overflow pipe (3). 3. Remove the oil filler flange (4). 4. Remove the idle adjusting bolt (1) and oil filler flange (3). 5. Remove the manual stop lever cover (4). 6. Remove the stop solenoid (1). Be careful not to drop the stop solenoid guide (2) (1) Injection Pipes (3) Overflow Pipe (2) Intake Manifold (4) Oil Filler Flange 3 1 (1) Idle Adjusting Bolt (2) Fuel Injection Pump (3) Oil Filler Flange (4) Manual Stop Lever Cover 2 (1) Stop Solenoid (2) Stop Solenoid Guide 704W2C5C T46W298B T46W299A 246 D704W01 Jun. 2008

127 SERVICING CK25/27/30/35 7. Remove the fuel injection pump (1). 8. Keep the shims just like they were. B. INJECTION PUMP INSTALLATION 1. Apply the liquid gasket (Three bond 1215, 1104 or equivalent) on the pump installation surface of the cylinder block. 2. Install the shims as they were. 3. Make sure that the lever of the pump control rack is on the outer side from the fork lever 1 when installing the pump. 4. Tighten the nuts to the specified torque in several steps in the correct sequence as shown in the figure. Tightening torque M ~ 27.4 Nm 2.4 ~ 2.8 kgfm 17.3 ~ 20.2 lbft 5. Tighten the idle limit spring mounting bolt. Tightening sequence of bolt or nut: Injection pump control rack lever Fork lever 1 704W2C6C 704W2C8B W2C9B INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

128 CK25/27/30/35 SERVICING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH C. INJECTION PUMP DISASSEMBLY IMPORTANT When disassembling the pump components, the amount of fuel injection should be adjusted on a designated bench. Only authorized service personnel should disassemble or reassemble the fuel injection pump. D. NOZZLE HOLDER DISASSEMBLY 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1) and take out the internal components. a. Installation Before installing the nozzle, soak it in clean fuel. When installing the push rod (4), be careful of its direction W2D0B (1) Pump Body (5) Delivery Valve (2) Control Rack (6) Tappet Roller (3) Delivery Valve Holder (7) Plunger (4) Delivery Valve Spring (8) Cylinder T46W297A (1) Nozzle Holder (5) Distance Piece (2) Adjusting Washer (6) Nozzle (3) Nozzle Spring (7) Nozzle Nut (4) Push Rod 248 D704W01 Jun. 2008

129 SERVICING CK25/27/30/35 E. GOVERNOR SPRING AND STOP SOLE NOID a. Removal 1. Remove the idle adjusting bolt (1), stop solenoid fuel injection pump (2) and oil filler flange (3). 2. Remove the manual stop lever cover (4). 3. Open the governor lever cover. 4. Remove the governor spring using a hook after removing the throttle cover (1). Be careful not to pop out the governor spring. The governor spring can also be removed by disengaging it from the fork lever and then removing it engaged with the throttle lever. 1 (1) Idle Adjusting Bolt (2) Fuel Injection Pump (3) Oil Filler Flange (4) Manual Stop Lever Cover (1) Throttle Cover 3 T46W298B T46W2A0A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

130 CK25/27/30/35 SERVICING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH b. Installation 1. When installing the governor spring, make sure that the governor spring 2 is installed on the inside of governor spring 1. CAUTION Be careful of the direction of the governor spring 1. The longer side should face the governor fork. If the governor spring is dropped during the installation, the crankcase should be disassembled again. Therefore, use a hook not to drop the governor spring. 2. The governor spring can also be installed by installing one end to the throttle lever first and then the other end to the long hole of the governor fork. (1) Governor Spring 1 (3) Fork Lever 2 (2) Governor Spring 2 T46W2A5A 250 D704W01 Jun. 2008

131 SERVICING CK25/27/30/ CRANKCASE A. REMOVAL 1. Straighten the locking washer (1) and remove the crankshaft nut (2). 2. Remove the fan drive pulley (3). Tightening torque Crankshaft nut ~ Nm 14.0 ~ 16.0 kgfm ~ lbft 3. Unscrew the crankcase mounting bolts to remove the gear case. B. INSTALLATION 1. Apply the liquid gasket (Three bond 1215 or equivalent) to the both sides of the gearcase gasket. 2. Apply the grease to the crankshaft oil seal (1) lip on the gearcase and take care not to damage it when installing. 3. Apply the grease on the Oring (2) and attach it to the gearcase to prevent it from coming off during reassembling. 4. Make sure that the gearcase mounting bolts are installed at correct locations. IMPORTANT In general, the bolt should be screwed as 1.5 times as the diameter of the bolt in length. 5. Install all bolts and increase the tightening torque gradually (in 2 to 3 steps). Tightening torque M ~ 27.4 Nm 2.4 ~ 2.8 kgfm 17.3 ~ 20.2 lbft T46W2A2A (1) Locking Washer (3) Fan Drive Pulley (2) Crankshaft Nut T46W2A3A 1 2 T46W2A4A (1) Crankshaft Oil Seal (2) Oring INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

132 CK25/27/30/35 SERVICING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH IDLE GEAR AND CRANK GEAR A. REMOVAL 1. Remove the crankshaft collar (6), Oring (5), oil slinger (4) and oil pump drive gear 1 (3) in order. 2. Remove the idle gear (1). 3. Remove the crankshaft gear (2) with a puller set. NOTE: The oil pump drive gear (3) is only for the B series engine. It is not installed to the A series engine. Instead, the crankshaft gear (2) of the A series engine is longer than that of the B series as much as the thickness of the oil pump drive gear (3). B. INSTALLATION 1. If necessary, heat the crankshaft (2) gear up to approx. 80 C (176 F) and insert it to the crankshaft. 2. Apply the oil to the Oring (5) on the left figure. 3. The tapered face of the crankshaft collar should be first to contact with the Oring. 4. Install the idle gear while aligning the marks on the all gears as shown in the figure. IMPORTANT Even the one misalignment of these marks on the gears can lead to fatal failure of the engine. T46W2A6B (1) Idle Gear (4) Oring (2) Crankshaft Gear (5) Crankshaft Collar (3) Oil Slinger (1) Idle Gear (2) Crankshaft Gear (3) Oil Pump Gear (4) Fuel Camshaft Gear (5) Valve Camshaft Gear T46W2A7A 252 D704W01 Jun. 2008

133 SERVICING CK25/27/30/ VALVE CAMSHAFT A. REMOVAL 1. Align the holes on the cam gear (2) with the bolt holes and unscrew the bolts through the service hole with a T handle wrench. 2. Remove the camshaft (1). 3. Remove the cam gear (2). B. INSTALLATION 1. If necessary, heat the cam gear up to approx. 80 C (176 F) and insert it to the camshaft (1) FUEL CAMSHAFT A. REMOVAL 1. Remove the fuel camshaft stopper (1). 2. Unscrew the fork lever holder screws and remove the fuel camshaft (4), fork lever holder (5), fork lever 1 (1) and fork lever 2 (2) at the same time. 3. Remove the fuel camshaft gear (3) from the fuel camshaft if necessary. B. INSTALLATION If necessary, heat the fuel camshaft gear up to approx. 80 C (176 F) and insert it to the camshaft. (1) Camshaft (2) Cam Gear (1) Fuel Camshaft Stopper Service hole T46W2A8A T46W2F5A T46W2A9A (1) Fork Lever 1 (4) Camshaft (2) Fork Lever 2 (5) Fork Lever Holder (3) Fuel Injection Pump Gear INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

134 CK25/27/30/35 SERVICING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH CONNECTING ROD AND PISTON A. OIL PAN AND OIL FILTER 1. Remove the oil pan. 2. Remove the oil strainer (1). (When reassembling) Be sure to install the Oring (2) between the oil strainer and the cylinder block. B. PISTON AND CONNECTING ROD 1. Remove the screws and the connecting rod cap. 2. Push out the rod and piston assembly. (When reassembling) Apply oil to the crankpin bearing, cylinder wall and connecting rod cap screw. Insert the connecting rod and piston assembly with the mark on the rod facing the injection pump, using a piston ring compressor. IMPORTANT Mark the cylinder number on the piston and connecting rod to prevent interchanging. Carefully insert the piston and ring assembly in the cylinder. Be careful when compressing the rings not to damage the chromeplate on the piston rings. If the connecting rod cap screws can not be screwed to the end by hand, replace the screw. (1) Oil Strainer (2) Oring 704W269A 704W270A 254 D704W01 Jun. 2008

135 SERVICING CK25/27/30/35 C. PISTON RING AND PISTON PIN 1. Remove the piston rings with a piston ring replacing tool. 2. Remove the piston pin. (When reassembling) Clean all the parts before 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 towards the flywheel and the mark on connecting rod towards the injection pump. Install the piston rings with their manufacture s mark to the top of piston. Install the expander in the oil ring with its gap opposite to the gap of oil ring. Install the top ring with its gap at 1.57 rad (90 ) from the piston pin to the exhaust port. Install the second ring and the oil ring with their gap at every 2.09 rad (120 ). (1) Piston Pin (2) Piston (3) Piston Pin Snap Ring (4) Top Ring 704W271A (5) Second Ring (6) Oil Ring (7) Connecting Rod 704W272A 704W273A (7) Connecting Rod (11) Expander Joint (8) Connecting Rod Cap (12) Oil Ring Gap (9) Casting Mark (13) Manufacturer s Mark (10) Marks INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

136 CK25/27/30/35 SERVICING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH CRANKSHAFT A. FLYWHEEL 1. Install the stopper to the flywheel and loosen the screw. 2. Remove the flywheel stopper and the flywheel. (When reassembling) Clean the end of the crankshaft and the mating surface of the flywheel. Apply oil to flywheel screws. Fit the flywheel hole to crankshaft hole and tighten the flywheel bolts to specified torque. NOTE: Screw longer screws to the flywheel to carry it if needed. Tightening torque Flywheel screw 98.1 ~ Nm 10.0 ~ 11.0 kgfm 72.3 ~ 79.6 lbft B. BEARING CASE COVER Loosen the screw first inside and next outside, and lift the cover (1) by screwing the two screws gradually and evenly, referring to the photo. (When reassembling) Apply grease to the oil seal lip. Take care that the lip seal is is not rolled while installing. Tightening torque Bearing case cover screw 23.5 ~ 27.5 Nm 2.4 ~ 2.8 kgfm 17.4 ~ 20.3 lbft up 704W274A T46W2D3B 256 D704W01 Jun. 2008

137 SERVICING CK25/27/30/35 C. CRANKSHAFT 1. Remove the bearing case screw Pull out the crankshaft, taking care not to damage the crankshaft bearing 1. (When reassembling) Apply oil to the bearing case screw 2. Clean the oil passage of the crankshaft with compressed air. Bearing case screw 2 D. MAIN BEARING CASE 1. Remove the bearing case screws 1 (4) and remove the main bearing case 1, 2, 3 (1, 2, 3). 2. Remove the thrust bearing from the flywheel end bearing case. IMPORTANT Mark the location line to the bearing case, to prevent interchanging. (When reassembling) Clean the parts and the oil passage of the bearing case. Apply oil to the journal, bearing inserts and the bearing case screws. Place the thrust bearings on the bearing case with their oil groove outside. Install the main bearing case with the mark FLY WHEEL toward the flywheel. Bearing case screw 1 3A139 3A150 3A165 TD1300 3A139 3A150 3A165 TD ~ 73.6 Nm 7.0 ~ 7.5 kgfm 50.6 ~ 54.2 lbft 63.8 ~ 68.7 Nm 6.5 ~ 7.0 kgfm 47.0 ~ 50.6 lbft 46.1 ~ 51.0 Nm 4.7 ~ 5.2 kgfm 34.0 ~ 37.6 lbft 29.4 ~ 34.3 Nm 3.0 ~ 3.5 kgfm (1) Bearing Case Scraw 2 (1,2,3) Main Bearing Case Assembly 1, 2, 3 (4) Bearing Case Screw 1 (5) Thrust Bearings (6) Bearing Case 704W276A 704W277A 704W278A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH 21.7 ~ 25.3 lbft D704W01 Jun

138 CK25/27/30/35 SERVICING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH 6.2 INSPECTION FOR OVERHAUL CYLINDER HEAD AND VALVE A. CYLINDER HEAD SURFACE FLATNESS 1. Thoroughly clean the cylinder head surface. 2. Place a straight edge on the cylinder head and measure the clearance with a feeler gage as shown in the figure. 3. If the measurement exceeds the allowable limit, replace the cylinder head. IMPORTANT Do not place the straight edge on the combustion chamber. Flatness NOTE: Allowable limit 0.05 mm in. When installing the main bearing case cover, the UP mark on it should be at the highest position so that its holes are aligned with the holes of the cylinder block. B. CYLINDER HEAD SURFACE FLAW 1. Prepare an air spray red check. 2. Clean the cylinder head surface with the detergent (B). 3. Spray the cylinder head surface with the red permeative liquid (A). 4. Wash away the red permeative liquid on the cylinder head surface with the detergent (B) after ten minutes. 5. Spray the cylinder head surface with the white developer (C). 6. If any flaw is found such as a red mark, replace the cylinder head. (A) Red Permeative Liquid (B) Detergent (C) White Developer 704W279A 196W2B0A 704W280A 258 D704W01 Jun. 2008

139 SERVICING CK25/27/30/35 C. VALVE STEM CLEARANCE 1. Remove the carbon from the valve guide. 2. Measure the valve stem O.D. with an outside micrometer. 3. Measure the valve guide I.D. of cylinder head, and calculate the clearance. 4. If the measurement exceeds the allowable limit, replace the valve guide of the valve. Valve stem clearance Valve guide bore I.D. Valve stem O.D. D. VALVE RECESSING 1. Clean the cylinder head, the valve face and the seat. 2. Insert the valve in the guide. 3. Measure the valve recessing with a depth gauge. 4. If the recessing exceeds the allowable limit, replace the valve and check the valve seating. Valve recessing Factory spec. Factory spec. Allowable limit 3A139 3A150 3A165 TD1300 Allowable limit Factory spec. Factory spec. 3A139 3A150 3A165 TD1300 3A139 3A150 3A165 TD1300 3A139 3A150 3A165 TD ~ mm ~ in ~ mm ~ in. 0.1 mm in ~ mm ~ in. 8.0 ~ mm ~ in ~ mm ~ in. 0.2 ~ 0.5 mm ~ in. 1.1 ~ 1.3 mm ~ in. 0.8 mm in. 1.6 mm in W281A 704W282A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

140 CK25/27/30/35 SERVICING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH E. VALVE SEAT 1. Coat the valve face lightly with red lead and put the valve on its seat to check the contact. 2. If the valve does not seat all the way around the valve seat or the valve contact is less than 70%, correct the valve seating as follows. 3. Apply compound on the valve face evenly. 4. Put the valve on its seat hold it with the valve flapper. 5. Turn and lap the valve back and forth on the valve seat to lap. 6. Remove the compound and clean the valve and the seat. 7. Apply oil on the valve face and finish to complete fitting. 8. Repeat lapping until the valve seats correctly. 704W283A 260 D704W01 Jun. 2008

141 SERVICING CK25/27/30/ VALVE SPRING A. VALVE SPRING 1. Measure the free length of the spring with venire calipers. 2. Place the spring on a spring compression tester and compress to the specified length, and get the tension. 3. If the measurement is less than the allowable limit, replace the valve spring. Tension Free length B. VALVE SPRING SQUARENESS (TILT) 1. Place the spring on the surface plate and a square at its side. 2. Measure the maximum distance A (See figure), rotating spring. 3. If the measurement exceeds the allowable limit replace. Valve spring square ness Factory spec. Allowable limit Factory spec. Allowable limit Allowable limit 17.7 N / mm 12.0 kgf / mm 26.5 lbs / in. 100 N / mm 10.2 kgf / mm 22.5 lbs / in ~ 42.2 mm ~ in mm in. 1.0 mm in. 704W284A 704W285A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

142 CK25/27/30/35 SERVICING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH CHECKING OIL CLEARANCE BE TWEEN ROCKER ARM SHAFT AND BUSHING A. ROCKER ARM BUSHING AND SHAFT CLEARANCE 1. Measure the rocker arm I.D. with an inside micrometer. 2. Measure the rocker arm shaft O.D. with an outside micrometer. 3. If the clearance exceeds the allowable limit, replace the rocker arm. 4. If the clearance still exceeds the allowable limit after replacing the rocker arm replace the rocker arm shaft. Clearance Rocker arm shaft O.D. Rocker arm I.D. Factory spec. Allowable limit Factory spec. Factory spec. 3A139 3A150 3A165 TD1300 3A139 3A150 3A165 TD1300 3A139 3A150 3A165 TD ~ mm ~ in ~ mm ~ in mm in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in W286A 262 D704W01 Jun. 2008

143 SERVICING CK25/27/30/ TIMING GEARS AND CAMSHAFTS A. TIMING GEAR BACKLASH 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear. 3. If the backlash exceeds the allowable limit, check the oil clearance of the shafts and the gear. 4. If the oil clearance is improper, replace the gear. Clearance Factory spec. Allowable limit 0.04 ~ 0.11 mm ~ in mm in. 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 feeler gauge. 3. If the clearance exceeds the allowable limit, replace the idle gear collar 1 (3). Side clearance 0.20 ~ 0.51 mm ~ in. 0.9 mm in. C. CAM GEAR SIDE CLEARANCE 1. Pull the cam gear (2) with the camshaft (1) to its end. 2. Measure the clearance A between the cam gear (2) and the camshaft stopper (3). 3. If the clearance exceeds the allowable limit, replace the camshaft stopper (3). Side clearance Factory spec. Allowable limit Factory spec. Allowable limit 0.07 ~ 0.22 mm ~ in. 0.3 mm in. (1) Idle Gear Collar 2 (2) Idle Gear 704W287A 704W288B 704W289A (1) Camshaft (3) Camshaft Stopper (2) Cam Gear INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

144 CK25/27/30/35 SERVICING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D. INJECTION PUMP GEAR SIDE CLEAR ANCE 1. Pull the fuel camshaft and pull the injection pump gear (1) to each end. 2. Measure the clearance A between the injection pump gear (1) and the snap ring (2) on the fuel camshaft. 3. If the clearance exceeds the allowable limit, check the gear, the bearing and the key. Side clearance E. IDLE GEAR OIL CLEARANCE 1. Measure the idle gear shaft O.D. with an outside micrometer. 2. Measure the idle gear bushings I.D. with an inside micrometer. 3. If the clearance exceeds the allowable limit, replace the bushing. Oil clearance Shaft O.D. Bushing I.D. Factory spec. Allowable limit Factory spec. Allowable limit Factory spec. Factory spec. 3A139 3A150 3A165 TD1300 3A139 3A150 3A165 TD1300 3A139 3A150 3A165 TD ~ 0.57 mm ~ in. 0.9 mm in ~ mm ~ in ~ mm ~ in. 0.1 mm in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in. F. REPLACING IDLE GEAR BUSHINGS 1. Press out the bushings using an idle gear bushing replacing tool. 2. Clean the bushings and the bore, and apply oil to them. 3. Press in the bushing using the replacing tool. A (1) Injection Pump Gear (2) Snap Ring 704W290A 704W291A 704W292A 264 D704W01 Jun. 2008

145 SERVICING CK25/27/30/35 G. CAMSHAFT OIL CLEARANCE 1. Measure the I.D. of the camshaft bore on the crankcase with an inside micrometer. 2. Measure the O.D. of the camshaft journal with an outside micrometer. 3. If the clearance exceeds the allowable limit, replace the shaft. Oil clearance Journal O.D. Bore I.D. 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 intermediate journal. 2. Rotate the camshaft in the V block and get the eccentricity (half of the measurement). 3. If the eccentricity exceeds the allowable limit, replace the camshaft. Eccentricity Factory spec. Allowable limit Factory spec. Factory spec. Allowable limit ~ 0.091mm ~ in mm in ~ mm ~ in ~ mm ~ in mm in. I. CAM HEIGHT 1. Measure the height of the camshaft lobes at their largest. O.D. with an outside micrometer. 2. If the measurement is less than the allowable limit, replace the camshaft. Cam height 3A139 3A150 3A165 (IN.) (EX.) TD1300 (IN.) (EX.) Specification Allowable limit Specification Allowable limit Specification Allowable limit Specification Allowable limit mm in mm in mm in mm in ~ 33.6 mm ~ in mm in ~ 33.6 mm ~ in mm in. 704W293A 704W294A 704W295A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

146 CK25/27/30/35 SERVICING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH CONNECTING ROD AND PISTON A. PISTON PIN BORE 1. Measure the I.D. of piston pin bore in piston (lengthwise and widthwise of the piston) with a cylinder gauge. 2. If the measurement exceeds the allowable limit, replace the piston. Piston pin bore I.D. 3A139 3A150 3A165 Factory spec. Allowable limit ~ mm ~ in mm in ~ mm ~ in mm in. B. PISTON PIN AND BRUSHING CLEARANCE 1. Measure the piston pin O.D. with an outside micrometer. 2. Measure the piston pin busing I.D. with an inside micrometer. 3. If the clearance exceeds the allowable limit with new bushing, replace the piston pin. Piston pin and bushing clearance Piston pin O.D. Bushing I.D. TD1300 Factory spec. Allowable limit Factory spec. Factory spec ~ mm ~ in mm in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in. C. REPLACING PISTON PIN BUSHING 1. Press out the bushing, using a piston pin bushing replacing tool. 2. Clean the new bushing and the bore and apply oil to them. 3. Press in the bushing, using the replacing tool. IMPORTANT Factory spec. Allowable limit 3A139 3A150 3A165 TD1300 3A139 3A150 3A165 TD1300 Align the oil holes of the connecting rod and the bushing. 704W296A 704W297A 704W298A 266 D704W01 Jun. 2008

147 SERVICING CK25/27/30/35 D. PISTON RING END GAP 1. Push down the ring into the cylinder to the lower limit of ring travel in the assembled engine with a piston. 2. Measure the ring gap with a feeler gauge. 3. If the gap exceed the allowable limit, replace the piston ring. Piston ring end gap E. PISTON RING CLEARANCE 1. Clean the ring and the ring grooves, and install each ring in its groove. 2. Measure the clearance between the ring and the groove with a feeler gauge. 3. If the clearance exceeds the allowable limit, replace the piston ring. 4. If the clearance still exceeds the allowable limit with the new ring, replace the piston. Piston ring clearance 2nd ring Top ring Oil ring Top ring, oil ring 2nd ring Oil ring Factory spec. Factory spec. 3A139 3A150 3A165 TD1300 Allowable limit Factory spec. Factory spec. Allowable limit Factory spec. 3A139 3A165 3A150 Allowable limit Allowable limit 0.55 ~ 0.70 mm ~ in ~ 0.40 mm ~ in mm in ~ 0.40 mm ~ in ~ 0.40 mm ~ in ~ 0.40 mm ~ in mm in. 3A ~ 0.08 mm 3A150 3A ~ in. TD ~ 0.10 mm ~ in mm in. 3A ~ 0.06 mm 3A150 3A ~ in. TD ~ 0.06 mm ~ in mm in. 704W299A 704W2A0A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

148 CK25/27/30/35 SERVICING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH 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 connecting rod alignment tool. 4. Put a gauge over the piston pin and move it against the face plate. 5. If the gauge does not fit squarely against the face plate, measure the space between the pin of the gauge and the face plate. 6. If the measurement exceeds the allowable limit, replace the connecting rod. Space between gauge pin and face plate Allowable limit 0.05 mm ( in.) at 100 mm (3.94 in.) of gauge pin span 704W2A1A 268 D704W01 Jun. 2008

149 SERVICING CK25/27/30/ CRANKSHAFT A. FLYWHEEL DEFLECTION AND CRANK SHAFT END PLAY 1. Set a dial indicator with its tip on the rear friction face of the flywheel near the edge. 2. Turn the flywheel and measure the deflection or the uneven wear. 3. If the measurement exceeds the allowable limit, remove the flywheel and check the mating faces of the crankshaft and flywheel. 4. If scored of worn excessively, regrind or replace the flywheel. 5. Move the crankshaft with flywheel back and forth to each end and measure the end play. 6. If the play exceeds the allowable limit, replace the side bearing. Deflection End play B. CRANKSHAFT ALIGNMENT 1. Support the crankshaft with V blocks on the surface plate at its front and rear journals and set a dial indicator with its tip on the intermediate journal. 2. Rotate the crankshaft in the V blocks and get the misalignment (half of the measurement). 3. If the misalignment exceeds the allowable limit, replace the crankshaft. Misalignment Allowable limit Factory spec. Allowable limit Allowable limit 0.05 mm in ~ 0.31 mm ~ in. 0.5 mm in mm in. 704W2A2A 704W2A3A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

150 CK25/27/30/35 SERVICING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH C. CRANKSHAFT JOURNAL AND 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 allowable limit, replace the bearing referring to Replacing Crankshaft Bearing 1. Oil clearance Journal O.D. Bearing 1 I.D. Factory spec. Allowable limit Allowable limit Allowable limit ~ mm ~ in mm in ~ mm ~ in ~ mm ~ in. D. REPLACING CRANKSHAFT BEARING 1 1. Press out the crankshaft bearing 1 using replacing tool. 2. Clean a new crankshaft bearing 1 and bore, and apply engine oil to them. 3. Press fit a new bearing 1 using a inserting tool, taking due care to see that the seam of bearing 1 faces the exhaust manifold side. Allowable limit 4.5 mm (0.177 in.) (1) Seam 704W2A4A 704W2A5A 270 D704W01 Jun. 2008

151 SERVICING CK25/27/30/35 E. CRANKSHAFT JOURNAL AND BEARING 2 OIL CLEARANCE 1. Put plasticgauge lengthwise in the center of the journal. 2. Install the bearing cap and tighten the screw to the specified torque once, and remove the cap again. 3. Measure the amount of the flattening with the scale and get the oil clearance. 4. If the clearance exceeds the allowable limit, replace replace the bearing. Oil clearance Journal O.D. Bearing 2 I.D. Factory spec. Allowable limit Allowable limit Factory spec ~ mm ~ in mm in ~ mm ~ in ~ mm ~ in. F. CRANK PIN AND CONNECTING ROD BEARING 2 OIL CLEARANCE 1. Put a strip of Plastigage lengthwise in the center of the crank pin. 2. Install the connecting rod and tighten the screws to the specified torque once, and remove the cap again. 3. Measure the amount of the flattening with the scale and get the oil clearance. 4. If the clearance exceeds the allowable limit, replace the bearing. Oil clearance Journal O.D. Bushing 1 I.D. Factory spec. 3A139 3A150 3A165 TD1300 Allowable limit Factory spec. Factory spec. 3A139 3A150 3A165 TD1300 3A139 3A150 3A165 TD ~ mm ~ in ~ mm ~ in mm in ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in. 704W2A6A 704W2A7A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

152 CK25/27/30/35 SERVICING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH CYLINDER BORE A. CYLINDER BORE DIAMETER 1. Measure the cylinder liner I.D. at sit positions shown in the figure to find the maximum wear. TD1300 3A139 3A150 3A ~ mm ~ in ~ mm ~ in ~ mm ~ in ~ mm ~ in. (A) Axial Direction (B) Transverse Direction 1,2,3 Measuring Points 704W2A8A 704W2A8A 272 D704W01 Jun. 2008

153 SERVICING CK25/27/30/ LUBRICATING SYSTEM A. OIL PRESSURE 1. Remove the oil pressure switch. Install the adapter and pressure tester in its place. 2. Start the engine and run it until it is warmed up. Measure the oil pressure at both idling and rated speed. 3. If the oil pressure is less than the allowable limit, check the oil level, oil filter, oil pump relief valve, oil passages and oil clearance. Engine oil pressure (Reference) Tightening torque At idle speed At rated speed B. OIL FILTER Oil pressure switch D704W01 Jun Factory spec. 3A139 3A150 3A165 TD1300 Factory spec. Allowable limit Factory spec. Allowable limit more than 68.6 kpa 0.7 kgf/cm² 7.11 psi 245 ~ 441 kpa 2.5 ~ 4.5 kgf/cm² 35.6 ~ 64.0 psi 245 kpa 2.5 kgf/cm² 35.6 psi 245 ~ 441 kpa 2.5 ~ 4.5 kgf/cm² 35.5 ~ 64.0 psi 245 kpa 2.5 kgf/cm² 35.6 psi 14.7 ~ 19.6 Nm 1.5 ~ 2.0 kgfm 10.8 ~ 14.5 lbft 1. Drain the engine oil and remove the oil filter to check it. 2. Check the relief valve for dirt, and the seat (2) and ball (1) for damage. 3. If damaged, replace the filter. 4. Check the free length of spring (3). 5. If it is less than the allowable limit, replace it. Spring free length Factory spec Allowable limit 35 mm 1.38 in. 30 mm 1.18 in. T46W262A 704W2B1A (1) Relief Valve Ball (3) Relief Valve Spring (2) Relief Valve Seat 273 INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH

154 CK25/27/30/35 SERVICING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH C. ROTOR AND LOBE CLEARANCE OF OIL PUMP 1. Measure the clearance between the outer and inner 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. Outer and inner rotor clearance Outer and inner housing clearance D. ROTOR END CLEARANCE OF OIL PUMP 1. Put a strip of plastigage on the rotor and assemble the pump. 2. Disassemble the pump and measure the amount of the flattening with the scale to get the clearance. 3. If the clearance exceeds the allowable limit, replace the pump. End clearance Factory spec. Allowable limit Factory spec. Allowable limit Factory spec. Allowable limit 0.10 ~ 0.16 mm ~ in mm in ~ 0.19 mm ~ in mm in ~ mm ~ in mm in. 704W2B2A 704W2B3A 704W2B4A 274 D704W01 Jun. 2008

155 SERVICING CK25/27/30/ COOLING SYSTEM A. CHECKING ADJUSTING FAN BELT 1. Measure the deflection, depressing the belt halfway between the fan drive pulley and the alternator pulley at 78 N (8 kgf, 18 lbs) of force. 2. If the deflection is not between the factory specifications, loosen the bolts and nuts, and relocate the alternator to adjust. 3. If the belt is damaged or worn (See figure), replace the belt. Belt tension (direction) Factory spec RADIATOR WATER TIGHTNESS 7 ~ 9 mm 0.28 ~ 0.35 in. at 78 N (8 kgf, 18 lbs) of force 1. Fill radiator with water to the specified amount 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. Pinhole water leaks may be repaired with radiator cement. Larger leaks require radiator replacement. Radiator water tightness Factory spec RADIATOR CAP TIGHTNESS No leaks at 137 kpa (1.4 kgf/cm², 20 psi) 1. Attach a radiator tester on the radiator cap. 2. Apply 88 kpa (0.9 kgf/cm², 13 psi) of pressure and measure the pressure for 10 seconds. 3. If the pressure falls below 59 kpa (0.6 kgf/cm², 9 psi), replace the radiator cap. Radiator cap tightness Factory spec More than 10 seconds for pressure fall from 88 ~ 59 kpa (0.9 ~ 0.6 kgf/cm², 13 ~ 9 psi) 704W2B5A 643W2D1A 704W2B6A 704W2B7A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

156 CK25/27/30/35 SERVICING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH B. DISASSEMBLING AND ASSEMBLING THERMOSTAT 1. Remove the thermostat cover (2). 2. Take out the thermostat (1). (When reassembling) Apply liquid gasket (Three Bond 1215 or equivalent) to the gasket. WATER PUMP NOTE: If the coolant is leaked from the hole indicated by the arrow in the figure, it means that the mechanical seal is damaged. a. Removal 1. Remove the fan and fan pulley. 2. Remove the water pump body from the gear case cover. 3. Remove the water pump flange (1). 4. Remove the impeller and water pump body (3). 5. Remove the impeller from the water pump shaft. 6. Remove the mechanical seal (4). b. Installation Replace the mechanical seal (4) with new one. CAUTION The components of the water pump is firmly assembled together and they cannot be easily disassembled or assembled without a special equipement. Therefore, it is recommended to replace the whole water pump assembly. 704W2B8A (1) Thermostat (2) Thermostat Cover S76W2P9B T46W2F4A (1) Water Pump Flange (4) Mechanical Seal (2) Water Pump Bearing (5) Impeller (3) Water Pump Body 276 D704W01 Jun. 2008

157 SERVICING CK25/27/30/35 C. SERVICING THERMOSTAT VALVE OPENING TEMPERA TURE 1. Suspend the thermostat in the water by a string with its end inserted between the valve and seat. 2. Heating the water gradually, read the temperature when the valve opens and then when the valve opens to approx. 8 mm (0.315 in.). 3. If the measurements are not within the factory specifications, replace the thermostat. Opening temperature Factory spec. 71 ± 1.5 C (160 ± 3 F) at beginning Lower than 85 C (185 F) At 8 mm (0.315 in.) Of opening 704W2C0A INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH D704W01 Jun

158 CK25/27/30/35 SERVICING INDEX ELECTRIC HYDRAULIC STEERING FRONT AXLE BARKE REAR AXLE HST TRANSMISSION CLUTCH FUEL SYSTEM A. INJECTION NOZZLE CAUTION Never contact with spraying diesel fuel under pressure, pressure, which can have sufficient force to penetrate the skin, causing serious personal injury. Be sure nobody is in direction of the spray. FUEL INJECTION PRESSURE 1. Set the injection nozzle to the nozzle tester. 2. Measure the injection pressure. 3. If the measurement is not within the factory specifications, adjust with the adjustment washer (1) inside the nozzle holder. (Reference) Each adjustment washer of 0.1 mm (0.004 in.) will adjust the fuel injection pressure by approx. 10 kgf/cm². Fuel injection pressure Factory spec MPa 150~160 kgf/cm² 2,134~2,276 psi FUEL TIGHTNESS OF NEEDLE VALVE SEAT 1. Connect the injection nozzle to the nozzle tester. 2. Apply a pressure 130 kgf/cm² (12.75 MPa, 1849 psi). Keep the nozzle under this pressure for 10 seconds. Check to see if fuel leaks from the nozzle. 3. If the fuel should leak, replace the nozzle. (1) Adjustment Washer 704W2C3A 704W2C4A 278 D704W01 Jun. 2008

159 MEMO

160 3. 4A,3B,4B Series Workshop Manual

161 DK35/40(C)/45(C)SE IDENTIFICATION 1. Engine identification 1.2 Engine number (B) The engine number is stamped near the fuel injection pump on the cylinder block, in case the bar code is not available due to damage. Important The engine number is necessary information that is requested on the warranty registration form. This number should be on the form as well as the tractor number and the amount of time used. SAFETY FIRST T46W201B Engine number assignment standard CLUTCH 1.1 Engine EPA decal (A) H D Serial number TRANSMISSION Engine model HST D78 D82 D79 3B183LWM 3B183LWH 4A200LWM REAR AXLE D83 4A200LWH D80 D84 4A220LWM 4A220LWH BRAKE T46W202C This aluminum decal is riveted on the engine cylinder head cover. This provides the information such as model number, displacement, rated output, valve clearance, injection timing, etc. This decal represents that this engine is in compliance with the U.S.EPA and California (CARB) exhaust emission regulation. D81 D85 Year of manufacturing 4B243LWM 4B243LWH D 2004 E 2005 F 2006 G 2007 H 2008 CABIN ELECTRIC HYDRAULIC STEERING FRONT AXLE For example, HD means that this engine is the first manufactured unit, 4B243 LWM, in A/C & HEATER DH14W00 Jul

162 IDENTIFICATION DK35/40(C)/45(C)SE CLUTCH SAFETY FIRST 1.3 Assignment standard for engine model code 4 B L W M Mechanical or HST D, B, A, M Mechanical E, H HST Tier3 type TRANSMISSION Displacement 139 Approx. 1,390 cc HST REAR AXLE BRAKE 150 Approx. 1,500 cc 165 Approx. 1,650 cc 183 Approx. 1,830 cc 200 Approx. 2,000 cc 220 Approx. 2,200 cc 243 Approx. 2,430 cc Stroke FRONT AXLE A B 92.4 mm (3.638 in.) mm (4.031 in.) STEERING HYDRAULIC Number of cylinders 3 3 cylinders 4 4 cylinders A/C & HEATER CABIN ELECTRIC 24 DH14W00 Jul. 2008

163 DK35/40(C)/45(C)SE SPECIFICATIONS 2. Specifications 2.1 General specifications Engine model Tractor model DK35SE DK40(C)SE DK45(C)SE DK50(C)SE Mechanical 3B183LWM 4A200LWM 4A220LWM 4B243LWM HST 3B183LWH 4A200LWH 4A220LWH 4B243LWH Bore I.D. X Stroke (mm) Ø Ø Ø Ø Honing Plateau honing Number of cylinders 3 4 Ignition sequence Displacement (l) Max./Min. speed (rpm) 2,800 / 1,000 Max. gross output kw(hp)/rpm. 28.3(38) / 2, (41) / 2, (45) / 2, (49) / 2,600 Max. torque (kg m/rpm) 119.6(12.2) / 1, (13.2) / 1, (14.3) / 1, (16.3) / 1,700 Compression ratio 22:1 21.7:1 22:1 Combustion chamber type Indirect injection type (Swirl chamber type) Injection timing (BTDC) Fuel injection pump type BOSCH K MINI Injection pressure kpa(kgf/cm 2 ) 14,700~15,680 (150 ~ 160) BOSCH K MINI (CTD) Engine oil capacity (l) Engine oil specification SAE 15W 40, CD or higher of API grade Coolant capacity (l) Antifreeze Ethylene glycol 50% with anticorrosive agent The engines for mechanical and HST tractors are the same except for the flywheel. They are compatible with each other once the flywheel is replaced. The engine gross output is measured with the cooling fan removed. The cylinder number for ignition sequence is given from the cylinder on the engine cooling fan side. If the coolant level drops due to its evaporation, add only water. If the coolant lever drops due to the leakage, add coolant mixed with antifreeze. The freezing point of the 50% coolant mixture is 37 C (34 F) in a normal condition. When replacing the coolant with a different type of coolant, flush the cooling system thoroughly beforehand. ELECTRIC HYDRAULIC STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH SAFETY FIRST A/C & HEATER CABIN DH14W00 Jul

164 SPECIFICATIONS DK35/40(C)/45(C)SE SAFETY FIRST 2.2 Engine performance curve 3B183LWM(H): DK35SE(H) Gross power 13 HST CLUTCH TRANSMISSION Torque (kg f f m) REAR AXLE 35 BRAKE FRONT AXLE STEERING Power (HP) HYDRAULIC ELECTRIC Fuel consumption (g/hphr) hr) CABIN A/C & HEATER Engine speed (rpm) T46W203A 26 DH14W00 Jul. 2008

165 DK35/40(C)/45(C)SE SPECIFICATIONS 4A200LWM(H): DK40(C)SE(H) SAFETY FIRST Gross power Torque (kg f f m) CLUTCH HST TRANSMISSION 35 REAR AXLE Power (HP) 30 BRAKE 25 FRONT AXLE Fuel consumption (g/hphr) hr) STEERING HYDRAULIC ELECTRIC Engine speed (rpm) CABIN T46W204A A/C & HEATER DH14W00 Jul

166 SPECIFICATIONS DK35/40(C)/45(C)SE SAFETY FIRST 4A220LWM(H): DK45(C)SE(H) Gross power ELECTRIC HYDRAULIC STEERING CABIN A/C & HEATER Fuel consumption (g/hp hr) FRONT AXLE BRAKE Power (HP) REAR AXLE HST TRANSMISSION CLUTCH Torque (kg f m) Engine speed (rpm) T46W205A 28 DH14W00 Jul. 2008

167 DK35/40(C)/45(C)SE SPECIFICATIONS 4B243LWM(H): DK50(C)SE(H) SAFETY FIRST Gross power ELECTRIC HYDRAULIC CABIN Fuel consumption (g/hp hr) STEERING FRONT AXLE Power (HP) BRAKE REAR AXLE HST A/C & HEATER TRANSMISSION Torque (kg f m) CLUTCH Engine speed (rpm) T46W206A DH14W00 Jul

168 SPECIFICATIONS DK35/40(C)/45(C)SE TRANSMISSION CLUTCH SAFETY FIRST 2.3 Engine performance curve analysis A. Torque When applying the rotating resistance to the flywheel, the engine speed drops and the rotating force of flywheel increases. Torque curve shows this force as a graph. Torque (kg f f m) Max. torque point b. Brake horse power (HP) The power is proportional to the rotating force (torque) and the rotating speed (rpm). Its formula is as follows: Power (HP) = Torque (Kg f m) rpm kw = HP If substituting the torque and rpm in the left figure for the above formula and getting the power value, the below curve is provided. As shown in the below figure, when the power reaches the maximum point at 2,600 rpm, the power starts to drop. This is because the rpm drops sharply even the torque increases gradually. HST rpm T46W207A Power 출력 (HP) Max. 최대 power 출력점 point REAR AXLE BRAKE FRONT AXLE When running the engine at full speed without load, the engine rotates at approx. 2,800 rpm as shown in the figure. When the resistance is applied to the flywheel by braking with some kind of dynomometer, the rotating force of the dynomometer increases (arrow direction) as shown in the figure. In this case, the engine speed gradually decreases. When the engine speed reaches approx. 1,700 rpm, the torque starts to decrease. In other words, this point (1,700 rpm) is the maximum torque point rpm T46W208A CABIN ELECTRIC HYDRAULIC STEERING c. S.F.C (Specific Fuel Consumption) The unit used here is "g/hphr". For example, 192g/HPhr means that 192g of fuel is consumed by 1 horse power when running the engine for 1 hour. This can be converted as follows: Since the fuel consumption at full power in the power curve (4B243) is 192g/HPhr, the fuel consumption for 44 horse power is 192g x 44/hr = kg/hr. When converting this value to volume value, l/hr = l/hr Because: Diesel fuel 1 l = kg A/C & HEATER 210 DH14W00 Jul. 2008

169 DK35/40(C)/45(C)SE SPECIFICATIONS 2.4 Servicing specifications A series engine (4A200, 4A220) Engine body A. Cylinder Head B. Valves C. Valve Timing D. Cylinder Bore I.D. Item Specification Allowable limit Cylinder head surface flatness T.D.C clearance Gasket Thickness Compression Pressure (When cranking with starter motor) Variance of compression pressure among cylinders should be 10% or less. Valve Clearance (Cold) ~ 0.9 mm ( ~ in.) Tightened 1.21( in.) 3.24 ~ 3.73 MPa 33 ~ 38 kgf/cm ~ 540 psi 0.05 mm / 100 mm (0.002 in. / 3.94 in.) 2.55 MPa 26 kgf/cm psi IN mm (0.010 in.) ± 0.05 mm (0.002 in.) EX mm (0.012 in.) ± 0.05 mm (0.002 in.) Valve Seat Angle IN. 60 (1.047 rad.) EX. 45 (0.785 rad.) Valve Face Angle IN. 60 (1.047 rad.) Valve recess Clearance Between Valve Stem and Valve Guide Valve Stem O.D. Valve Stem I.D. EX. 45 (0.785 rad.) 0.2 ~ 0.5 mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) Intake Valve Open 0.14 rad (8 ) before T.D.C Close rad (35 ) after B.D.C 0.8 mm ( in.) 0.10 mm (0.039 in.) Exhaust Valve Open rad (45 ) before B.D.C Close rad (8 ) after T.D.C 4A200 4A ~ mm ( ~ in.) ~ mm (3.425 ~ in.) (4A200, 4A220) 0.15 mm ( in.) 0.15 mm ( in.) CABIN ELECTRIC HYDRAULIC STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH SAFETY FIRST A/C & HEATER DH14W00 Jul

170 SPECIFICATIONS DK35/40(C)/45(C)SE A/C & HEATER CABIN ELECTRIC HYDRAULIC STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH SAFETY FIRST E. Valve spring F. Rocker Arm G. Tappet H. Camshaft I. Timing Gear Free length Item Specification Allowable limit Load after assembled / Length after assembled Squareness Rocker arm shaft O.D. Rocker arm bushing I.D. Clearance between tappet and guide Tappet O.D. Tappet guide I.D. Camshaft alignment 41.7 ~ 42.2 mm ( ~ in.) 12.0 kgf / mm (26.5 lbs / in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) 0.01 mm ( in.) Cam height IN mm Clearance between camshaft Camshaft journal O.D. Camshaft counter bore I.D. EX. Clearance between camshaft gear (axial direction) Timing gear backlash Idle gear side clearance Clearance between Idle gear shaft and idle gear bushing Idle gear shaft O.D. Idle gear bushing I.D. ( in.) mm ( in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) 0.07 ~ 0.22 mm (0.003 ~ in.) 0.04 ~ 0.11 mm ( ~ in.) 0.20 ~ 0.51 mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) (4A200, 4A220) 41.2 mm ( in.) 10.2 kgf / mm (22.5 lbs / in.) 1.0 mm (0.039 in.) 0.07 mm ( in.) 0.05 mm ( in.) mm ( in.) mm ( in.) 0.15 mm ( in.) mm ( in.) 0.15 mm ( in.) 0.9 mm (0.035 in.) 0.1 mm ( in.) 212 DH14W00 Jul. 2008

171 DK35/40(C)/45(C)SE SPECIFICATIONS J. Piston Ring K. Connecting Rod L. Crankshaft Item Specification Allowable limit Piston pin bore I.D. Clearance between Oil ring and ring groove Oil ring groove width Oil ring width Clearance between 2nd ring and ring groove 2nd ring groove width 2nd ring width Top ring, oil ring end gap 2nd ring end gap Connecting rod alignment Clearance between Piston and small end bushing Piston pin O.D. Piston pin bushing I.D. Crankshaft alignment (Deflection) Clearance between Crankshaft and crankshaft bearing 1 Crankshaft O.D. Crankshaft bearing 1 I.D. Clearance between Crankshaft and crankshaft bearing 2 Crankshaft O.D. Crankshaft bearing 2 I.D. Clearance between crankshaft pin and crank pin bearing Crankshaft pin O.D. Crankshaft pin bearing I.D. Crankshaft side clearance 4A200 4A ~ mm ( ~ in.) ~ mm ( ~ in.) 3.01 ~ 3.03 mm ( ~ in.) 2.97 ~ 2.99 mm ( ~ in.) 0.04 ~ 0.08 mm ( ~ in.) 2.03 ~ 2.05 mm ( ~ in.) 1.97 ~ 1.99 mm ( ~ in.) mm ( in.) 0.15 mm ( in.) 0.15 mm ( in.) 0.20 ~ 0.40 mm ( ~ in.) 1.25 mm 0.25 ~ 0.40 mm ( in.) ( ~ in.) 0.55 ~ 0.70 mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) 47 ~ mm ( ~ in.) 0.15 ~ 0.31 mm ( ~ in.) (4A200, 4A220) 1.25 mm ( in.) 0.05 mm ( in.) 0.15 mm ( in.) 0.08 mm ( in.) 0.20 mm ( in.) 0.20 mm ( in.) 0.20 mm ( in.) 0.5 mm (0.020 in.) A/C & HEATER CABIN ELECTRIC HYDRAULIC STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH SAFETY FIRST DH14W00 Jul

172 SPECIFICATIONS DK35/40(C)/45(C)SE TRANSMISSION CLUTCH SAFETY FIRST Lubricating system A. Oil Pump Item Specification Allowable limit Engine oil pressure (oil temp. 85 ~ 95 C) At idle speed At rated speed Clearance between inner rotor and outer rotor Clearance between outer rotor and pump Clearance between inner rotor and cover over 68.6 kpa 0.7 kgf/cm psi ~ kpa 2.5 ~ 4.5 kgf/cm ~ 64.0 psi 0.10 ~ 0.16 mm ( ~ in.) 0.11 ~ 0.19 mm ( ~ in.) ~ mm ( ~ in.) (4A200, 4A220) kpa 2.5 kgf/cm psi 0.2 mm ( in.) 0.25 mm ( in.) 0.2 mm ( in.) STEERING FRONT AXLE BRAKE REAR AXLE HST Cooling system A. Thermostat B. Radiator Item Specification Allowable limit Valve opening temperature at beginning 69.5 ~ 72.5 (157.1 ~ F) Opened completely (height: 8 mm) 85 C (185 F) Radiator tightness No leak at 1.4 kgf/cm 2 (137 kpa, 20 psi) Radiator cap tightness Fan belt tension [deflection at 98 N (10 kgf, 22 lbs) of force] 10 seconds or more for pressure drop from kgf/cm 2 (88 59 kpa, 13 9 psi) 7 ~ 9 mm (0.28 ~ 0.35 in.) (4A200, 4A220) HYDRAULIC ELECTRIC Fuel system A. Fuel injection pump (4A200, 4A220) Item Specification Allowable limit Injection timing (BTDC) 18 CABIN B. injection Nozzle Fuel injection pressure 150~160 kgf/cm 2 (14.7~15.7 MPa, 2,133~2,275 psi) Tightness of nozzle valve seat No fuel leak at 130 kgf/cm 2 (12.75 MPa, 1,849 psi) A/C & HEATER 214 DH14W00 Jul. 2008

173 DK35/40(C)/45(C)SE SPECIFICATIONS Tightening torques for engine Item Size x Pitch Tightening torque Nm kgfm lbft Cylinder head screws M11 x ~ ~ ~ 79.6 Head cover bolt M8 x ~ ~ ~ 8.7 * Bearing case bolt 1 (Case cover bolt) * Bearing case bolt 2 (Case mounting bolt) (4A200, 4A220) M9 x ~ ~ ~ 37.6 M10 x ~ ~ ~ 54.2 * Flywheel bolt M12 x ~ ~ ~ 79.6 * Connecting rod screws M8 x ~ ~ ~ 37.6 Rocker arm bracket bolt M10 x ~ ~ ~ 52.1 Drain plug M12 x ~ ~ ~ 37.3 Glow plug M10 x ~ ~ ~ 18.1 Oil switch PT1/ ~ ~ ~ 14.5 Nozzle holder assembly M20 x ~ ~ ~ 50.6 Injection pipe nut M12 x ~ ~ ~ 25.3 Temperature meter switch PT1/ ~ ~ ~ 11.6 D.C alternator pulley nut M15 x ~ ~ ~ 39.8 REAR AXLE HST TRANSMISSION CLUTCH SAFETY FIRST CAUTION For * marked screw, bolts and nuts on the table, apply engine oil to their threads and seats before tightening. The letter M in Size Pitch means that the screw, bolt or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between two threads. BRAKE FRONT AXLE A/C & HEATER CABIN ELECTRIC HYDRAULIC STEERING DH14W00 Jul

174 SPECIFICATIONS DK35/40(C)/45(C)SE SAFETY FIRST B series engine (3B183, 4B243) Engine body (3B183, 4B243) CABIN ELECTRIC HYDRAULIC STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH A. Cylinder Head B. Valves C. Valve Timing D. Cylinder Bore I.D. Item Specification Allowable limit Cylinder head surface flatness T.D.C clearance Gasket Thickness Compression Pressure (When cranking with starter motor) Variance of compression pressure among cylinders should be 10% or less. Valve Clearance (Cold) ~ 0.9 mm ( ~ in.) Tightened 1.21 mm ( in.) 3.24 ~ 3.73 MPa 33 ~ 38 kgf/cm ~ 540 psi 0.05 mm / 100 mm (0.002 in. / 3.94 in.) 2.55 MPa 26 kgf/cm psi IN mm (0.010 in.) ± 0.05 mm (0.002 in.) EX. 0.3 mm (0.012 in.) ± 0.05 mm (0.002 in.) Valve Seat Angle IN. 60 (1.047 rad.) EX. 45 (0.785 rad.) Valve Face Angle IN. 60 (1.047 rad.) Valve recess Clearance Between Valve Stem and Valve Guide Valve Stem O.D. Valve Stem I.D. EX. 45 (0.785 rad.) 0.2 ~ 0.5 mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) Intake Valve Open 0.14 rad (8 ) before T.D.C Close rad (35 ) after B.D.C 0.8 mm ( in.) 0.10 mm (0.039 in.) Exhaust Valve Open rad (45 ) before B.D.C Close rad (8 ) after T.D.C 3B183 4B ~ mm (3.425 ~ in.) ~ mm (3.425 ~ in.) 0.15 mm ( in.) 0.15 mm ( in.) A/C & HEATER 216 DH14W00 Jul. 2008

175 DK35/40(C)/45(C)SE SPECIFICATIONS E. Valve spring F. Rocker Arm G. Tappet H. Camshaft I. Timing Gear Free length Item Specification Allowable limit Load after assembled / Length after assembled Squareness Rocker arm shaft O.D. Rocker arm bushing I.D. Clearance between tappet and guide Tappet O.D. Tappet guide I.D. Camshaft deflection 41.7 ~ 42.2 mm ( ~ in.) 12.0 kgf / mm (26.5 lbs / in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) 0.01 mm ( in.) Cam height IN mm Journal oil clearance Camshaft journal O.D. Camshaft counter bore I.D. EX. Clearance between camshaft gear (axial direction) Timing gear backlash Idle gear axial clearance Clearance between Idle gear shaft and idle gear bushing Idle gear shaft O.D. Idle gear bushing I.D. (1.335 in.) 33.9 mm (1.335 in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) 0.07 ~ 0.22 mm (0.003 ~ in.) 0.04 ~ 0.11 mm ( ~ in.) 0.20 ~ 0.51 mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) (3B183, 4B243) 41.2 mm ( in.) 10.2 kgf / mm (22.5 lbs / in.) 1.0 mm (0.039 in.) 0.07 mm ( in.) 0.05 mm ( in.) mm ( in.) mm ( in.) 0.15 mm ( in.) mm ( in.) 0.15 mm ( in.) 0.9 mm (0.035 in.) 0.1 mm ( in.) A/C & HEATER CABIN ELECTRIC HYDRAULIC STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH SAFETY FIRST DH14W00 Jul

176 SPECIFICATIONS DK35/40(C)/45(C)SE A/C & HEATER CABIN ELECTRIC HYDRAULIC STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH SAFETY FIRST J. Piston Ring K. Connecting Rod L. Crankshaft Item Specification Allowable limit Piston pin bore I.D. Clearance between Oil ring and ring groove Oil ring groove width Oil ring width Clearance between 2nd ring and ring groove 2nd ring groove width 2nd ring width Top ring, oil ring end gap 2nd ring end gap Connecting rod deflection limit Clearance between piston and small end bushing Piston pin O.D. Piston pin bushing I.D. Crankshaft deflection limit Clearance between Crankshaft and crankshaft bearing 1 Crankshaft O.D. Crankshaft bearing 1 I.D. Clearance between Crankshaft and crankshaft bearing 2 Crankshaft O.D. Crankshaft bearing 2 I.D. Clearance between crankshaft pin and crank pin bearing Crankshaft pin O.D. Crankshaft pin bearing I.D. Crankshaft axial clearance ~ mm ( ~ in.) ~ mm ( ~ in.) 3.01 ~ 3.03 mm ( ~ in.) 2.97 ~ 2.99 mm ( ~ in.) 0.04 ~ 0.08 mm ( ~ in.) 2.03 ~ 2.05 mm ( ~ in.) 1.97 ~ 1.99 mm ( ~ in.) 0.25 ~ 0.40 mm ( ~ in.) 0.55 ~ 0.70 mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) 0.05 ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm ( ~ in.) 47 ~ mm ( ~ in.) 0.15 ~ 0.31 mm ( ~ in.) (3B183, 4B243) mm ( in.) 0.15 mm ( in.) 0.15 mm ( in.) 1.25 mm ( in.) 1.25 mm ( in.) 0.05 mm ( in.) 0.15 mm ( in.) 0.08 mm ( in.) 0.20 mm ( in.) 0.20 mm ( in.) 0.20 mm ( in.) 0.5 mm (0.020 in.) 218 DH14W00 Jul. 2008

177 DK35/40(C)/45(C)SE SPECIFICATIONS Lubricating system A. Oil Pump Item Specification Allowable limit Engine oil pressure (oil temp. 85 ~ 95 C) At idle speed At rated speed Clearance between inner rotor and outer rotor Clearance between outer rotor and pump Clearance between inner rotor and cover over 68.6 kpa 0.7 kgf/cm psi ~ kpa 2.5 ~ 4.5 kgf/cm ~ 64.0 psi 0.10 ~ 0.16 mm ( ~ in.) 0.11 ~ 0.19 mm ( ~ in.) ~ mm ( ~ in.) (3B183, 4B243) 245 kpa 2.5 kgf/cm psi 0.2 mm ( in.) 0.25 mm ( in.) 0.2 mm ( in.) TRANSMISSION CLUTCH SAFETY FIRST Cooling system A. Thermostat B. Radiator Item Specification Allowable limit Valve opening temperature at beginning 69.5 ~ 72.5 (157.1 ~ F) Opened completely (height: 8 mm) 85 C (185 F) Radiator tightness Radiator cap tightness Fan belt tension [deflection at 98 N (10 kgf, 22 lbs) of force] No leak at 1.4 kgf/cm 2 (137 kpa, 20 psi) 10 seconds or more for pressure drop from kgf/cm 2 (88 59 kpa, 13 9 psi) 7 ~ 9 mm (0.28 ~ 0.35 in.) (3B183, 4B243) STEERING FRONT AXLE BRAKE REAR AXLE HST Fuel system A. Fuel injection pump Item Specification Allowable limit Injection timing (BTDC) 3B B (3B183, 4B243) HYDRAULIC ELECTRIC B. injection Nozzle Fuel injection pressure 150~160 kgf/cm 2 (14.7~15.7 MPa, 2,133~2,275 psi) Tightness of nozzle valve seat No fuel leak at 130 kgf/cm 2 (12.75 MPa, 1,849 psi) CABIN A/C & HEATER DH14W00 Jul

178 SPECIFICATIONS DK35/40(C)/45(C)SE REAR AXLE HST TRANSMISSION CLUTCH SAFETY FIRST Tightening torques for engine Item Size x Pitch Tightening torque Nm kgfm lbft Cylinder head screws M11 x ~ ~ ~ 79.6 Head cover bolt M8 x ~ ~ ~ 8.7 * Bearing case bolt 1 (Case cover bolt) * Bearing case bolt 2 (Case mounting bolt) (3B183, 4B243) M9 x ~ ~ ~ 37.6 M10 x ~ ~ ~ 54.2 * Flywheel bolt M12 x ~ ~ ~ 79.6 * Connecting rod bolt M8 x ~ ~ ~ 37.6 Rocker arm bracket bolt M10 x ~ ~ ~ 52.1 Drain plug M12 x ~ ~ ~ 37.3 Glow plug M10 x ~ ~ ~ 18.1 Oil switch PT1/ ~ ~ ~ 14.5 Nozzle holder assembly M20 x ~ ~ ~ 50.6 Injection pipe nut M12 x ~ ~ ~ 25.3 Temperature meter switch PT1/ ~ ~ ~ 11.6 D.C alternator pulley nut M15 x ~ ~ ~ 39.8 BRAKE FRONT AXLE CAUTION For * marked screw, bolts and nuts on the table, apply engine oil to their threads and seats before tightening. The letter M in Size Pitch means that the screw, bolt or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between two threads. A/C & HEATER CABIN ELECTRIC HYDRAULIC STEERING 220 DH14W00 Jul. 2008

179 DK35/40(C)/45(C)SE OPERATING PRINCIPLE 3. Operating principle 3.1 Body and power train system A. Cylinder head B. Cylinder Block SAFETY FIRST CLUTCH (1) Intake port (2) Exhaust port T46W209A The cylinder head is made of special alloy cast iron which can resist high temperature and pressure caused by combustion. The intake and exhaust ports are arranged crossflow type to get high combustion efficiency by protecting the suction air from being heated and expanded by heated exhaust air. The engine has a high durability tunneltype cylinder block. Furthermore, liner less type, allows effective cooling, less distortion, and greater wearresistance using special material. The noise is reduced to a minimum level because each cylinder has its own chamber. C. Cylinder honing T46W211A TRANSMISSION HST REAR AXLE 3 4 Standard honing Plateau honing BRAKE 2 FRONT AXLE 1 HYDRAULIC STEERING (1) Combustion chamber (2) Injection nozzle (3) Glow plug (4) Cylinder head T46W210A The Daedong swirl type combustion chamber is designed for high combustion efficiency and reducing fuel consumption. The glow plug helps to start the engine even at 15 C (5 F). T46W212A ELECTRIC CABIN A/C & HEATER The DAEDONG engine has adopted the plateau honing in manufacturing to enhance the oil tightness of the cylinder bore and the durability of the cylinder for the longer engine life time. DH14W00 Jul

180 OPERATING PRINCIPLE DK35/40(C)/45(C)SE SAFETY FIRST D. Crankshaft F. Connecting Rod REAR AXLE HST TRANSMISSION CLUTCH (1) Crankshaft (2) Crankshaft bearing 1 (3) Main bearing case E. Piston and piston ring 4 T46W213A (4) Crankshaft bearing 2 (5) Thrust bearing (side metal) The crankshaft is made of forged steel and the journals, the crankpins and the bearing surface for the oil seal are inductionhardened to increase wear resistance. Each crankshaft journal is supported by the main bearing case (3) having a bearing (4) inside. The front crankshaft bearing (2) is a cylinder type bushing and rear and intermediate bearings are a split type (4). The crankshaft, crankshaft bearings have oil holes for lubricant. (1) Small end bushing (2) Connecting rod (3) Crank pin bearing The connecting rod (2), which converts the reciprocating motion of the pistons caused by the fuel combustion into the rotating motion of the crankshaft, is made of hard forged steel. The connecting rod has bearings at both ends. The small end has a cylinder type bearing (small end bushing (2)) and the big end has a split type bearing (crank pin bearing (3)). G. Camshaft T46W215A FRONT AXLE BRAKE STEERING 3 HYDRAULIC (1) Top ring (2) 2nd ring (3) Oil ring T46W214A (1) Cam gear (2) Camshaft stopper (3) Camshaft T46W216A ELECTRIC CABIN A/C & HEATER The piston is made of an aluminum alloy that is temperature and pressure resistant. Three rings are installed in the grooves of the piston. The top ring (1) is a keystone type, which can withstand heavy loads, and the barrel face on the ring fits well to the cylinder wall. The second ring (2) is an undercut type, which prevents the oil from being carried up. The oil ring (3) has chamfered faces and an expander ring, which increase the pressure of the oil ring against the cylinder wall to scrape the oil. The top ring is plated with hard chrome to increase wear resistance. The camshaft (3) is made of forged steel and its journal and cams are hardened to increase wear resistance. The cams on the camshaft open and close the intake and exhaust valves with the push rods and rocker arms. The journals and their bearings are forcelubricated. 222 DH14W00 Jul. 2008

181 DK35/40(C)/45(C)SE OPERATING PRINCIPLE H. Fuel camshaft 1 J. Intake and exhaust valves 1 2 SAFETY FIRST (1) Fuel camshaft (2) Fuel camshaft gear T46W217A This fuel camshaft is made of forged steel and its cams are hardened and tempered to increase wear resistance. The cams on the fuel camshaft (1) drive the fuel injection pump and the fuel feed pump. The governor balls are installed on the fuel camshaft gear (2) to control the engine speed. (1) Valve spring collet (2) Valve spring retainer (3) Valve spring (4) Valve stem seal (5) Exhaust valve (6) Intake valve T46W219A The valve and its guide of the intake are different from those for the exhaust. Other parts, such as the spring, spring retainers, valve spring collets, valve stem seals are the same for both the intake and the exhaust. The diameter of the intake valve is always larger than the that of the exhaust valve. The intake valve is located prior to exhaust valve when seeing them from the cooling fan side. REAR AXLE HST TRANSMISSION CLUTCH I. Rocker arm assembly K. Timing Gear BRAKE FRONT AXLE 5 STEERING (1) Rocker arm (4) Rocker arm bracket (2) Lock nut (5) Rocker arm shaft (3) Adjusting screw T46W218A The rocker arm assembly includes the rocker arms (1) and an adjusting screw (3), which is at the end of rocker arm and rests on the push rod, rocker arm brackets (4) and rocker arm shaft (5). The rocker arms are activated by the reciprocating movement of the push rods and open or close the intake and exhaust valves. The rocker arm and other parts are lubricated through the drilled holes of the brackets and the rocker arm shaft. (1) Fuel camshaft gear (2) Fuel camshaft (3) Valve camshaft gear (4) Valve camshaft 6 7 (5) Idle gear (6) Crankshaft gear (7) Crankshaft T46W220A The crankshaft drives the camshaft and the idle gear engaged with fuel camshaft. The timings for opening and closing the valves is extremely important to achieve the effective air intake and sufficient gas exhaust. When assembling, the appropriate timing can be obtained by aligning the mark on the crankshaft gear (6) with idle gear (5), idle gear with camshaft gear, and idle gear with fuel injection pump gear. A/C & HEATER CABIN ELECTRIC HYDRAULIC DH14W00 Jul

182 OPERATING PRINCIPLE DK35/40(C)/45(C)SE SAFETY FIRST L. Flywheel 2 3 FRONT AXLE BRAKE 1 CLUTCH TRANSMISSION HST (1) Ring gear (2) Flywheel (3) Crankshaft REAR AXLE T46W221A The ring gear (1) for connecting the start motor is compressed in the flywheel. Therefore, it cannot be replaced separately. m. MLS cylinder head gasket A/C & HEATER CABIN ELECTRIC HYDRAULIC STEERING S76W2t4A The MLS (Multi Layer Steel) cylinder head gasket has a triplelayered steel structure complemented with nonasbestos gasket features. The top clearance variation is minimized and the thermal load is reduced while increasing durability. CAUTION When disassembling the cylinder head, its gasket should be replaced with a new one. Be sure that there is no scratch or foreign material between the cylinder head and the surface of the block. 224 DH14W00 Jul. 2008

183 DK35/40(C)/45(C)SE OPERATING PRINCIPLE 3.2 Lubricating system Engine oil flow HYDRAULIC STEERING FRONT AXLE SAFETY FIRST ELECTRIC CABIN BRAKE REAR AXLE HST TRANSMISSION CLUTCH A/C & HEATER T46W222C Components (1) Piston (2) Idle gear (3) Oil pump (4) Relief valve (5) Oil strainer (6) Oil filter (7) Bypass valve (8) Oil pan (9) Rocker arm shaft (10) Rocker arm (11) Push rod (12) Tappet (13) Oil pressure gauge (14) Camshaft (15) Crankshaft DH14W00 Jul

184 OPERATING PRINCIPLE DK35/40(C)/45(C)SE SAFETY FIRST Engine oil flow chart Rocker arm shaft Rocker arm Rocker arm Rocker arm Engine 엔진오일 oil pressure 압력센서 sensor CLUTCH Valve cam shaft gear Valve cam shaft journal Valve cam shaft Valve cam shaft Valve cam shaft Valve cam shaft Valve cam shaft journal journal Valve cam shaft journal TRANSMISSION HST Fuel cam shaft gear Fuel cam shaft Tappet Tappet Tappet REAR AXLE Bore Piston Connecting rod's small end Bore Piston Connecting rod's small end Bore Piston Connecting rod's small end FRONT AXLE BRAKE No.1 1번 connecting 커넥팅로드 rod's 대단부 big end No.2 2번 connecting 커넥팅로드 rod's 대단부 big end No.3 3번 connecting 커넥팅로드 rod's big 대단부 end STEERING HYDRAULIC Idle gear Journal 저널베어링 bearing No.1 main bearing No.2 main bearing No.3 main bearing Main oil gallery ELECTRIC Crank shaft gear Oil pump gear Oil pump gerotor Relief valve Oil fiter CABIN Pressurized 압송 Splash, 비산, 흘러내림 flow Oil pan Strainer A/C & HEATER T46W223A 226 DH14W00 Jul. 2008

185 DK35/40(C)/45(C)SE OPERATING PRINCIPLE Function of lubricating system CABIN ELECTRIC HYDRAULIC STEERING SAFETY FIRST A/C & HEATER FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH T46W224C DH14W00 Jul

186 OPERATING PRINCIPLE DK35/40(C)/45(C)SE CABIN ELECTRIC HYDRAULIC STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH SAFETY FIRST A. Oil strainer (refer to figure (a) on page 227) B. Oil pump (refer to figure (b) on page 227) 1. A series engine (4A200, 4A220 refer to page 227) Type: Gerotor type Oil: SAE15W40 Standard oil temperature: 80 C Discharge pressure: 4.5 kg/cm 2 Displacement: Over 10l/min (1,000rpm) Over 24.3l/min (2,000rpm) Drive gear speed ratio (crankshaft gear/pump gear) = 34/45 = B series engine (3B183, 4B243) Type: Gerotor type Oil: SAE15W40 Standard oil temperature: 80 C Discharge pressure: 4.5 kg/cm 2 Displacement: Over 8.81l/min (1,000 rpm) Over 21.41l/min (2,000 rpm) Drive gear speed ratio (crankshaft gear/pump gear) = 40/39 = C. Oil filter and relief valve A series engine (1) Relief valve (2) Bypass valve (3) Oil filter outlet (To metal, idle gear, camshaft, lock arm shaft) (4) Oil filter inlet (5) Oil filter outlet (To crankshaft main bearing) 4 1 T46W225B B series engine (1) Bypass valve (2) Filter element (3) Relief valve (4) Oil cooler s76w224b (A) Oil filter outlet (to crankshaft metal 1, idle gear, camshaft and lock arm shaft) (B) Oil filter outlet (to crankshaft journal and pin) Oil (C) Oil filter inlet (D) Coolant (Inlet Outlet) Relief valve opening pressure: 4.5 ~ 5.4 kgf/cm 2 (64 ~ 76 PSI) Oil filter Filter paper fineness: Max.: 99 ± 5 microns, Average: 75 ± 5 microns Filtered area: 1680 cm 2 Bypass valve opening pressure (pressure difference between inner and outer side of filter paper): 1 ± 0.2 kgf/cm 2 D. Valve camshaft (refer to figure (D) page 227) The oil enters the first journal bearing of the valve camshaft and is sent to each journal through the oil holes in the center of the camshaft. Then, it is sent to the oil pressure sensor through the last journal. E. Rocker arm shaft (refer to figure (E) page 227) The oil from the valve camshaft comes through the hole in the support bracket of rocker arm, supplied to each rocker arm through the hole in the center of rocker arm shaft. The oil drained from the hole on top of the rocker arm is used in lubrication on the contact surface of the valve and the rocker arm. Then, it flows along the push rod to lubricate the contact surface between the push rod and the tappet and between the tappet and the valve cam. A/C & HEATER 228 DH14W00 Jul. 2008

187 DK35/40(C)/45(C)SE OPERATING PRINCIPLE f. oil flow (refer to figure (F) page 227) The oil in the oil gallery flows to the main bearing (or metal bearing) and then to the connecting rod big end journal bearing. The oil flowed out of the gap of the connecting rod big end journal bearing is sprayed to the connecting rod small end (piston pin), piston interior and cylinder bore as the crankshaft rotates. SAFETY FIRST G. Oil pressure switch (refer to figure (G) page 227) A/C & HEATER STEERING FRONT AXLE BRAKE REAR AXLE CABIN ELECTRIC HYDRAULIC HST TRANSMISSION CLUTCH 1 1 T46W226A The oil pressure switch is installed on the cylinder block at the end of the valve camshaft and leads to the oil passage which is passing through the valve camshaft. When the oil pressure falls below the specified value, the circuit is connected by the diaphragm in the switch to turn on the warning lamp (1) on the instrument panel. When the key switch is turned to the "ON" position with the engine stopped, the warning lamp comes on. When the oil pressure rises, this lamp goes off. Min. operating pressure of oil switch: 0.5 ± 0.1 kgf/cm ± PSI ± Kpa DH14W00 Jul

188 OPERATING PRINCIPLE DK35/40(C)/45(C)SE SAFETY FIRST 3.3 Cooling system A. Coolant flow route BRAKE REAR AXLE HST TRANSMISSION CLUTCH A/C & HEATER CABIN ELECTRIC HYDRAULIC STEERING FRONT AXLE When the centrifugal water pump (1) connected to the cooling fan shaft rotates, the coolant in the cylinder block flows from the No. 1 cylinder to the No. 3 via the No. 2 cylinder (subsequently to the No. 4 cylinder for 4cylinder model) and also flows to the cylinder head (from lower to upper side). In the cylinder head, the coolant flows from the No. 3 or 4 cylinder to the No. 1 cylinder through the No. 2 cylinder (from rear to front side). The coolant collected in the thermostat flange (2) flows to the inlet of the water pump impeller through the return hose (3), and then returns to the cylinder block through the outlet of the impeller. When the coolant temperature rises over 71 C (160 F), the thermostat (4) opens and most coolant flows to the radiator through the thermostat. The coolant flowed to the top of the radiator through the radiator upper hose (7) is cooled down by the cooling air and sinks. Then, it flows to the inlet of the water pump impeller through the radiator lower hose (8) to return to the cylinder block. T46W227B The drain hose (5) is to completely drain the coolant in cylinder block when opening the radiator lower cock (6). The tractor equipped with the cabin heater draws hot water from the return hose (3) to heat the heater and then sends it back to the drain hose (5). Also, For the engine equipped with the engine oil cooler, such as the turbo engine or 4B243, cools down the engine oil by connecting the cylinder block drain line to the engine oil cooler. 230 DH14W00 Jul. 2008

189 DK35/40(C)/45(C)SE OPERATING PRINCIPLE B. Water pump C. Thermostat (A series engine: 4A200, 4A220) SAFETY FIRST Location of hole (A) (1) Seat (6) Wax (Solid) (2) Valve (7) Spring (3) Pellet (8) Leak hole (4) Spindle (9) Wax (Liquid) (5) Synthetic rubber T46W229A CLUTCH TRANSMISSION (a) From thermostat (b) To cylinder block (c) From radiator (1) Bearing (3) Mechanical seal (2) Pump body (4) Pump impeller T46W228A The water pump sucks the cooled water, forces it into the cylinder block and draws out the hot water to the radiator repeatedly. The mechanical seal (3) prevents the water from entering into the bearing (1). Notes If the coolant is leaked from hole (A), it means that the mechanical seal is damaged. Therefore, the water pump assembly should be replaced. The thermostat is wax pellet type, which controls the flow of the cooling water to the radiator to keep the proper temperature. The case has a seat (1) and the pellet has a valve (2). The spindle attached to the case is inserted into the synthetic rubber in the pellet. The pellet is charged with wax. (A) At low temperature: below 71 C (160 F) The valve (2) is seated by the spring (7) and the cooling water circulates in the engine through the water return pipe but does not enter the radiator. (B) At high temperature: over 71 C (160 F) As the water temperature rises, the wax in the pellet (3) becomes liquid and it pushes out the spindle. The pellet lowers and the valve (2) opens to send the cooling water to the radiator. HYDRAULIC STEERING FRONT AXLE BRAKE REAR AXLE HST Bypass valve T46W230 For the engine for cabin model, the thermostat is equipped with the bypass valve. Therefore, the cooling efficiency is enhanced as all coolant passes through the radiator since the internal circulation circuit is blocked as soon as the thermostat opens. ELECTRIC CABIN A/C & HEATER DH14W00 Jul

190 OPERATING PRINCIPLE DK35/40(C)/45(C)SE SAFETY FIRST D. Radiator 2 E. Radiator cap 1 1 FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH 3 (1) Cooling air (3) Pin (2) Tube T46W231A The radiator core consists of water tubes (2) with fin (3) at a right angle to it. The water in the radiator is cooled down by the air flowing between the tube wall and the fin. (1) Pressure valve (2) Vacuum valve The radiator cap is equipped with the pressure valve (1) and vacuum valve (2). (A) At High Pressure Over 88 kpa (0.9 kgf/cm², 13 psi) When the water temperature rises and the pressure in the radiator increases above the specified value, the pressure valve (1) opens to drain the coolant to the reservoir tank to reduce the internal pressure. (B) At Low Pressure When the water temperature drops down and a vacuum is generated in the radiator, the vacuum valve (2) opens to allow the coolant in the reservoir tank to enter into the radiator. 2 T46W232A A/C & HEATER CABIN ELECTRIC HYDRAULIC STEERING 232 DH14W00 Jul. 2008

191 DK35/40(C)/45(C)SE OPERATING PRINCIPLE 3.4 Fuel system Fuel flow route FRONT AXLE SAFETY FIRST CLUTCH TRANSMISSION HST REAR AXLE 7 BRAKE Components (1) Fuel tank (2) Fuel filter (3) Fuel injection pump (4) Injection pipe (5) Injection nozzle (6) Fuel overflow pipe (hose) The fuel in the fuel tank (1) is drawn to the fuel feed pump (7) and then is supplied to the fuel injection pump (3) passed through the fuel filter (2). Then, the fuel injection pump feeds the fuel to the injection nozzles (5) which then inject the fuel into the cylinders for combustion. The excessive fuel from the fuel injection pump to the injection nozzles is collected in the fuel overflow pipes (6) and returns to the fuel tank. (7) Fuel feed pump (8) Bleeding bolt (9) Bleeding hose CABIN ELECTRIC HYDRAULIC STEERING A/C & HEATER T46W233A Notes For air bleeding, see the next page. DH14W00 Jul

192 OPERATING PRINCIPLE DK35/40(C)/45(C)SE SAFETY FIRST Fuel filter a Fuel feed pump (A) From 연료 fuel 탱크에서 tank (B) 연료 To fuel 필터로 filter STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH 2 1 c (a) To fuel tank (c) To fuel injection pump (b) From fuel feed pump (1) Cock (4) Retainer ring (2) Air vent (5) Port (3) Filter body (6) Filter element The fuel from fuel feed pump enters into the filter port through the (b) port and passes through the filter paper. Then, it is drained through the (c) port and supplied to the fuel injection pump. The filter paper collects the particles bigger than 90 microns ( in.) at 20 kpa (0.2 kgf/cm², 3 psi). b T46W234A Bleeding the fuel system 1. Make sure that the amount of fuel in the fuel tank is sufficient. 2. If there is air in the fuel filter, turn the filter cock (1), shown in the figure (3.4.2), to the air side and crank the engine. Then, the air in the filter port is discharged through the bleeding hose (9) shown in the figure (3.4.1). CAUTION Do not crank for over 5 seconds. Crank the engine for several times while keeping the cranking time below 5 seconds (1) Intake valve (5) Chamber (2) Push rod (6) Diaphragm (3) Tappet (7) Fuel camshaft (4) Exhaust Valve The diaphragm (6) is linked to the tappet (3) with the push rod (2). The tappet is reciprocated by the eccentric cam on the fuel camshaft (7). (A) Intake stroke When the diaphragm is pulled down by the spring, vacuum in the chamber (5) causes the exhaust valve (4) to close and the atmospheric pressure in the fuel tank to force the fuel into the chamber, opening the intake valve (1). (B) Scavenging stroke T46W235A When the diaphragm is pushed up by the cam, the pressure in the chamber causes the intake valve to close and forces out the fuel, opening the exhaust valve. A/C & HEATER CABIN ELECTRIC HYDRAULIC When the amount of fuel in the fuel filter port goes over 3/4 level, stop cranking the engine and turn the cock (1) of the figure (3.4.2) to the "ON" position. Notes The bleeding process could be skipped if installing the fuel port after filling the bowl with fuel. Loosen the bleeding bolt (8) in the figure (3.4.1) and crank the engine to bleed air. Then tighten the bolt again. If the engine still cannot be started, loosen 1 or 2 nozzle holders (No. 10 of figure 3.4.1) and crank the engine to bleed air. When the air bubble is not seen anymore in the bleeding fuel, tighten the loose parts and start the engine. 234 DH14W00 Jul. 2008

193 DK35/40(C)/45(C)SE OPERATING PRINCIPLE Fuel injection pump a Operation of Pump Element SAFETY FIRST b CLUTCH 8 (a) To injection nozzle (b) From fuel filter T46W236A TRANSMISSION (1) Delivery valve holder (5) Plunger (2) Delivery valve spring (6) Control rack (3) Delivery valve (7) Plunger spring (4) Cylinder (8) Tappet This fuel injection pump is Bosch K type fuel injection pump. It features a compact and light weight design. Pump element 2 4 (1) Delivery chamber (4) Feed hole (2) Plunger (5) Fuel chamber (3) Delivery valve (6) Control groove T46W238A (A) Before Delivery As the plunger (2) lowers, fuel is drawn into the delivery chamber (1) through the feed hole (4) from the fuel chamber (5). (B) Beginning of Delivery When the plunger is pushed up by the cam and the head of the plunger closes the feed hole (4), the pressure in the delivery chamber (1) rises to push the delivery valve (3) open. FRONT AXLE BRAKE REAR AXLE HST (C) Delivery While the plunger (2) is rising, delivery of fuel continues. STEERING 3 (1) Pump element (5) Control sleeve (2) Cylinder (6) Control groove (3) Plunger (7) Sliding surface (4) Feed hole 7 T46W237A (D) End of Delivery When the plunger rises further and the control groove (6) on its periphery meets the feed hole, the injection stops because the pressure in the delivery chamber (1) is reduced to the opening pressure. HYDRAULIC ELECTRIC The pump element (1) consists of a plunger (3) and cylinder (2) which their sliding surfaces are finely machined to maintain the fuel tightness. The plunger (3) is installed in the control sleeve (5) and the sleeve is engaged with the control rack that rotates the plunger in the cylinder to control the amount of fuel delivered. CABIN A/C & HEATER DH14W00 Jul

194 OPERATING PRINCIPLE DK35/40(C)/45(C)SE SAFETY FIRST Amount of Fuel Delivery 1 Delivery Valve CLUTCH 5 6 TRANSMISSION 3 T46W239A T46W241A FRONT AXLE BRAKE REAR AXLE HST (1) Slot (4) Delivery chamber (2) Plunger (5) Feed hole (3) Control rack (6) Control groove (A) No Fuel Delivery When the control rack (3) is at the engine stop position, the lengthwise slot (1) on the plunger (2) aligns with the feed hole (5). The pressure in the delivery chamber does not build up and no fuel is forced to the injection nozzle since the delivery chamber (4) is opened to the feed hole during the entire stroke of the plunger. Location 연료공급 of fuel supply 구멍의 hole위치 a b c (1) Valve spring (4) Fuel chamber (2) Delivery valve (5) Valve face (3) Valve seal (6) Relief plunger The delivery valve (2) prevents the fuel in the injection pipe from flowing back into the delivery chamber and the fuel in the injection nozzle from dribbling after injection. The relief plunger (6) sucks the fuel back from the injection pipe to prevent the leakage dribbling and unnecessary subsequent injection after the major injection. The stroke of A corresponds to the amount of fuel sucked back (35 mm 3 ). STEERING A A A/C & HEATER CABIN ELECTRIC HYDRAULIC (B) Fuel Delivery Stop 정지 Low 저속 speed High 고속 speed T46W240A The plunger is rotated by the control rack and the feed hole is not aligned with the lengthwise slot. When the plunger is pushed up, the feed hole is closed by the plunger. The pressure in the delivery chamber builds up and forces the fuel to the injection nozzle until the control groove (6) meets the feed hole. The amount of the fuel to be forced into the nozzle corresponds to distance A. In the above figure, the amount of injected fuel in (c) is larger than the amount of injected fuel in (b). 236 DH14W00 Jul. 2008

195 DK35/40(C)/45(C)SE OPERATING PRINCIPLE Injection Nozzle SAFETY FIRST Supplied 공급유fuel CLUTCH TRANSMISSION 1 Excessive 잉여유 fuel 2 3 HST 4 5 REAR AXLE BRAKE 8 FRONT AXLE (1) Nozzle holder assembly (2) Adjusting washer (3) Nozzle spring (4) Push rod (5) Lock nut (6) Nozzle body (7) Needle valve (8) Heat seal (9) Packing T46W242A STEERING HYDRAULIC This injection nozzle is throttle type nozzle. It features the low fuel consumption and works well with DAE DONG combustion chamber. The nozzle valve opening pressure is about 14.7~15.7 MPa (150~160 kgf/cm², 2,134~2,276 psi). When the pressure overcomes the counterforce of nozzle valve spring (3), the pressure pushes up the needle valve (7) constantly and then the proper amount of fuel is injected into the swirling air in the combustion chamber for combustion. The opening pressure can be adjusted by adding or reducing the washer (2). A washer of 0.1 mm corresponds to 980 kpa (10 kgf/cm², 142 psi) change in opening pressure. The heat seal (8) is adopted to improve the durability and reliability of the nozzle. ELECTRIC CABIN A/C & HEATER DH14W00 Jul

196 OPERATING PRINCIPLE DK35/40(C)/45(C)SE SAFETY FIRST CTD pump (for 4B243 or any other turbo charged) 서브 Sub port 포트 CTD stroke 행정 상부 Upper 리드 lid 메인 Main port 포트 CLUTCH TRANSMISSION CTD 컷cut 메인 Main lid 리드 T46W243A HST REAR AXLE The CTD (Compact Timing Control Device) pump controls the injection timing depending on the engine condition to reduce the exhaust gas and noise of the engine. The basic structure is the same as for the standard pump. However, the plunger for CTD pump has the CTD cut and the sub port with its diameter of 0.4 mm (0.016in.). BRAKE CTD cut 컷 서브 Sub 포트 port 서브 Sub port 포트 blocked 막힘 메인 Main port 포트 blocked 막힘 FRONT AXLE Main 메인 port 포트 상부 Upper 리드lid Delayed 지연 도 STEERING 메인 Main 리드 lid HYDRAULIC ELECTRIC CABIN T46W244A For the standard pump, the fuel is injected by the pressure applied on the top of the plunger as the plunger rises and the side of the plunger blocks the main port. For the CTD pump, the sub port is still open due to the CTD cut even after the main port is blocked. Therefore, the fuel is not injected until the sub port is blocked. In other words, the injection is delayed as much as the height of the CTD cut. T46W245A The injection is hardly delayed by the reciprocation of the plunger at high speed since the diameter of the sub port is as small as 0.5 mm. Therefore, the CTD pump delays the injection timing at low speed and high torque to reduce the exhaust gas and noise. A/C & HEATER 238 DH14W00 Jul. 2008

197 DK35/40(C)/45(C)SE OPERATING PRINCIPLE 3.5 Governor and stop system Basic principle of governor system SAFETY FIRST TRANSMISSION REAR AXLE BRAKE STEERING HYDRAULIC A/C & HEATER FRONT AXLE HST CLUTCH Torque spring ELECTRIC CABIN Torque control screw T46W246A Components (1) Governor spring 1, 2 (2) Solenoid guide (3) Stop solenoid (4) Pump rack (5) Rack pin (6) Steel ball (7) Governor lever (8) Idle spring (9) Start spring (10) Idle control shaft (11) Governor sleeve (12) Fork lever 2 (13) Fork lever 1 (14) Fuel limit bolt (15) Torque spring As shown in the above figure, the steel ball (6) in the fuel camshaft gear is supported by the governor sleeve (11) to prevent from coming out. The sleeve pushes the fork lever 1 (13) to transfer the power to the fuel injection pump pin (5). DH14W00 Jul

198 OPERATING PRINCIPLE DK35/40(C)/45(C)SE A/C & HEATER CABIN ELECTRIC HYDRAULIC STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH SAFETY FIRST Operation of Governor 1. When stopped The fuel is blocked since the solenoid (3) pushes the injection pump control rack (4) of the injection pump to the left. 2. When turning the key switch ON When the electromagnet in the stop solenoid operates and the pin is retracted, the injection pump control rack (4) is pushed to the right by the start spring (9) and the idle control shaft (10) to supply the sufficient amount of fuel in order to start the engine. 3. When starting the engine and running the engine at low idle speed When the engine is started, the steel ball (6) pushes the governor sleeve (11) to the left as the centrifugal force of the steel ball increases. Therefore, the governor fork lever 1 (13) pushes the pump rack (4) to the left to reduce the amount of fuel supplied. As the control rack is stopped by the idle spring (8), it keeps the balance with the centrifugal force of the steel ball so that at least minimum amount of fuel is delivered for stable engine running at idle speed. 4. Acceleration and deceleration When depressing the accelerator pedal, the governor spring (1) pulls the fork lever 2 (12) to the right and then pushes the fork lever 1 (13) to the right. The fork lever (13) is stopped by the governor 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 determined by the driver, the stable speed is maintained. 5. Load increase at high speed When a load is applied to the engine running at a high speed, the centrifugal force of steel ball (6) decreases as the engine speed drops. Also, the fork lever 2 (12) is pulled to the right by the governor spring until it contacts the fuel limit bolt (14). Until then, the amount of injected fuel per one stroke of the injector plunger and the torque increase. This range (a) is between the max. speed point with no load and the max. power point of the torque curve. When the fork lever 2 is blocked by the fuel limit bolt (14) and does not move any more and the load is increased, the centrifugal force of steel ball drops further and the torque spring (15) compressed between the fork lever 1 and 2 is loosened. Then, the fork lever 2 moves to the right until the torque spring is free, and the amount of fuel supplied and the torque increase simultaneously. This range (b) is between the max. power and the max. torque point in the torque curve. Important b The fuel limit bolt (14), idle spring (9) and max. rpm setting bolt are set at factory. Unauthorized adjustment of such components can negatively effect the performance of the engine. Therefore, never adjust them without permission from DAEDONG. Such action violates the EPA regulation and also can void the warranty. 6. When stopped a Torque 토오크 curve 곡선 T46W247A When the key switch is moved to the "OFF" position, the stop solenoid power is cut off to release the electromagnet. Therefore, the stop pin comes off by the return force of the spring and pushes the solenoid guide (2) and fuel injection pump rack to the stop position to stop the engine. 240 DH14W00 Jul. 2008

199 DK35/40(C)/45(C)SE OPERATING PRINCIPLE 3.6 PCV valve A/C & HEATER CABIN SAFETY FIRST CLUTCH ELECTRIC TRANSMISSION HST T46W248B REAR AXLE HYDRAULIC STEERING FRONT AXLE BRAKE 9 T46W249A (1) Head cover bolt (7) Bleeding pipe (2) Oil filler flange (8) Intake valve (3) Oil baffle plate (9) Cylinder head (4) Head cover gasket (10) Cylinder head cover (5) Cylinder head cover (11) Oil baffle plate (6) Intake manifold (12) Bleeding pipe connection A. PCV (Positive Crankcases Ventilation) The PCV system is a system that prevents air pollution by returning the blowby gas to the intake manifold through the bleeding pipe of the cylinder head cover for recirculation of the gas. (However, the turbo charged engine has the open crankcase type that discharges the blowby gas to the air.) DH14W00 Jul

200 TROUBLE SHOOTING DK35/40(C)/45(C)SE A/C & HEATER CABIN ELECTRIC HYDRAULIC STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH SAFETY FIRST 4. TROUBLESHOOTING Symptom Causes Remedy Engine Does Not Start Start motor Does Not Run Engine Running is Not Smooth Either White or Blue Exhaust Smoke is Produced Either Black or Dark Gray Exhaust Smoke is Produced Insufficient Output No fuel Air in fuel system Water in fuel system Clogged fuel pipe Clogged fuel filter Excessively high viscosity of fuel or engine oil at low temperature Fuel with low cetane number Fuel leak due to loose injection pipe mounting nut Incorrect injection timing Worn fuel camshaft Clogged injection nozzle Defective fuel injection pump Defective fuel transfer pump Seizure of transfer pump, defective piston, cylinder bore or bearing Compression leak from cylinder Improper valve seating, damaged valve spring, valve seized Improper valve timing Worn piston ring and bore Excessive valve clearance Discharged battery Defective start motor Defective key switch Disconnected wiring Clogged or dirty fuel filter Clogged Air cleaner Fuel leak due to loose injection pipe mounting nut Defective fuel injection pump Incorrect nozzle opening pressure Seized or clogged nozzle Clogged fuel overflow pipe Defective governor Excessive engine oil Worn piston ring and bore or seized piston ring Incorrect injection timing Insufficient compression pressure Overheat or overload Low grade fuel used Clogged fuel filter Clogged Air cleaner Incorrect injection timing Seized engine components Uneven fuel injection Insufficient nozzle injection Compression pressure leak Add fuel Bleed air Change fuel and repair or flush fuel system Clean Clean or replace Use the specified fuel or engine oil Use the specified fuel Tighten nut Adjust Replace Clean or replace Repair or replace Repair or replace Repair or replace Replace head gasket, tighten cylinder head screws, glow plug and nozzle holder Repair or replace Correct or replace timing gear Repair or replace Adjust Charge Repair or replace Repair or replace Connect Clean or replace Clean or replace Tighten nut Repair or replace Adjust or replace Repair or replace Clean or replace Repair or replace Reduce to the specified level Repair or replace Adjust Adjust valve clearance Reduce load Use the specified fuel Clean or replace Clean or replace Adjust Repair or replace Repair or replace the fuel injection pump Repair or replace the nozzle Replace cylinder head gasket, check tightness of cylinder head screws and nuts, glow plug and nozzle holder 242 DH14W00 Jul. 2008

201 DK35/40(C)/45(C)SE TROUBLE SHOOTING Symptom Causes Remedy Excessive Engine Oil Consumption Fuel in Engine Oil (Increased oil amount) Hydraulic Oil in Engine Oil (Increased oil amount) Water in Engine Oil Low Oil Pressure High Oil Pressure Engine Overheating Aligned gaps of piston rings Worn or seized oil ring Worn piston ring groove Worn valve stem and guide Worn crankshaft bearings and crank pin bearings Worn fuel injection pump plunger Damaged fuel transfer pump Damaged hydraulic pump seal Defective cylinder head gasket Cracked cylinder block or cylinder head Insufficient engine oil Clogged oil strainer Clogged oil filter cartridge Relief valve stuck with dirt Weak or broken relief valve spring Excessive oil clearance of crankshaft bearings Excessive oil clearance of crank pin bearings Excessive oil clearance of rocker arm bushings Clogged oil passage Improper type of oil Defective oil pump Improper type of oil Defective relief valve Insufficient engine oil Damaged fan belt or improper tension Insufficient coolant Radiator screen and radiator fin clogged with dirt Corroded radiator Corroded coolant flow line Defective radiator cap Damaged coolant pipe Defective thermostat Defective coolant pipe Overload running Defective cylinder head gasket Incorrect injection timing Improper fuel used Change the ring gap direction Replace Replace piston Replace Replace Replace pump element or pump Replace Replace or repair Replace Replace Add Clean Replace Clean Replace Replace Replace Replace Clean Use the specified type of oil Repair or replace Use the specified type of oil Replace Add Replace or adjust Add Clean Clean or replace Clean or replace Replace Replace Replace Replace Reduce load Replace Adjust Use the specified fuel Coolant leakage Damaged mechanical seal on water pump Replace water pump Frequently Discharged Battery Insufficient battery electrolyte Fan belt slip Disconnected wiring Defective regulator or alternator Defective battery Add distilled water and charge Adjust fan belt tension or replace it Connect Replace Replace CABIN ELECTRIC HYDRAULIC STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH SAFETY FIRST A/C & HEATER DH14W00 Jul

202 MEASUREMENT AND ADJUSTMENT DK35/40(C)/45(C)SE SAFETY FIRST 5. Measurement and adjustment 5.1 Fan belt 5.2 piston compression pressure measurement A/C & HEATER CLUTCH REAR AXLE HST TRANSMISSION T46W250A Measure the deflection by depressing the center of the belt between the fan drive pulley and the alternator pulley at 98 N (10 kgf, 22 lbs) of force. If the deflection is out of the specified value, loosen the bolts and nuts and adjust the location of the alternator. If the belt is damaged or worn (see figure), replace the belt. Fan belt deflection... 7 ~ 9 mm (0.28 ~ 0.35 in.) T46W251A Run the engine until it is warmed up. Stop the engine and remove the air cleaner, the muffler and all nozzle holders. Connect a compression tester to the nozzle holder hole. Pull the stop lever or close the fuel filter with the cock to cut the fuel and crank the engine with the starter motor for 5 to 10 seconds. Measure the maximum pressure several times while engine running. BRAKE 6. If the pressure does not reach the allowable limit, apply few drops of oil to the cylinder wall through the nozzle holder hole and check the pressure again. FRONT AXLE If the pressure rises after applying the oil, check the cylinder wall and piston ring for wear. If the pressure is still low, check the top clearance, valve clearance and cylinder head. STEERING Compression pressure Specified value HYDRAULIC ELECTRIC CABIN 3.24 ~ 3.73 MPa 33 ~ 38 kgf/cm² 469 ~ 540 psi Pressure difference between two cylinders CAUTION Allowable lower limit Allowable limit 2.55 MPa 26 kgf/cm² 370 psi 10 % Check the compression pressure and adjust the valve clearance to the specified value. 244 DH14W00 Jul. 2008

203 DK35/40(C)/45(C)SE MEASUREMENT AND ADJUSTMENT 5.3 Valve clearance A. 4 cylinders The valve clearance should be measured only when the engine temperature is same to the ambient temperature. Disconnect the battery cables. Remove the cylinder head cover. Turn the crankshaft slowly and then stop it when 5. Measure the clearance of the closed valves in the below table, which are the intake and exhaust valves of the No. 1 cylinder, the intake valve of the No. 2 cylinder and the exhaust valve of the No. 3 cylinder. Adjust the clearance if necessary. When the No. 4 cylinder is overlapped the No. 4 cylinder (flywheel side) is at the overlap period IN EX IN EX IN EX IN EX Notes Special socket for rotating crankshaft : closed, : open, : Overlap Overlap TRANSMISSION CLUTCH SAFETY FIRST REAR AXLE A/C & HEATER BRAKE CABIN HST T46W252A 6. T46W254A HYDRAULIC STEERING FRONT AXLE ELECTRIC Turn the crankshaft just one turn (360 ) to position the No. 1 cylinder valves to the overlap period. Notes Overlap: T46W253A When turning the crankshaft, use only special service tool (socket) with socket wrench. How to make the crankshaft turning socket a. Cut the coupler (DAEDONG part No.: ) in half. b. Weld the 1/2 socket to the coupler. When the exhaust stroke is completed and the intake stroke is about to start, the exhaust valve is about to close, which is still open, and the intake valve starts to open. This period is called "overlap" and the center of the overlap period is when the height of the locker arms which push two valves is same. At this time, the clearance cannot be measured since the locker arms push the intake and exhaust valves. You may also use DAEDONG special tool kit (part No.: G0611B0010). DH14W00 Jul

204 MEASUREMENT AND ADJUSTMENT DK35/40(C)/45(C)SE HST TRANSMISSION CLUTCH SAFETY FIRST 7. Measure the clearance of the closed valves in the below table, which are the exhaust valve of No. 2 cylinder, the intake valve of the No. 3 cylinder and the intake and exhaust valves of the No. 4 cylinder. Adjust the clearance if necessary. When the No. 1 cylinder is overlapped IN EX IN EX IN EX IN EX : closed, : open, : Overlap Overlap B. 3 cylinders 1. The valve clearance should be measured only when the engine temperature is same to the ambient temperature. 2. Disconnect the negative battery cable. 3. Remove the cylinder head cover. 4. Turn the crankshaft using the crankshaft turning socket until the intake valve of the No. 2 cylinder and the exhaust valve of the No. 3 cylinder move simultaneously and the rocker arm height of these two valves is same. When the No. 1 cylinder is at T.D.C IN EX IN EX IN EX : closed, : open REAR AXLE T46W255A 5. Measure the clearance of the intake and exhaust valves of the No. 1 cylinder, the exhaust valve of the No. 2 cylinder and the intake valve of the No. 3 cylinder. Adjust the clearance if necessary. BRAKE Important Valve clearance (3, 4 cylinders) IN EX 6. Turn the crankshaft 360 and measure the clearance of the intake valve of the No. 2 cylinder and the exhaust valve of the No. 3 cylinder. Adjust the clearance if necessary. FRONT AXLE A series B series 0.25 mm ( in.) 0.30 mm ( in.) After one turn STEERING IN EX IN EX IN EX : closed, : open A/C & HEATER CABIN ELECTRIC HYDRAULIC 246 DH14W00 Jul. 2008

205 DK35/40(C)/45(C)SE MEASUREMENT AND ADJUSTMENT 5.4 Valve lift (deflection and worn condition of valve cam, tappet, push rod, rocker arm, etc.) 5.5. injection timing measurement and adjustment SAFETY FIRST Remove the cylinder head cover. Adjust the valve clearance according to the section 5.3. Set the dial gauge so that its pointer is on the valve. The valve should be closed and the rocker arm should move as much as the free play. Measure the max. valve movement while turning the crankshaft. Notes Perform the work with the engine installed in the tractor Measure the max. vertical movement of other valves according to the above process. The vertical movement for all valves should be in the tolerance range of 0.5 mm (0.02 in.). If the measured value is out of the tolerance, check the corresponding valve for the deflection of the pushrod, worn condition, engagement with the tappet, worn tappet and worn valve cam. TRANSMISSION CLUTCH T46W256A HST 1. Remove the engine stop solenoid. REAR AXLE FRONT AXLE BRAKE T46W257A A/C & HEATER CABIN ELECTRIC HYDRAULIC STEERING Remove the timing check window cover of the flywheel housing. Turn the flywheel to find 1, 4 FI mark for 4cylinder engine or 1 FI mark for 3cylinder engine on the flywheel. When the mark was found, turn the crankshaft counterclockwise approx. 30 (when looking at the front of the engine). "1, 4 FI" means the injection timing of the No. 1 or 4 cylinders. For 4B243 engine equipped with the CTD pump, it is marked on 18 and 22 of the flywheel. DH14W00 Jul

206 MEASUREMENT AND ADJUSTMENT DK35/40(C)/45(C)SE SAFETY FIRST 연료 Fuel ELECTRIC HYDRAULIC STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH T46W258A When turning the crankshaft, use a special service tool (socket) for turning the crankshaft by engaging it with the socket wrench. Notes How to make the crankshaft turning socket a. Cut the coupler (DAEDONG part No.: ) in half. b. Weld the 1/2 socket to the coupler. c. You can use DAEDONG speical tool kit (part No.: G0611B0010). T46W259A T46W261A 6. Remove the fuel in the nozzle holder with clean cloth and leave only small amount of fuel. 7. Observe the fuel of the nozzle holder while turning the crankshaft clockwise (when looking at the front of the 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 already. Repeat the above process to identify the moment when the amount of fuel starts to increase. If the fuel does not increase, it means that it is the exhaust cycle. Therefore, turn the crankshaft 360 to find the compression cycle and repeat the above procedures. 9. Mark the measured injection timing on the flywheel through the timing window and measure the distance between the "1, 4 FI" or "1 FI" and the mark you made. 10. To advance the injection timing, reduce the amount of shims. To delay the injection timing, increase the amount of shims. CABIN A/C & HEATER T46W260A Remove the No. 1 high pressure pipe. Unscrew the nozzle holder (1) slightly and tighten it when it is filled with fuel. 248 DH14W00 Jul. 2008

207 DK35/40(C)/45(C)SE MEASUREMENT AND ADJUSTMENT Model Injection timing Diameter of flywheel Flywheel circumference for 1 Amount of shims to adjust oil pressure measurement SAFETY FIRST 3B183 4B243 (for domestic model) BTDC mm (12.4 in.) 2.74 mm (0.108 in.) 0.1 mm (0.004 in.) 4A200, 4A220 BTDC mm (12.64 in.) 2.8 mm (0.11 in.) 0.1 mm (0.004 in.) 4B243 (for export model) BTDC mm (12.64 in.) 2.8 mm (0.11 in.) 0.1 mm (0.004 in.) T46W262A CLUTCH BTDC: Before top dead center Example) For 4A200, if the measured injection timing is on the 2.8 mm (2.74 mm for 3B183) above the FI mark, it means that the injection timing is 1 advanced. Therefore, the measured injection timing is BTDC 19. In this case, the injection is adjusted to 18 if adding 0.1 mm of shim under the fuel injection pump Remove the oil pressure switch and install the adapter and the pressure tester. Start and warm up the engine. Then, measure the oil pressure at idle and rated speed. If the oil pressure is less than the allowable limit, check the oil level, oil filter, oil pump relief valve, oil passages and oil clearance. Engine oil pressure At idle speed At rated speed Specified value Specified value Allowable limit (lower limit) over 49 kpa 0.5 kgf/cm² 7.11 psi 294 ~ 441 mm 2.5 ~ 4.5 kgf/cm² 35.6 ~ 64.0 psi 245 kpa 2.5 kgf/cm² 35.6 psi Oil pressure switch Tightening torque ~ 19.6 Nm 1.5 ~ 2.0 kgfm 10.8 ~ 14.5 lbft STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION A/C & HEATER CABIN ELECTRIC HYDRAULIC DH14W00 Jul

208 MEASUREMENT AND ADJUSTMENT DK35/40(C)/45(C)SE TRANSMISSION CLUTCH SAFETY FIRST 5.7 Bubble test for radiator Notes Checking if air is leaked through the crack on the cylinder wall Check the coolant level of the radiator and the reservoir tank. Add the coolant if necessary. Start the engine with the radiator cap closed and the reservoir tank cap open. Check if any bubble can be seen in the overflow hose on the bottom of the reservoir tank around 5 minutes later. If any bubble can be seen, remove the engine cylinder head to check the head gasket for damage, the cylinder bore for crack and the cylinder head for crack. Replace the components if necessary. 5.8 injection nozzle Inspection CAUTION Never contact with spraying diesel under pressure. It may penetrate the skin and cause the serious injury. Be sure nobody is in direction of the spray. A. Fuel injection pressure A/C & HEATER CABIN ELECTRIC REAR AXLE BRAKE FRONT AXLE HYDRAULIC STEERING HST T46W263A Set the injection nozzle to the nozzle tester. Measure the injection pressure. If the measurements are not within the specified range, replace the injection nozzle. Specified value of fuel injection pressure ~ MPa 150 ~ 160 kgf/cm² 2,133 ~ 2,275 psi 250 DH14W00 Jul. 2008

209 DK35/40(C)/45(C)SE MEASUREMENT AND ADJUSTMENT A/C & HEATER CABIN ELECTRIC REAR AXLE BRAKE HYDRAULIC STEERING FRONT AXLE HST TRANSMISSION CLUTCH SAFETY FIRST B. Fuel tightness of needle valve seat T46W264A Set the injection nozzle to the nozzle tester. Apply 130 kgf/cm² of pressure consistently for 10 seconds and check if the fuel is leaked from the nozzle. If the fuel is leaked, replace the nozzle. DH14W00 Jul

210 EXPLODED VIEW DK35/40(C)/45(C)SE SAFETY FIRST 6. Exploded view Notes The manufacturing parts are subject to change without notice. Therefore, check the parts catalog or electronic manual for latest information. 6.1 E010 cylinder block HYDRAULIC ELECTRIC CABIN STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION A/C & HEATER CLUTCH T46W2F9B Components (1) Cylinder block assembly (2) Cylinder block (3) Plug (4) Plug (5) Plug (6) Plug (7) Plug (8) Plug (9) Straight pin (10) Straight pin (11) Straight pin (12) Straight pin (13) Pipe pin (14) Coolant return pipe (15) Plug (16) Gasket (17) Pipe pin (18) Oil pump assembly (19) Oil pump gasket (20) Bolt with captive washer (21) Oil pump drive gear (22) Key (23) Flange nut (24) Oil switch (25) Oil gauge guide 252 DH14W00 Jul. 2008

211 DK35/40(C)/45(C)SE EXPLODED VIEW 6.2 E020 oil pan A/C & HEATER HYDRAULIC STEERING FRONT AXLE SAFETY FIRST ELECTRIC BRAKE REAR AXLE HST TRANSMISSION CLUTCH CABIN Components T46W2H0B (1) Oil pan assembly (2) Oil pan gasket (3) Flange bolt with captive pin (4) Bolt with captive washer (5) Drain plug (6) Seal washer (7) Oil filter 1 (8) Flange bolt with captive pin (9) Oring (10) Oil gauge (11) Oil gauge guiding pipe (12) Packing DH14W00 Jul

212 EXPLODED VIEW DK35/40(C)/45(C)SE SAFETY FIRST 6.3 E030 cylinder head HYDRAULIC STEERING FRONT AXLE ELECTRIC CABIN A/C & HEATER BRAKE REAR AXLE HST TRANSMISSION CLUTCH Components T46W2H1B (1) Cylinder hear assembly (2) Cylinder head (3) Plug (4) Plug (5) Plug (6) Intake valve guide (7) Exhaust valve guide (8) Combustion chamber (9) Plug (10) Stud bolt (11) Engine hook (12) Spring washer (13) Nut (14) Engine hook (15) Bolt with captive washer (16) Head gasket (17) Head bolt 254 DH14W00 Jul. 2008

213 DK35/40(C)/45(C)SE EXPLODED VIEW 6.4 E040 gear case STEERING SAFETY FIRST A/C & HEATER CABIN ELECTRIC HYDRAULIC FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH T46W2H2B Components (1) Gear case assembly (2) Gear case (3) Plug (4) Oring (5) Oring (6) Oring (7) Straight pin (8) Oil filter support (9) Oring (10) Bolt with captive washer (11) Connecting pipe (12) Spring (13) Belt seat (14) Steel ball (15) Cover (16) Cover bolt (17) Oring (18) Oring (19) Flange bolt (20) Gear case gasket (21) Bolt with captive washer (22) Bolt with captive washer (23) Bolt with captive washer (24) Bolt with captive washer (25) Bolt with captive washer (26) Plain washer (27) Coolant return flange (28) Gaske (29) Bolt with captive washer (30) Stud bolt (31) Nut (32) Spring washer (33) Oil filter (34) Oil filter DH14W00 Jul

214 EXPLODED VIEW DK35/40(C)/45(C)SE SAFETY FIRST 6.5 E050 main bearing case A/C & HEATER CLUTCH TRANSMISSION HST DK REAR AXLE STEERING FRONT AXLE BRAKE HYDRAULIC 12 ELECTRIC Components T46W2H3A CABIN (1) Main bearing case assembly (2) Bearing case bolt 1 (3) Bearing case gasket (4) Main bearing case cover (5) Bearing case cover gasket (6) Flange bolt with captive pin (7) Oil seal (8) Main bearing case assembly 1 (9) Main bearing case assembly 2 (10) Main bearing case assembly 3 (11) Washer (12) Bearing case bolt 2 (13) Straight pin 256 DH14W00 Jul. 2008

215 DK35/40(C)/45(C)SE EXPLODED VIEW 6.6 E080 valve rocker arm HYDRAULIC STEERING FRONT AXLE SAFETY FIRST ELECTRIC CABIN A/C & HEATER BRAKE REAR AXLE HST TRANSMISSION CLUTCH Components T46W2H4B (1) Intake valve (2) Exhaust valve (3) Valve spring (4) Valve spring support (5) Valve spring collet (6) Valve stem seal (7) Rocker arm shaft assembly (8) Rocker arm shaft (9) Sealing cap (10) Rocker arm support (11) Plain washer (12) Rocker arm spring (13) Snap ring (14) Rocker arm (15) Control nut (16) Control screw (17) Rocker arm support bolt DH14W00 Jul

216 EXPLODED VIEW DK35/40(C)/45(C)SE SAFETY FIRST 6.7 E030 cylinder head cover A/C & HEATER HYDRAULIC STEERING FRONT AXLE ELECTRIC CABIN BRAKE REAR AXLE HST TRANSMISSION CLUTCH Components T46W2H5B (1) Cylinder hear cover assembly (2) Cylinder head cover (3) Valve cover (4) Oring (5) Oil baffle plate (6) Screw with captive washer (7) Bleeding connection (8) Cylinder head cover gasket (9) Blowby hose (10) Band (11) Head cover bolt 258 DH14W00 Jul. 2008

217 DK35/40(C)/45(C)SE EXPLODED VIEW 6.8 E100 camshaft HYDRAULIC STEERING FRONT AXLE SAFETY FIRST BRAKE ELECTRIC CABIN REAR AXLE HST TRANSMISSION CLUTCH DK 35 A/C & HEATER Components T46W2H6B (1) Tappet (2) Push rod (3) Camshaft assembly (4) Camshaft (5) Filler plug (6) Camshaft gear (7) Key (8) Camshaft stopper (9) Bolt with captive washer (10) Idle gear assembly (11) Idle gear (12) Idle gear bushing (13) Spacer 2 (14) Snap ring (15) Idle gear shaft (16) Flange bolt with captive pin DH14W00 Jul

218 EXPLODED VIEW DK35/40(C)/45(C)SE SAFETY FIRST 6.9 E110 piston crankshaft HYDRAULIC HST BRAKE ELECTRIC CABIN STEERING FRONT AXLE REAR AXLE TRANSMISSION CLUTCH series A series B Components A/C & HEATER T46w2H7B (1) Piston assembly (2) Piston (3) Piston pin (4) Piston ring assembly (5) Piston ring 1 (6) Piston ring 2 (7) Oil ring assembly (8) Piston pin snap ring (9) Connecting rod assembly (10) Connecting rod (11) Piston pin bushing (12) Connecting rod bolt (13) Crank pin metal (14) Crankshaft assembly (15) Crankshaft (16) Filling plug (17) Crankshaft metal 1 (18) Crankshaft metal 2 (19) Side metal 1 (20) Side metal 2 (21) Key (22) Crankshaft gear (23) Oil slinger (24) Oring (25) Space cylinder (26) Oil seal (27) Crankshaft nut (28) Oil pump drive gear 260 DH14W00 Jul. 2008

219 DK35/40(C)/45(C)SE EXPLODED VIEW 6.10 E120 flywheel HST SAFETY FIRST mechanical HYDRAULIC ELECTRIC CABIN STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH A/C & HEATER Components T46W2H8A (1) Flywheel assembly (2) Flywheel (3) Ring gear (4) Flywheel bolt (5) Flywheel housing (6) Plug (7) Straight pin (8) Cover gasket (9) Timing mark cover (10) Bolt with captive washer (11) Flange bolt with captive pin (12) Bolt with captive washer (13) Starter assembly (14) Starter gasket (15) Nut (16) Spring washer (17) Starter (18) Stud bolt (19) Nut (20) Spring washer (21) Spline hub(dk35) DH14W00 Jul

220 EXPLODED VIEW DK35/40(C)/45(C)SE SAFETY FIRST 6.11 E130 nozzle holder A/C & HEATER STEERING FRONT AXLE HYDRAULIC ELECTRIC CABIN BRAKE REAR AXLE HST TRANSMISSION CLUTCH The DK35 is 3cylinder engine which has three nozzles and three glow plugs. Components T46W2H9B (1) Nozzle holder assembly (2) Heat seal (3) Gasket (4) Injection pipe 1 (5) Injection pipe 2 (6) Injection pipe 3 (7) Injection pipe 4 (8) Pipe clamp 1 (9) Pipe holder (10) Screw with captive washer (11) Glow plug (12) Glow plug powerstrip (13) Overflow pipe assembly (14) Fuel tube (15) Hose clamp 262 DH14W00 Jul. 2008

221 DK35/40(C)/45(C)SE EXPLODED VIEW 6.12 E140 fuel camshaft STEERING SAFETY FIRST A/C & HEATER CABIN ELECTRIC HYDRAULIC FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH T46W2i1B Components (1) Fuel injection camshaft assembly (2) Fuel injection camshaft (3) Ball bearing (4) Ball bearing (5) Key (6) Injection pump gear assembly (7) Injection pump gear (8) Steel ball (9) Governor sleeve (10) Steel ball (11) Governor ball case (12) Ball case clip (13) Clip (14) Snap ring (15) Fuel camshaft stopper (16) Bolt with captive washer (17) Stud bolt (18) Injection pump shim (T0.45) (19) Injection pump shim 1 (T0.3) (20) Injection pump shim 2 (T0.15) (21) Injection pump shim 3 (T0.1) (22) Injection pump assembly (23) Spring washer (24) Nut (25) Bolt with captive washer (26) Fuel pipe joint (27) Eye bolt (28) Stud bolt (29) Fuel pump gasket (30) Fuel pump assembly (31) Spring washer (32) Nut DH14W00 Jul

222 EXPLODED VIEW DK35/40(C)/45(C)SE SAFETY FIRST 6.13 E150 speed control plate HYDRAULIC STEERING FRONT AXLE ELECTRIC CABIN A/C & HEATER BRAKE REAR AXLE HST TRANSMISSION CLUTCH Components T46W2i2B (1) Fuel control bolt (2) Control nut (3) Gasket (4) Cap nut (5) Snap ring (6) Cap (7) Speed control lever (8) Speed control plate (9) Speed control gasket (10) Spring (11) Spring pin (12) Oil seal (13) Bolt with captive washer (14) Stud bolt (15) Flange nut (16) Stop screw (17) Nut (18) Wire (19) Seal copper 264 DH14W00 Jul. 2008

223 DK35/40(C)/45(C)SE EXPLODED VIEW 6.14 E160 engine stop lever STEERING SAFETY FIRST A/C & HEATER CABIN ELECTRIC HYDRAULIC FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH T46W2i3B Components (1) Idle limit system assembly (2) Spring (3) Idle control shaft (4) Bushing (5) Idle control body (6) Idle control bolt (7) Spring (8) Nut (9) Oring (10) Packing (11) Cap (12) Speed control plate (13) Engine stop lever 2 assembly (14) Oil seal (15) Spring (16) Engine stop lever 1 (17) Spring pin (18) Speed control plate gasket (19) Bolt with captive washer (20) Stud bolt (21) Flange nut (22) Solenoid assembly (23) Engine stop solenoid guide (24) Oring (25) Stud bolt (26) Flange nut (27) Oil filler plug cover (28) Gasket (29) Bolt with captive washer (30) Bolt with captive washer (31) Cable bracket (32) Oil filler plug DH14W00 Jul

224 EXPLODED VIEW DK35/40(C)/45(C)SE SAFETY FIRST 6.15 E170 governor HYDRAULIC STEERING FRONT AXLE ELECTRIC CABIN A/C & HEATER BRAKE REAR AXLE HST TRANSMISSION CLUTCH Components T46W2i4B (1) Governor lever assembly (2) Fork lever assembly (3) Fork lever 1 (4) Fork lever pin 1 (5) Fuel limit pin (6) Fuel control spring (7) Mounting screw (8) Fork lever shaft (9) Fork lever 2 (10) Bolt (11) Spring washer (12) Fork lever holder (13) Bolt (14) Bolt with captive washer (15) Bolt with captive washer (16) Governor spring 1r (17) Governor spring DH14W00 Jul. 2008

225 DK35/40(C)/45(C)SE EXPLODED VIEW 6.16 E180 water pump SAFETY FIRST TRANSMISSION HST HYDRAULIC REAR AXLE BRAKE FRONT AXLE CLUTCH STEERING Components T46W2i5A ELECTRIC CABIN A/C & HEATER (1) Water pump assembly (2) Water pump body (3) Water pump bearing (4) Impeller (5) Mechanical seal assembly (6) Flange (7) Fan pulley (8) Water pump body gasket (9) Bolt with captive washer (10) Bolt (11) Stud bolt (12) Nut (13) Spring washer (14) Stud bolt (15) Spring washer (16) Nut (17) Timing screw DH14W00 Jul

226 EXPLODED VIEW DK35/40(C)/45(C)SE SAFETY FIRST 6.17 E190 coolant pipe HYDRAULIC STEERING FRONT AXLE ELECTRIC CABIN A/C & HEATER BRAKE REAR AXLE HST TRANSMISSION CLUTCH Components T46W2i6C (1) Coolant flange (2) Coolant flange gasket (3) Bolt with captive washer (4) Stud bolt (5) Bolt with captive washer (6) Nut (7) Spring washer (8) Coolant return pipe (9) Pipe (10) Pipe band (11) Thermostat (12) Gasket (13) Thermostat cover (14) Bolt with captive washer (15) Dual sensor (16) Nut (17) Pipe (18) Pipe band 268 DH14W00 Jul. 2008

227 DK35/40(C)/45(C)SE EXPLODED VIEW 6.18 E200 AC generator HYDRAULIC STEERING FRONT AXLE SAFETY FIRST ELECTRIC CABIN A/C & HEATER BRAKE REAR AXLE HST TRANSMISSION CLUTCH Components T46W2i7B (1) AC generator assembly (2) Spacer (3) Bolt (4) Plain washer (5) Spring washer (6) Nut (7) Generator support (8) Plain washer (9) Bolt with captive washer (10) Cooling fan (11) Fan collar (12) Bolt with captive washer (13) Plain washer (14) Fan drive pulley (15) Key (16) Fan belt (17) Plain washer (18) Spring washer (19) Nut DH14W00 Jul

228 EXPLODED VIEW DK35/40(C)/45(C)SE SAFETY FIRST 6.1 E220 manifold A/C & HEATER HYDRAULIC STEERING FRONT AXLE ELECTRIC CABIN BRAKE REAR AXLE HST TRANSMISSION CLUTCH Components T46W2i8B (1) Inlet manifold (2) Inlet manifold gasket (3) Bolt with captive washer (4) Stud bolt (5) Exhaust Manifold gasket (6) Exhaust manifold (7) Flange nut (8) Bolt with captive washer (9) Exhaust pipe 270 DH14W00 Jul. 2008

229 DK35/40(C)/45(C)SE SERVICING 7. SERVICING 7.1 engine assembly Removal and installation SAFETY FIRST 1 4 T46W265A 2 3 T46W268A CLUTCH 1. Park the tractor on level ground and disconnect the negative battery cable. Drain the coolant, engine oil, hydraulic fluid and fuel if necessary Disconnect or remove the accelerator cables (1). Remove the rubber hose of hydraulic suction pipe connection (2). TRANSMISSION 10. * Drain the transmission fluid before removing any hydraulic parts. Separate two hydraulic pipes (3) from the hydraulic pump or remove them from the tractor. HST 11. Disconnect two steering hoses (LH, RH) (4) from the left and right steering cylinders and disconnect the steering return hose and steering supply hose. (See Steering for details.) REAR AXLE 2. T46W266A Remove the hood (1) and side covers (LH/RH) (2). Symbols for 4 types of steering hoses P (Pump): This is the hydraulic supply hose installed between modulator valve and steering unit. It is indicated by red tape on both ends. T (Return): FRONT AXLE BRAKE This is the return hose installed between the steering unit and the hydraulic block on the gear pump. It doesn't have any mark. For the HST tractor, this hose comes out of the steering unit and is connected to the HST oil cooler. STEERING T46W267A Remove the floor mat (1). Remove the clutch link pin (2) to disconnect the link. Remove the LH/RH brake rod pins (3) under the floor deck to separate the rod and link. R (Right turn): This hose is installed between steering unit and RH steering cylinder. It is indicated by white tape on both ends. L (Left turn): This hose is installed between steering unit and LH steering cylinder. It is indicated by yellow tape on both ends. CABIN ELECTRIC HYDRAULIC 6. Disconnect the shuttle lever rod connection (4). 7. Disconnect the connectors of wiring between the panel and engine and wiring harness between the panel and transmission. A/C & HEATER DH14W00 Jul

230 SERVICING DK35/40(C)/45(C)SE HST TRANSMISSION CLUTCH SAFETY FIRST 1 2 T46W269A 12. Remove the panel mounting bolts (1) at both sides. 13. Remove all mounting bolts (2) from floor deck. 14. Remove the steering column by lifting it slowly with a hoist. * Be careful not to damage the hoses, wirings and cables. 17. Remove the docking bolts and nuts from the clutch housing and flywheel housing. * M12 tightening torque ~ 90.2 Nm 7.9 ~ 9.2 kgfm 57.1 ~ 66.5 lbft 18. Chock the rear wheels. 19. Separate the mating section by rolling the front wheels to forward direction. * Liquid gasket for contact surface of mating section: Three Bond 1206D * For detailed installation procedures, refer to the chapter "Clutch". 20. Drain the fuel in the fuel tank by disconnecting the inlet hose of the fuel feed pump. 21. Remove the fuel tank (1). 2 1 BRAKE REAR AXLE FRONT AXLE STEERING 1 T46W270A 15. Remove the shaft cover to remove the front wheel drive shaft (1). 22. Remove the muffler (1), air filter hose (2) and radiator hose (3). 3 T46W272A HYDRAULIC 1 ELECTRIC CABIN A/C & HEATER T46W271A 16. Place two hydraulic jacks on the rail as shown in the figure and position them under the transmission housing and engine oil pan. T46W273A 23. Hook the chain on the engine towing eyes and lift the engine slightly using a hoist. WARNING Support the front frame with a stand so that the tractor does not fall forward when the engine is removed from it. 272 DH14W00 Jul. 2008

231 DK35/40(C)/45(C)SE SERVICING 24. Remove the engine frame mounting bolts. * M12(9T) tightening torque 77.4 ~ Nm 7.9 ~ 10.2 kgf.m 57.1 ~ 73.7 lbft * The engine cylinder block is made by casting. Therefore, the 9T bolt should be tightened to the torque specified for the 7T bolt. 25. Remove the engine by lifting it gently. 7.2 PCV valve SAFETY FIRST HST A/C & HEATER REAR AXLE CABIN BRAKE ELECTRIC HYDRAULIC STEERING FRONT AXLE TRANSMISSION CLUTCH T46W275B 1. Remove the blowby hose (1). T46W274A 26. Remove the cooling fan, fuel filter, alternator, gear pump, clutch cover, starter motor and reservoir tank if necessary Remove the cylinder head cover bolts (2). Remove the head cover (3) and gasket (4). Remove the PCV valve cover (5) or oil baffle plate (6) if necessary. 27. Install in the reverse order of removal. DH14W00 Jul

232 SERVICING DK35/40(C)/45(C)SE SAFETY FIRST 7.3 head cover installation 7.5 heat seal Removal BRAKE REAR AXLE HST TRANSMISSION CLUTCH T46W276b Make sure that the head cover gasket is well seated on the groove of the cylinder head cover. When installing the head cover, keep the specified tightening torque and tighten the bolts gradually into 3 ~ 4 steps. Ensure that the cylinder head cover gasket (1) is not defective. Cylinder head cover bolt (M8) ~ 11.8 Nm 0.9 ~ 1.2 kgfm 6.5 ~ 8.7 lbft 7.4 Glow plug and fuel overflow pipe (1) Philips screwdriver (2) Nozzle T46W278A (3) Injection nozzle gasket (4) Heat seal Drive the Philips screwdriver lightly into the heat seal hole. Turn the Philips screwdriver three or four times each way. While turning the Philips screwdriver, slowly pull out the heat seal together with the injection nozzle gasket. If the heat seal drops, repeat the above procedure. The heat seal and injection nozzle gasket must be replaced once the injection nozzle has been removed for cleaning or service. Notes FRONT AXLE Use a Philips screwdriver with the size of ø 0.6 mm. This is slightly larger than the hole diameter of heat seal. STEERING HYDRAULIC ELECTRIC CABIN A/C & HEATER T46W277A Disconnect the highpressure injection pipe (5) and the overflow pipe (6). Remove the glow plugs (4). Remove the injection nozzle (1), gasket (2) and heat seal (3). Refer to "7.5 Removal of heat seal". 274 DH14W00 Jul. 2008

233 DK35/40(C)/45(C)SE SERVICING 7.6 Rocker arm assembly Removal and installation A/C & HEATER SAFETY FIRST CLUTCH REAR AXLE BRAKE FRONT AXLE STEERING ELECTRIC HYDRAULIC HST TRANSMISSION Components T46W280A (1) Rocker arm shaft (2) Rocker arm (3) Rocker arm support (4) Rocker arm support bolt A. Removal 1. Remove the rocker arm mounting bolts (4) by loosening them in several steps. B. Installation 2. CABIN Remove the rocker arm assembly and the push rod. Push rod Tappet T46W281A 1. Make sure that the push rod is seated on the concaved area of the tappet. DH14W00 Jul

234 SERVICING DK35/40(C)/45(C)SE SAFETY FIRST rocker arm assembly check 3 cylinders 4 cylinders Installation order CLUTCH Installation order REAR AXLE HST TRANSMISSION T46W279A Tighten the rocker arm support bolts to the specified torque in several steps with the specified sequence as shown in the figure. Adjust the valve clearance after assembling the rocker arm assembly. Important Bolt T46W282A Measure the rocker arm I.D. with an inside micrometer. Measure the rocker arm shaft O.D. with an outside micrometer. If the clearance exceeds the allowable limit, replace the rocker arm. If the clearance still exceeds the allowable limit after replacing the rocker arm, replace the rocker arm shaft. FRONT AXLE BRAKE Rocker arm shaft T46W2J0A To tighten the rocker arm support bolt, the groove on the rocker arm shaft should face the bolt. Clearance Rocker arm shaft O.D. Specified size Allowable limit Specified size ~ mm ( ~ in.) 0.15 mm ( in.) ~ mm ( ~ in.) HYDRAULIC STEERING Rocker arm mounting bolt (M10) ~ 73.5 Nm 6.2 ~ 7.2 kgfm 44.8 ~ 54.2 lbft Rocker arm I.D. Specified size ~ mm ( ~ in.) A/C & HEATER CABIN ELECTRIC 276 DH14W00 Jul. 2008

235 DK35/40(C)/45(C)SE SERVICING 7.7 cylinder head Cylinder head removal cylinder head installation Apply the liquid gasket (Three bond 1215 or equivalent) on both sides of coolant flange gasket. Always replace the head gasket with a new one. Pay particular attention to its direction and orientation. Remove any gasket residue out of mating surfaces of the cylinder head and cylinder block before installing the new cylinder head gasket. Be careful not to get the residue enter into the block or the head. (Use a vacuum cleaner to clean the residue.) Before installing the tappets, apply engine oil around them. CLUTCH SAFETY FIRST T46W283A Installation sequence for head bolts Unscrew from No. 14 to No. 1 Tighten from No. 1 to No. 14 Flywheel Gear case side side Unscrew from No. 18 to No. 1 Tighten from No. 1 to No. 18 T46W284A (1) Cylinder head (2) Coolant flange Important Apply the oil to the thread of head bolts and tighten them to the specified torque in several steps and the specified sequence shown in the figure. Retighten them in 30 minutes after running the engine and adjust the valve clearance. Cylinder head bolts Tightening torque ~ Nm 10.5 ~ 11.0 kgfm 75.9 ~ 79.6 lbft Cylinder head surface flatness check BRAKE REAR AXLE HST TRANSMISSION Loosen the head bolts in the reverse sequence as shown in the figure. (Follow the sequence in the figure when tightening them.) Lift it slightly with a hoist by using the hook. Remove the coolant flange (2) if necessary. Remove the tappets from the cylinder block. STEERING FRONT AXLE CAUTION Mark the cylinder number to the tappets to prevent them from interchanging T46W285A Thoroughly clean the cylinder head surface. Place a straight edge on the cylinder head and measure the clearance with a feeler gage as shown in the figure. If the measured value exceeds the allowable limit, replace the cylinder head. ELECTRIC HYDRAULIC Important Do not place the straight edge on the combustion chamber. Allowable limit mm in. A/C & HEATER CABIN DH14W00 Jul

236 DK35/40(C)/45(C)SE SAFETY FIRST 7.8 intake and exhaust valves valve Removal Valve recess check SERVICING 3 A/C & HEATER CABIN ELECTRIC HYDRAULIC STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH valve Installation (1) Valve (4) Valve spring (2) Collet (5) Valve stem seal (3) Retainer 1 T46W286A Compress the valve spring with the replacer and remove the collet (2). Remove the retainer (3), valve spring (4), valve stem seal (5) and the valve (1). Important Be careful not to interchange the valves and related components. Mark the cylinder number on the valve and the parts to prevent interchanging. Apply oil to the stem of valve and install it into the cylinder head. Lubricate the valve and its related parts after installation Clean the cylinder head, the valve face and the valve seat. Insert the valve into the valve guide. Measure the valve recess with a depth gauge. If the recess value exceeds the allowable limit, replace the valve and check the valve seat. Valve recess Specified value Allowable limit Valve seat check 0.2 ~ 0.5 mm ~ in. 0.8 mm in. T46W287A T46W288A Coat the valve face lightly with red lead and put the valve on its seat to check the contact. If the valve does not seat all the way around the valve seat or the valve contact is less than 70%, correct the valve seating as follows. Apply compound on the valve face evenly. Put the valve on its seat and hold it with the valve flapper. Turn the valve back and forth on the valve seat to lap. Remove the compound and clean the valve and the seat. Apply oil on the valve face and finish to complete fitting. Repeat lapping until the valve seats correctly. 278 DH14W00 Jul. 2008

237 DK35/40(C)/45(C)SE SERVICING Valve spring check Valve spring squareness (Tilt) SAFETY FIRST CLUTCH BRAKE REAR AXLE HST TRANSMISSION A/C & HEATER FRONT AXLE CABIN ELECTRIC HYDRAULIC STEERING T46W289A T46W290A Measure the free length of the spring with vernier calipers. Place the spring on a spring compression tester and compress to the specified length to measure the tension. If the measured value is less than the allowable limit, replace the valve spring. Tension Free length Specified value Allowable limit Specified value 117 N / mm 12.0 kgf / mm 26.5 lbs / in. 100 N / mm 10.2 kgf / mm 22.5 lbs / in ~ 42.2 mm ~ in Place the spring on the flat plate and then put a square at its side. Measure the maximum distance "A" while rotating the spring. If the measurement exceeds the allowable limit, replace the spring. Valve spring squareness Allowable limit 1.0 mm in. Allowable limit 41.2 mm in DH14W00 Jul

238 SERVICING DK35/40(C)/45(C)SE SAFETY FIRST 7.9 injection pump injection pump Removal injection pump Installation Apply the liquid gasket (Three bond 1215, 1104 or equivalent) on the pump installation surface of the cylinder block. Install the shims as they were. 3 2 Injection pump control rack lever Fork lever 1 CLUTCH 4 TRANSMISSION T46W291A Remove the injection pipes (1) and the intake manifold (2). Remove the overflow pipe (3). 3. T46W294A Make sure that the lever of the pump control rack is on the outer side from the fork lever 1 when installing the pump. HST 3. Remove the oil filler flange (4). REAR AXLE Tightening sequence of bolt or nut: BRAKE FRONT AXLE 2 STEERING 4. Remove the idle limit spring mounting bolt (1). WARNING T46W292A T46W293B HYDRAULIC Never remove the idle limit spring seal (2). Otherwise, it could negatively affect the emission control and the engine may not be covered by warranty any more. A/C & HEATER CABIN ELECTRIC Remove the fuel injection pump. Keep the shims just like they were T46W295B Tighten the nuts to the specified torque in several steps in the correct sequence as shown in the figure. M ~ 27.4 Nm 2.4 ~ 2.8 kgfm 17.3 ~ 20.2 lbft Tighten the idle limit spring mounting bolt. 280 DH14W00 Jul. 2008

239 DK35/40(C)/45(C)SE SERVICING injection pump disassembly nozzle holder disassembly SAFETY FIRST CLUTCH A/C & HEATER TRANSMISSION HST REAR AXLE BRAKE FRONT AXLE STEERING HYDRAULIC CABIN ELECTRIC (1) Pump body (5) Delivery valve (2) Control rack (6) Tappet roller (3) Delivery valve holder (7) Plunger (4) Delivery valve spring (8) Cylinder T46W296A (1) Nozzle holder (5) Distance piece (2) Adjusting washer (6) Nozzle (3) Nozzle spring (7) Nozzle nut (4) Push rod T46W297A Important When disassembling the pump components, the amount of fuel injection should be adjusted on a designated bench. Only authorized service personnel should disassemble or reassemble the fuel injection pump. 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1) and take out the internal components. Installation Before installing the nozzle, soak it in clean fuel. When installing the push rod (4), be careful of its direction. DH14W00 Jul

240 SERVICING DK35/40(C)/45(C)SE SAFETY FIRST 7.10 governor spring and stop solenoid Removal installation 1 3 CLUTCH T46W298A TRANSMISSION Remove the idle adjusting bolt (1), fuel injection pump (2) and oil filler flange (3). Remove the manual stop lever cover (4). HST 1 2 REAR AXLE T46W2A5A FRONT AXLE BRAKE 3. T46W299A Remove the stop solenoid (1). Be careful not to drop the stop solenoid guide (2). 1. (1) Governor spring 1 (3) Fork lever 2 (2) Governor spring 2 (4) Governor lever When installing the governor spring, make sure that the governor spring 2 is installed on the inside of governor spring 1. CAUTION ELECTRIC HYDRAULIC STEERING 4. T46W2A0A Remove the governor spring using a hook after removing the throttle cover (1). 2. Be careful of the direction of the governor spring 1. The longer side should face the governor fork. If the governor spring is dropped during the installation, the crankcase should be disassembled again. Therefore, use a hook not to drop the governor spring. The governor spring can also be installed by installing one end to the throttle lever first and then the other end to the long hole of the governor fork. A/C & HEATER CABIN Be careful not to pop out the governor spring. The governor spring can also be removed by disengaging it from the fork lever and then removing it engaged with the throttle lever. 282 DH14W00 Jul. 2008

241 DK35/40(C)/45(C)SE SERVICING 7.11 gear case removal installation SAFETY FIRST A/C & HEATER CABIN CLUTCH TRANSMISSION HST REAR AXLE 1 2 (1) Crankshaft nut (2) Fan drive pulley T46W2A2b 1. Remove the crankshaft nut (1). 2. Remove the fan drive pulley (2). Crankshaft nut Tightening torque ~ Nm 14.0 ~ 16.0 kgfm ~ lbft 1. BRAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC T46W2A4A Apply the grease to the crankshaft oil seal (1) lip on the gear case and take care not to damage it when installing. Apply the grease on the Oring (2) and attach it to the gear case to prevent it from coming off during reassembling. Make sure that the gear case mounting bolts are installed at correct locations. Important In general, the bolt should be screwed as 1.5 times as the diameter of the bolt in length. 5. Install all bolts and increase the tightening torque gradually (in 2 to 3 steps). M8 tightening torque ~ 27.4 Nm 2.4 ~ 2.8 kgfm 17.3 ~ 20.2 lbft 3. T46W2A3A Unscrew the crankcase mounting bolts to remove the gear case. DH14W00 Jul

242 SERVICING DK35/40(C)/45(C)SE SAFETY FIRST 7.12 idle gear and crank gear Removal Installation If necessary, heat the crankshaft (2) gear up to approx. 80 C (176 F) and insert it to the crankshaft. Apply the oil to the Oring (5) on the left figure. The tapered face of the crankshaft collar should be first to contact with the Oring. Install the idle gear while aligning the marks on the all gears as shown in the figure. TRANSMISSION A/C & HEATER FRONT AXLE BRAKE REAR AXLE HST CABIN ELECTRIC HYDRAULIC STEERING CLUTCH (1) Idle gear (4) Oil slinger (2) Crankshaft gear (5) Oring (3) Oil pump drive gear 1 (6) Crankshaft collar T46W2A6A Remove the crankshaft collar (6), Oring (5), oil slinger (4) and oil pump drive gear 1 (3) in order. Remove the idle gear (1). Remove the crankshaft gear (2) with a puller set. Notes The oil pump drive gear (3) is only for the B series engine. It is not installed to the A series engine. Instead, the crankshaft gear (2) of the A series engine is longer than that of the B series as much as the thickness of the oil pump drive gear (3). (1) Idle gear (2) Crankshaft gear (3) Oil pump gear Important T46W2A7A (4) Fuel camshaft gear (5) Valve camshaft gear Even the one misalignment of these marks on the gears can lead to fatal failure of the engine. 284 DH14W00 Jul. 2008

243 DK35/40(C)/45(C)SE SERVICING 7.13 valve camshaft Removal 7.14 Fuel camshaft Removal SAFETY FIRST A/C & HEATER HST TRANSMISSION REAR AXLE BRAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC CABIN CLUTCH Service hole 1. (1) Camshaft (2) Cam gear T46W2A8A Align the holes on the cam gear (2) with the bolt holes and unscrew the bolts through the service hole with a T handle wrench. 1. Remove the fuel camshaft stopper (1). T46W2F5A 2. Remove the camshaft (1). 3. Remove the cam gear (2). Installation If necessary, heat the cam gear up to approx. 80 C (176 F) and insert it to the camshaft (1) (1) Fork lever 1 (2) Fork lever 2 (3) Fuel injection pump gear (4) Camshaft (5) Fork lever holder T46W2A9A Unscrew the fork lever holder screws and remove the fuel camshaft (4), fork lever holder (5), fork lever 1 (1) and fork lever 2 (2) at the same time. Remove the fuel camshaft gear (3) from the fuel camshaft if necessary. Installation If necessary, heat the fuel camshaft gear up to approx. 80 C (176 F) and insert it to the camshaft. DH14W00 Jul

244 SERVICING DK35/40(C)/45(C)SE SAFETY FIRST 7.15 Crank gears and shafts check Timing gear backlash Valve camshaft gear side clearance BRAKE REAR AXLE HST TRANSMISSION CLUTCH STEERING FRONT AXLE T46W2B0A Set a dial indicator (lever type) with its tip on the gear tooth. Move the timing gear to measure its backlash while holding the engaged gear to it. If the backlash exceeds the allowable limit, check the oil clearance of the shafts and the gear. (See ) If the oil clearance is OK but the backlash is over the allowable limit, replace the gear. Backlash Specified value 0.04 ~ 0.11 mm ~ in. Allowable limit 0.15 mm in idle gear side clearance (1) Camshaft (3) Camshaft stopper (2) Camshaft gear T46W2B2A 1. Pull the cam gear (2) and the camshaft (1). 2. Measure the clearance (A) between cam gear (2) and camshaft stopper (3). 3. If the clearance exceeds the allowable limit, replace the camshaft stopper (3). Side clearance Specified value Allowable limit 0.07 ~ 0.22 mm ~ in. 0.3 mm in Fuel camshaft gear side clearance A/C & HEATER CABIN ELECTRIC HYDRAULIC (1) Idle gear collar 2 (2) Idle gear Pull the idle gear collar 2 (1) and push the idle gear (2) at its end. Measure the clearance (A) between idle gear and idle gear collar 2 with a feeler gauge. If the clearance exceeds the allowable limit, replace the idle gear (2). Side clearance Specified value Allowable limit T46W2B1B 0.20 ~ 0.51 mm ~ in. 0.9 mm in (1) Fuel injection pump gear (2) Snap ring T46W2B3A Measure the clearance (A) between fuel injection pump gear (1) and snap ring (2) on the fuel camshaft. If the clearance exceeds the allowable limit, check the gear, the bearing and the key. Side clearance Specified value Allowable limit 0.15 ~ 0.57 mm ~ in. 0.9 mm in. 286 DH14W00 Jul. 2008

245 DK35/40(C)/45(C)SE SERVICING idle gear oil clearance measurement valve camshaft oil clearance measurement SAFETY FIRST TRANSMISSION HST REAR AXLE BRAKE FRONT AXLE ELECTRIC HYDRAULIC STEERING CLUTCH 1. T46W2B4A Measure the idle gear shaft O.D. with an outside micrometer. 1. T46W2B6A Measure the I.D. of the camshaft bore on the crankcase with an inside micrometer Measure the idle gear bushings I.D. with an inside micrometer. If the clearance exceeds the allowable limit, replace the bushing Measure the O.D. of the camshaft journal with an outside micrometer. If the clearance exceeds the allowable limit, replace the shaft. Oil clearance Specified value Allowable limit ~ mm ~ in. 0.1 mm in. Oil clearance Specified value Allowable limit ~ mm ~ in mm in. Shaft O.D. Bushing I.D. Specified value Specified value ~ mm ~ in ~ mm ~ in. Journal O.D. Bore I.D. Specified value Specified value CABIN A/C & HEATER ~ mm ~ in ~ mm ~ in idle gear bushing replacement T46W2B5A Press out the bushing using replacing tool. Clean the bore, and apply the oil on it. Press in the new bushing using the replacing tool. DH14W00 Jul

246 SERVICING DK35/40(C)/45(C)SE SAFETY FIRST valve Camshaft deflection check 7.16 piston and connecting rod Removal CLUTCH BRAKE T46W2B7A T46W2b9A TRANSMISSION Place the camshaft on V blocks with its journals supported and set a dial indicator with its tip on the intermediate journal. Measure the eccentricity (half of the measured value) while turning the camshaft on the V blocks Remove the oil pan and oil pan gasket. Remove the oil strainer (1). Installation Be sure to install the Oring (2) between oil strainer and cylinder block. HST 3. If the eccentricity exceeds the allowable limit, replace the camshaft. REAR AXLE Eccentricity Allowable limit 0.05 mm in valve Cam height measurement T46W2C0A FRONT AXLE 3. Rotate the crankshaft so that the connecting rod cap (4) comes to the bottom. Then, remove the bolt (3) and the cap (4). STEERING 4. Rotate the crankshaft so that the piston (5) comes to the top. Then, tap the connecting rod with a rubber hammer to pop the piston out of the top of the block. A/C & HEATER CABIN ELECTRIC HYDRAULIC Measure the height of the camshaft lobe at largest O.D. with an outside micrometer. If the measured value is below the allowable limit, replace the camshaft. Cam height 3A183 4A200 4A220 4B243 IN. Specification mm in. Allowable limit mm in. EX. Specification mm in. Allowable limit T46W2B8A mm in T46W2C2A Remove the piston rings with a piston ring replacing tool. Remove the piston pin snap ring (1) and then remove the piston pin (2). 288 DH14W00 Jul. 2008

247 DK35/40(C)/45(C)SE SERVICING Installation SAFETY FIRST Exhaust 배기 manifold 매니폴드측side Top 톱링ring end 엔드 gap 갭 Mark 표시 (Y (Y 또는 or R) R) Undercut Side mark 각인측 Injection 분사펌프측 pump side 2nd 2차 ring 링 end 엔드 gap 갭 오일 Oil ring 링엔드 end gap 갭 T46W2C5A T46W2C3A 8. (1) Top ring (2) 2nd ring (3) Ring Make sure that the undercut of the 2nd ring faces downward. CLUTCH 1 9. Apply the oil on the crankpin bearing, cylinder wall and connecting rod cap screw. HST TRANSMISSION T46W2F6A REAR AXLE T46W2C4A Clean all the parts before installation. Warm up the piston by soaking it in hot oil (approx. 80 C) for 10 to 15 minutes before inserting the piston pin into the piston. Install the piston and connecting rod with the mark FW on the piston facing the flywheel and the side marks on the connecting rod facing the fuel injection pump. The manufacturer mark (Y or R) (3) on the top ring should face the top of the piston. The cutout of expander (1) should face the opposite side of the oil ring (2) end gap. The top ring end gap ring should be on the opposite side of the combustion chamber on piston. The 2nd ring end gap and the oil ring end gap should be 120 far from the top ring end gap. 10. Insert the connecting rod and piston assembly with the arrow mark (1) on the piston and the stamped number (2) on the connecting rod facing the fuel injection pump using a piston ring compressor. 11. Apply the engine oil to the connecting rod cover bolts and hand tighten them all the way down. Then, tighten them with a torque wrench. If they would not be tightened to the specified torque, replace the bolts. The both stamped numbers should be seen from one side. Connecting rod cover bolt 44.1 ~ 49.0 Nm 4.5 ~ 5.0 kgfm 32.5 ~ 36.1 lbft Important 2 T46W2C1A Mark the cylinder number on the piston and connecting rod to prevent them from interchanging. CABIN ELECTRIC HYDRAULIC STEERING FRONT AXLE BRAKE Be careful not to damage the chromeplate area on the piston ring when pressing the piston and ring assembly into the cylinder. A/C & HEATER DH14W00 Jul

248 SERVICING DK35/40(C)/45(C)SE SAFETY FIRST 7.17 piston and connecting rod check piston pin bore piston pin and bushing Clearance STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH Measure the I.D. of piston pin bore (lengthwise and widthwise of the piston) with a cylinder gauge. If the measured value exceeds the allowable limit, replace the piston. Piston pin bore I.D. Specified value Allowable limit T46W2C7A ~ mm ( ~ in.) mm ( in.) Clearance between piston pin and bushing Piston pin O.D. Bushing I.D. Specified value Allowable limit Specified value Specified value T46W2C8A 1. Measure the piston pin O.D. with an outside micrometer. 2. Measure the piston pin busing I.D. with an inside micrometer. 3. If the clearance still exceeds the allowable limit after replacing the bushing with new one, replace the piston pin ~ mm ( ~ in.) 0.15 mm ( in.) ~ mm ( ~ in.) ~ mm ( ~ in.) piston pin bushing replacement A/C & HEATER CABIN ELECTRIC HYDRAULIC Removal 제거 Press 압입in T46W2C9A Press out the bushing using a bushing replacing tool. Clean the new bushing and the bore and apply the oil to them. Press in the bushing using the replacing tool. Important Align the oil holes (1) of the connecting rod and the bushing. 290 DH14W00 Jul. 2008

249 DK35/40(C)/45(C)SE SERVICING 7.18 piston ring measurement piston ring end gap piston ring clearance A/C & HEATER SAFETY FIRST CABIN ELECTRIC HYDRAULIC CLUTCH Place the piston ring to be measured on the top face of piston in cylinder block and slightly push in the piston and piston ring. (Do not put the piston ring on the carbon layer.) Measure the ring end gap with a feeler gauge. If the gap exceed the allowable limit, replace the piston ring. Piston ring end gap 4. 2nd ring Top ring, oil ring Specified value Allowable limit Specified value Allowable limit 0.55 ~ 0.70 mm ( ~ in.) 1.25 mm ( in.) 0.25 ~ 0.40 mm ( ~ in.) 1.25 mm ( in.) T46W2D0A If the gap is still over the allowable limit with even new ring, measure the diameter of bore (see page 297) Clean the ring and ring grooves, and install each ring in its groove. Measure the clearance between the ring and the ring groove with a feeler gauge. If the clearance exceeds the allowable limit, replace the piston ring. If the clearance still exceeds the allowable limit after removing the ring with new one, replace the piston. STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION Piston ring clearance 2nd ring Oil ring Specified value Allowable limit Specified value Allowable limit 0.04 ~ 0.08 mm ( ~ in.) 0.15 mm ( in.) 0.02 ~ 0.06 mm ( ~ in.) 0.15 mm ( in.) T46W2D1A DH14W00 Jul

250 SERVICING DK35/40(C)/45(C)SE SAFETY FIRST 7.1 Crankshaft and flywheel Removal TRANSMISSION HST FRONT AXLE CLUTCH REAR AXLE 1. T46W2D2A Install the stopper on the flywheel and unscrew the bolts. Notes The crankshaft wrench or the ring gear can be used as a flywheel stopper. T46W2D4A 3. Remove all main bearing case bolts (1). 4. Remove the crankshaft by tapping it to the flywheel direction with a rubber hammer. CAUTION Securely hold the main bearing so that it does not strike the cylinder block or crankshaft when removing it. BRAKE Installation STEERING HYDRAULIC 3 up 1 T46W2D5A ELECTRIC CABIN A/C & HEATER 2. 2 T46W2D3A Loosen the inner bolts (2) first and then outer bolts (3) on the main bearing cover (1). 1. Install the main bearing case with its "Flywheel" mark facing flywheel side. Apply the oil on the metal bearing. Important If the main bearing case is installed backwards, its oil delivery hole will not be aligned with the hole of the cylinder block which can cause engine stall. 292 DH14W00 Jul. 2008

251 DK35/40(C)/45(C)SE SERVICING 2. The number of lines (1) on the edge indicates the main bearing case number. SAFETY FIRST The first bearing from the crankcase 1 line The second bearing from the crankcase 2 lines The third bearing from the crankcase No line. different in shape for 3cylinder type The fourth bearing from the crankcase No line, different in shape * For some models, the number is stamped on the edge T46W2D7A Align the main bearing mounting bolt hole with the hole on the cylinder block. Apply the sufficient amount of oil to the mounting bolt and tighten it with a hand completely. Tighten them with the torque wrench. TRANSMISSION CLUTCH Main bearing mounting bolt torque (A, B series) ~ 73.5 Nm 7.0 ~ 7.5 kgfm 50.6 ~ 54.2 lbft HST T46W2D6A REAR AXLE 3. When installing the main bearing case cover bolts, apply the oil on them and tighten them with a hand until they are not screwed in. Then, tighten them with the torque wrench in several steps. Main bearing cover bolt (A, B series) ~ 50.9 Nm 4.7 ~ 5.2 kgfm 33.9 ~ 37.6 lbft FRONT AXLE BRAKE 4. Insert the crankshaft with the main bearing cases assembled into the cylinder block. Apply the sufficient amount of oil on the main bearing. 7. T46W4J2A Assemble the main bearing case cover (1) with the oil seal (2). * Be sure to assemble the bearing cover gasket (3) and bearing case cover gasket (4). HYDRAULIC STEERING A/C & HEATER CABIN ELECTRIC DH14W00 Jul

252 SERVICING DK35/40(C)/45(C)SE SAFETY FIRST 9. Crankshaft and flywheel have their own reference hole on the mating surface. When installing the crankshaft and the flywheel, align the holes. Notes A/C & HEATER TRANSMISSION HST STEERING FRONT AXLE BRAKE REAR AXLE CABIN ELECTRIC HYDRAULIC CLUTCH 3 up 2 T46W2D3A 8. Notes When installing the main bearing case cover, the "UP" mark on it should be at the highest position so that its holes are aligned with the holes of the cylinder block. Tighten the outer bolts (3) first, then tighten the inner bolts (2). M ~ 27.4 Nm 2.4 ~ 2.8 kgfm 17.4 ~ 20.2 lbft T46W2F8A If the flywheel is turned from the original position and then installed, the bolts cannot be tightened. Align the installation reference holes (arrow in the figure) before installation. 294 DH14W00 Jul. 2008

253 DK35/40(C)/45(C)SE SERVICING 10. When installing the flywheel bolts, apply the oil on them and tighten them with a hand until they are handtightened. Then, tighten them with a torque wrench to the specified torque. Tighten the bolts diagonally in several steps. SAFETY FIRST Notes A/C & HEATER HST REAR AXLE BRAKE CABIN ELECTRIC HYDRAULIC STEERING FRONT AXLE TRANSMISSION CLUTCH T46W2D2A It is recommended to insert a long bolt (M8, pich 1.25) into the flywheel for easier installation. Flywheel bolt Tightening torque ~ Nm 10.0 ~ 11.0 kgfm 72.3 ~ 79.6 lbft DH14W00 Jul

254 SERVICING DK35/40(C)/45(C)SE SAFETY FIRST 7.20 METAL journal bearings A/C & HEATER HST 2 Mating notch 홈 3 CLUTCH 1 TRANSMISSION REAR AXLE 6 20 BRAKE CABIN ELECTRIC HYDRAULIC STEERING FRONT AXLE The crank pin metal bearing (1) should be aligned with the mating notch of the connecting rod (2) or connecting rod cap (3) before installation. Apply sufficient amount of oil to the bearing before and after the installation. The crankshaft metal bearing 2 (4) should be aligned with the notch of the main bearing case and main bearing case cap (6). Apply sufficient amount of oil to the bearing before and after the installation. The side metal 1 (19) and side metal 2 (20) can only be installed to the main bearing case cover assembly (21), which is right next to the flywheel. Apply sufficient amount of oil before and after the installation. Important Notes T46W2F7A The oil groove of the side metal 1, 2 should face outward. In other words, the oil groove should be seen after the side metal is installed to the main bearing case. If it is installed backwards, it can cause engine stall. The protrusion part of the side metal 2 (20) should face doward. Install the bearing case and cap to the crankshaft immediately after installing the crankshaft bearing and side metal to prevent the misplace of the bearing. 296 DH14W00 Jul. 2008

255 DK35/40(C)/45(C)SE SERVICING 7.21 FLYwheel and crankshaft check Flywheel deflection and crankshaft end play Crankshaft journal and bearing 1 Oil clearance SAFETY FIRST Set a dial indicator with its tip on the rear friction face of the flywheel near the edge. Turn the flywheel to measure the deflection or the uneven wear. If the measured value exceeds the allowable limit, remove the flywheel and check the mating faces of the crankshaft and flywheel. If it is scored or worn excessively, regrind the surface of the flywheel or replace the flywheel. Measure the end play while moving the crankshaft with flywheel back and forth to each end. If the end play exceeds the allowable limit, replace the side bearing. Deflection End play Allowable limit Specified value Allowable limit 0.05 mm ( in.) 0.15 ~ 0.31 mm ( ~ in.) 0.5 mm (0.020 in.) Crankshaft deflection Eccentricity Allowable limit 0.08 mm ( in.) T46W2D8A T46W2D9A Place the crankshaft on V blocks with its journals supported and set a dial indicator with its tip on the intermediate journal. Measure the eccentricity (half of the measured value) while turning the crankshaft on the V blocks. If the eccentricity exceeds the allowable limit, replace the crankshaft Oil clearance Journal O.D. Bearing 1 I.D. Specified value Allowable limit Specified value Specified value ~ mm ( ~ in.) 0.20 mm ( in.) T46W2E0A Measure the I.D. of the crankshaft bearing 1 with an inside micrometer. Measure the O.D. of the crankshaft journal with an outside micrometer. If the clearance exceeds the allowable limit, replace the crankshaft metal bearing. A series engine (4A200, 4A220) B series engine (3B183, 4B243) Oil clearance Journal O.D. Bearing 1 I.D. Specified value Allowable limit Specified value Specified value ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm (0.002 ~ in.) 0.20 mm ( in.) ~ mm ( ~ in.) ~ mm (2.362 ~ in.) A/C & HEATER CABIN ELECTRIC HYDRAULIC STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH DH14W00 Jul

256 SERVICING DK35/40(C)/45(C)SE SAFETY FIRST Crankshaft metal bearing 1 replacement Crankshaft journal and bearing 2 Oil clearance A/C & HEATER CLUTCH STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION (1) Seam T46W2E1A Press out the crankshaft metal bearing 1 (1) using the replacing tool. Clean a new crankshaft metal bearing 1 (1) and bore and apply the engine oil on them. Press in a new bearing 1 (1) using a pressingin tool while checking the seam of the metal bearing (1) is facing the exhaust manifold. Press in the metal bearing for 4.2 ~ 4.5 mm (A) deeper than the cylinder block Place a plastigauge in lengthwise on the center of the journal. Install the bearing cap, tighten the bolts to the specified torque once and remove the cap again. Measure the amount of the flatness with a scale and get the oil clearance. If the clearance exceeds the allowable limit, replace the bearing. A series engine (4A200, 4A220) Oil clearance Journal O.D. Bearing 1 I.D. Specified value Allowable limit Specified value Specified value B series engine (3B183, 4B243) ~ mm ( ~ in.) 0.20 mm ( in.) T46W2E2A ~ mm ( ~ in.) ~ mm ( ~ in.) HYDRAULIC ELECTRIC Oil clearance Journal O.D. Specified value Allowable limit CABIN Specified value ~ mm (0.002 ~ in.) 0.20 mm ( in.) ~ mm ( ~ in.) Bearing 2 I.D. Specified value ~ mm (2.361 ~ in.) 298 DH14W00 Jul. 2008

257 DK35/40(C)/45(C)SE SERVICING Crank pin and connecting rod bearing 2 Oil clearance 7.22 CYLinder bore check Check the worn condition of the honing groove on the bore. Check the bore for scuffing or scoring. CLUTCH SAFETY FIRST Place a plastigauge in lengthwise on the center of the crankpin. Install the connecting rod, tighten the bolts to the specified torque once and remove the cap again. Measure the amount of the flatness with the scale and get the oil clearance. If the clearance exceeds the allowable limit, replace the bearing. A series engine (4A200, 4A220) Oil clearance Crankshaft pin O.D. Crankshaft pin Bearing I.D. Specified value Allowable limit Specified value Specified value B series engine (3B183, 4B243) Oil clearance Crankshaft pin O.D. Crankshaft pin Bearing I.D. Specified value Allowable limit Specified value Specified value ~ mm ( ~ in.) 0.20 mm ( in.) T46W2E3A ~ mm ( ~ in.) ~ mm ( ~ in.) ~ mm (0.002 ~ in.) 0.20 mm ( in.) ~ mm ( ~ in.) ~ mm ( ~ in.) (A) Axial direction 1,2,3 Measuring Points 3. 4A200 4A220 3B183 4B243 (B) Transverse direction ~ mm ( ~ in.) ~ mm (3.425 ~ in.) T46W2E4A T46W2E5A A/C & HEATER CABIN ELECTRIC HYDRAULIC STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION Measure the cylinder liner I.D. at six locations as shown in the figure to find the largest worn area. DH14W00 Jul

258 SERVICING DK35/40(C)/45(C)SE SAFETY FIRST 7.23 Oil pump, oil filter, relief valve and oil strainer relief valve of engine oil Oil pump check Clearance between rotor and lobe clearance of oil pump CLUTCH TRANSMISSION (1) Relief valve ball (3) Relief valve spring (2) Relief valve seat T46W2E6B T46W2E8A HST Remove the oil pump. Drain the engine oil and remove the oil filter to check it. REAR AXLE Check the relief valve for dirt. Check the seat (2) and ball (1) for damage. If they are damaged, replace them. Check the free length of the spring (3). BRAKE 6. If it is less than the allowable limit, replace the spring. T46W2E9A FRONT AXLE Spring free length Specified value Allowable limit 35 mm (1.38 in.) 30 mm (1.18 in.) Measure the clearance between the outer rotor and inner rotor with a feeler gauge. Measure the clearance between the outer rotor and the housing with a feeler gauge. HYDRAULIC STEERING CAUTION Install the relief valve cover with the mark ( ) faces upside. 3. If the clearance exceeds the allowable limit, replace the pump. Clearance between outer rotor and inner rotor Specified value Allowable limit 0.10 ~ 0.16 mm ( ~ in.) 0.20 mm ( in.) ELECTRIC Clearance between outer rotor and housing Specified value Allowable limit 0.11 ~ 0.19 mm ( ~ in.) 0.25 mm ( in.) CABIN A/C & HEATER Tightening torque of relief cover bolt ~ 36.3 Nm 3.3 ~ 3.7 kgfm 23.9 ~ 36.8 lbft 2100 DH14W00 Jul. 2008

259 DK35/40(C)/45(C)SE SERVICING End clearance of rotor in oil pump A/C & HEATER CABIN SAFETY FIRST CLUTCH TRANSMISSION HST REAR AXLE ELECTRIC HYDRAULIC STEERING FRONT AXLE BRAKE T46W2F0A Place a plastigauge on the rotor and assemble the pump. Disassemble the pump and measure the amount of the flatness with a scale to get the clearance. If the clearance exceeds the allowable limit, replace the pump. End clearance Specified value Allowable limit ~ mm ( ~ in.) 0.20 mm ( in.) DH14W00 Jul

260 SERVICING DK35/40(C)/45(C)SE SAFETY FIRST 7.24 Thermostat 7.25 water pump CLUTCH T46W2F1A (1) Thermostat (2) Thermostat cover S76W2P9B TRANSMISSION Removal 1. Remove the thermostat cover (2). 2. Pull out the thermostat (1). HST REAR AXLE BRAKE Installation Apply the liquid gasket (Three Bond 1215 or equivalent) on the gasket. (The paper gasket can be used for some models.) Opening temperature of thermostat valve (1) Water pump flange (2) Water pump bearing (3) Water pump body Notes (4) Mechanical seal (5) Impeller T46W2F4A A/C & HEATER CABIN ELECTRIC HYDRAULIC STEERING FRONT AXLE Suspend the thermostat in the water by a string with its end inserted between valve and seat. While heating the water slowly, read the temperatures when the valve starts to open and when the valve opens for approx. 8 mm. If the measured values are not within the specified value, replace the thermostat. Opening temperature Specified value T46W2F2A Initial opening temperature: 71 ± 1.5 C (160 ± 3 F) Below 85 C (185 F) at opening by 8 mm (0.315 in.) If the coolant is leaked from the hole indicated by the arrow in the figure, it means that the mechanical seal is damaged. Removal 1. Remove the fan and fan pulley. 2. Remove the water pump body from the gear case cover. 3. Remove the water pump flange (1). 4. Remove the impeller and water pump body (3). 5. Remove the impeller from the water pump shaft. 6. Remove the mechanical seal (4). Installation Replace the mechanical seal (4) with new one. CAUTION The components of the water pump is firmly assembled together and they cannot be easily disassembled or assembled without a special equipement. Therefore, it is recommended to replace the whole water pump assembly DH14W00 Jul. 2008