Page 1 DSC48 COMBINE HARVESTER WORKSHOP MANUAL...
Page 3 Therefore, some of the information in this manual may differ from the machine you have. DAEDONG (KIOTI) has a principle to apply update to the next edition of the manual if there is any. However, DAEDONG (KIOTI) has no obligation to modify the contents in this manual, especially the contents in the manual which is already distributed or pub- lished.
Page 5 TABLE OF CONTENTS CHAPTER 0 SAFETY FIRST CHAPTER 1 GENERAL CHAPTER 2 ENGINE CHAPTER 3 REAPING UNIT CHAPTER 4 THRESHING UNIT CHAPTER 5 DRIVING CHAPTER 6 HYDRAULIC CHAPTER 7 ELECTRICAL CHAPTER INDEX...
Page 7: Table Of Contents
DSC48 SAFETY FIRST TABLE OF CONTENTS 1. FOR SAFETY .......... 0-3 3.2.4 Loading and unloading the combine harvester to the transporting vehicle 1.1 Alert symbols ..........0-3 ............0-10 3.3 Harvesting ..........0-11 2. SAFETY TIPS .......... 0-4 3.3.1 Driving onto and out of the ﬁ eld ..0-11 2.1 Safety gear ..........
Page 9: For Safety
DSC48 1. FOR SAFETY • Most accidents can be avoided if basic safety instruc- tions and regulations are followed. Always follow the safety regulations and avoid any dangerous situation to prevent an accident. • You can be unexpectedly injured if inspecting or ser- vicing the combine harvester without full knowledge of it.
Page 10: Safety Tips
DSC48 2. SAFETY TIPS 2.1 SAFETY GEAR When working on the combine harvester, wear safety gloves, safety shoes, ear plugs, safety goggles, safety helmet, working clothes, etc. appropriate for your work- ing environment. Never wear loose ﬁ tting clothing or a tie which can be caught to the rotating part.
Page 11: Safety Instructions When Preparing Combine Harvester
DSC48 2.3 SAFETY INSTRUCTIONS WHEN PREPARING COMBINE HARVESTER T46W010A • Stop the engine and remove the key. Put "Do not operate" label on the combine harvester if necessary. 2.4 AVOID FIRES T46W011A T46W013A • Never smoke or allow ﬂ ames in your work area when •...
Page 12: Cautions When Handling The Battery
DSC48 2.5 CAUTIONS WHEN HANDLING THE 2.6 CAUTIONS FOR HIGH PRESSURE BATTERY HOSES T46W015A T46W019A • Always disconnect the negative battery cable ﬁ rst and reconnect it last to avoid sparks from an accidental • The hydraulic ﬂ uid leaked from high pressure hoses or short circuit.
Page 13: Use Of Appropriate Tools And Equipment
DSC48 2.7 USE OF APPROPRIATE TOOLS AND 2.9 HANDLING OF ROTATING BLADE, EQUIPMENT SHAFT AND DRIVING BELT T46W022A • Use the appropriate tools in proper size. If an inappro- priate tool is used, it can be slipped which can dam- age parts or injure you.
Page 14: Prevention Of Scald
DSC48 2.10 PREVENTION OF SCALD 2.11 DISPOSAL OF ENVIRONMENTAL WASTE T46W027A T46W029A • Do not open the radiator cap when the radiator is hot. • Observe all relevant environmental protection regula- Hot coolant or steam can be surged leading to a seri- tions when disposing used oil, transmission ﬂ...
Page 15: For Your Safety
DSC48 3. FOR YOUR SAFETY • Important safety instructions are described with symbols ( ) throughout this manual. It is essential that you read these instructions carefully before you attempt to operate this unit. • The safety instructions described in this chapter are for the general issues of the combine harvester. These instructions are described in other chapters in the same way.
Page 16: Driving
DSC48 3.2 DRIVING 3.2.2 DRIVING ON A NARROW RURAL PATH, BUMPY ROAD OR SLOPE • Remain at a low speed when driving on a narrow rural or bumpy road. • Do not get too close to the edge of a road to avoid ve- hicles coming in the opposite direction.
Page 17: Harvesting
DSC48 3.3 HARVESTING 3.4 AFTER COMPLETING INTENDED OPERATION AND STORAGE 3.3.1 DRIVING ONTO AND OUT OF THE FIELD 3.4.1 AFTER DAILY WORK IS COMPLETED • Drive slowly at a right angle from a ﬁ eld bank. • Apply the parking brake on a level ground and pull out the ignition key.
Page 18: General Precaution Before Operation
DSC48 4. GENERAL PRECAUTION BEFORE OPERATION You must follow Accident occurred when not followed! Do not modify the combine harvester. Modifying the combine harvester may damage the system or cause an accident. 417W110A Check the condition of the combine harvester before An unexpected accident may happen due to the poor and after each operation.
Page 19: When Servicing, Repairing And Cleaning Before Operation
DSC48 5. WHEN SERVICING, REPAIRING AND CLEANING BEFORE OPERATION You must follow Accident occurred when not followed! When refueling or adding oil, stop the engine. Do not You may get burnt or it can set ﬁ re. add fuel, oil and ﬂ uid while the engine is running or hot.
Page 20 DSC48 You must follow Accident occurred when not followed! Check the safety parts, such as turn signal lights, be- It can cause an accident. fore driving the combine harvester. 417W118A The cover and other parts removed for inspection and You can be trapped or entangled into the engine system repair should be installed again after the work is done.
Page 21 DSC48 You must follow Accident occurred when not followed! When servicing or operating the combine harvester, They can be trapped or entangled into the rotating part don’t let other people, especially children, approach the and get injured. combine harvester. 417W122A...
Page 22: When Starting The Engine
DSC48 6. WHEN STARTING THE ENGINE You must follow Accident occurred when not followed! Do not allow anyone, especially children, to come near If anyone, including a child, approaches the combine har- the combine harvester before starting the engine. vester, an accident may occur.
Page 23: When Driving
DSC48 7. WHEN DRIVING You must follow Accident occurred when not followed! Check immediate vicinity of the combine harvester for It can cause an injury. bystanders before starting off. • Do not allow anyone, especially children, to come near the combine harvester before driving off.
Page 24 DSC48 You must follow Accident occurred when not followed! Avoid working and driving at night. It can cause an accident, overturn or fall resulting in an injury or even death. • If it is inevitable, turn on the headlamps and work lamp.
Page 25: Driving On A Narrow Path, Bumpy Road Or Slope
DSC48 8. DRIVING ON A NARROW PATH, BUMPY ROAD OR SLOPE You must follow Accident occurred when not followed! Do not get too close to the edge of a road. The edges can collapse and the combine harvester can roll over.
Page 26: Loading And Unloading The Combine Harvester To The Transporting Vehicle
DSC48 9. LOADING AND UNLOADING THE COMBINE HARVESTER TO THE TRANSPORTING VEHICLE You must follow Accident occurred when not followed! Use ramps that are strong, wide and long (4 times long The ramps can be broken and the combine harvester can as the height of the cargo bed of the vehicle) enough roll over.
Page 27 DSC48 You must follow Accident occurred when not followed! Do not turn the combine harvester on the ramps. The combine harvester may be abruptly turned or driven off and slip off the ramps. • Do not operate the power steering lever, range shift lever and brake pedal on the ramps.
Page 28: After Daily Work Is Completed
DSC48 10. AFTER DAILY WORK IS COMPLETED You must follow Accident occurred when not followed! When the work is completed, stop the engine on level It can catch ﬁ re. ground and check the combine harvester to remove any foreign materials.
Page 29 DSC48 You must follow Accident occurred when not followed! Secure the body, cutter, binder, dust-proof cover and You can be trapped into the rotating part and get injured. grain tank with the prop when they are open. 417W146A Do not run the engine with the body, cutter, binder, You can be trapped or entangled into the rotating part and dust-proof cover and grain tank open.
Page 30: For Long-Term Storage
DSC48 11. FOR LONG-TERM STORAGE You must follow Accident occurred when not followed! On level ground, clean the exterior with water, stop the Children may climb up to the combine harvester which engine, apply the parking brake and remove the ignition can lead to an accident.
Page 31: Safety Decals
DSC48 12. SAFETY DECALS • When replacing parts, be sure to install the appropriate safety decal as well. Otherwise, the customer's safety will be threatened. • If a decal is damaged or detached, always replace with the appropriate decal. •...
Page 32 DSC48 1. Label T-4682-53561 2. Label C7343-53121 Warning Warning 1. Danger! Under this cover is a fast rotating blade. Never put hands inside. 2. Shut off the engine before clearing straws caught in the cutter shaft. C7343-53121 During the engine's running or right after the engine's stopping, explosive release of highly 3.
Page 33 DSC48 10. Label C7610-71231 11. Label C7610-64181 Warning 1. If your hand touches the blade, the blade can cut Warning off the hand. Do not put your hand into here. 2. If your hand touches the chain, belt or blade, they can cause serious injuries.
Page 34 When replacing the cutter blade, follow this manual. (Ensure that the sharpened blade is downward (toward the grain)). Tension lever Use only genuine Daedong blades. C7341-55131 20. Label C7331-64221 Caution When installing the chaff container, the rubber plate must be installed as specified in the following figure.
Page 35 DSC48 21. Label C7313-43371 Caution Before operation 1. To ensure safety, read the user guide carefully and be familiar with the operating method of the machine. 2. When turning on the engine, disengage all clutches and engage the main shift lever at the stop position.
Page 36 DSC48 24. Label C7311-50661 25. Label C7313-11411 Warning Clean-out opening Inside is a rotor that can cause 1. Always follow the instructions of the manual injury. Shut off the engine Caution and safety-alert labels. before cleaning. Close this 2. Always follow the guidelines for safe driving cover after cleaning.
Page 37 DSC48 29. Label C7343-51741 30. Label C7343-51841 Caution Caution Be careful when dismantling the cutter frame. Do not clear stalks with bare hands after dismantling Fire extinguisher the concave sieve. Fire extinguisher must be available during operation. Do not rotate the threshing cylinder with bare hands.
Page 38 MEMO...
Page 39 DSC48 GENERAL TABLE OF CONTENTS 1. OVERVIEW ..........1-3 1.9 Check and maintenance ....... 1-17 1.9.1 Check before starting engine ..1-17 1.1 Combine harvester identiﬁ cation ....1-3 1.9.2 Adjusting the belts ...... 1-18 1.2 Speciﬁ cations ........... 1-4 1.9.3 Initial 50 hours ......1-19 1.3 Maintenance schedule table...
Page 41: Overview
DSC48 1. OVERVIEW 1.1 COMBINE HARVESTER IDENTIFICATION When contacting your local KIOTI distributor, always specify its model number, serial number, engine model and manufac- turing serial numbers, and hour meter reading. 417W101A 417W102A (1) Manufacturing Label (2) Engine Serial Number...
Page 42: Specifications
DSC48 1.2 SPECIFICATIONS Model DSC 48 Structural Quality Crawler self-propelled half-feed model Dimensions Length (mm) 4,340 Width (mm) 1,780 Height (mm) 2,270 Toral weight (kg) 2,180 Engine Model 4A220C-CH Type Water-cooled 4-cycle 4 cylinder in-line diesel Displacement (cc) 2,197 Power/Revolutions KW / (r/min) 35.3 / 2,800...
Page 43 DSC48 Model DSC 48 Other systems Micro computer Grain fullness indicators Overload Indicators Concentrated oiling system Automation Automatic straw discharge warning lamp Automatic threshing height adjustment Automatic engine shut off Productivity (min/1000m 1000m /approx 9-14 min Productivity per hour of pure work /hr) 0.25 ~ 0.45...
Page 44: Maintenance Schedule Table (* If There Is Any Faulty Part, Replace It.)
DSC48 1.3 MAINTENANCE SCHEDULE TABLE (* If there is any faulty part, replace it.) : Inspect and service (if necessary) after a test drive : Inspect and service : Replace (if necessary) after a test drive : Replace Schedule After...
Page 45 DSC48 : Inspect and service (if necessary) after a test drive : Inspect and service : Replace (if necessary) after a test drive : Replace Schedule After Item Every 50 hr: Check Reaping drive belt Every 250 hr: Change Every 100 hr: Check...
Page 46 DSC48 : Inspect and service (if necessary) after a test drive : Inspect and service : Replace (if necessary) after a test drive : Replace Schedule After Item Plant guide rail (left) Plant guide rail (middle) Supplying part frame Every 800 hr: Change...
Page 47 DSC48 : Inspect and service (if necessary) after a test drive : Inspect and service : Replace (if necessary) after a test drive : Replace Schedule After Item Every 500 hr: Change Straw discharge feeding rake (ear) Every 150 hr: Change...
Page 48: Oil And Coolant Change Schedule
DSC48 1.4 OIL AND COOLANT CHANGE SCHEDULE 1.4.1 TABLE FOR CHANGING OF OIL/COOLANT : Check, : Replenish, : Change Schedule Every Remark Items time hour hour hour hour hour hour hour hour hour hour hour Fuel In the winter, drain the radiator or reﬁ ll a 50/50 mixture of anti-freezing engine Coolant coolant and pure water for a long term parking.
Page 49: Loctite And Liquid Gasket Application
DSC48 1.5 LOCTITE AND LIQUID GASKET APPLICATION 1.5.1 LOCTITE APPLICATION Apply LOCTITE to the following bolts and nuts. Section LOCTITE application • Mounting bolts of reaping shaft case 1 & 2 (M12·9T) - 4 EA × 3 • Mounting nuts of cutting blade connecting shaft - 2EA •...
Page 50: Liquid Gasket Application
DSC48 1.5.2 LIQUID GASKET APPLICATION Apply liquid gasket (Three Bond 1215 or equivalent) to the following parts. Section LOCTITE application • Brake case gasket • Transmission case gasket • Vehicle speed sensor gasket • Rubber cap and oil seal of reaping drive pulley Driving unit •...
Page 51: Oil Specification And Capacity
Daedong TF65 or Shell: DoNAX TD Exxonmobil: Mobil ﬂ uid 423 or 424 22 (ℓ) Caltex: TDH ﬂ uid KBT Castrol: Castrol agri TFD Chain drive case oil Gear oil #90, #80 or Daedong TF65 0.3 (ℓ) Grease Reaping unit Standard Grease As reguired Threshing unit 15W-40 can be used in any season.
Page 52: Tightening Torque
DSC48 1.7 TIGHTENING TORQUE 1.7.1 GENERAL USE BOLTS AND NUTS Indication on No-grade or 4T top of bolt Bolt material SS400, S20C S43C, S48C SCr435, SCM435 Corresponding Ordinariness Aluminum Ordinariness Aluminum Ordinariness part's material Unit kgf-m lb-ft kgf-m lb-ft kgf-m lb-ft...
Page 53: American Standard Screws, Bolts And Nuts With Unc Or Unf Threads
DSC48 1.7.3 AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS Grade SAE GR.5 SAE GR.5 Unit Diameter kgf-m lb-ft kgf-m lb-ft 5/16 23.1 ~ 27.8 2.35 ~ 2.84 17.0 ~ 20.5 32.5 ~ 39.3 3.31 ~ 4.01 24.0 ~ 29.0...
Page 54: Unit Conversion Table
DSC48 1.8 UNIT CONVERSION TABLE Torque Length Volume Pressure Temperature Kgf-m lb-ft Inch ℓ U.S.gal. kgf/cm ºC ºF 25.4 0.26418 14.22 19.6 14.5 50.8 142.2 29.4 21.7 76.2 1960 284.4 39.2 28.9 101.6 2940 426.6 36.2 3920 568.8 58.8 43.4 152.4...
Page 55: Check And Maintenance
DSC48 1.9 CHECK AND MAINTENANCE 1.9.1 CHECK BEFORE STARTING ENGINE A. CHECKING ENGINE COOLANT Radiator capacity 8.1 ℓ Auxiliary coolant tank 1.0 ℓ capacity 417W141A (1) Coolant reservoir (A) FULL (B) LOW B. CHECKING ENGINE OIL Temperature Type of oil...
Page 56: Adjusting The Belts
DSC48 1.9.2 ADJUSTING THE BELTS Adjust each belt’s tension with an adjusting bolt or cable bolt to maintain the proper return spring length as shown in the following table. Belts Speciﬁ cation Quantity Spring length (installed) Engine unit Transmission drive belt...
Page 57: Initial 50 Hours
DSC48 1.9.3 INITIAL 50 HOURS A. CHANGING ENGINE OIL CAUTION • Be sure to stop the engine before changing engine oil. 1. Stop the engine. Then, drain the engine oil before it gets cool. Drain the oil completely and then add the speciﬁ...
Page 58 DSC48 C. REPLACING HYDRAULIC OIL, HST FILTER AND TANK FILTER CAUTION • Be sure to stop the engine before changing oil or ﬁ lter. 1. Remove the drain plug and drain the oil. 2. Remove the level check bolt. Add oil until oil ﬂ ows out from the level check hole.
Page 59 DSC48 E. ADJUSTING CRAWLER TENSION 1. Lift the front and rear of the frame with a jack. Tighten the tension bolt to loose the tension of the crawler. 2. Unscrew the crawler mounting nut and tighten the ten- sility bolt.
Page 60 DSC48 G. ADJUSTING STEM SIDE CHAINS (LH/RH) • Check and adjustment Check whether the chain is stretched or the roller is broken or worn. • Replacement If it is severely damaged or worn, sits on the drive sprocket due to deﬂ ection, or cannot be corrected with the adjusting...
Page 61 DSC48 I. ADJUSTING FEEDING DEPTH CONTROL CHAIN • Check and adjustment Check whether the chain is deﬂ ected or the roller is broken or worn. • Replacement If the chain is severely worn or damaged, sits on the drive sprocket due to deﬂ ection, or doesn't have enough gap to...
Page 62 DSC48 K. ADJUSTING STRAW DISCHARGE CHAIN (STRAW END SIDE) • Check and adjustment Check whether the chain is deﬂ ected or the roller is broken or worn. • Replacement If it is severely worn or damaged or sits on the drive...
Page 63: Every 50 Hours
DSC48 N. ADJUSTING STRAW DISCHARGE WIRE Wire spring extension 5 mm (0.197 in.) 417W163A (1) Adjusting bolt (A) Stretch: 5 mm 1.9.4 EVERY 50 HOURS A. CLEANING AIR CLEANER ELEMENT 1. When dry dust is accumulated on the element, blow compressed air from the inside to the upper and lower sides to remove the dust.
Page 64 DSC48 B. ADJUSTING PARKING BRAKE CABLE • Check Check if the cable is deﬂ ected or damaged. • Replacement If it is malfunctioning • Adjustment - Adjust the cable so that the margin of the parking brake pedal play is 0~5 mm.
Page 65: Every 100 Hours
DSC48 1.9.5 EVERY 100 HOURS A. CHANGING ENGINE OIL: see page 1-17 B. ADJUSTING GRAIN SIDE CHAIN (RH) If the adjustable hole is visible due to the deﬂ ected chain, move the stopper to let the hole and shaft contact slightly.
Page 66 DSC48 I. CHECKING CONVEYER RAKE • Check Check if it is deformed, worn or retracted. • Replacement If it is damaged or is pushed away from the guide rod or conveyer guide 417W171A The rake edge should be at a level with the guide.
Page 67: Every 150 Hours
DSC48 1.9.6 EVERY 150 HOURS A. CHECKING FUEL PIPE • Check and adjustment Check any fuel leakage, due to any damage or crack around the clip. • Replacement If fuel deﬁ nitely or probably leaks 417W174A (1) Clip (4) Fuel pipe 3...
Page 68 DSC48 B. REPLACING STRAW CHOPPER BLADE • Detachment 1. Open the threshing chamber cover. 2. Disengage the blade lock pin and remove the bolt. 3. Open the threshing cylinder. 417W177A 417W178A 4. Remove the blade support. 5. Unscrew the straw chopper blade bolts and nuts to de- tach the straw chopper blade.
Page 69 DSC48 C. REPLACING CUTTER DRIVE BELT Belt speciﬁ cation: B-55 417W180A (1) Drive belt D. CHECKING NO. 2 AUGER BLADE • Check and adjustment Check if it is worn and the liner steel plates are at proper interval. • Replacement...
Page 70: Every 250 Hours
DSC48 1.9.8 EVERY 250 HOURS A. CHECKING IDLE ROLLER • Check Check if the roller does not rotate properly or is worn. • Replacement If it is worn 3.4 mm or more B. CHECKING DRIVE ROLLER • Check Check the roller's proper rotation and its rubber's separa- tion or excessive wear.
Page 71 DSC48 K. CHECKING FRONT COVER • Check Check if it is worn or damaged. • Replacement If its bottom is worn 4 mm or more 417W184A (1) Front seal 1 from front cover (2) Front seal 2 from front cover...
Page 72: Every 350 Hours
DSC48 O. REPLACING CUTTING BLADE CRANK ARM BEARING • Check Check the crank arm play. • Replacement If there is abnormal noise due to stuck or unevenly applied oil or the bearing play is excessive 417W187A (1) Bearing wear (A) Play 1.9.10 EVERY 350 HOURS...
Page 73: Every 400 Hours
DSC48 1.9.11 EVERY 400 HOURS A. REPLACING FUEL FILTER 1. Remove the fuel ﬁ lter with a hand or a tool. 2. Apply thin ﬁ lm of oil to the packing of the new fuel ﬁ lter and hand-tighten it ﬁ rmly.
Page 74 DSC48 H. CHECKING SIEVE • Check Check if the sieve protrusion is worn or the welding sec- tions on the sieve support and arch metal are damaged. • Replacement (check every 600 hours) If its wire diameter is 1.6 mm or less 417W192A (A) 1.6 mm or less (new one: 2.6 mm)
Page 75: Every 500 Hours
DSC48 1.9.12 EVERY 500 HOURS A. CHECKING DRIVE SPROCKET • Check Check if it is worn. • Replacement If it is worn 5.5 mm or more 417W194A (1) Wear (A) New: 38 mm B. REPLACING PACKER • Check Check if the packers are not at the same level or they are abnormally worn or damaged.
Page 76: Every 600 Hours
DSC48 1.9.13 EVERY 600 HOURS 1.9.15 EVERY 1000 HOURS A. REPLACING IDLE ROLLER: see page 5-8 A. REPLACING AXLES (LH/RH): see page 5-12 B. REPLACING ROCKER ROLLER: see page 5-9 B. REPLACING AXLE COVERS: see page 5-12 C. REPLACING NO. 2 LINER (NO. 2 THROWER): see page 4-18 1.9.14 EVERY 800 HOURS...
Page 77 DSC48 ENGINE TABLE OF CONTENTS 1. GENERAL ..........2-2 2.4 Fuel system ..........2-13 2.4.1 Flow of fuel ........2-13 1.1 Appearance ..........2-2 2.4.2 Fuel feed pump ......2-13 1.2 Speciﬁ cations ........... 2-3 2.4.3 Fuel injection pump ...... 2-14 1.3 Dimensions ..........
Page 78: General
DSC48 1. GENERAL 1.1 APPEARANCE 417W201A The KIOTI engine is a vertical, water-cooled, 4-cycle, and four-cylinder diesel engine. It integrates KIOTI's foremost technologies. With swirl combustion chamber, BOSCH K type fuel injection pump, and well-balanced designs, this engine features great power, low fuel consumption, and less vibration and noise.
Page 79: Specifications
DSC48 1.2 SPECIFICATIONS Model 4A220C-CH Type Vertical, water-cooled, 4-cycle, diesel engine Number of cylinders Bore x stroke 87.0 x 92.4 (mm) Total displacement 2,197 (cc) Combustion chamber Swirl chamber Power (NET) 48 / 2,800 (HP/rpm) Max. idling speed without load 3,000 (rpm) Min.
Page 80: Dimensions
DSC48 1.3 DIMENSIONS 417W202A SPECIFICATIONS mm (in.) 4A220C-CH 4A220C-CH 655.8 (25.82) 772.8 (30.43) 824.3 (32.45) 296.7 (11.68) 280 (11.02) 240 (9.45) φ 400 (15.75) φ 328 (12.91) 516.5 (20.35) 92.5 (3.64) 282.4 (11.19) 545.9 (21.49) 1.4 GENERAL PRECAUTIONS • When disassembling the engine, arrange each part in a clean area.
Page 81: Structure And Function
DSC48 2. STRUCTURE AND FUNCTION 2.1 BODY 2.1.1 CYLINDER HEAD 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 in a cross-ﬂ ow type to get high combustion efﬁ ciency by protecting sucked air from being heated and expanded by heated exhausted air.
Page 82: Crankshaft
DSC48 2.1.3 CRANKSHAFT The crankshaft is made of forged steel. The journals, crankpins and oil seals are induction-hardened to increase wear resistance. While the front journal is supported by a unit type bearing, the middle journal is supported by a split type bearing.
Page 83: Camshaft
DSC48 2.1.6 CAMSHAFT The camshaft (3) is made of forged steel. Its journals 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 lubricated.
Page 84: Intake And Exhaust Valves
DSC48 2.1.9 INTAKE AND EXHAUST VALVES The valve and its guide of the intake are different from those for the exhaust. Other parts, such as the spring (3), spring retainers (2), valve spring collets (1), valve stem seals (4) are the same for both the intake and the exhaust.
Page 85: Lubricating System
DSC48 2.2 LUBRICATING SYSTEM 2.2.1 FLOW OF LUBRICATING OIL 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 parts such as the push rods (11), tappets (12), piston pins, and timing gears.
Page 86: Oil Filter And Relief Valve
DSC48 2.2.3 OIL FILTER AND RELIEF VALVE The engine oil force-fed by the pump is ﬁ ltered by the ﬁ lter cartridge, passing through the ﬁ lter element from outside to the inside. When the ﬁ lter element accumulates dirt and the pressure difference between the inside and outside rises 98 kPa (1.0...
Page 87: Cooling System
DSC48 2.3 COOLING SYSTEM 2.3.1 FLOW OF COOLING WATER The cooling system consists of the radiator (5), water pump (7), cooling fan (6), and thermostat (2). Water is cooled as it ﬂ ows through the radiator tube, and the cooling fan be- hind the radiator pulls the cooling air through the radiator core.
Page 88: Radiator
DSC48 2.3.3 RADIATOR The radiator core consists of water carrying tubes (2) with ﬁ ns (3) at a right angle to it. The water in the radiator is cooled by the air ﬂ owing through the tube wall and the ﬁ n.
Page 89: Fuel System
DSC48 2.4 FUEL SYSTEM 2.4.1 FLOW OF FUEL The fuel pump (7) sucks up fuel from the fuel tank (1) and pushes the fuel to the fuel ﬁ lter (2) which removes dust, water, etc. from the fuel. Then, the fuel is supplied to the injection pump (3).
Page 90: Fuel Injection Pump
DSC48 2.4.3 FUEL INJECTION PUMP The injection pump is BOSCH K type mini injection pump. It features a compact and light weight design. 417W227A (a) From fuel ﬁ lter (b) To injection pump (1) Delivery valve holder (5) Plunger (2) Delivery valve spring (6) Control rack...
Page 91 DSC48 B. OPERATION OF PUMP ELEMENT (A) Before fuel compression As the tappet lowers, the plunger (2) lowers and the fuel is drawn into the delivery chamber (1) through the feed hole (4) from the fuel chamber (5). (B) Beginning of fuel compression...
Page 92: Fuel Injection Nozzle
DSC48 D. DELIVERY VALVE The delivery valve has the following functions: (A) It prevents the fuel in the injection pipe from flowing back into the delivery chamber. (B) It prevent the fuel in the injection nozzle from dribbling after injection.
Page 93: Governor
DSC48 2.4.6 GOVERNOR A. DISASSEMBLED VIEW The governor works to keep the engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in the load. Balance between the centrifugal force of the steel balls (13) (produced by...
Page 94 DSC48 ► AT IDLING When the speed control lever (15) is at the idling position, the governor spring 1 (2) is free and the governor spring 2 (3) only acts slightly. The governor sleeve (12) is pushed leftward by a centrifugal force of the steel ball (13). There-...
Page 95 DSC48 ► TO STOP ENGINE When the stop lever is moved to the "STOP" position, the fork lever 1 (4) is moved to the left and the control rack (14) is moved to the non-injection position, causing the engine to stop.
Page 96: Intake And Exhaust System
DSC48 2.5 INTAKE AND EXHAUST SYSTEM 2.5.1 FLOW OF INTAKE AIR AND EXHAUST GAS 417W238A (a) Intake air (1) Inlet manifold (4) Mufﬂ er (7) Inlet port (b) To inlet manifold (2) Air cleaner (5) Exhaust manifold (8) Air cleaner element...
Page 97: Disassembly And Service
DSC48 3. DISASSEMBLY AND SERVICE 3.1 TROUBLESHOOTING Symptom Probable cause Solution Engine does not start • No fuel Replenish fuel • Air in the fuel system Bleeding air • Water in the fuel system Clean fuel tank or change fuel in pipe •...
Page 98 DSC48 Symptom Probable cause Solution Insufﬁ cient Output • Incorrect injection timing Adjust • Engine's moving parts seem to be seizing Repair or replace • Uneven fuel injection Repair or replace injection pump • Insufﬁ cient nozzle injection Repair or replace nozzle •...
Page 99: Service Specifications
DSC48 3.2 SERVICE SPECIFICATIONS 3.2.1 ENGINE BODY A. CYLINDER HEAD Item Factory speciﬁ cation Allowable limit Cylinder head surface ﬂ atness 0.05 mm / 100 mm 0.002 in. / 3.94 in. Top clearance 0.75 ~ 0.9 mm 0.0295 ~ 0.0354 in.
Page 100 DSC48 D. CYLINDER Item Factory speciﬁ cation Allowable limit φ 87 (0~+ 0.022 ) mm Cylinder bore I.D. 0.15 mm φ 3.4252 (0~+ 0.022 ) in. 0.0059 in. E. VALVE SPRING Item Factory speciﬁ cation Allowable limit Free length 41.7 ~ 42.2 mm 41.2 mm...
Page 101 DSC48 I. TIMING GEAR Item Factory speciﬁ cation Allowable limit Timing gear backlash 0.04 ~ 0.11 mm 0.15 mm 0.016 ~ 0.0043 in. 0.0059 in. Idle gear side clearance 0.20 ~ 0.51 mm 0.9 mm 0.0079 ~ 0.0201 in. 0.035 in.
Page 102 DSC48 K. CONNECTING ROD Item Factory speciﬁ cation Allowable limit Connecting rod misalignment 0.05 mm 0.0020 in. Clearance between piston pin and piston pin bushing 0.014 ~ 0.038 mm 0.15 mm 0.00055 ~ 0.00150 in. 0.0059 in. Piston pin O.D.
Page 103: Lubricating System
DSC48 3.2.2 LUBRICATING SYSTEM A. OIL PUMP Item Factory speciﬁ cation Allowable limit Engine oil pressure At idle speed 68.6 kPa (Oil temp.: 85 ~ 95°C) 0.7 kgf/cm 9.95 psi At rated speed 245 ~ 441 kPa 245 kPa 2.5 ~ 4.5 kgf/cm 2.5 kgf/cm...
Page 104 DSC48 3.2.5 TIGHTENING TORQUE Item Size x Pitch kgf-m lb-ft Cylinder head bolts M11 x 1.25 103.0 ~ 107.9 10.5 ~ 11.0 75.9 ~ 79.6 Head cover nuts M10 x 1.25 8.8 ~ 10.8 0.9 ~ 1.1 6.5 ~ 8.0 * Bearing case bolt 1 M9 x 1.25...
Page 107: Tightening Torque
DSC48 3.3.2 EXTERNAL COMPONENTS A. CHECKING AND ADJUSTING ► FAN BELT 1. Measure the deﬂ ection by depressing the belt halfway between the fan drive pulley and alternator pulley at 10 kgf of force. 2. If the deﬂ ection is not between the factory speciﬁ cations, loosen the bolts and nuts and move the alternator to adjust.
Page 108: Engine Body
DSC48 3.3.3 ENGINE BODY A. CHECKING AND ADJUSTING ► COMPRESSION PRESSURE 1. Run the engine until warmed up. 2. Stop the engine and remove the air cleaner, muffler and nozzle holders. 3. Install the adapter to the nozzle holder and secure the compression tester.
Page 109: Disassembly And Assembly
DSC48 3.3.4 DISASSEMBLY AND ASSEMBLY A. CYLINDER HEAD AND VALVES ► CYLINDER HEAD COVER AND INJECTION NOZZLE 1. Remove the injection pipes and overﬂ ow pipe. 2. Remove the glow plugs. 3. Remove the injection nozzles and gaskets. 4. Remove the heat seals.
Page 110 DSC48 ► CYLINDER HEAD 1. Remove the bolts in the speciﬁ ed sequence as shown in the ﬁ gure. Remove the cylinder head (1) and head gas- ket. • To loosen: (18) to (1), To tighten: (1) to (18) 2. Remove the water ﬂ ange (2).
Page 111 DSC48 B. TIMING GEARS AND CAMSHAFTS ► INJECTION PUMP 1. Remove the injection pump cover (3) with the engine stop lever (2). 2. Remove the injection pump. <When reassembling> • Apply a liquid gasket to the shim (6) and both sides of the injection pump cover gasket before installing them.
Page 112 DSC48 ► FAN DRIVE PULLEY 1. Install the stopper to the ﬂ ywheel so that the crankshaft does not turn. 2. Unscrew the crankshaft nut. 3. Pull out the pulley. 48.1 ~ 55.9 Nm Tightening torque of 4.9 ~ 5.7 kgf-m crankshaft nut 35.4 ~ 41.2 lb-ft...
Page 113 DSC48 ► IDLE GEAR AND CRANK GEAR 1. Remove the crankshaft collar (6), O-ring (5), oil slinger (4), and crank gear collar (3) in order. 2. Remove the idle gear (1). 3. Remove the crank gear (2). CAUTION • When removing the oil pump, loosen the pump gear nut if the oil pump gear (7) and crank gear (2) do not move.
Page 114 DSC48 ► FUEL CAMSHAFT 1. Remove the fuel camshaft stopper. 2. Loosen the fork lever holder bolts and remove the fuel camshaft (4) with fork lever holder (5) and fork levers 1 (1) and 2 (2). 3. Remove the injection pump gear (3).
Page 115 DSC48 ► PISTON RING AND PISTON PIN 1. Pull out the piston ring 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 of oil for 10 to 15 min- utes, before inserting the piston pin into the piston.
Page 116 DSC48 D. CRANKSHAFT ► FLYWHEEL 1. Install the stopper to the ﬂ ywheel and loosen the bolt. 2. Remove the ﬂ ywheel stopper and ﬂ ywheel. <When reassembling> • Clean the end of the crankshaft and the mating surface of the ﬂ ywheel.
Page 117 DSC48 ► MAIN BEARING CASE 1. Remove the main bearing case bolt 1 and main bearing case (1). 2. Remove the thrust bearing from the ﬂ ywheel end's bear- ing case. IMPORTANT • Mark the location number on the bearing case to prevent interchanging.
Page 118: Servicing
DSC48 3.3.5 SERVICING A. CYLINDER HEAD AND VALVE ► 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 ﬁ gure.
Page 119 DSC48 ► VALVE RECESSING 1. Clean the cylinder head, valve face and valve 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 or check the valve seat.
Page 120 DSC48 ► VALVE SPRING SQUARENESS (TILT) 1. On a ﬂ at table, place the spring and a square by the spring. 2. Measure the maximum distance "A" (see ﬁ gure), while rotating the spring. 3. If the measurement exceeds the allowable limit, replace Factory spec.
Page 121 DSC48 B. TIMING GEARS AND CAMSHAFTS ► TIMING GEAR BACKLASH 1. Set a dial indicator's tip on the gear tooth. 2. Move the timing gear to measure the backlash, while holding its mating gear. 3. If the backlash exceeds the allowable limit, check the oil clearance of the shaft and gear.
Page 122 DSC48 ► INJECTION PUMP GEAR SIDE CLEARANCE 1. Pull each end of the fuel camshaft and injection pump gear (1). 2. Measure the clearance (A) between the injection pump gear (1) and snap ring (2) on the fuel camshaft. 3. If the measurement exceeds the allowable limit, check the gear, bearing and key.
Page 123 DSC48 ► CAMSHAFT OIL CLEARANCE 1. Measure the I.D. of the camshaft bore on the crank- case with an inside micrometer. 2. Measure the O.D. of the camshaft journal with an out- side micrometer. 3. If the clearance exceeds the allowable limit, replace the shaft.
Page 124 DSC48 C. CONNECTING ROD AND PISTON ► PISTON PIN BORE 1. Measure the I.D. of the piston pin bore in the piston (lengthwise and widthwise of the piston) with a cylinder gauge. 2. If the measurement exceeds the allowable limit, replace the piston.
Page 125 DSC48 ► PISTON RING END GAP 1. Push the piston ring into the cylinder's lower side. 2. Measure the ring gap with a feeler gauge. 3. If the gap exceeds the allowable limit, replace the pis- ton ring. Factory spec.
Page 126 DSC48 D. CRANKSHAFT ► FLYWHEEL DEFLECTION AND CRANKSHAFT END PLAY 1. Set a dial indicator's top on the rear friction face of the ﬂ ywheel near the edge. 2. Turn the ﬂ ywheel and measure the deﬂ ection or uneven wear.
Page 127 DSC48 ► REPLACING CRANKSHAFT BEARING 1 1. Press out the crankshaft bearing 1 using the replacing tool. 2. Clean the cylinder block bore and crankshaft bearing 1. And apply engine oil to them. 3. Install the crankshaft bearing 1 to the cylinder block so that its seam faces the exhaust manifold side.
Page 128 DSC48 E. CYLINDER BORE ► CYLINDER BORE 1. Measure the cylinder I.D. at six positions shown in the ﬁ gure to ﬁ nd the maximum wear. 0 ± 0.022 mm Cylinder I.D. ( φ 87) 0 ± 0.001 in. 417W2A4A 417W2A5A Apr.
Page 129: Lubricating System
DSC48 3.3.5 LUBRICATING SYSTEM A. CHECKING ► ENGINE OIL PRESSURE 1. Remove the oil pressure switch. Then, install the pres- sure tester and adapter. 2. Start the engine and run it until it warms up. Measure the oil pressure both at idling and rated speeds.
Page 130 DSC48 B. SERVICING ► ROTOR AND LOBE CLEARANCE 1. Measure the clearance between the outer and inner ro- tors with a feeler gauge. 2. Measure the clearance between the outer rotor and housing with a feeler gauge. 3. If the clearance exceeds the allowable limit, replace the pump.
Page 131: Cooling System
DSC48 3.3.6 COOLING SYSTEM A. CHECKING AND ADJUSTING ► FAN BELT 1. Measure the deﬂ ection by depressing the belt halfway between the fan drive pulley and alternator pulley at 10 kgf of force. 2. If the deﬂ ection is not within the factory speciﬁ cation, loosen the bolts and nuts and move the alternator to adjust the deﬂ...
Page 132 DSC48 B. DISASSEMBLY AND ASSEMBLY ► WATER PUMP 1. Remove the cooling fan and fan pulley. 2. Remove the water pump assembly from the gear case. 3. Remove the water pump ﬂ ange (1). 4. Pull out the impeller and water pump bearing.
Page 133: Fuel System
DSC48 3.3.7 FUEL SYSTEM A. CHECKING AND ADJUSTING ► INJECTION PUMP (1) Injection timing 1. Remove the injection pipe. 2. Set the speed control lever to the maximum fuel dis- charge position. 3. Turn the ﬂ ywheel counterclockwise (facing the ﬂ ywheel) until the fuel level reaches the hole of the delivery valve holder (1).
Page 134 DSC48 ► INJECTION NOZZLE CAUTION • Never come in contact with sprayed diesel fuel under pressure. It can penetrate your skin, causing serious personal injury. • Make sure nobody is in direction of the spray. (1) Nozzle injection pressure 1. Set the injection nozzle to the nozzle tester.
Page 135 DSC48 B. DISASSEMBLY AND ASSEMBLY ► INJECTION PUMP CAUTION • If any fuel pump component is replaced, the amount of fuel injection should be adjusted with the speciﬁ ed tool. 417W2C1A (1) Pump body (2) Control rack (3) Delivery valve holder...
Page 136 MEMO...
Page 137 DSC48 REAPING UNIT TABLE OF CONTENTS 1. REAPING UNIT ........3-3 1.5.3 Adjustment and replacement of stem side chain (LH) ......3-14 1.1 Sectional view .......... 3-3 1.5.4 Adjustment and replacement of grain 1.2 Detachment and attachment of reaping unit side chain (LH) ......
Page 141: Reaping Unit
DSC48 1.2 DETACHMENT AND ATTACHMENT OF REAPING UNIT 1.2.1 DETACHMENT 1. Park the combine harvester on a ﬁ rm level ground. 2. Start the engine and raise the reaping unit slightly to ﬁ x the reaping unit stand (1). 3. Lower the reaping unit and stop the engine.
Page 142: Cutting Blade Unit
DSC48 1.3 CUTTING BLADE UNIT CAUTION • Never touch the blade. It may operate abruptly and lead to an accident. • When removing the cutting blade unit, always wear protective gloves. The unit should be removed by two persons from the machine by holding both ends of it.
Page 143 DSC48 C. ADJUSTMENT OF CLEARANCE BETWEEN CUTTING BLADE AND BASE BLADE 1. Remove the blade clip from the base blade plate. 2. Remove any foreign materials. 3. Adjust the clearance between the cutting blade and the base blade to be 0 ~ 0.5 mm by adding or removing the shim 2.
Page 144: Components Related To Cutting Blade Crank
DSC48 1.3.2 COMPONENTS RELATED TO CUTTING BLADE CRANK CAUTION • The oil seal for the cutting blade crank should be installed in the reverse direction from the normal installation direction as shown in the ﬁ gure. (should be lubricated beforehand) A.
Page 145: Components Related To Cutting Blade Drive Case
DSC48 1.3.3 COMPONENTS RELATED TO CUTTING BLADE DRIVE CASE When installing the drive case assembly, make sure to align the mating surface of the bearing holder. - Align with the spline boss in the case. 417W312A (1) Cutting blade drive case...
Page 146: Elevator
DSC48 1.4 ELEVATOR 1.4.1 ADJUSTMENT OF ELEVATOR CHAIN TENSION AND REPLACEMENT OF ELEVATOR CHAIN 1. Measure the clearance between the elevator tension hook and pulling nut. 2. If the measure clearance is not within 0.5 ~ 2.5 mm, adjust the clearance with the pulling bolt.
Page 147: Elevator Rake And Cushion Rubber Installation
DSC48 1.4.3 ELEVATOR RAKE AND CUSHION RUBBER INSTALLATION 1. One side rake should be slightly above the other side rake to avoid getting caught by each other. 2. Install the cushion rubber to the rotating direction of the chain. • A: Clearance between front and back, left and right - within 9 mm •...
Page 148: Elevator Shift Case
DSC48 1.4.5 ELEVATOR SHIFT CASE 1. Apply grease on the gear and the shaft. 2. When installing the shift plug, apply LOCTITE on it. 417W321A (1) Elevator shift case (2) Shift plug Apr. 2007...
Page 149: Conveyor
DSC48 1.5 CONVEYOR 1.5.1 ADJUSTMENT AND REPLACEMENT OF PROTRUSION BELT A. ADJUSTMENT 1. Loosen the threaded screw (M10) of the tension pulley and pull the belt. Then, tighten the screw to adjust the tension. Standard deﬂ ection of 5 ~ 10 mm belt at its center B.
Page 150: Adjustment And Replacement Of Stem Side Chain (Lh)
DSC48 1.5.3 ADJUSTMENT AND REPLACEMENT OF STEM SIDE CHAIN (LH) A. ADJUSTMENT Standard spring length 124 ~ 128 mm (installed) B. REPLACEMENT 1. Same procedures as for the stem side chain (RH) 417W325A (1) Stem side chain (LH) (A) 124 ~ 128 mm 1.5.4 ADJUSTMENT AND REPLACEMENT...
Page 151: Adjustment And Replacement Of Grain Side Chain (Rh)
DSC48 4. When installing the chain, ensure its clip's opening is opposite the chain's rotating direction. 5. Apply grease on the tension sliding surface. 417W328A (1) Tension metal (A) Direction of clip (2) Stem side chain (LH) (B) Rotating direction 1.5.5 ADJUSTMENT AND REPLACEMENT...
Page 152: Adjustment And Replacement Of Stem Side Feeding Chain
DSC48 4. When installing the chain, ensure its clip's opening is opposite the chain's rotating direction. 5. Apply grease on the tension sliding surface. 417W331A (1) Grain side chain (RH) (B) Direction of clip 1.5.6 ADJUSTMENT AND REPLACEMENT OF STEM SIDE FEEDING CHAIN A.
Page 153: Adjustment And Replacement Of Feeding Depth Control Chain
DSC48 1.5.7 ADJUSTMENT AND REPLACEMENT OF FEEDING DEPTH CONTROL CHAIN A. ADJUSTMENT Check if the chain is deflected or the roller is broken or worn. Standard interval 1 ~ 2 mm B. REPLACEMENT 1. Replace the chain, when the chain is visibly worn or damaged, sits on the drive sprocket due to its deﬂ...
Page 154: Replacement Of Packer
DSC48 1.5.8 REPLACEMENT OF PACKER A. REPLACEMENT OF PACKERS (CENTER, 2 EA) 1. Unscrew four bolts on the bottom and pull out of packer. <When assembling> • When installing the mounting bolts for the packer, use plain washers. 417W335A (1) Packer CAUTION •...
Page 155: Installation Of Stem Side Conveyor Prop
DSC48 3. Unscrew two nuts (LOCTITE applied) on the bearing holder. 4. Unscrew four mounting bolts on the packer shaft. 5. Pull out the bearing holder and packer shaft assembly. 6. Pull out the packer shaft bearings in order. Use a puller when separating the packer shaft case and the shaft.
Page 156: Installation Of Chain Lock Plate
DSC48 1.5.11 INSTALLATION OF CHAIN LOCK PLATE 417W341A (1) Anti chain lock plate (2) Feeding guide (3) Feeding chain (A) 2.8 ~ 3.2 mm 1.5.12 INSTALLATION OF STEM SIDE PROP 417W342A (A) 26 ~ 34 mm 417W343A (1) Stem side prop...
Page 157: Installation Of Feeding Guide
DSC48 1.5.13 INSTALLATION OF FEEDING GUIDE 417W344A (1) Feeding chain (2) Feeding guide (A) Minimum Clearance: 4 ~ 7 mm - Adjust the clear- ance with the shim of the feeding guide support. (B) 6 ~ 9 mm: parallel 1.5.14 INSTALLATION OF FEEDING CHAIN...
Page 158: Vertical Adjustment Of Feeding Depth Control Chain
DSC48 1.5.16 VERTICAL ADJUSTMENT OF FEEDING DEPTH CONTROL CHAIN 417W347A (1) Prop (2) Chain plate (A) 6 ~ 9 mm (B) Adjust with the turnbuckle (C) Clearance between the prop and chain plate when the feeding depth control chain is at deepest position...
Page 159: Other Bolts And Nuts, Loctite And Grease Application
DSC48 1.6 OTHER BOLTS AND NUTS, LOCTITE AND GREASE APPLICATION 417W351A (1) Reaping unit shaft case 1 (9) Feeding depth control rotating shaft support (2) Reaping unit shaft case 2 (10) Nut (LOCTITE applied) (3) Bolt (LOCTITE applied) (11) Feeding depth control case 1 (gear and bushing,...
Page 160 MEMO...
Page 161 DSC48 THRESHING UNIT TABLE OF CONTENTS 1. THRESHING UNIT ........4-3 1.7 No. 2 auger ..........4-18 1.7.1 Removal and installation of No. 2 au- 1.1 Sectional view .......... 4-3 ger ..........4-18 1.2 Check and adjustment of belt ....4-6 1.8 Separator drum and No.
Page 163: Threshing Unit
DSC48 1. THRESHING UNIT 1.1 SECTIONAL VIEW 417W401A (1) Vertical auger (5) Sieve case (9) Straw rack (12) No. 1 screw (2) Threshing cylinder (6) Reprocessing cylinder (10) Blower (13) No. 2 screw (manually adjusted) (3) Concave (7) Separator drum (14) No.
Page 164 DSC48 417W403A (1) Tension pulley (4) No. 2 thrower (7) Vertical auger (10) No. 1 auger (2) 115 V-pulley (5) No. 2 rotation sensor (8) 14T bevel gear (11) No. 1 drive pulley (3) No. 2 auger (6) No. 1 rotation sensor (9) 15T bevel gear Apr.
Page 165 DSC48 417W404A (1) 90-132 idle pulley (9) Rocker shaft 1 (17) Separator drum shaft (24) Shift pulley 1 (2) Tension pulley (10) Rocker shaft 3 (18) Sprocket (driving con- (25) Shift pulley 2 veyor chain) (3) Tension lever (11) Attachment metal...
Page 166: Check And Adjustment Of Belt
DSC48 1.2 CHECK AND ADJUSTMENT OF BELT (Check every 100 hours, replace every 300 hours) • The length of the springs for the following belts should be kept in the speciﬁ ed ranges. Adjust their length us- ing the adjusting bolt and wire adjusting bolt if neces- sary.
Page 167: Components Around Engine
DSC48 1.2.3 COMPONENTS AROUND ENGINE 417W408A (1) HST pulley (5) Threshing drive belt (2) Reaping drive belt 3 (6) Engine pulley (3) Reaping unit pulley (A) 141 ~ 145 mm (4) Transmission drive belt 1.2.4 LH ON THRESHING UNIT 417W409A (1) Blower drive belt (5) No.
Page 168: Feeding Chain
DSC48 1.3 FEEDING CHAIN (Check after the initial 20 hours of operation, then check every 100 hours, and replace every 500 hours) 1.3.1 ADJUSTMENT AND REPLACEMENT OF FEEDING CHAIN A. ADJUSTMENT Standard spring length 150 ~ 155 mm (installed) B. REPLACEMENT 1.
Page 169: Components Related To Threshing Cylinder
DSC48 1.4 COMPONENTS RELATED TO THRESHING CYLINDER (Replace every 200 hours) 1.4.1 REPLACEMENT OF STRAW CHOPPER BLADE CAUTION • Never touch the blade. • When removing the chopper blade, remove it holding both ends. 1. Open the threshing chamber cover.
Page 170: Removal And Installation Of Threshing Cylinder Concave
DSC48 1.4.2 REMOVAL AND INSTALLATION OF THRESHING CYLINDER CONCAVE 1. Open the threshing chamber cover. 2. Loosen the bolts (3) (FR/RR) and pull out the blade support mounting plate (2). 3. Open the threshing cylinder. 4. Remove the blade support (4).
Page 171: Replacement Of Base Cutter Disc
DSC48 1.4.3 REPLACEMENT OF BASE CUTTER DISC 1. Open the threshing cylinder. 2. Lock the open stopper. 3. Open the threshing cylinder cover and unscrew the ﬂ ange nut. • No. 1 threshing knives (2 EA), supplementary teeth (plate, 4 EA) •...
Page 172: Removal And Installation Of Threshing Cylinder
DSC48 1.4.4 REMOVAL AND INSTALLATION OF THRESHING CYLINDER 1. Detach the reaping unit. 2. Remove the front cover. The bolt can be seen with the chamber cover 1 open. 3. Remove the inlet plate 2. 417W417A (1) Inlet plate 1...
Page 173 DSC48 9. Open two disc type covers which are close to the cir- cumference joint of the threshing cylinder. Unscrew one mounting bolt on the threshing cylinder boss 1 (front) and two mounting bolts on the threshing cylin- der boss 2 (rear).
Page 174: Installation Of
DSC48 1.4.5 INSTALLATION OF FRONT COVER 1. Install the front covers in the correct order (1, 3, 2) as shown in the ﬁ gure. Be careful with the overlapped sec- tions. 417W426A (1) Front cover 1 (2) Front cover 2 (3) Front cover 3 Apr.
Page 175: Components Related To Blower
DSC48 1.5 COMPONENTS RELATED TO BLOWER (Check every 200 hours) 1.5.1 REMOVAL AND INSTALLATION OF BLOWER A. RIGHT SIDE 1. Unscrew two mounting bolts on the blower bearing holder. B. LEFT SIDE 1. Remove the split pin from the nut before removing the belt.
Page 176: Vertical Auger And No. 1 Auger
DSC48 1.6 VERTICAL AUGER AND NO. 1 AUGER (Replace every 400 hours) 1.6.1 REMOVAL AND INSTALLATION OF VERTICAL AUGER AND NO. 1 AUGER 1. Remove the No. 1 pulley mounting bolt and belt to re- move the No. 1 pulley.
Page 177 DSC48 5. Remove the No. 1 bevel case. 6. Remove the No. 1 auger. 417W432A (1) No. 1 bevel case (A) Rotating direction (2) No. 1 screw (3) No. 1 blade edge <When assembling> 1. Secure the edge of the No. 1 auger blade end to be perpendicular to the combine harvester front-rear direc- tion.
Page 178: 2 Auger
DSC48 1.7 NO. 2 AUGER (Replace every 500 hours) 1.7.1 REMOVAL AND INSTALLATION OF NO. 2 AUGER 1. Remove the No. 2 pulley mounting nut and the belt. <When assembling> • Adjust the installed spring's length to adjust the belt tension.
Page 179: Separator Drum And No. 2 Processing Cylinder
DSC48 1.8 SEPARATOR DRUM AND NO. 2 PROCESSING CYLINDER 1.8.1 REMOVAL AND INSTALLATION OF SEPARATOR DRUM AND NO. 2 PROCESSING CYLINDER 1. Remove the cover. 417W437A (1) Cover 2. Before removing the belt, loosen the pulley mounting bolt and boss mounting nut.
Page 180: Components Related To Sieve Case And Rocker Shaft
DSC48 1.9 COMPONENTS RELATED TO SIEVE CASE AND ROCKER SHAFT 1.9.1 REMOVAL AND INSTALLATION OF SIEVE CASE A. REMOVAL PROCEDURE 1. Push up the tension lever and remove the rocker belt. When removing the rocker shaft components, loosen the nut and bolt of the pulley before removing the belt.
Page 181 DSC48 B. PRECAUTIONS DURING INSTALLATION 1. Fold the separator cover to the front and ﬁ x it to the No. 1 walker. 2. Insert the No. 2 cover into the No. 2 walker. 417W446A (A) Separator cover (B) No. 2 cover...
Page 182: Removal Of Components For Sieve Case
DSC48 1.9.2 REMOVAL OF COMPONENTS FOR SIEVE CASE 1. Remove four bolts which ﬁ x the straw sieve and chaff sieve together. Then, remove the straw sieve. 2. Unscrew the bolt and remove the chaff operating arm. 3. Unscrew four mounting bolts and nuts on the chaff sup- port.
Page 183: Removal Of Components Related To Rocker Shaft
DSC48 7. Pull out the straw rack and remove the chaff sieve as- sembly. 417W452A 1.9.3 REMOVAL OF COMPONENTS RELATED TO ROCKER SHAFT 1. Unscrew the mounting bolts on both sides of the rocker arm and remove the components of the rocker shaft.
Page 184 DSC48 4. Remove the key and pull out the rocker bearing holder with a puller. 5. Remove the mounting nut and the washer from the rocker shaft 2. 417W455A 6. Install the nut to the threaded section of the rocker shaft 1 to be protruded a little or just to contact with.
Page 185: Straw Discharging Section
DSC48 2. STRAW DISCHARGING SECTION 2.1 STRAW DISCHARGING CHAIN 2.1.1 CHECK AND ADJUSTMENT A. TENSION OF STRAW DISCHARGING CHAIN DRIVE BELT 1. Adjust the inner length of the straw discharging tension spring. 2. If its length is out of the standard, adjust it by the ten- sion rod.
Page 186 DSC48 D. STRAW DISCHARGING SENSOR 1. Measure the clearance A between the straw discharg- ing sensor and sensor plate. 2. If the clearance is out of the standard, adjust it by loos- ening the nut. Clearance A between straw discharging sensor 6.5 ~ 7.5 mm...
Page 187: Removal And Installation
DSC48 2.1.2 REMOVAL AND INSTALLATION A. PRECEDING WORK BEFORE REMOVING STRAW DISCHARGING CONVEYOR CASE 1. Remove the tension arm and pull out the belt. 2. Unscrew the bolt which puts the upper frame 2 and bevel case together and two mounting bolts on the up- per frame 2 and grain side conveyor case.
Page 188 DSC48 D. REPLACEMENT OF GRAIN SIDE CHAIN 1. Remove the grain side chain tension 3 and remove the grain side conveyor case 2. 2. Undo the chain connection and remove the 20T sprock- et 1. • When assembling the chain connection, compress the straw discharging roller (grain side) (4) and ten- sion.
Page 189: Cutter
DSC48 2.2 CUTTER 2.2.1 CHECK AND ADJUSTMENT A. ADJUSTMENT OF CUTTER DRIVE BELT TENSION 1. Measure the inner length between the tension spring hooks of the cutter drive belt. 2. If its length is out of the standard, adjust it by the ten- sion bolt.
Page 190 DSC48 D. CUTTER DISC 1. Adjust the gap between the base disc and cutting disc as follows. The interval between the 1st and 16th base discs and cutting discs seen from the drive pulley should be 4.5 ~ 7.0 mm.
Page 191 DSC48 F. REPLACEMENT OF CUTTER DISC CAUTION • Wear protective gloves during work. • Be careful not to touch the cutter blade when removing or installing the cutter shaft. 1. Remove both side covers and the cutter drive belt 1.
Page 192 DSC48 5. Open the cutter and secure it with the ﬁ xing metal. 417W478A (1) Prop (A) Insert 6. Pull out the cutter shaft assembly while tilting the shaft support on the grain side downward. CAUTION • Be careful not to touch the cutter blade.
Page 193 DSC48 F. CUTTING DISC 1. Remove the shaft support 2 (1) and install the spanner (26 mm) to the hexagonal shaft of the discharge foil 2 (3). Unscrew the hex. nut (LH, 2) clockwise. 2. Remove the spring washer 20 (6) from the discharge foil 2.
Page 194: Components Related To Base Shaft
DSC48 2.3 COMPONENTS RELATED TO BASE SHAFT 2.3.1 TENSION PLATE 1. Unscrew the nut and remove the tension spring and its plate. 2. Undo three bolts and remove the tension plate and 16 T gear as a unit. 417W483A (1) Tension plate...
Page 195: Base Disc
DSC48 2.3.4 BASE DISC <When assembling> 1. Set a spanner (26 mm) to the hex. shaft of the dis- charge wing 1 (7) and turn the hex. nut (RH, 1) to re- • Install the scraper guide to the 5th position seen from move it.
Page 196 MEMO...
Page 197 DSC48 DRIVING SYSTEM TABLE OF CONTENTS 1. DRIVING SYSTEM ............5-3 1.1 Sectional view ..............5-3 1.1.1 Brake turn (right turn) ..........5-3 1.2 Maintenance ................5-4 1.2.1 Transmission ﬂ uid, Hydraulic oil and ﬁ lters....5-4 1.2.2 Transmission drive belt ..........5-5 1.2.3 Power brake cable ............5-5 1.2.4 Cam clutch of reaping drive pulley ......5-6...
Page 199: Driving System
DSC48 1. DRIVING SYSTEM 1.1 SECTIONAL VIEW 1.1.1 BRAKE TURN (RIGHT TURN) 417W501A (1) HST output shaft (4) No. 1 shaft (7) Side clutch shaft (10) Axle shaft (RH) (2) Transmission case (LH) (5) 101 pulley (reaping) (8) Pressure plate...
Page 200: Maintenance
DSC48 1.2 MAINTENANCE 1.2.1 TRANSMISSION FLUID, HYDRAULIC OIL AND FILTERS A. TRANSMISSION FLUID 1. Remove the level check bolt and check whether or not the oil comes out. • Transmission ﬂ uid type Speciﬁ ed amount of 7.1 ℓ KIOTI genuine oil TF65...
Page 201: Transmission Drive Belt
DSC48 C. HST SUCTION FILTER 1. Take out the HST suction ﬁ lter. Clean it with cleaning oil. If cleaning oil is not available, use uncontaminated gasoline. 417W505A (1) HST suction ﬁ lter 1.2.2 TRANSMISSION DRIVE BELT 1. Remove the threshing drive belt as well as the trans- mission drive belt.
Page 202: Cam Clutch Of Reaping Drive Pulley
DSC48 1.2.4 CAM CLUTCH OF REAPING DRIVE PULLEY 1. Remove the seal plug (6) and shaft snap ring (8). 2. Remove the reaping drive pulley (5) by turning it clock- wise (from the seal plug side) and pulling it out.
Page 203: Track Roller, Idle Roller And Rocker Roller
DSC48 1.2.6 TRACK ROLLER, IDLE ROLLER AND ROCKER ROLLER A. TRACK ROLLER SHAFT 1. Remove the cap (12) and bolt (11). 2. Remove the plain washer (10) to take out the 160 roller (7) from the track roller shaft (3).
Page 204 DSC48 C. ROCKER ROLLER SHAFT 1. Remove the roller shaft in the following order. <When assembling> • Apply grease to the oil seal (8) before installing it. • Apply a sufﬁ cient amount of grease to the gap between the oil seal (8) and its cap (15).
Page 205: Removal Of Transmission Case
DSC48 1.2.7 REMOVAL OF TRANSMISSION CASE A. DETACHMENT OF REAPING UNIT: see page 3-5 B. REMOVAL OF CRAWLER: see page 5-6 C. TRANSMISSION FLUID DRAIN 1. Open the fluid inlet cover and remove the fluid drain plug to drain the transmission ﬂ uid.
Page 206 DSC48 3. Remove the clutch cylinder. <When assembling> • Apply LOCTITE to the mounting bolt of the side clutch cylinder. 417W519A (1) Clutch cylinder 4. Remove the transmission drive belt (1). 5. Remove the bolt (2) and plain washer (3).
Page 207 DSC48 E. REMOVAL OF CAM CLUTCH AND BRAKE CASE 1. Detach the reaping belt. 2. Remove the rubber cap and then the snap ring. 3. Remove the 101 pulley (cam clutch) by turning it coun- terclockwise and pulling it. <When assembling>...
Page 208: Removal Of Axle Oil Seal
DSC48 G. REMOVAL OF TRANSMISSION CASE 1. Remove the bolts from the transmission case. 2. Push the No. 1 shaft to separate the transmission case (LH). 417W525A <When assembling> • Apply a small amount of liquid gasket (Three Bond 1215 or equivalent) to the mounting surface of the transmission case.
Page 209: Adjustment After Installation
DSC48 1.2.9 ADJUSTMENT AFTER INSTALLATION A. ADJUSTMENT OF PARKING BRAKE CABLE Depress the brake pedal 5 times. Adjust the parking brake pedal free play so that its depressed point is 0 mm to 5 mm from the top position. Then, adjust the brake cable so that the left and right clutch levers do not pull the brake cable.
Page 210: Area Around Engine
DSC48 1.3 AREA AROUND ENGINE 1.3.1 CHECK AND ADJUSTMENT A. CLEANING RADIATOR AND OIL COOLER (check every 50 hours) • Open the engine compartment and remove any straw and dust stuck in the radiator or oil cooler. • Be careful not to damage the pan with a screwdriver. A damaged fan can result in poor cooling.
Page 211 DSC48 C. ENGINE OIL FILTER (Replace after the initial 50 hours of operation, then re- place every 200 hours) [Replacement] 1. Remove the ﬁ lter with a ﬁ lter wrench. Apply thin ﬁ lm of oil to the O-ring of the new ﬁ lter and install the ﬁ lter.
Page 212 DSC48 F. BATTERY CABLE (Check every 50 hours) 1. When replenishing the battery with electrolyte, use dis- tilled water and do not overﬁ ll. 2. Use only the speciﬁ ed battery. 3. When disconnecting the battery cables, disconnect the negative (ground) cable ﬁ rst. When connecting the cables, connect the positive cable ﬁ...
Page 213 DSC48 H. FAN DRIVE BELT 1. Unscrew the mounting bolts on the alternator and tight- en the bolts while pulling the alternator. Deﬂ ection of belt center (B) 7 ~ 9 mm 417W540A (1) Fan drive belt (2) Bolt (A) Pull I.
Page 214 DSC48 K. RADIATOR HOSE AND CONNECTING HOSE (Check every 200 hours and replace every 2 years) • Make sure that the hose is not aged or the hose clamp is not loose. 417W544A (1) Water pipe 1 (3) Water pipe 3 (2) Water pipe 2 L.
Page 215 DSC48 HYDRAULIC SYSTEM TABLE OF CONTENTS 1. HYDRAULIC SYSTEM ......6-3 2. HST (HYDROSTATIC TRANSMISSION) ............... 6-16 1.1 Overview ..........6-3 2.1 Overview ..........6-16 1.1.3 Circuit diagram for hydraulic system ............6-3 2.1.1 Sectional view of HST ....6-17 1.1.1 Direction control solenoid valve ..
Page 217: Hydraulic System
DSC48 1. HYDRAULIC SYSTEM 1.1 OVERVIEW The hydraulic system in the combine harvester has three The valve unit is composed of the solenoid valve and hy- major functions as below: draulic block DH as one unit. It also protects the hydraulic system by controlling the max.
Page 218: Power Steering
DSC48 1.2 POWER STEERING The power steering lever can raise up, lower or turn the reaping unit or change directions of the unit. These opera- tions can simultaneously be performed. • The reaping unit is lifted or lowered when pushing the power steering lever forward or rearward.
Page 219: Turning And Cornering
DSC48 1.2.2 TURNING AND CORNERING 417W604A (1) Power steering lever (5) Power brake cable (8) Brake return spring (A) Right turn (2) Valve unit (6) Direction control lever (9) Brake arm (LH) (B) Lever point pin switch (3) Brake arm...
Page 220: Components Of Valve Unit
DSC48 1.3 COMPONENTS OF VALVE UNIT 417W606A (1) Direction port (LH, DL) (9) Low pressure Relief Valve (2) Steering control solenoid valve (10) High Pressure Relief Valve (3) Direction pump port (P, D) (11) Reaping unit height control pump port (PH)
Page 221: Valve Plate Of Hydraulic Block Dh
DSC48 1.3.1 VALVE PLATE OF HYDRAULIC BLOCK DH The oil sucked through the oil ﬁ lter from the oil tank by the hydraulic pumps (equipped with two hoses) is carried to the PD and PH ports of the hydraulic block DH.
Page 222 DSC48 C. LOW PRESSURE RELIEF VALVE It limits the maximum oil pressure (from the hydraulic pump D) of the hydraulic circuit operating the right and left steer- ing clutch cylinders. Set pressure of low pres- 72 ~ 78 kgf/cm sure relief valve...
Page 223: Reaping Unit Lifting Solenoid Valve
DSC48 1.3.2 REAPING UNIT LIFTING SOLENOID VALVE The threshing controller sends electric current to the reap- ing unit lifting solenoid (Solenoid A). The current changes the spool’s position and lifts up the reaping unit. When in neutral, oil sent to the pump port P ﬂ ows to the R port through the spool.
Page 224: Steering Clutch Cylinder
DSC48 1.4 STEERING CLUTCH CYLINDER When changing direction or cornering, the steering control solenoid value switches and the oil from the right and left steering clutch cylinders pushes out the appropriate piston. As this occurs, the steering clutch in the transmission case is disengaged.
Page 225: Check For Normal Operation
DSC48 1.5 CHECK FOR NORMAL OPERATION 1.5.1 CHECKING SOLENOID VALVE WITH THE MANUAL PUSH BUTTON 1. Put the range shift lever to the neutral position and start the engine. 2. Check whether each solenoid valve operates correctly by pressing the following manual push buttons.
Page 226: Troubleshooting With Hydraulic System
DSC48 1.5.2 TROUBLESHOOTING WITH HYDRAULIC SYSTEM If each solenoid value is correctly operating when its corresponding manual push button is pressed and if the hydraulic system is believed to be the cause of malfunction, perform the following troubleshooting. The next system to be checked is the electric system of each controller.
Page 227: Check And Adjustment
DSC48 1.6 CHECK AND ADJUSTMENT 1.6.1 CHECK FOR PRESSURE OF LOW PRESSURE RELIEF VALVE 1. Disconnect the PD port hydraulic hose and install the pressure gauge (150 kgf/cm ) between the hydraulic hose and PD port using the adapter. 2. Put the range shift lever to the "Neutral" position and start the engine.
Page 228: Check For Pressure Of High Pressure Relief Valve
DSC48 1.6.2 CHECK FOR PRESSURE OF HIGH PRESSURE RELIEF VALVE 1. Disconnect the PH port hydraulic hose. Install the pres- sure gauge (250 ~ 300 kgf/cm ) between the hydraulic hose and PH port using the adapter. 2. Put the range shift lever to the "Neutral" position and start the engine.
Page 229: Removal And Installation
DSC48 1.7 REMOVAL AND INSTALLATION 1.7.1 REMOVAL OF VALVE UNIT Power brake cable, clutch pedal rod, wiring, and hydraulic hoses 1. Remove the step cover (FR). 2. Disconnect the power brake cable (4). 3. Disconnect each solenoid valve's connector (3 EA).
Page 230: Hst (Hydrostatic Transmission)
DSC48 2. HST (HYDROSTATIC TRANSMISSION) 2.1 OVERVIEW 417W620A 417W621A 417W622A (1) Oil cooler (8) Oil tank (14) Swash plate shaft (2) Oil ﬁ lter (9) Transmission case (15) Check & high pressure relief valve (for reverse driving) (3) HST (Hydrostatic transmission) (10) HST pulley (16) Check &...
Page 231: Sectional View Of Hst
DSC48 2.1.1 SECTIONAL VIEW OF HST 417W623A (1) Oil outlet (9) Port block (16) Thrust plate (2) Pump shaft (10) Valve plate P (17) Piston (3) Piston (11) Charge pump (18) Drain Plug (4) Motor shaft (12) Cylinder block P...
Page 232: Structure And Function
DSC48 2.2 STRUCTURE AND FUNCTION 2.2.1 PUMP AND MOTOR The structures of the pump and motor are very similar. But, the pump is a variable capacity type with the variable swash plate, while the motor is a ﬁ xed capacity type with the ﬁ...
Page 233: Charge Relief Valve
DSC48 2.2.4 CHARGE RELIEF VALVE The oil drawn from the charge pump is ﬁ ltered by the oil ﬁ lter cartridge, passes through the check valve shaft of the check & high pressure relief valve in the low pressure sec- tion, and, then, ﬂ...
Page 234: Hst Hose Diagram And Pressure Check
DSC48 2.3 HST HOSE DIAGRAM AND PRESSURE CHECK [HST hose diagram] 417W629A (1) HST drain hose 1 (2) HST drain hose 2 (3) HST suction hose 2.3.1 PRESSURE CHECK 1. Remove the plug from where the pressure should be checked.
Page 235: Hst Troubleshooting List
DSC48 2.4 HST TROUBLESHOOTING LIST [Malfunction] [Check] [Cause] [Action] The combine is not Input shaft rotation No rotation Defective delivery Service delivery driven. system from engine system Insufficient oil supplied Replenish oil Noise and vibration Input shaft rotation Insufficient occur during driving.
Page 236 DSC48 [Malfunction] [Check] [Cause] [Action] Combine does not Position in neutral Adjustable Cannot adjust neutral Adjust neutral position stop in neutral. position Non-adjustable Too large play Incorrectly tightened Tightening of plug and Adjust neutral position plug and valve valve Oil is leaked.
Page 237 DSC48 [Malfunction] [Check] [Cause] [Action] Oil temperature in tank Oil level in tank Insufficient Insufficient oil supplied Replenish oil is excessively high. Oil leakage Clogged oil cooler Clogged cooler core Clean core with compressed air Clogged oil hole in cooler...
Page 238: Check And Adjustment
DSC48 2.5 CHECK AND ADJUSTMENT 2.5.1 ADJUSTMENT OF NEUTRAL (STOP) POSITION 1. Start the engine and set the engine speed to 2000 rpm or higher. 2. Check whether the reaping drive pulley stops rotating, when the range shift lever is in the neutral position and the main shift lever is in the stop position.
Page 239: Removal Of Hst
DSC48 2.6 REMOVAL OF HST 2.6.1 REMOVAL WITHOUT DETACHING REAPING UNIT 1. Set the reaping unit to the highest position and put the reaping unit lowering lock switch to the lock position. 2. For safety, support the reaping unit with proper support- ing materials.
Page 240: Removal After Detaching Reaping Unit
DSC48 2.6.2 REMOVAL AFTER DETACHING REAPING UNIT 1. Detach the reaping unit. 2. Remove the HST rod (1). 3. Remove the range shift rod for easier removal. 4. Remove the brake pedal and parking brake lever. 5. Disconnect the suction hose (2) and drain hose. Clamp them to prevent oil leakage.
Page 241 DSC48 ELECTRICAL SYSTEM TABLE OF CONTENTS 1. CHECKING INSTRUMENT PANEL ..7-3 2.5 Troubleshooting ........7-13 2.5.1 Straw discharge alarm ....7-13 1.1 Overview ..........7-3 2.5.2 Grain alarm ........7-13 1.2 Check for normal operation ...... 7-3 2.5.3 No. 1 alarm and No. 2 alarm ..7-14 1.3 Troubleshooting ........
Page 242 TABLE OF CONTENTS 4.2.5 Output stop of shallow and deep feed- 7.1.3 Checking feeding depth control motor ing motors ........7-21 ............7-33 4.2.6 Motor protection ......7-21 7.1.4 Checking engine stop motor ..7-34 4.3 Wiring diagram ........7-22 7.1.5 Checking fuel gauge unit ....
Page 243: Checking Instrument Panel
DSC48 1. CHECKING INSTRUMENT PANEL 1.1 OVERVIEW When turning the ignition from the "OFF" to "ON" position, six lamps (straw discharge alarm lamp, grain alarm lamp, check lamp, No. 1 and 2 warning lamps, and reaping warn- ing lamp) come on and go out within a few seconds.
Page 244: Troubleshooting
DSC48 1.3 TROUBLESHOOTING Symptom Cause Action All lamps on the instrument If no sound comes from the MICOM unit and the LED Power to the MICOM unit panel do not come on. displays nothing (fuse, slow-blow fuse) • Power is not supplied to the MICOM unit and lamps on the instrument panel.
Page 245: Alarm Buzzer, Lamps On Instrument Panel And Automatic Engine Stop Function
DSC48 2. ALARM BUZZER, LAMPS ON INSTRUMENT PANEL AND AUTOMATIC ENGINE STOP FUNCTION 2.1 OVERVIEW The alarm buzzer, lamps on the instrument panel, and The alarms, warning lamps and automatic engine stop automatic engine stop function operate to prevent any function, except the coolant temperature alarm, are con- problems during work.
Page 246: Alarm Control
DSC48 2.2 ALARM CONTROL 2.2.1 STRAW DISCHARGE ALARM (ALARM BUZZER, INSTRUMENT PANEL AND AES) When the threshing clutch is ON (threshing unit switch: ON) and any straw discharging sensor (on the feeding chain side or straw discharging chain side) is ON for over 1.5...
Page 247: 2 Alarm (Alarm Buzzer And Instrument Panel)
DSC48 2.2.3 NO. 2 ALARM (ALARM BUZZER AND INSTRUMENT PANEL) With the threshing clutch ON (threshing unit switch: ON), the front buzzer sounds continuously and the No. 2 lamp on the instrument panel blinks if the rotating speed of the No.
Page 248: Reverse Driving Alarm (Alarm Buzzer)
DSC48 2.2.6 REVERSE DRIVING ALARM (ALARM BUZZER) When the shift lever is moved to the "Reverse" position and the reverse switch in the shift lever switch is ON with the ignition switch in the "ON" position, the reverse driving alarm sounds at short intervals.
Page 249: Grain Sensor Alarm (Alarm Buzzer, Etc.)
DSC48 B. FRONT BUZZER OPERATION When all the above conditions are met, the front buzzer sounds at short intervals if the difference between the cur- rent and memorized engine rpms is over the standard. C. STOPPING BUZZER OPERATION If any of the below conditions is met, the buzzer stops.
Page 250: Charge Lamp (Instrument Panel)
DSC48 2.2.10 CHARGE LAMP (INSTRUMENT PANEL) When the alternator does not generate enough power due to its malfunction during the engine's running, the charge lamp comes on to warn the malfunction in the charge system. Also, this lamp comes on when the ignition switch is in the "ON"...
Page 251: Wiring Diagram
DSC48 2.3 WIRING DIAGRAM 417W717A Apr. 2007...
Page 252: Checking Normal Operation
DSC48 2.4 CHECKING NORMAL OPERATION A. STRAW DISCHARGE ALARM (ALARM D. REVERSE DRIVING ALARM BUZZER, INSTRUMENT PANEL AND AES) (ALARM BUZZER) 1. Turn the ignition switch to the "ON" position. 1. Turn the ignition switch to the "ON" position. 2. Engage the threshing clutch (threshing unit switch: 2.
Page 253: Troubleshooting
DSC48 2.5 TROUBLESHOOTING 2.5.1 STRAW DISCHARGE ALARM Symptom Cause Action The straw discharge alarm • If the check lamp does not operate correctly when (buzzer, lamp and automatic turning the ignition switch to the "ON" position engine stop function) does •...
Page 254: 1 Alarm And No. 2 Alarm
DSC48 2.5.3 NO. 1 ALARM AND NO. 2 ALARM Symptom Cause Action The No. 1 and No. 2 alarms • If the check lamp does not operate correctly when • Power to MICOM unit (front buzzer and lamp) do turning the ignition switch to the "ON" position •...
Page 255: Load Alarm
DSC48 2.5.5 LOAD ALARM Symptom Cause Action The front buzzer does not • Faulty input signal from the electronic pick-up • Input signal wire sound. sensor • Faulty input signal from the vehicle speed sensor • Input signal wire • Faulty input signal from the reverse switch (ground) •...
Page 256: Ignition Switch
DSC48 2.5.8 IGNITION SWITCH Symptom Cause Action All AES does not operate. • If the check lamp does not operate correctly when turning the ignition switch to the "ON" position The MICOM unit is not supplied with power. • Power to MICOM unit Or faulty ground of the MICOM unit •...
Page 257: Load Level
DSC48 3. LOAD LEVEL 3.1 CONTROL 3.1.1 DISPLAY ON INSTRUMENT PANEL 3.1.2 COOLANT TEMPERATURE GAUGE AND FUEL GAUGE The MICOM unit determines the difference between the max. engine speed without load when starting reaping When the coolant temperature rises, the resistance of the and the engine speed during reaping.
Page 258: Check For Normal Operation
DSC48 3.3 CHECK FOR NORMAL OPERATION 3.3.1 IGNITION SWITCH Initial operation for the "ON" position • Ignition switch: After turning it from the "OFF" to "ON" position, all load lamps come on for 1.5 seconds. • Ignition switch: Only No. 1 load lamp stays on for 1.5 seconds after turning the ignition...
Page 259: Feeding Depth Control
DSC48 4. FEEDING DEPTH CONTROL 4.1 OVERVIEW 1. Two grain sensors are installed between the reaping and threshing units to detect precise length of crops for suitable control. 2. When starting reaping, optimal delay time is applied ac- cording to the combine harvester's moving speed. As...
Page 260: Delay Of Shallow And Deep Feeding Output
DSC48 A. STANDARD The following outputs are sent intermittently depending on the condition of the grain sensors so that the grain is be- tween the grain sensors S1 and S2 (S1: ON, S2: OFF). Grain sensor Threshing controller Motor Deep feeding...
Page 261: Operation Of Automatic Feeding Depth Control Lamp
DSC48 4.2.4 OPERATION OF AUTOMATIC FEEDING DEPTH CONTROL LAMP The automatic feeding depth control lamp is automatically turned on by the automatic feeding depth selection switch. This lamp is turned off if the manual switch is operated. If an error 1 is generated during self-diagnosis, it blinks.
Page 262: Wiring Diagram
DSC48 4.3 WIRING DIAGRAM 417W723A Apr. 2007...
Page 263: Checking Normal Operation
DSC48 4.4 CHECKING NORMAL OPERATION A. CHECKING MANUAL OPERATION B. CHECKING AUTOMATIC OPERATION 1. Turn the ignition switch to the "ON" position. 1. Set the straw sensor ON with a tape or equivalent. 2. When the automatic feeding depth control switch is 2.
Page 264: Troubleshooting
DSC48 4.5 TROUBLESHOOTING Symptom Cause Action The automatic feeding depth • The check lamp does not operate correctly when control function does not turning the ignition switch. operate and the automatic - The MICOM unit is not supplied with power.
Page 265: Removal Of Feeding Depth Control Motor And Limit Switch
DSC48 4.6 REMOVAL OF FEEDING DEPTH CONTROL MOTOR AND LIMIT SWITCH 4.6.1 REMOVAL OF FEEDING DEPTH CONTROL MOTOR 1. Disconnect the feeding depth control wiring (1). 2. Remove the pin (3) from the end of the feeding depth control rod (2).
Page 266: Power Steering Function
DSC48 5. POWER STEERING FUNCTION 5.1 OVERVIEW The power steering lever can raise up, lower or turn the reaping unit or change directions of the unit. These opera- tions can simultaneously be performed. • The reaping unit is lifted or lowered when pushing the power steering lever forward or rearward.
Page 267: Lifting And Lowering The Reaping Unit
DSC48 5.2. LIFTING AND LOWERING THE REAPING UNIT A. LIFTING 1. When the lever is pushed to the lifting direction (rear- ward), the lever and its lever point move around from the pivot. 2. As the A section of the lever point pin moves, the reap- ing unit height control lever switch moves to the left and the switch for lifting comes on.
Page 268: Turning And Cornering
DSC48 5.3 TURNING AND CORNERING 417W732A (1) Valve unit (5) Direction control lever switch (9) Brake return spring (2) Brake arm (6) Power steering lever (10) Direction control lever switch (3) Variable relief valve (7) Brake arm (LH) (11) Point bolt...
Page 269: Wiring Diagram
DSC48 5.4 WIRING DIAGRAM 417W733A 5.5 CHECKING NORMAL OPERATION 1. Start the engine. 2. When moving the power steering lever to the right, the piston (RH) of the direction control cylinder operates. 3. When moving the power steering lever to the left, the piston (LH) of the direction control cylinder operates.
Page 270: Troubleshooting
DSC48 5.6 TROUBLESHOOTING Start the engine and check whether the piston of the cylinder moves by pressing the manual push button for the solenoid valve's check valve. If the piston does not move, it indicates malfunction in the hydraulic system. In this case, inspect the hydraulic system.
Page 271: Problems Involved With Turning And Cornering
DSC48 5.6.2 PROBLEMS INVOLVED WITH TURNING AND CORNERING Symptom Cause Action The combine harvester • Faulty ground of the threshing controller • Main wiring connector of cannot be turned (direction the threshing controller control cylinder) and the • Faulty ground wiring in the threshing controller •...
Page 272: Self-Diagnosis
DSC48 6. SELF-DIAGNOSIS 6.1 OVERVIEW The self-diagnosis function checks the signals from the grain sensor, electronic pick up, vehicle speed sensor, No. 2 rota- tion sensor, shift lever switch, vehicle speed upper limit switch, and engine stop motor to the MICOM unit. If there is mal- function, the check lamp on the instrument panel blinks.
Page 273: Electrical System
DSC48 7. ELECTRICAL SYSTEM 7.1 CHECKING EACH PART 7.1.1 CHECKING AUTOMATIC ENGINE STOP RELAY 1. Disconnect the connector and measure the resistance at the relay side. Approx. 60 Ω Between 5 and 1 Between 2 and 4 Continuity Between 2 and 3 Approx.
Page 274: Checking Engine Stop Motor
DSC48 7.1.4 CHECKING ENGINE STOP MOTOR 1. Disconnect the connector and measure at the relay side. (+) terminal: 1P connector Runs and stops (-) terminal: 2 of 2P connector (+) terminal: 1 of 2P connector Runs and stops (-) terminal: 2 of 2P connector If the above operation occurs, the motor is normal.
Page 275: Checking Vehicle Speed (Rotary) Sensor
DSC48 7.1.7 CHECKING VEHICLE SPEED (ROTARY) SENSOR 1. Remove the vehicle speed sensor from the combine harvester. 2. With the connector connected, install the measuring terminal of the tester between the connectors 1 and 3. • (-) terminal: 1, (+) terminal: 3 3.
Page 276: Checking Grain Sensor
DSC48 7.1.10 CHECKING GRAIN SENSOR (grain sensor, straw sensor, neutral switch) Operation Continuity No operation No continuity If the above operation occurs, it is normal. • If the sensor is normal, check the connector and wiring. 417W743A (1) Sensor side 7.1.11 CHECKING NO.
Page 277: Checking Ignition Switch
DSC48 7.1.13 CHECKING IGNITION SWITCH Preheat Ignition Between Conti- 3 and 1 nuity Between Conti- Conti- 3 and 4 nuity nuity Between Conti- Conti- Conti- 3 and 2 nuity nuity nuity • -: No continuity • If all the above operations correctly occur, check the 417W746A connector and wiring.
Page 278: Checking Manual Switch (Afc)
DSC48 7.1.16 CHECKING MANUAL SWITCH (AFC) Deep Continuity Between 1 and 2 No operation No continuity Shallow Continuity Between 3 and 2 No operation No continuity If the above operation occurs, it is normal. • If the switch is normal, check the switch operation, con- nector and wiring.
Page 279: Checking Feeding Depth Control Stop Switch
DSC48 7.1.19 CHECKING FEEDING DEPTH CONTROL STOP SWITCH Between 2 and 1 No continuity Right turn end Between 3 and 1 Continuity Between 2 and 1 Continuity Left turn end Between 3 and 1 No continuity Between 2 and 1...
Page 280: Checking Lights And Turn Signal Switch
DSC48 7.1.22 CHECKING LIGHTS AND TURN SIGNAL SWITCH Light switch Turn signal lamp switch Terminal Terminal Position Position Left Ο Ο Ο Ο Ο Ο Ο Right Ο Ο Set the tester to the resistance range and contact each ter-...
Page 283: Components By Malfunction
DSC48 8. COMPONENTS BY MALFUNCTION THE ENGINE DOES NOT START. THE COMBINE HARVESTER CANNOT BE TURNED TO THE LEFT OR RIGHT. A. Lamps on the instrument panel come on and the 1. Lever switch starter does not operate with the ignition switch in 2.
Page 284 DSC48 REVERSE HORN 1. Shift lever switch 2. MICOM STRAW DISCHARGE ALARM LAMP, ENGINE STOP LAMP, BUZZER 1. Straw discharging sensor 2. MICOM 3. Automatic engine stop relay 4. Engine stop motor OIL LAMP 1. Oil switch 2. Instrument panel FUEL GAUGE 1.
Page 285 DSC48 INDEX...
Page 286 DSC48 NUMBER 38T gear ............4-34 Cam clutch of reaping drive pulley ...... 5-6 Camshaft ............. 2-7 Cautions for high pressure hoses ......0-6 Adjusting the belts ..........1-18 Cautions when handling the battery ....0-6 Adjustment after installation ......5-13 Charge lamp (instrument panel) ......
Page 287 DSC48 Checking instrument panel ........7-3 Cooling system ...........2-11 Checking lights and turn signal switch....7-40 Crankshaft ............2-6 Checking manual switch (AFC) ......7-38 Crawler ..............5-6 Checking No. 1 and No. 2 sensors (cushion switch) Cutter ..............4-29 ..............
Page 288 DSC48 Every 300 hours ..........1-32 Grain sensor and feeding depth control motor out- put ..............7-19 Every 350 hours ..........1-34 Every 400 hours ..........1-35 Every 50 hours ..........1-25 Handling of hazardous materials ......0-7 Every 500 hours ..........1-37 Handling of rotating blade, shaft and driving belt 0-7 Every 600 hours ..........
Page 289 DSC48 Loading and unloading the combine harvester to the transporting vehicle ........0-20 Piston and piston ring ..........2-6 Location of decals..........0-25 Power brake cable ..........5-5 Loctite and liquid gasket application ....1-11 Power steering ............6-4 Loctite application ..........1-11 Power steering function ........
Page 290 DSC48 Removal without detaching reaping unit ....6-25 Threshing unit ............4-3 Replacement of base cutter disc ......4-11 Tightening torque for service ....... 2-28 Replacement of elevator rakes ......3-10 Tightening torque ..........1-14 Replacement of packer ........3-18 Timing gear ............2-8 Replacement of straw chopper blade ....

Daedong DSC48 Workshop Manual

Dsc48 Safety First

1 For Safety

2 Safety Tips

3 For Your Safety

4 General Precaution before Operation

5 When Servicing, Repairing and Cleaning before Operation

6 When Starting the Engine

7 When Driving

8 Driving on a Narrow Path, Bumpy Road or Slope

9 Loading and Unloading the Combine Harvester to the Transporting Vehicle

10 After Daily Work Is Completed

11 For Long-Term Storage

12 Safety Decals

Dsc48 General

Dsc48 Engine

1 General

2 Structure and Function

3 Disassembly and Service

Dsc48 Reaping Unit

Dsc48 Threshing Unit

1 Threshing Unit

2 Straw Discharging Section

Dsc48 Driving System

Dsc48 Hydraulic System

1 Hydraulic System

2 Hst (Hydrostatic Transmission)

Dsc48 Electrical System

1 Checking Instrument Panel

2 Alarm Buzzer, Lamps on Instrument Panel and Automatic Engine Stop Function

3 Load Level

4 Feeding Depth Control

5 Power Steering Function

6 Self-Diagnosis

7 Electrical System

8 Components by Malfunction

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Chapters

Troubleshooting

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Summary of Contents for Daedong DSC48