Branson 2000 series Service Manual
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Branson 2000 series Service Manual

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Service Manual
(00 series - Chassis)
KUKJE MACHINERY CO., LTD

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Summary of Contents for Branson 2000 series

  • Page 1 Service Manual (00 series - Chassis) KUKJE MACHINERY CO., LTD...

  • Page 2: Table Of Contents

    GENERAL CONTENTS 1. (GENERAL) 1. ABOUT WARRANTY ………………………………………………………………………………………………… 2. OVERVIEW OF THE TRACTOR <1> OVERVIEW ……………………………………………………………………………………………..... <2> OPERATION PART 1) MANUAL TRANSMISSION …………………………………………………………………….... 2) HST TRANSMISSION …………………………………………………………………………………….. 3. LOCATION OF SAFETY DECALS …………………………………………………………………………………. 4. SPECIFICATIONS <1> SPECIFICATION ……………………………………………………………………………………….... <2> TRAVELING SPEED …………………………………………………………………………………..... 5.

  • Page 3: About Warranty

    GENERAL 1. ABOUT WARRANTY *. WARRANTY You will need the “Warranty Registration” when your tractor requires warranty service. Read it and keep in a safe place. < Information you will need when contacting the dealer for service > Type of model and machine s/n number. In case of engine, the engine s/n number.

  • Page 4: Overview Of The Tractor

    GENERAL 2. OVERVIEW OF THE TRACTOR <1> OVERVIEW ROPS Steering Wheel Fuel Tank Direction Lamp Hood Seat Head Lamp Rear Tire Front Tire Combination Lamp Drawbar Lower Link KUKJE MACHINERY CO., LTD.

  • Page 5: 2> Operation Part

    GENERAL 2. OVERVIEW OF THE TRACTOR <2> OPERATION PART 1) Manual transmission Instrument Panel Emergency Stop S/W Steering Wheel Accelerator Lever Combination S/W Key Switch Side Lamp S/W Brake Pedal Clutch Pedal Emergency Lamp S/W Main Shift Lever Range Shift Lever Accelerator Pedal Position Lever PTO Shift Lever...

  • Page 6: Hst Transmission

    GENERAL 2. OVERVIEW OF THE TRACTOR 2) HST transmission Instrument Panel Emergency Stop S/W Cruise S/W Steering Wheel Combination S/W Accelerator Lever Brake Pedal Forward Pedal Clutch Pedal Key Switch Side Lamp S/W Emergency Lamp S/W Parking Lever Backward Pedal Range Shift Lever MFWD Lever Differential Lock Pedal...

  • Page 7: Location Of Safety Decals

    GENERAL 3. LOCATION OF SAFETY DECALS LOCATION OF SAFETY DECALS Safety decals are provided to ensure safe operation. Keep the safety decals clean at all times and protect them from damage. In case of loss or damage, replace with a new decal. 12.
  • Page 8 GENERAL 3. LOCATION OF SAFETY DECALS LOCATION OF SAFETY DECALS Safety decals are provided to ensure safe operation. Keep the safety decals clean at all times and protect them from damage. In case of loss or damage, replace with a new decal. 3.

  • Page 9: Specifications

    GENERAL TZE5130000B4 LABEL, MUFFLER TA0016517A LABEL, SAFETY LABEL, START NTE5270000A4 CAUTION TZE5170000B4 LABEL, ROPS WARNING 4. SPECIFICATIONS <1> SPECIFICATION Manual transmission HST transmission Items Unit 2100 2400 2800 2400h 2800h Drive System 4 Wheel Drive Main Dimensions Overall Length 106 (2692mm) Overall Width 44.3 (1124mm) Overall Height...
  • Page 10 GENERAL Type of Air Cleaner Dry, element Fuel Tank Capacity 6.08 (23L) 4. SPECIFICATION Manual transmission HST transmission Items Unit 2100 2400 2800 2400h 2800h Battery Volt Steering Hydrostatic Clutch Dry, single stage Brake Wet disc Transmission Gear Shifting 6F x 2R Hydrostatic, high low gear shift (F x R) Tires (Agricultural)

  • Page 11: 2> Traveling Speed

    GENERAL 4. SPECIFICATIONS <2> TRAVELING SPEED SHIFTING MODEL LEVEL Manual transmission HST transmission MAIN RANGE 2100, 2400, 2800 2400h,2800h 0.7(1.1Km/h) 3.9(6.2Km/h) 1.1(1.8Km/h) 2.1(3.3Km/h) Forward 2.7(4.4Km/h) 9.6(15.5Km/h) 4.8(7.8Km/h) 8.8(14.1Km/h) 0.8(1.3Km/h) 2.3(3.7Km/h) Reverse 3.4(5.5Km/h) 5.8(9.3Km/h) ◎ Rated Engine rpm: 2600 rpm Tire: agri 9.5-16 (423mm) ※...

  • Page 12: Periodic Maintenance Schedule

    GENERAL 5. PERIODIC MAINTENANCE SCHEDULE < SCHEDULE > Running hours Check items Engine oil Transmission fluid ○ ○ ○ ○ ○ ○ ○ ○ ○ Front axle fluid ○ ○ ○ ○ ○ ○ ○ ○ ○ Engine oil filter Transmission fluid filter Radiator cleaning At the time the coolant is replaced...

  • Page 13: Oil, Grease, Anti-Freeze, Fuel And Coolant Chart

    Anti - Freeze International genuine product No.2 of KSM 2142,permanent type Transmission, Steering, -Texaco TDH oil, 1893 Branson origin oil Front axle fluid -Chevron Tractor HYD Fluid Note) Use winter diesel when temperature is below 50’F. <2> FUEL, OIL AND COOLANT...

  • Page 14: Check And Maintenance

    GENERAL Front axle oil 0.79 gal (3.0L) 0.79 gal (3.0L) 7. CHECK AND MAINTENANCE ▶ Be sure to check and service the tractor on a flat place with the engine shut off, the parking brake on and chock the wheels. <1>...

  • Page 15: 2> Check Points Of Initial 50 Hours

    GENERAL < Checking > ▶ Check areas where previous trouble was experienced. ▶ Walk around the tractor. 1. Check the tire pressure, and check for wear and damage. 2. Check for oil and water leaks. 3. Check the engine oil level. 4.
  • Page 16 GENERAL < Changing engine oil > ▶ Be sure to stop the engine. ▶ Allow engine to cool down sufficiently, oil can be hot and can burn. 1. Place an oil pan underneath the engine. 2. To drain the used oil, remove the drain plug(1) at the bottom of the engine and drain the oil completely.
  • Page 17 Then, replenish the engine oil up to the specified level. ◈ Important To prevent serious damage to the engine, replacement element must be highly efficient. Use only a Branson genuine filter. *. PART NAME 1) Engine oil filter 7. DISASSEMBLING AND SERVICING KUKJE MACHINERY CO., LTD.
  • Page 18 GENERAL < Changing transmission fluid > ▶ Be sure to stop the engine before checking and changing the transmission fluid. 1. Place an oil pan under the tractor. 2. Remove the drain plugs(1) at the bottom of the rear axle cases, transmission case and front transmission case.
  • Page 19 *. PART NAME To prevent serious damage to the hydraulic 1) Hydraulic oil filter (HST) 2) Hydraulic oil filter system. Use only a genuine Branson filter. < Cleaning transmission oil strainer (HST) > 1. Clean the strainer with nonflammable solvent. ▶ NOTE...

  • Page 20: 3> Check Points Of Every 50 Hours

    GENERAL < Checking clutch pedal free travel > ▶ When checking, park the tractor on flat ground, apply the parking brake, stop the engine and remove the key. 1. Slightly depress the clutch pedal and measure stroke “A” at top of stopper bolt(1). 2.
  • Page 21 GENERAL < Checking engine start system > ▶ Do not allow anyone near the tractor while testing. ▶ If the tractor does not pass the test do not operate the tractor. ▷ Preparation before testing 1. Sit on operator’s seat. 2.
  • Page 22 5. Stand up. (Do not get off the machine.) 6. The engine must shut off after approximately 1 second. 7. If it does not stop, consult your local Branson Dealer for this service. ▶ NOTE 1) If the engine cranks during nay of these tests, *.

  • Page 23: 4> Check Points Of Every 100 Hours

    GENERAL < Checking wheel mounting screws and nuts tightening torque > ▶ Never operate tractor with a loose rim, wheel, or axle. ▶ Any time bolts and nuts are loosened, retighten to specified torque. ▶ Check all bolts and nuts frequently and keep them tight.
  • Page 24 GENERAL ▶ Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely with water immediately and get medical attention. ▶ Wear eye protection and rubber gloves when working around battery. 1. Mishandling the battery shortens the service life and adds to maintenance costs.
  • Page 25 GENERAL 1. Make sure each electrolyte level is to the bottom of vent wells, if necessary add distilled water in a well-ventilated area. 2. The water in the electrolyte evaporates during recharging. Liquid shortage damages the battery. Excessive liquid spills over and damages the tractor body.
  • Page 26 GENERAL < Cleaning air cleaner element > 1. Remove the air cleaner cover(1) and primary element(2). 2. Cleaning the primary element : ▷ When dry dust adheres to the element, blow compressed air from the inside turning the element. Pressure of compressed air must be under 205kPa (2.1 kgf/㎠, 30 psi).
  • Page 27 GENERAL < Cleaning fuel filter > This job should not be done in the field, but in a clean place. 1. Loosen and remove the fuel filter bowl(2), and rinse the inside with kerosene. 2. Take out the filter element(4) and dip it in the kerosene to rinse.
  • Page 28 GENERAL < Adjusting brake pedal free travel > ▶ Stop the engine and chock the wheels before checking the brake pedal. ▶ The difference between the right and left pedal free travel must be less than 4.0 mm (0.16 in.). 1.

  • Page 29: 5> Check Points Of Every 200 Hours

    GENERAL < Checking fuel line > ▶ Stop the engine when attempting the check and change prescribed below. ▶ Remember to check the fuel line periodically. The fuel line is subject to wear and aging, fuel may leak out onto the running engine, causing a fire.

  • Page 30: 6> Check Points Of Every 300 Hours

    GENERAL < Replacing engine oil filter cartridge > -. Reference the page 15. < Checking intake air line > 1. Check to see that hoses and hose clamps are tight and not damaged. 2. If hoses and clamps are found worn or damaged, replace or repair them at once.

  • Page 31: 7> Check Points Of Every 400 Hours

    After ten minutes, check the oil level again, add 1) Filling plug with dipstick 2) Drain plug oil to proper level. A) Oil level is acceptable within this range Use Branson genuine fluid. 2100 3.0 L Front axle case 2400(h) 3.17 U.S.qts...

  • Page 32: 8> Check Points Of Every 800 Hours

    GENERAL < Front axle rocking force > 1. Jack up the front side of tractor. 2. Set a spring balance to the front axle flange. 3. Measure the front axle rocking force. 4. If the measurement is not within the factory specifications, adjust by the adjusting screw(1).
  • Page 33 GENERAL < Replacing radiator hose (Water pipes) > 1. Replace the hoses and clamps. -. Reference the page 28. < Replacing fuel hose > 1. Replace the fuel hoses and clamps. -. Reference the page 27. < Replacing intake air line > 1.
  • Page 34 GENERAL ◈ Important Do not start the engine without coolant. Use clean, fresh water and anti-freeze to fill the radiator. When the anti-freeze is mixed with water, the anti-freeze mixing ratio must be less than 50%. Securely tighten radiator cap. If the cap is loosen or improperly fitted, water may leak out and the engine could overheat.

  • Page 35: 13> Others

    GENERAL 4. Mix the anti-freeze with water, and then fill in to the radiator. Vol % Freezing point Boiling point Anti-freeze ℃ ℉ ℃ ℉ * At 760 mmHg pressure (atmospheric). A higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system.
  • Page 36 GENERAL < Bleeding fuel system > Air must removed : 1. When the fuel filter or lines are removed. 2. When tank is completely empty. 3. After the tractor has not been used for a long period of time. Bleeding procedure is as follows : 1.
  • Page 37 CLUTCH CONTENTS 2. (CLUTCH) 1. LINKAGE MECHANISM …………………………………………………………………………………………….. 2. SERVICING SPECIFICATIONS …………………………………………………………………………………….. 3. TIGHTENING TORQUES ……………………………………………………………………………………………. 4. CHECKING, DISASSEMBLING AND SERVICING <1> CHECKING AND ADJUSTING ……………………………………………………………………………. <2> PREPARATION 1) SEPARATING ENGINE FROM CLUTCH HOUSING ……………………………………………… <3> DISASSEMBLING AND ASSEMBLING ………………………………………………………………… <4>...

  • Page 38: Linkage Mechanism

    CLUTCH 1. LINKAGE MECHANISM 1) Engine Flywheel 2) Clutch Disc 3) Clutch Cover 4) Pressure Plate 5) Diaphragm Spring 6) Clutch Rod 7) Clutch Release Fork 8) Clutch Adjusting Bolt 9) Clutch Pedal 10) Clutch Release Hub 11) Clutch Release Bearing 12) Clutch Shaft 13) Pressure Plate Assembly Engine torque is transmitted to the pressure plate assembly(13) via the flywheel(1) which is connected to...

  • Page 39: Servicing Specifications

    CLUTCH 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit (Reference) 20.0 to 30.0 mm Clutch Pedal On Clutch Pedal 0.8 to 1.2 in. Clearance “A” 7.0 to 9.0 mm Clutch pedal stopper bolt between Stopper Bolt 0.28 to 0.35 in. and Clutch Housing Clearance “B”...

  • Page 40: Tightening Torques

    CLUTCH 3. TIGHTENING TORQUES Tightening torque of screws, bolts and nuts on the table below are especially specified. Item N·m kgf·m ft-lbs Steering wheel mounting nut 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2 Delivery pipe nut for HST 34.3 to 39.2 3.5 to 4.0 25 to 28...

  • Page 41: Checking, Disassembling And Servicing

    CLUTCH 4. CHECKING, DISASSEMBLEING AND SERVICING <1> CHECKING AND ADJUSTING < Checking clutch pedal free travel > When checking, park the tractor on flat ground, apply the parking brake, stop the engine and remove the key. 1. After adjusting it, measure total stroke “A” between stopper bolt(1) and clutch housing(4).

  • Page 42: 2> Preparation

    CLUTCH 4. CHECKING, DISASSEMBLEING AND SERVICING <2> PREPARATION 1) Separating Engine From Clutch Housing. < Draining transmission fluid > 1. Place and oil pan underneath the transmission case, and remove the drain plugs(1). 2. Drain the transmission fluid. 3. Reinstall the drain plug. ▷...
  • Page 43 CLUTCH 4. CHECKING, DISASSEMBLING AND SERVICING < Hood and battery cord > Open the hood(1). Disconnect the battery grounding cord(2). Disconnect the head light connectors and remove the hood(1). ▶ NOTE 1) When disconnecting battery cords, disconnect the grounding cord first. When connecting the battery cords, connect the positive cord first.
  • Page 44 CLUTCH 4. CHECKING, DISASSEMBLING AND SERVICING < Fuel tank > 1. Disconnect the fuel house(1) at the fuel filter side, then drain fuel completely. 2. Disconnect the hazard unit, controller, starter relay and regulator connectors and remove the lead wire for fuel gauge. 3.
  • Page 45 CLUTCH 4. CHECKING, DISASSEMBLEING AND SERVICING < Universal joint and bearing holder > 1. Loosen the clamp and slide the universal joint cover(1) to the rear. 2. Remove the bearing holder(4) with the propeller shaft and universal joint. 3. Tap out the spring pins(3) and then slide the universal joint(2) to the rear.
  • Page 46 CLUTCH 4. CHECKING, DISASSEMBLING AND SERVICING < Separating the engine from clutch housing > (5) (4) 1. Disconnect the connector for the engine stop solenoid(4) 2. Disconnect the three point hitch delivery pipe(3), suction house(2) and PST delivery pipe(1). 3. Disconnect the glow plug lead wire and thermo sensor lead wire.

  • Page 47: 3> Disassembling And Assembling

    CLUTCH 4. CHECKING, DISASSEMBLEING AND SERVICING <3> DISASSEMBLING AND ASSEMBLING < Separating the clutch assembly > 1. Remove clutch assembly(2) from flywheel. ▷ Reassembling Direct the shorter end of the clutch disc boss toward the flywheel. Apply molybdenum disulphide to the spline of clutch disc boss.

  • Page 48: 4>Servicing

    CLUTCH 4. CHECKING, DISASSEMBLEING AND SERVICING <4>SERVICING < Backlash between clutch disc and clutch shaft > 1. Mount the clutch disc onto the propeller shaft. 2. Hold the propeller shaft so that it does not rotate. 3. Slightly move disc measure displacement around disc edge.
  • Page 49 CLUTCH 4. CHECKING, DISASSEMBLEING AND SERVICING < Checking pressure plate and diaphragm > 1. Check the pressure plate and if it is scratched on its surface, correct with sandpaper or replace 2. Check the diaphragm for crack and scratches. If defects are found, replace it.
  • Page 50 FRONT AXLE CONTENTS 3. (FRONT AXLE) 1. STRUCTURE ……………………………………………………………………………………………………………. 2. SERVICING SPECIFICATIONS …………………………………………………………………………………….. 3. TIGHTENING TORQUES ……………………………………………………………………………………………. 4. CHECKING, DISASSEMBLING AND SERVICING <1> CHECKING AND ADJUSTING ……………………………………………………………………………. <2> DISASSEMBLING AND ASSEMBLING 1) SEPARATING FRONT AXLE …………………………………………………………………………….. 2) DISASSEMBLING FRONT AXLE ………………………………………………………………………. <3>...

  • Page 51: Structure

    FRONT AXLE 1. STRUCTURE (20) (21) 1) Axle 2) Axle Flange 3) Bevel Gear 4) Bevel Gear 5) Bevel Gear Case 6) Bevel Gear 7) Differential Yoke Shaft, LH 8) Front Axle Case 9) Differential Gear Assembly 10) Differential Pinion Gear 11) Spiral Bevel Gear 12) Collar 13) Front Axle Bracket, Front...

  • Page 52: Servicing Specifications

    FRONT AXLE 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit 0.0 to 8.0 mm Front wheel alignment Toe-in 0.0 to 0.315 in. 49.0 to 98.1 N Front axle Rocking force 5.0 to 10.0 kgf 11.0 to 22.1 lbs 0.032 to 0.068 mm 0.2 mm Clearance 0.00126 to 0.00268 in.

  • Page 53: Tightening Torques

    FRONT AXLE 3. TIGHTENING TORQUES Item N·m kgf·m ft-lbs Drag link slotted nut 17.7 to 34.5 1.8 to 3.5 13.0 to 25.3 Front wheel bracket mounting screw 77.5 to 90.1 7.9 to 9.2 57.1 to 66.5 Front axle bracket mounting screw 124.0 to 147.0 12.6 to 15.0 91.0 to 108.0...

  • Page 54: Checking, Disassembling And Servicing

    FRONT AXLE 4. CHECKING, DISASSEMBLING AND SERVICING <1> CHECKING AND ADJUSTING < Measuring toe-in > 1. Park the tractor on a flat surface. 2. Inflate the tires to the specified pressure. 3. Turn steering wheel so front wheels are in the straight ahead position.

  • Page 55: 2> Disassembling And Assembling

    FRONT AXLE 4. CHECKING, DISASSEMBLING AND SERVICING <2> DISASSEMBLING AND ASSEMBLING 1) Separating Front Axle < Draining front axle case oil > 1. Place the oil pan underneath the front axle case. 2. Remove the both the right and left hand side drain plugs(2) and filling plug(1) to drain the oil.
  • Page 56 FRONT AXLE 4. CHECKING, DISASSEMBLING AND SERVICING < Front axle assembly > 1. Lift up the front side of tractor and place the disassembling stand under the front axle frame. 2. Remove the front wheels. 3. Place the disassembling stand under the front axle.

  • Page 57: Disassembling Front Axle

    FRONT AXLE 4. CHECKING, DISASSEMBLING AND SERVICING 2) Disassembling Front Axle < Tie-rod and axle bracket > 1. Remove the slotted nut and remove the tie- rod(3). 2. Remove the front axle brackets(1),(2). ▷ Reassembling Apply grease to the thrust collars(4),(9), o- ring(6),(7) and oil seal(10).
  • Page 58 FRONT AXLE 4. CHECKING, DISASSEMBLING AND SERVICING < Front gear case > 1. Remove the knuckle arm(Left side only). 2. Remove the axle flange(2). 3. Remove the external snap ring(3). 4. Remove the bevel gear case(4) from front gear case(1). 5.
  • Page 59 FRONT AXLE 4. CHECKING, DISASSEMBLING AND SERVICING < Bevel gear case and front gear case > 1. Remove the internal snap ring(1). 2. Take bevel gears(4),(5) with ball bearings(3),(6) and shims(2). ▷ Reassembling Install the shims(2) to their original position. ▷...
  • Page 60 FRONT AXLE 4. CHECKING, DISASSEMBLING AND SERVICING < Spiral bevel pinion shaft and differential gear assembly > 1. Remove the internal snap ring(1). 2. Tap put the spiral bevel pinion shaft(2) by the brass rod and hammer. 3. Take out the differential gear assembly(3) with differential yoke shafts, from right side of front axle case(4).

  • Page 61: 3> Servicing

    FRONT AXLE 4. CHECKING, DISASSEMBLING AND SERVICING < Differential gear > 1. Tap out the spring pins(5) and remove the external snap ring(2), and then pull out both of the differential yoke shafts(1),(9). 2. Remove the differential side gears(4). 3. Remove the differential pinions(6). (11) (10) 4.
  • Page 62 FRONT AXLE 4. CHECKING, DISASSEMBLING AND SERVICING < Clearance between differential case differential pinion > 1. Measure the differential pinion boss O.D. with an outside micrometer. 2. Measure the differential case bore I.D. with a cylinder gauge, calculate the clearance. 3.
  • Page 63 FRONT AXLE 4. CHECKING, DISASSEMBLING AND SERVICING < Turning torque of spiral bevel pinion shaft > 1. Install the spiral bevel pinion shaft assembly only to the front axle case. 2. Measure the turning torque of the spiral bevel pinion shaft. 3.
  • Page 64 FRONT AXLE 4. CHECKING, DISASSEMBLING AND SERVICING < Clearance between front axle case bosses and bracket bushing > 1. Measure the front axle case bosses O.D. with an outside micrometer. 2. Measure the bracket bushing I.D. with a cylinder gauge, and calculate the clearance. 3.
  • Page 65 TRANSMISSION CONTENTS 4. (TRANSMISSION) 1. POWER TRAIN FOR TRAVELING SYSTEM <1> MAIN GEAR SHAFT SECTION (MANUAL TRANSMISSION TYPE) …………………………... <2> HI-LO GEAR SHIFT SECTION …………………………………………………………………………….. <3> FRONT WHEEL DRIVE SECTION ………………………………………………………………………… 2. POWER TRAIN FOR PTO GEAR <1> REAR PTO SHIFT SECTION 1) MANUAL TRANSMISSION TYPE ……………………………………………………………………….

  • Page 66: Power Train For Traveling System

    TRANSMISSION 1. POWER TRAIN FOR TRAVELING SYSTEM <1> MAIN GEAR SHAFT SECTION (MANUAL TRANSMISSION TYPE) 1) Gear shaft 2) Gear reverse 3) Gear 4) Gear shaft A : Front cover B : Transmission case 1) Ball joint shaft 2) Gear shaft 3) Gear shaft 4) Gear 5) Gear shaft...

  • Page 67: 2> Hi-Lo Gear Shift Section

    TRANSMISSION 1. POWER TRAIN FOR TRAVELING SYSTEM <2> HI-LO GEAR SHIFT SECTION 1) Gear shaft 2) 19T gear 3) 13T, 32T gear 4) Counter shaft 5) Front cover A : Front cover B : Transmission case C : Diff. gear case <3>...

  • Page 68: Power Train For Pto Gear

    TRANSMISSION 2. POWER TRAIN FOR PTO GEAR <1> REAR PTO SHIFT SECTION 1) Manual Transmission Type 1) Gear shaft 2) Gear 3) Cam, one way clutch 4) Gear shaft 5) Gear A : Rear cover ① : Low (540 rpm) ②...

  • Page 69: Hst Type

    TRANSMISSION 2. POWER TRAIN FOR PTO GEAR 2) HST Type 1) HST pump shaft 2) Gear shaft 3) Shaft 4) Coupling 5) Gear shaft 6) Shaft PTO ① : Low (540 rpm) ② : High (960 / 2500 rpm) KUKJE MACHINERY CO., LTD.

  • Page 70: Servicing Specifications

    TRANSMISSION 3. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit 30.9 to 31.9 MPa Check and high pressure relief Setting pressure 315.0 to 325.0 kgf/㎠ valve (Relief valve) 4480 to 4622 psi 392.0 to 490.0 MPa Charge relief valve Setting pressure 4.0 to 5.0 kgf/㎠...
  • Page 71 TRANSMISSION 3. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit 0.1 to 0.3 mm 0.4 mm Backlash 0.004 to 0.012 in. 0.016 in. Differential pinion to differential 0.8 mm, 0.0315 in. side gear Adjusting shim 1.0 mm, 0.0394 in. (Thickness) 1.2 mm, 0.0472 in. 0.025 to 0.066 mm 0.30 mm Clearance...

  • Page 72: Tightening Torques

    TRANSMISSION 4. TIGHTENING TORQUES Tightening torque of screws, bolts and nuts on the table below are especially specified. Item N·m kgf·m ft-lbs Rear wheel bolt and nut 108.0 to 125.0 11.0 to 12.7 79.0 to 92.2 3-Point hitch shaft setting screw 14.7 to 19.6 1.5 to 2.0 10.8 to 14.5...
  • Page 73 TRANSMISSION 4. TIGHTENING TORQUES Item N·m kgf·m ft-lbs Rear axle case mounting screw 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2 Transmission case mounting screw and nut 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2 Mid-PTO case mounting screw 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2...

  • Page 74: Checking, Disassembling And Servicing

    TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING <1> CHECKING AND ADJUSTING < Adjusting maximum speed (HST Type) > 1. Depress the speed control pedal(1) all the way and measure the tractor speed. 2. If the measurement is not within factory specification, loosen the lock nut(3) and adjust with bolt(2).
  • Page 75 TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING ▶ NOTE 1) When the wheels tend to turn forward, rotate neutral adjuster clockwise. 2) When the wheels tend to turn reverse, rotate neutral adjuster counterclockwise. < Charge relief pressure and high relief pressure > When checking, park the tractor on flat ground and fully engage the parking brake.
  • Page 76 TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING ◎ High relief pressure 1. Remove the neutral valve assembly forward(1), then install the assembled HST adaptor (Tool for pressure test) to its neutral valve port. 2. Install the cable and high pressure gauge to HST adaptor (Tool for pressure test).
  • Page 77 TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING < Neutral valve actuation test > To avoid personal injury : Do not operate if tractor moves on level ground with foot off speed control pedal. When checking, park the tractor on flat ground, apply the parking brake.

  • Page 78: 2> Preparation

    TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING <2> PREPARATION 1) Separating Housing < Draining transmission fluid > 1. Place an oil pan underneath the transmission case, and remove the drain plugs(1). 2. Drain the transmission fluid. 3. Reinstall the drain plug. ▷...
  • Page 79 TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING < Hood, side cover and battery cord > 1. Open the hood(1) and remove. 2. Disconnect the battery grounding cable(2). 3. Disconnect the head light connectors remove the hood(1). ▶ NOTE 1) When disconnecting battery cables, disconnect the grounding cable(-) first.
  • Page 80 TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING < Fuel tank > (6) (4) 1. Disconnect the fuel hose(1) at the fuel filter side, then drain fuel completely. 2. Disconnect the hazard unit, controller, starter relay and regulator connectors and remove the cable wire for fuel gauge.
  • Page 81 TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING < Universal joint and bearing holder > 1. Loosen the clamp and slide the universal joint cover(1) to the rear. 2. Remove the bearing holder(4) with propeller shaft and universal joint. 3. Tap out the spring pins(2) and then slide the universal joint(3) to the rear.
  • Page 82 TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING < Steering assembly > 1. Remove the seat under cover, rubber mat and side step LH. 2. Disconnect the accelerator rod(4). 3. Disconnect the speed set rod(5) and parking brake rod(2). 4. Remove the power steering delivery pipe(3) and disconnect the power steering return pipe(6).
  • Page 83 TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING < Separating the engine from clutch housing > 1. Disconnect the three point hitch delivery pipe and suction hose. 2. Disconnect the glow plug lead wire and heat sensor lead for alternator connector and starter motor cable.

  • Page 84: Separating Center Frame And Transmission Case

    TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING 2) Separating Center Frame and Transmission Case < Draining transmission fluid > -. Reference the page 76. < Battery connector > 1. Open the hood(1). 2. Disconnect the battery ground cord(2). 3. Disconnect the head light connectors remove the hood(1).
  • Page 85 TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING < Seat, panel, step, rear wheel and others > 1. Remove the seat(2), seat under cover and rubber mat(3). 2. Remove the tool box(7). 3. Disconnect the 2P connectors from the seat switches, and then remove the seat stay(1). 4.
  • Page 86 TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING < Propeller shaft cover and coupling > -. Reference the page 78. < Universal joint and bearing holder > -. Reference the page 79. < HST Pedal > 1. Remove the brake rod RH(1). 2.
  • Page 87 TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING < Delivery pipes and HST safety switch holder > 1. Remove the pipe clamps and delivery pipe joint bolt(1). 2. Disconnect the differential lock rod. 3. Remove the accelerator rod and pedal, and then remove the delivery pipe.

  • Page 88: Separating Hst (Hst Type)

    TRANSMISSION 4. CHECKING, DISASSEMBLING AND SERVICING < Separating transmission assembly > 1. Disconnect the suction pipe at the transmission case side. 2. Separate the transmission case from center frame. ▷ Reassembling (A) HST Type 77.5 to 90.2 Nm Tightening HST and center (B) Manual transmission type 7.9 to 9.4 kgfm torque...

  • Page 89: 3> Disassembling And Assembling

    TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING <3> DISASSEMBLING AND ASSEMBLING 1) Disassembling Clutch Housing < Clutch rod and clutch release fork > 1. Remove the external snap ring at the end of *. PART NAME clutch rod. 1) Clutch rod 2.

  • Page 90: Disassembling Hst (Hst Type)

    TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING 2) Disassembling HST (HST Type) < Neutral holder and neutral holder arm > 1. Place parting marks on the neutral adjuster(3) and the neutral holder arm(2). 2. Remove the neutral holder arm(2) with neutral adjuster(3).

  • Page 91: Disassembling Transmission Case (Hst Type)

    TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING 3) Disassembling Transmission Case (HST Type) < Separating hydraulic cylinder, rear axle cases and others > 1. Remove the external snap ring and remove the PTO shift lever(7) and range gear shift lever(8). 2. Remove the front wheel driver lever(1). 3.
  • Page 92 TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING < 4 Gear shaft and spiral bevel pinion shaft > 1. Remove the spiral bevel pinion shaft(3) with 15T- 29T shifter gear(2), 13T gear(8) and shift fork(4). 2. Remove the 4 gear shaft(1) with 18T gear. ▷...
  • Page 93 TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING < 2 Gear shaft and middle shaft > 1. Remove the 2 gear shaft(1) with bearings. 2. Remove the 3 shaft assembly(2) and shift fork(3) with shift rod. 3. Remove the middle shaft(4) and 19T gear with bearing.

  • Page 94: Disassembling Transmission Case (Manual Transmission Type)

    TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING 4) Disassembling Transmission Case (Manual transmission Type) < Separating hydraulic cylinder and main shift cover > 1. Remove the connecting pipe and propeller shaft. 2. Tap out the spring pins and remove the universal joint(2) with front wheel drive propeller shaft.
  • Page 95 TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING < Separating rear axle case, mid-PTO case, drawbar frame and transmission case > 1. Remove the front wheel drive lever(3). 2. Remove the rear axle cases(5) from differential case. 3. Remove the mid-PTO case(1) from transmission case.
  • Page 96 TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING < 4 gear shaft > 1. Remove the bearing, 30T shifter gear and 13T- 17T shifter gear. 2. Draw out the 4 gear shaft(1) with 19T gear rearward. *. PART NAME 1) 4 Gear shaft <...
  • Page 97 TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING < Middle shaft and 3 shaft > 1. Tap out the middle shaft(1) and remove the 19T gear with bearing. 2. Draw out the 3 shaft(2) with 13T-17T shifter gear(3) and shift fork(4) with shift rod. ▷...

  • Page 98: Disassembling Differential Gear Case

    TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING < Main gear shift fork > 1. Remove the cotter pin(1) and remove the spring(2) and ball(3). 2. Draw out the shift rod(4) and remove the 1 reverse gear shift fork(5). 3. Remove the 2 gear shift fork(6), in the same way as the 1 -reverse shift fork removing...
  • Page 99 TRANSMISSION 4. CHECKING, DISASSEMBLING AND SERVICING < Differential gear assembly > 1. Remove the bearing holder mounting screws and remove the bearing holder(1). (2) (1) 2. Take out the differential gear assembly(3). ▷ Reassembling Install the differential gear assembly, noting the number of shims(2) in the differential case left side and bearing holder side.

  • Page 100: Clutch Housing

    TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING <4> SERVICING 1) Clutch Housing < Checking bearing > 1. Hold the inner race, and push and pull the outer race in all directions to check for wear and roughness. 2. Apply transmission fluid to the bearing, and hold the inner race.

  • Page 101: Transmission Case

    TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING 2) Transmission Case < Checking bearing > 1. Hold the inner race, and push and pull the outer race in all directions to check for wear and roughness. 2. Apply transmission fluid to the bearing, and hold the inner race.
  • Page 102 TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING < Clearance between gear and shaft > 1. Measure the gear I.D. with a cylinder gauge, and then shaft O.D. with an outside micrometer. 2. Measure the O.D. of two needles in the needle bearing with an outside micrometer.

  • Page 103: Differential Gear

    TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING 3) Differential Gear < Clearance between differential case and differential side gear > 1. Measure the differential side gear boss O.D. with an outside micrometer. 2. Measure the differential case I.D. and the spiral bevel gear I.D.
  • Page 104 TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING < Clearance between differential pinion shaft and differential pinion > 1. Measure the differential pinion shaft O.D. with an outside micrometer. 2. Measure the differential pinion I.D. with an inside micrometer, and calculate the clearance. 3.
  • Page 105 TRANSMISSION 5. CHECKING, DISASSEMBLING AND SERVICING < Backlash between spiral bevel pinion and spiral bevel gear > 1. Set the dial indicator(lever type) with its finger on the end of spiral bevel pinion(4). 2. Move the spiral bevel pinion back and forth to each end and measure the side clearance.
  • Page 106 REAR AXLE CONTENTS 5. (REAR AXLE) 1. STRUCTURE ……………………………………………………………………………………………………………. 2. TIGHTENING TORQUE ……………………………………………………………………………………………… 3. DISASSEMBLING AND SERVICING <1> DISASSEMBLING AND SERVICING 1) SEPARATING REAR AXLE CASE ………………………………………………………………………... 2) DISASSEMBLING REAR AXLE CASE ………………………………………………………………….. KUKJE MACHINERY CO., LTD.

  • Page 107: Structure

    REAR AXLE 1. STRUCTURE 1) Differential Gear Shaft 2) Ball Bearing 3) Rear Axle Case 4) Rear Axle 5) Spur Gear 6) Differential Gear 7) Spiral Bevel Gear The rear axles are the rigid type with ball bearings(2) between the rear axle(4) and the rear axle case(3), which supports the rear wheel load as well as transmitting power to the rear wheels.

  • Page 108: Tightening Torque

    REAR AXLE 2. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. Item N·m kgf·m ft-lbs Rear wheel bolt and nut 108.0 to 125.0 11.0 to 12.7 79.0 to 92.2 Rear axle case mounting screw 39.2 to 44.1 4.0 to 4.5 28.9 to 32.5...

  • Page 109: Disassembling And Servicing

    Fill new oil into filling port after removing the filling plug(2) up to the upper notch on the dipstick(3). After running the engine for few minutes, stop it <Branson 2100, 2400, 2800 Euro> and check the oil lever again. If low, add oil to proper level. ◈ Important Use only multi-grade transmission oil.
  • Page 110 REAR AXLE 3. DISASSEMBLING AND SERVICING < Rear wheel > 1. Place a jack under the transmission case. 2. Loosen the rear wheel bolt(1) and nut(2). 3. Take out the rear wheel. ◈ Important When re-fitting or adjusting a wheel, tighten the bolts to the following torques and then recheck them after driving the tractor approximately 200m (200 yards).
  • Page 111 REAR AXLE 3. DISASSEMBLING AND SERVICING 2) Disassembling Rear Axle Case < Differential lock shift fork, differential lock clutch(Right side only), 57T gear and rear axle > 1. Remove the spring(1). 2. Draw out the differential lock shift fork(2) and differential lock clutch(3).

  • Page 112: Disassembling Rear Axle Case

    BRAKE CONTENTS 6. (BRAKE) 1. LINKAGE ………………………………………………………………………………………………………………… 2. OPERATION ……………………………………………………………………………………………………………. 3. SERVICING SPECIFICATIONS …………………………………………………………………………………….. 4. TIGHTENING TORQUE ……………………………………………………………………………………………… 5. CHECKING, DISASSEMBLING AND SERVICING <1> CHECKING AND ADJUSTING ……………………………………………………………………………. <2> DISASSEMBLING AND ASSEMBLING 1) BRAKE PEDAL ……………………………………………………………………………………………….. 2) SEPERATING REAR AXLE CASE ………………………………………………………………………… 3) DISASSEMBLING REAR AXLE CASE …………………………………………………………………..

  • Page 113: Linkage

    BRAKE 1. LINKAGE 1) Rear Axle Case 2) Brake Cam Lever 3) Brake Rod 4) Turnbuckle 5) Brake Pedal 6) Side Brake Lever Independent mechanical wet disc brakes are used for the right and left brakes. They are operated by the brake pedals through the mechanical linkages and provide stable braking and require little adjustment.

  • Page 114: Operation

    BRAKE 2. OPERATION 1) Cam Plate 2) Friction Plate 3) Brake Disc 4) Rear Axle Case 5) Steel Ball 6) Brake Shaft (Differential gear shaft) 7) Brake Cam 8) Brake Cam Lever The brake body is incorporated in the rear axle case(4) filled with transmission oil and is designed to brake when the brake disc(3) splinted with the differential gear shaft(6) is pressed against the cam plate(1) by means of the cam mechanism incorporating steel balls(5).

  • Page 115: Servicing Specifications

    BRAKE 3. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit 30.0 to 40.0 mm Brake Pedal Free travel 1.18 to 1.57 in. 0.0 to 0.165 mm 1.0 mm Clearance 0.0 to 0.00649 in. 0.0039 in. 24.967 to 25.030 mm Pedal Shaft to Center Frame Pedal Shaft(O.D.) 0.98295 to 0.98543 in.
  • Page 116 BRAKE 4. TIGHTENING TORQUES Item N·m kgf·m ft-lbs Rear wheel bolt and nut 108.0 to 125.0 11.0 to 12.7 79.0 to 92.2 Rear axle case mounting screw 48.1 to 55.8 4.9 to 5.7 35.5 to 41.2 KUKJE MACHINERY CO., LTD.

  • Page 117: 1> Checking And Adjusting

    BRAKE 5. CHECKING, DISASSEMBLING AND SERVICING <1> CHECKING AND ADJUSTING < Adjusting brake pedal free travel > Stop the engine and check the wheels before checking brake pedal. The difference between the right and left pedal free travel must be less than 4.0mm 1.

  • Page 118: 2> Disassembling And Assembling

    BRAKE 5. CHECKING, DISASSEMBLING AND SERVICING <2> DISASSEMBLING AND ASSEMBLING 1) Brake Pedal (14) 1. Remove the spring lock pin(10), pin fastener(14) *. PART NAME of brake rod(12) and pull out the brake rod(12). 1) External snap ring 2) Collar 2.
  • Page 119 Fill new oil into filling port after removing the filling plug(2) up to the upper notch on the dipstick(3). After running the engine for few minutes, stop it <Branson 2100, 2400, 2800 Euro> and check the oil level again, if low, add oil to proper level. ◈ Important Use only multi-grade transmission oil.
  • Page 120 BRAKE 5. CHECKING, DISASSEMBLING AND SERVICING < Rear wheel > 1. Place a jack under the transmission case. 2. Loosen the rear wheel bolt(1) and nut(2). 3. Take out the rear wheel. ◈ Important When re-fitting or adjusting a wheel, tighten the bolts to the following torques and then recheck them after driving the tractor approximately 200m (200 yards).

  • Page 121: Disassembling Rear Axle Case

    BRAKE 5. CHECKING, DISASSEMBLING AND SERVICING 3) Disassembling Rear Axle Case < Differential lock shift fork, differential lock clutch, 57T gear and rear axle > 1. Remove the spring(1). 2. Draw out the differential lock shift fork(2) and differential lock clutch(3) 3.

  • Page 122: 3> Servicing

    BRAKE 5. CHECKING, DISASSEMBLING AND SERVICING <3> SERVICING < Clearance between brake pedal shaft and center frame bush > 1. Measure the brake pedal shaft O.D. with an outside micrometer. 2. Measure the bush(3) I.D. with a cylinder gauge. 3. If the clearance exceeds the allowable limit, replace it.
  • Page 123 BRAKE 5. CHECKING, DISASSEMBLING AND SERVICING < Height of cam plate and ball > 1. Measure the dimensions of the cam plate with the ball installed. 2. If the measurement is less than the allowable limit, replace the cam plate and ball. 3.
  • Page 124 STEERING CONTENTS 7. (STEERING) 1. STRUCTURE ……………………………………………………………………………………………………………. 2. SERVICING SPECIFICATIONS …………………………………………………………………………………….. 3. TIGHTENING TORQUE ……………………………………………………………………………………………… 4. CHECKING, DISASSEMBLING AND SERVICING <1> CHECKING AND ADJUSTING ………………………………………………………………………….. <2> DISASSEMBLING AND ASSEMBLING 1) SEPARATING POWER STEERING ASSEMBLY ……………………………………………………… KUKJE MACHINERY CO., LTD.
  • Page 125 STEERING 1. STRUCTURE 1) PST Valve 2) PST cylinder / Tie Rod 3) Oil Filter 4) Transmission Case 5) Clutch Housing cover 6) Hydraulic pump (Front Transmission) KUKJE MACHINERY CO., LTD.
  • Page 126 STEERING 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit 0.8 to 1.4 Nm Steering wheel Turning torque 0.08 to 0.14 kgfm 0.59 to 1.03 ft-lbs KUKJE MACHINERY CO., LTD.
  • Page 127 STEERING 3. TIGHTENING TORQUES Item N·m kgf·m ft-lbs (Power steering type) Steering wheel mounting nut 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2 Delivery pipe nut for HST 34.3 to 39.2 3.5 to 4.0 25.3 to 28.9 Oil cooler pipe nut 50.0 to 57.9 5.1 to 5.9 36.9 to 42.8...
  • Page 128 STEERING 4. CHECKING, DISASSEMBLING AND SERVICING <1> DISASSEMBLING AND ASSEMBLING 1) Separating power steering assembly < Hood, side cover and battery cord > 1. Open the hood(1). 2. Disconnect the battery grounding cord(2). 3. Disconnect the head light connectors remove the hood(1). ▶...
  • Page 129 STEERING 4. CHECKING, DISASSEMBLING AND SERVICING < Hydraulic hose > 1. Remove the hydraulic hose(1) from the front cylinder assy(2). *. PART NAME 1) Hydraulic hose 2) Front cylinder assy < Step > 1. Remove the lowering speed adjusting knob(3). 2.
  • Page 130 STEERING 4. CHECKING, DISASSEMBLING AND SERVICING < Fuel tank > 1. Disconnect the fuel hose(1) at the fuel filter side, then drain fuel completely. 2. Remove the steering bracket stay(7). 3. Disconnect the hazard unit, controller, starter relay and regulator connectors and remove the cable for fuel gauge.
  • Page 131 STEERING 4. CHECKING, DISASSEMBLING AND SERVICING < Steering assembly > 1. Remove the seat under cover, rubber mat and side step LH. 2. Disconnect the accelerator rod(4). 3. Disconnect the power steering delivery pipe(1). 4. Remove the power steering delivery pipe(3) and disconnect the power steering return pipe.
  • Page 132 HYDRAULIC SYSTEM CONTENTS 8. (HYDRAULIC SYSTEM) 1. STRUCTURE <1> HYDRAULIC CIRCUIT 1) Manual Transmission, Power Steering, Control valve …………………………………………. 2) Manual Transmission, Power Steering, Position Control Valve ……………………………. <2> AUXILIARY HYDRAULICS 1) Hydraulic Block Type Outlet …………………………………………………………………………… 2. SERVICING SPECIFICATIONS <1>...

  • Page 133: Structure

    HYDRAULIC SYSTEM 1. STRUCTURE <1> HYDRAULIC CIRCUIT 1) Manual Transmission, Power Steering, Control valve 1) Hydraulic control valve 2) Oil filter 3) Power steering (Controller) 4) Hydraulic pump 5) Hydraulic pump 6) Hydraulic block type outlet (for 3-point hitch) (for power steering) 7) Relief valve 8) Hydraulic cylinder 9) Lowering speed adjusting valve...
  • Page 134 HYDRAULIC SYSTEM 1. STRUCTURE 2) HST Transmission, Power Steering, Position Control Valve 1) Position control valve 2) Rear hydraulic outlet 3) Power steering (Controller) 4) Hydraulic block type outlet 5) Oil filter 6) Hydraulic pump (for power steering) 7) Hydraulic pump (for 3-point hitch) 8) Hydraulic cylinder 9) Lowering speed adjusting valve 10) Relief valve...

  • Page 135: 2> Auxiliary Hydraulics

    HYDRAULIC SYSTEM 1. STRUCTURE <2> AUXILIARY HYDRAULICS 1) Hydraulic Block Type Outlet *. PART NAME 1) Block cover 2) Block outlet cover (option) 3) Outlet 4) Inlet 5) Hydraulic block (A) : When implement is not attached (B) : When implement is attached X : From gear pump Y : To implement inlet Max.

  • Page 136: Servicing Specifications

    HYDRAULIC SYSTEM 2. SERVICING SPECIFICATIONS <1> POWER STEERING Item Factory Specification Allowable Limit <Operation Force Condition> Engine Speed : Less than 10.0 N Steering Wheel Approx. 2600 rpm, 1.2 kgf Oil Temperature : 2.2 lbs 45 to 55℃ (133 to 131℉) 0.0 to 0.02 mm 0.004 mm Rack(Piston) Assembly...

  • Page 137: 2> Hydraulic Pump For Power Steering

    HYDRAULIC SYSTEM 2. SERVICING SPECIFICATIONS <2> HYDRAULIC PUMP FOR POWER STEERING Item Factory Specification Allowable Limit 11.9 L/min. At no pressure 3.2 U.S.gal/min. 2.6 lmp.gal/min. Pump Delivery 11.3 to 12.3 ㎫ 10.9 L/min. 115.0 to 125.0 kgf/㎠ 2.9 U.S.gal/min. 1,636.0 to 1,778.0 psi 2.4 lmp.gal/min.

  • Page 138: 3> Hydraulic Pump For Three Point Hydraulic System

    HYDRAULIC SYSTEM 2. SERVICING SPECIFICATIONS <3> HYDRAULIC PUMP FOR THREE POINT HYDRAULIC SYSTEM Item Factory Specification Allowable Limit 17.1 L/min. At no pressure 4.5 U.S.gal/min. 3.8 lmp.gal/min. Pump Delivery At 13.7 ㎫ 15.6 L/min. 140.0 kgf/㎠ 4.1 U.S.gal/min. 1,991.0 psi 3.4 lmp.gal/min.

  • Page 139: 4> Three Point Hydraulic System

    HYDRAULIC SYSTEM 2. SERVICING SPECIFICATIONS <4> THREE POINT HYDRAULIC SYSTEM Item Factory Specification Allowable Limit 13.7 to 13.7 ㎫ 0.30 mm Relief Valve Setting pressure 135 to 140 kgf/㎠ 0.0118 in. 1,920.0 to 1,991.0 psi 5.0 to 15.0 mm Lift Arm Clearance 0.20 to 0.59 in.

  • Page 140: Tightening Torques

    HYDRAULIC SYSTEM 3. TIGHTENING TORQUES Item N·m kgf·m ft-lbs (Power Steering Body) Steering column mounting screw 48.1 35.4 Valve housing mounting hex. Head screw 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3 Delivery pipe nut for power steering 65.0 to 75.0 6.6 to 7.7 47.9 to 55.3 (Hydraulic Pump)

  • Page 141: Checking, Disassembling And Servicing

    HYDRAULIC SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING <1> CHECKING AND ADJUSTING 1) Power Steering System < Steering wheel operating force > 1. Park the tractor on flat concrete place. 2. Start the engine. After warming up, set the engine speed at approx. 2600 rpm. 3.

  • Page 142: Hydraulic Pump For Power Steering

    HYDRAULIC SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING 2) Hydraulic Pump for Power Steering < Flowmeter connecting and test preparation > ◈ Important When using a flowmeter other than Branson specified flowmeter, sure instructions with that flowmeter. In this hook-up, there is no relief valve. Therefore while testing, do not close the flowmeter loading valve completely.
  • Page 143 HYDRAULIC SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING < Pump test > ▶ NOTE 1) Before pump testing, perform the flowmeter connecting and test preparation. 1. Open the loading valve completely. 2. Start the engine and set at approx. 2600rpm. 3. Read and note the pump delivery at no pressure. 4.

  • Page 144: Hydraulic Pump For Three Point Hydraulic System

    3) Hydraulic Pump for Three Point Hydraulic System < Flometer connection and test preparation > ◈ Important When using a flowmeter other than a Branson specified flometer, be sure to use the instructions with that flowmeter. In this hook-up, there is no relief valve. Therefore while testing, do not close the flowmeter loading valve completely.

  • Page 145: Three Point Hydraulic System

    HYDRAULIC SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING 4) Three Point Hydraulic System < Relief valve setting pressure > 1. Remove the seat under cover. 2. Remove the plug from front of hydraulic cylinder body. 3. Install the adapter. Then connect the cable and pressure gauge to adapter.
  • Page 146 HYDRAULIC SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING < Lift arm free play > 1. Set the hydraulic control lever to the lowest position. 2. Start the engine, and set at the idling speed. 3. Move the hydraulic control lever to lift position until the lift arm moves to the uppermost position.

  • Page 147: 2> Disassembling And Assembling

    HYDRAULIC SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING <2> DISASSEMBLING AND ASSEMBLING 1) Power Steering Body < Steering column > 1. Turn the steering shaft several times to drain oil. 2. Loose the steering column mounting screws, and remove the steering column with steering shaft and universal joint.

  • Page 148: Hydraulic Pump For Power Steering

    HYDRAULIC SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING 2) Hydraulic Pump for Power Steering < Removing hydraulic pump > 1. Open the hood then remove the hood and disconnect the battery grounding cord. 2. Disconnect the accelerator rod(3). 3. Disconnect the power steering delivery hose(4) and 3-point hitch delivery pipe(6).

  • Page 149: Hydraulic Cylinder And Control Valve

    HYDRAULIC SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING 3) Hydraulic Cylinder and Control Valve < Seat and seat stay > 1. Remove the seat. 2. Remove the lowering speed adjusting knob and dipstick, then remove the seat under cover. 3. Remove the tool box(3). 4.
  • Page 150 HYDRAULIC SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING < Control valve > 1. Remove the control valve mounting screws, and remove the control valve(1). ▷ Reassembling Take care not to damage the O-ring. 23.6 to 27.4 N·m Tightening Cover mounting 2.4 to 2.8 kgf·m torque screw 17.4 to 20.2 ft-lbs...

  • Page 151: Hydraulic Cylinder

    HYDRAULIC SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING < Hydraulic piston > 1. Inject the compressed air into the hydraulic cylinder, and take out the hydraulic piston. ▷ Reassembling Take care not to damage the O-ring and backup ring. Apply transmission fluid to the O-ring. Replace the O-ring if it is defective, worn or scratched, which may case oil leakage.
  • Page 152 HYDRAULIC SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING < Lift arm, hydraulic arm shaft and hydraulic arm> 1. Remove the external snap ring, and remove the lift arm LH. 2. Draw out the hydraulic arm shaft and lift arm RH as a unit. ▷...
  • Page 153 HYDRAULIC SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING < Relief valve > 1. Remove the plug(1), and draw out the o-ring(2), spring(3), poppet(4) and the valve seat(5). ▷ Reassembling Take care not to damage the O-rings. 49.0 to 68.6 N·m Tightening Relief valve plug 5.0 to 7.0 kgf·m torque...
  • Page 154 ELECTRIC SYSTEM CONTENTS 9. (ELECTRIC SYSTEM) 1. WIRING COLOR ABBREVIATIONS 2. WIRING DIAGRAM 3. STARTING & STOPPING SYSTEM 4. LIGHTING SYSTEM 5. INSTRUMENT PANNEL 6. OTHERS 7. TROUBLE SHOOTING 8. CHECKING DISSEMBLING AND SERVICING KUKJE MACHINERY CO., LTD.
  • Page 155 ELECTRIC SYSTEM 1. WIRE COLOR ABBREVIATIONS W ……. White WR ……. White/Red LW ……. Blue/White R ……. Red WY ……. White/Yellow LG ……. Blue/Green L ……. Blue WL ……. White/Blue LR ……. Blue/Red Y ……. Yellow RW ……. Red/White LB ……. Blue/Black B …….
  • Page 156 ELECTRIC SYSTEM 2. WIRING DIAGRAM <1> MANUAL TRANSMISSION KUKJE MACHINERY CO., LTD.
  • Page 157 ELECTRIC SYSTEM 2. WIRING DIAGRAM <2> HST TRANSMISSION KUKJE MACHINERY CO., LTD.
  • Page 158 ELECTRIC SYSTEM 3. STARTING & STOPPING SYSTEM <2> Components 1. Seat Switch This switch is located under the seat. When Sitting on the seat, the seat switch (1) is pushed in and electrical circuit is closed. When the seat is vacant, this switch is not pushed and electric is opened.
  • Page 159 ELECTRIC SYSTEM 3. STARTING & STOPPING SYSTEM 5. Start Glow Timer(Engine Control Unit) The start glow timer is located inside of the dashboard. 6. Neutral Switch (Manual Transmission) This switch is equipped only with manual transmission type, and located on the transmission case upper cover. When the main speed change lever is not in neutral, this switch is pushed in and electric circuit is opend.
  • Page 160 ELECTRIC SYSTEM 3. STARTING & STOPPING SYSTEM position (Mid PTO position). When the PTO gear shift lever is shifted to 2 PTO speed position (Mid PTO position), this switch is pushed in and electric circuit is opened. The Mid PTO switch is equipped Mid PTO type. <2>...
  • Page 161 ELECTRIC SYSTEM 4. LIGHTING SYSTEM The lighting system consists of the combination switch (light switch and hazard), head lights, tail lights, hazard lights, etc. <1> Head Light The light switch, which forms a combination switch with the turn signal light switch, has two positions OFF and ON.
  • Page 162 ELECTRIC SYSTEM 4. LIGHTING SYSTEM <3> Hazard Light The Hazard switch has two positions; ON and OFF. The hazard light is operative when the key switch is in either the ON or OFF positions. KUKJE MACHINERY CO., LTD.
  • Page 163 ELECTRIC SYSTEM 5. INSTRUMENT PANNEL To check the conditions of your tractor before and during operation, refer to the indication items below. <1> Indication Items 1 Charge Lamp When the charging system is not functioning properly, this lamp illuminates. 2. Pre-heat Indicator Lamp When the key switch is in the “Pre-heat”...
  • Page 164 ELECTRIC SYSTEM 6. OTHERS Refer to Workshop manual for Diesel Engine Mechanism and Tractor Mechanism as following terms. [1] ENGINE STARTING SYSTEM AND STOPPING SYSTEM (1) Main Switch : [Type 1] in Workshop Manual for Tractor Mechanism. (2) Starter Motor(MT) : [Electromagnetic Drive Type] in Workshop Manual for Engine Mechanism. (3) Starter Motor(HST) : [Planetary Gear Reduction Type] in Workshop Manual for Engine Mechanism.
  • Page 165 ELECTRIC SYSTEM 7. TROUBLE SHOOTING Symptom Probable Cause Solution Reference All Electrical Battery discharged or defective Recharge or Replace Equipments Do Battery positive cable disconnected or improperly Repair or Replace Not Operate connected Battery negative cable disconnected or improperly Repair or Replace connected Slow blow fuse blown Replace...
  • Page 166 ELECTRIC SYSTEM 7. TROUBLE SHOOTING STARTING SYSTEM Symptom Probable Cause Solution Reference Starter Motor Battery discharged or defective Recharge or Does Not Replace Operate Slow blow fuse blown Repair or Replace Safety switch improperly adjusted or Repair or replace defective Wiring harness disconnected or improperly connected (between main switch 50 terminal and operator presence controller, between...
  • Page 167 ELECTRIC SYSTEM 7. TROUBLE SHOOTING AUTOMATIC ENGINE STOP Symptom Probable Cause Solution Reference Engine Does Solenoid fuse blown (10A ) Replace Not Stop Key stop timer defective Replace When Main Key stop relay defective Replace Switch Is Engine stop solenoid defective Replace Turned OFF Operator presence controller defective...
  • Page 168 ELECTRIC SYSTEM 7. TROUBLE SHOOTING CHARGING SYSTEM Symptom Probable Cause Solution Reference Charging Lamp Fuse blown(10A) Replace Does Not Light Wiring harness disconnected or improperly When Main connected (between main switch AC terminal and Repair or Replace Switch Is Turned panel board, between panel board and dynamo) Dynamo defective Repair or Replace...
  • Page 169 ELECTRIC SYSTEM 7. TROUBLE SHOOTING Symptom Probable Cause Solution Reference Hazard Light Does Fuse blown(10A) Replace Not Light Bulb blown Replace Wiring harness disconnected or improperly Repair or Replace connected Flasher unit defective Replace Hazard switch defective Replace Hazard Indicator Bulb blown Replace Lamp Does Not...
  • Page 170 ELECTRIC SYSTEM 7. TROUBLE SHOOTING INSTRUMENT PANNEL Symptom Probable Cause Solution Reference Oil Pressure Lamp Engine oil pressure too low Repair engine Lights Up When Engine oil insufficient Replenish Engine Is Running Oil pressure switch defective Replace Short circuit between oil pressure switch lead Replace and chassis Circuit in panel board defective...
  • Page 171 ELECTRIC SYSTEM 8. CHECKING DISASSEMBLING AND SERVICING 『CAUTION』 To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before the negative cable is attached to the negative terminal. Never remove the battery cap while the engine is running. Keep electrolyte away from eyes, hands and clothes.
  • Page 172 ELECTRIC SYSTEM 8. CHECKING DISASSEMBLING AND SERVICING (2) Main Switch(Key Switch) Main Switch 1. Remove the panel board 2. Disconnect the 4P connector and remove the main switch 3. Perform the following checks. Connector Voltage 1. Measure the voltage with a voltmeter across the connector 30 terminal and chassis.
  • Page 173 ELECTRIC SYSTEM 8. CHECKING DISASSEMBLING AND SERVICING 2) Main Switch Key at On Position 1. Set the main switch to ON position. 2. Measure the resistance with an ohmmeter across the 30 terminal and the AC terminal. 3. If 0 Ω is not indicated, the 30 – AC contact of the main switch are faulty.
  • Page 174 ELECTRIC SYSTEM 8. CHECKING DISASSEMBLING AND SERVICING (3) Engine Control Unit Engine Control Unit 1. Open the panel board and remove the relay. 2. Apply battery voltage across 2 terminal and 4 terminal, and check for continuity across 1 terminal and 3 terminal. 3.
  • Page 175 ELECTRIC SYSTEM 8. CHECKING DISASSEMBLING AND SERVICING (5) Safety Switches Safety Switch Continuity 1. Disconnect the safety switch leads. 2. Connect the circuit tester to the safety switch leads. 3. Measure the resistance between leads. 4. If the safety switch is defective, replace it. Safety Switch State Resistance...
  • Page 176 ELECTRIC SYSTEM 8. CHECKING DISASSEMBLING AND SERVICING (6) Starter Motor Test 『CAUTION』 Secure the starter to prevent it from jumping up and down while testing the motor. 1. Disconnect the battery negative cable from the battery. 2. Disconnect the battery positive cable and the leads form the starter M terminal.
  • Page 177 ELECTRIC SYSTEM 8. CHECKING DISASSEMBLING AND SERVICING (8) Combination Switch Combination Switch 1. Remove the meter panel, and disconnect the combination switch connector. 2. Remove the combination switch (1) and perform the following checks 1) to 1) Connector Voltage 1. Measure the voltage with a voltmeter across the connector B1 terminal and chassis when the main switch is “ON”...
  • Page 178 ELECTRIC SYSTEM 8. CHECKING DISASSEMBLING AND SERVICING 4) Turn Signal Light Switch Continuity When Setting Switch Knob OFF Position 1. Set the hazard switch knob to the OFF position. 2. Measure the resistance with an ohmmeter across the B2 terminal and L terminal, and across B2 terminal and R terminal.
  • Page 179 ELECTRIC SYSTEM 8. CHECKING DISASSEMBLING AND SERVICING (9) Hazard Switch Hazard Switch 1. Remove the meter panel and disconnecting the 4P connector from hazard switch after disconnect the battery negative code. 2. Remove the hazard switch. 3. Perform the following. Connector Voltage 1.
  • Page 180 ELECTRIC SYSTEM 8. CHECKING DISASSEMBLING AND SERVICING (10) Flasher Unit Flasher Unit connector Voltage 1. Remove the instrument panel. 2. Disconnect the connector (2) from the flasher unit (1). 3. Measure the voltage with a voltmeter across the h terminal and chassis.
  • Page 181 ELECTRIC SYSTEM 8. CHECKING DISASSEMBLING AND SERVICING (11) Instrument Pannel Easy Checker 1. Remove the panel board and disconnect the connector from it. 2. Turn the main switch on. 3. Measure the voltage with a voltmeter across the terminal (Red/Yellow) and the earth terminal (Black). 4.
  • Page 182 ELECTRIC SYSTEM 8. CHECKING DISASSEMBLING AND SERVICING Engine Oil Pressure Switch Continuity 1. Measure the resistance with an ohmmeter across the switch terminal and the chassis. 2. If 0 Ω is not indicated in the normal state, the switch is faulty. 3.
  • Page 183 ELECTRIC SYSTEM 8. CHECKING DISASSEMBLING AND SERVICING (12) Gauges Fuel Level Sensor 1) Sensor Continuity 1. Remove the fuel level sensor from the fuel tank. 2. Measure the resistance with an ohmmeter across the sensor terminal and its body. 3. If the reference values are not indicated, the sensor is faulty. Resistance Reference value Float at upper-...
  • Page 184 ELECTRIC SYSTEM 8. CHECKING DISASSEMBLING AND SERVICING Fuel Gauge and Coolant Temperature Gauge Continuity 1. Remove the panel board from the tractor. 2. Check the continuity with an ohmmeter across the U terminal(2) and + terminal(3) and across the U terminal(2) and - terminal(1). 3.

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