Daedong CK22 Workshop Manual
  1. Manuals
  2. Brands
  3. Daedong Manuals
  4. Tractor
  5. CK22
  6. Workshop manual
Daedong CK22 Workshop Manual

Daedong CK22 Workshop Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
CK22/CK22H
TRACTORS
WORKSHOP MANUAL

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the CK22 and is the answer not in the manual?

Questions and answers

Related Manuals for Daedong CK22

Summary of Contents for Daedong CK22

  • Page 1 CK22/CK22H TRACTORS WORKSHOP MANUAL...
  • Page 3 Therefore, some of the information in this manual may differ from the machine you have. DAEDONG has a principle to apply update to the next edition of the manual if there is any. However, DAEDONG has no obligation to modify the contents in this manual, especially the contents in the manual which are already distributed or published.

  • Page 5: Chapter 0 Safety First

    TABLE OF CONTENTS CHAPTER 0 SAFETY FIRST CHAPTER 1 GENERAL CHAPTER 2 ENGINE CHAPTER 3 CLUTCH CHAPTER 4 TRANSMISSION CHAPTER 5 CHAPTER 6 REAR AXLE CHAPTER 7 BRAKE CHAPTER 8 FRONT AXLE CHAPTER 9 STEERING SYSTEM CHAPTER 10 HYDRAULIC SYSTEM CHAPTER 11 ELECTRIC SYSTEM CHAPTER 12...

  • Page 7: Table Of Contents

    CK22/CK22H SAFETY FIRST TABLE OF CONTENTS 1. FOR SAFETY ................0-2 1.1 Alert symbols ..............0-2 2. SAFETY TIPS ................0-3 2.1 Safety gear ................ 0-3 2.2 Work place ................. 0-3 2.2.1 Ventilating system ..........0-3 2.2.2 Safe working place ..........0-3 2.2.3 Illumination ..............

  • Page 8: For Safety

    SAFETY FIRST - FOR SAFETY CK22/CK22H 1. FOR SAFETY • Most accidents can be avoided if basic safety in- structions and regulations are followed. Always fol- low the safety regulations and avoid any dangerous situation to prevent an accident. •...

  • Page 9: Safety Tips

    SAFETY FIRST - SAFETY TIPS CK22/CK22H 2. SAFETY TIPS 2.1 SAFETY GEAR When working on the tractor, always wear safety gloves, safety shoes, ear plugs, safety goggles, safety helmet, working clothes, etc. appropriate for your working environment. Never wear loose fitting clothing or a tie which can be caught to the rotating part.

  • Page 10: Safety Instructions When Preparing Tractor

    SAFETY FIRST - SAFETY TIPS CK22/CK22H 2.3 SAFETY INSTRUCTIONS WHEN 2.4 FIRE HAZARDS PREPARING TRACTOR T46W011A T46W009A • Never smoke or allow flames in your work area when servicing the fuel system. • Lower the implement on to the ground.

  • Page 11: Cautions When Handling The Battery

    SAFETY FIRST - SAFETY TIPS CK22/CK22H 2.5 CAUTIONS WHEN HANDLING THE BATTERY T46W015A T46W018A • Always disconnect the negative battery cable first • The battery contains acid that can burn you. If it and reconnect it last to avoid sparks from an acci- makes contacts with your eyes, you can lose your dental short circuit.

  • Page 12: Cautions For High Pressure Hoses

    The pipe or hose can be heated and ex- age your health. plode which can lead to fire or burn. NOTE: • Genuine DAEDONG parts contain no asbetos. • These materials should be rinsed or wiped away after spraying oil. DS35-W00 May. 2007...

  • Page 13: Handling Of Rotating Blade, Shaft And Driving Belt

    SAFETY FIRST - SAFETY TIPS CK22/CK22H 2.9 HANDLING OF ROTATING BLADE, 2.10 PREVENTING SCALDING SHAFT AND DRIVING BELT T46W023A T46W027A • Do not open the radiator cap when the radiator is hot. Hot coolant or steam can surge leading to se- rious scalding.

  • Page 14: Disposal Of Environmental Waste

    SAFETY FIRST - SAFETY TIPS CK22/CK22H 2.11 DISPOSAL OF ENVIRONMENTAL 2.12 CAUTIONS WHEN HANDLING WASTE TIRES T46W029A T46W030A • Observe all relevant environmental protection regu- • The tire rims can fall out of the tires. Therefore, stay lations when disposing used oil, transmission fluid, out of its way when checking or inflating tires.

  • Page 15: Safety Decals

    SAFETY FIRST - SAFETY DECALS CK22/CK22H 3. SAFETY DECALS • When replacing parts, be sure to replace with the appropriate safety decal. • If a decal is damaged or detached, always replace with the appropriate decal. • The decal and its attaching location are as follows.
  • Page 16 SAFETY FIRST - SAFETY DECALS CK22/CK22H (4) Parts No. : T2325-50743 (5) Parts No. : T2325-50512 (6) Parts No. : T2445-50724 (7) Parts No. : T2615-53561 (8) Parts No. : T2350-54141 (9) Parts No. : T2615-54112 DS35-W00 May. 2007...
  • Page 17 CK22/CK22H GENERAL TABLE OF CONTENTS 1. TRACTOR IDENTIFICATION ..... 1-3 8.3 Every 100 hours ........1-17 8.3.1 Changing engine oil ....1-17 2. DIMENSIONS ..........1-4 8.3.2 Checking fuel line ....1-17 3. SPECIFICATIONS ........1-5 8.3.3 Cleaning air cleaner primary 4.
  • Page 18 TABLE OF CONTENTS 8.8 Once a year ........1-28 9. TIRES ............1-32 8.8.1 Replacing air cleaner element 9.1 Inflation pressure ........ 1-32 ..........1-28 9.2 Tread ............ 1-33 8.9 Every 2 years ........1-28 9.2.1 Front wheels ......1-33 8.9.1 Flush cooling system and chang- 9.2.2 Rear wheels ......

  • Page 19: Tractor Identification

    GENERAL - TRACTOR IDENTIFICATION CK22/CK22H 1. TRACTOR IDENTIFICATION When contacting your local DAEDONG distributor, always specify engine serial number, tractor serial number and hour meter reading. 196W102A 196W101B (1) Statutory plate (2) Identification plate (3) Engine serial number 196W100A 196W103A...

  • Page 20: Dimensions

    GENERAL - DIMENSIONS CK22/CK22H 2. DIMENSIONS mm (in.) 196W167A DS35-W00 May. 2007...

  • Page 21: Specifications

    GENERAL - SPECIFICATIONS CK22/CK22H 3. SPECIFICATIONS MODEL MECHANICAL Engine Model 3C100A Type Liquid-cooled, 3-cylinder diesel Engine gross HP (kW) 22 (16.4) P.T.O HP (kW) 17.6 (13.1) 17.2 (12.8) Displacement cc (cu.in) 1,007 (61.45) Rated revolution r.p.m min-1 2,800 Fuel tank capacity (gal.)

  • Page 22: Lubricants, Fuel And Coolant

    GENERAL - LUBRICANTS, FUEL AND COOLANT CK22/CK22H 4. LUBRICANTS, FUEL AND COOLANT Capacities Locations Lubricants Mechanical No.2-D diesel fuel Fuel (5.28 U.S.gal.) No.1-D diesel fuel if temperature is below -10°C (14°F) Coolant (1.50 U.S.gal.) Fresh clean water with anti-freeze (Ethylene glycol 50%)

  • Page 23: Tightening Torques

    GENERAL - TIGHTENING TORQUES CK22/CK22H 5. TIGHTENING TORQUES 5.1 GENERAL USE SCREWS, BOLTS AND NUTS If the tightening torques are not specified for some screws, bolts and nuts in this manual, tighten them according to the table below. Indication on...

  • Page 24: American Standard Screws, Bolts And Nuts With Unc Or Unf Threads

    GENERAL - TIGHTENING TORQUES CK22/CK22H 5.3 AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS Grade SAE GR.5 SAE GR.8 Unit Nominal kgf-m lb-ft kgf-m lb-ft diameter 23.1 ~ 27.8 2.35 ~ 2.84 17.0 ~ 20.5 32.5 ~ 39.3 3.31 ~ 4.01...

  • Page 25: Unit Conversion Table

    GENERAL - UNIT CONVERSION TABLE CK22/CK22H 6. UNIT CONVERSION TABLE Torque Length Volume Pressure Temperature Kgf-m lb-ft Inch U.S.gal kgf/cm °C °F 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...

  • Page 26: Maintenance Schedule Chart

    *3 Replace only if necessary. • The items listed above (# marked) are registered as emission related critical parts by DAEDONG in the U. S.EPA exhaust emission standards non-road emission regulation. As the tractor owner, you are respon- sible for the performance of the required maintenance on the engine according to the above instruction.

  • Page 27: Check And Mainienance

    GENERAL - CHECK AND MAINIENANCE CK22/CK22H 8. CHECK AND MAINIENANCE 8.1 DAILY CHECK For your own safety and maximum service life of the A. WALK AROUND INSPECTION machine, make a thorough daily inspection before op- Look around and under the tractor for such items as erating the machine to start the engine.

  • Page 28: Checking Engine Oil Level

    If the radiator cap has to be removed, follow the • caution above and securely retighten the cap. Use clean, fresh water and anti-freeze to fill the • recovery tank. If water should leak, consult your local DAEDONG • Dealer. 1-12 DS35-W00 May. 2007...

  • Page 29: Checking Head Lights, Hazard Light Etc

    GENERAL - CHECK AND MAINIENANCE CK22/CK22H 8.1.4 CHECKING HEAD LIGHTS, HAZARD LIGHT ETC. 1. Inspect the lights for broken bulbs and lenses. 2. Replace if broken. 8.1.5 CHECKING SEAT BELT AND ROPS 1. Always check condition of seat belt and ROPS hard- ware before operating tractor.

  • Page 30: Checking Brake Pedals And Clutch Pedal

    GENERAL - CHECK AND MAINIENANCE CK22/CK22H 8.1.7 CHECKING BRAKE PEDALS AND CLUTCH PEDAL 1. Examine the brake and clutch pedals for free travel, and smooth operation. 2. Adjust if necessary. (See “Adjusting Clutch and Brake Pedal” in every 100 hours maintenance.)

  • Page 31: Every 50 Hours

    GENERAL - CHECK AND MAINIENANCE CK22/CK22H 8.2 EVERY 50 HOURS 8.2.1 LUBRICATING GREASE FITTINGS Apply a small amount of multipurpose grease to the following points every 50 hours: If you operated the machine in extremely wet and muddy conditions, lubricate grease fittings more often.

  • Page 32: Checking Wheel Bolt Torque

    GENERAL - CHECK AND MAINIENANCE CK22/CK22H 8.2.2 CHECKING WHEEL BOLT TORQUE CAUTION To avoid personal injury: Never operate tractor with a loose rim, wheel, or • axle. • Any time bolts and nuts are loosened, retighten to specified torque. •...

  • Page 33: Every 100 Hours

    GENERAL - CHECK AND MAINIENANCE CK22/CK22H 8.3 EVERY 100 HOURS 8.3.1 CHANGING ENGINE OIL CAUTION To avoid personal injury: • Be sure to stop the engine before changing the oil. Allow engine to cool down sufficiently, oil can be •...

  • Page 34: Cleaning Air Cleaner Primary Element

    GENERAL - CHECK AND MAINIENANCE CK22/CK22H 8.3.3 CLEANING AIR CLEANER PRIMARY ELEMENT 1. Remove the air cleaner cover and element. 2. Clean the element: 1) When dry dust adheres to the element, blow com pressed air from the inside, turning the element.

  • Page 35: Adjusting Brake Pedal

    GENERAL - CHECK AND MAINIENANCE CK22/CK22H 8.3.6 ADJUSTING BRAKE PEDAL CAUTION To avoid personal injury: • Stop the engine and chock the wheels before checking brake pedal. 1. Release the parking brake. 2. Slightly depress the brake pedals and measure free travel at top of pedal stroke.

  • Page 36: Battery

    GENERAL - CHECK AND MAINIENANCE CK22/CK22H 8.3.8 BATTERY CAUTION To avoid personal injury: Never remove the vent caps while the engine is • running. Keep battery acid away from eyes, hands and • clothes. If you are spattered with it, wash it away completely with water immediately and get medi- cal attention.
  • Page 37 GENERAL - CHECK AND MAINIENANCE CK22/CK22H A. BATTERY CHARGING B. TABLE 1 Capacity at CAUTION Battery TYPE Volts (v) 20HR (A.H) To avoid personal injury: 70D23L DF65D When the battery is being activated, hydrogen and • oxygen gases in the battery are extremely explosive.

  • Page 38: Every 200 Hours

    (A) Close 8.4.2 REPLACING ENGINE OIL FILTER IMPORTANT • To prevent serious damage to the engine, use only a genuine DAEDONG filter. CAUTION To avoid personal injury: • Be sure to sop the engine before changing oil fil- ter cartridge.

  • Page 39: Replacing Transmission Oil

    GENERAL - CHECK AND MAINIENANCE CK22/CK22H 8.4.3 REPLACING TRANSMISSION OIL CAUTION To avoid personal injury: Be sure to stop the engine before changing the oil • filter cartridge. Allow engine to cool down sufficiently, oil can be • hot and can burn.

  • Page 40: Checking Radiator Hose And Clamp

    GENERAL - CHECK AND MAINIENANCE CK22/CK22H IMPORTANT • To prevent serious damage to the hydraulic system, use only a genuine DAEDONG filter. 196W141A (1) Oil inlet (2) Gauge (A) Oil level is acceptable within this range 8.4.4 CHECKING RADIATOR HOSE AND...

  • Page 41: Checking Hst Oil Line & Power Steering Line

    GENERAL - CHECK AND MAINIENANCE CK22/CK22H 8.4.5 CHECKING HST OIL LINE & POWER STEERING LINE 1. Check to see that all hydraulic lines and hose clamps are tight and undamaged. 2. If damage is found you should replace the hose or clamp at once.

  • Page 42: Every 400 Hours

    2. After draining reinstall the drain plug. 3. Fill with the new DAEDONG TF65 fluid up to the up- per line of the gauge. (See “LUBRICANTS” in the maintenance section) 196W146B 4.

  • Page 43: Replacing Fuel Filter Element

    1/6 turn. Retighten the lock nut. 196W150A (1) Adjusting screw (2) Lock nut 8.7 EVERY 800 HOURS 8.7.1 ADJUSTING ENGINE VALVE CLEAR- ANCE Consult your local DAEDONG Dealer for this service. DS35-W00 May. 2007 1-27...

  • Page 44: Once A Year

    GENERAL - CHECK AND MAINIENANCE CK22/CK22H 8.8 ONCE A YEAR 8.8.1 REPLACING AIR CLEANER ELEMENT (See “Cleaning Air Cleaner Element” in every 100 hours maintenance.) 8.9 EVERY 2 YEARS 8.9.1 FLUSH COOLING SYSTEM AND CHANGING COOLANT IMPORTANT Do not start engine without coolant.

  • Page 45: Replacing Radiator Hose (Water Pipes)

    GENERAL - CHECK AND MAINIENANCE CK22/CK22H A. ANTI-FREEZE 8.9.2 REPLACING RADIATOR HOSE (WATER PIPES) If cooling water freezes, it can damage the cylinders and radiator. It is necessary, if the ambient tempera- Replace the hoses and clamps. ture falls below 0°C (32°F), to remove coolant after op- (See “Checking Radiator Hose and Clamp”...

  • Page 46: Service As Required

    GENERAL - CHECK AND MAINIENANCE CK22/CK22H 8.10 SERVICE AS REQUIRED 8.10.1 BLEEDING FUEL SYSTEM Air must be 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.

  • Page 47: Replacing Fuse

    Fail- ure to follow this procedure may result in serious damage to the tractor electrical system. Refer to the troubleshooting section of this manual or your local DAEDONG Dealer for specific information dealing with electrical problems. PREHEAT HEAD...

  • Page 48: Tires

    GENERAL - TIRES CK22/CK22H 9. TIRES CAUTION To avoid personal injury: • Do not attempt to mount a tire. This should be done by a qualified person with the proper equipment. Always maintain the correct tire pressure. • Do not inflate tires above the recommended pres- sure shown in the operator’s manual.

  • Page 49: Tread

    GENERAL - TIRES CK22/CK22H 9.2 TREAD 9.2.1 FRONT WHEELS Front tread can not be adjusted. IMPORTANT • Do not turn front discs to obtain wider tread. NOTE: • IND… for Industrial 6 - 12 23 X 8.50 - 12 23 X 8.50 - 12...

  • Page 50: Ballast

    A. FRONT END WEIGHTS The front end weights can be attached to the bumper. 196W163A See your implement operator’s manual for required (1) Front end weights number of weights or consult your local DAEDONG Dealer to use. (2) Rear wheel weights IMPORTANT •...

  • Page 51: Traveling Speed

    GENERAL - TIRES CK22/CK22H 9.4 TRAVELING SPEED At rated engine rpm with standard tires. CK22 km/h (mile/h) HI - LOW Speed Main 1.10 (0.680) Forward 1.70 (1.056) 3.50 (2.170) 1.36 (0.845) Reverse 5.11 (3.175) Forward 7.88 (4.896) 16.24 (10.091) 6.31 (3.920)
  • Page 52 MEMO ...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 53 CK22/CK22H ENGINE TABLE OF CONTENTS 1. ENGINE IDENTIFICATION ......2-3 3. OPERATING PRINCIPLE ......2-13 1.1 General features ........2-3 3.1 Body and power train ......2-13 1.2 Engine EPA decal ........ 2-4 3.1.1 Cylinder head ......2-13 1.3 Bar code for engine number ....2-4 3.1.2 Cylinder block ......
  • Page 54 7.2.4 Checking top clearance ..2-64 5.5 Engine oil pressure ......2-39 7.2.5 Timing gears and camshafts ... 2-65 6. EXPLODED VIEW (CK22/CK22H) ... 2-41 7.2.6 Connecting rod and piston ..2-68 7. SERVICING ..........2-43 7.2.7 Crankshaft ......2-71 7.1 Removal and reassemble ....

  • Page 55: Engine Identification

    1.1 GENERAL FEATURES 196W207B The 3C100A is a vertical, water-cooled, 4-cycle diesel engine. They are incorporated with DAEDONG’s lead- ing technologies. They feature greater power, lower fuel consumption, and little vibration and quiet opera- tion due to the DAEDONG’s circular combustion chamber, well-known Bosch K type injection pump and well-balanced designs.

  • Page 56: Engine Epa Decal

    This engine is certified to operate on commercially available diesel fuel. Refer to owner's manual for maintemance specifications and adjustmints. E6305-99506 1.3 BAR CODE FOR ENGINE NUMBER The bar code for the DAEDONG engine number is located on the intake manifold. T46W202A 1.4 ENGINE NUMBER ASSIGNMENT STANDARD...

  • Page 57: Specifications

    ENGINE - SPECIFICATIONS CK22/CK22H 2. SPECIFICATIONS 2.1 GENERAL SPECIFICATIONS Item Factory Specification Model 3C100A Type Vertical, water-cooled 4 cycle diesel engine Number of cylinders 75 X 76 mm Bore stroke Total displacement 1007 cm , 61.45 cu.in. Engine gross power 22 HP (16.2 kW) / 2,800 rpm.

  • Page 58: Performance Curve

    ENGINE - SPECIFICATIONS CK22/CK22H 2.2 PERFORMANCE CURVE 196W203B NOTE: • Performance curve, obtained in accordance with SAE J 1995. • SFC (Specific Fuel Consumption) According to the curve, 197g/Hp-hr at 2,800 rpm → 197g/Hp-hr X 22 HP = 4,334 kg/hr →...

  • Page 59: Dimensions

    ENGINE - SPECIFICATIONS CK22/CK22H 2.3 DIMENSIONS mm (in.) 494 (19.4) 502 (19.7) 196W204B DS35-W00 May. 2007...

  • Page 60: Service Specifications

    ENGINE - SPECIFICATIONS CK22/CK22H 2.4 SERVICE SPECIFICATIONS 2.4.1 CYLINDER HEAD Item Reference Value Allowable Limit Distortion of cylinder head surface length. 0.05 mm (0.0020 in.) / 100 mm (4 in.) of cylinder head surface length. Thickness of gasket When tightened 1.15 ~ 1.25 mm (0.045 ~ 0.049 in.)

  • Page 61: Valve Rocker Arms

    ENGINE - SPECIFICATIONS CK22/CK22H 2.4.4 VALVE ROCKER ARMS Item Reference Value Allowable Limit O.D. of rocker arm shafts 12.955 ~ 12.980 mm 0.5100 ~ 0.5110 in. I.D. of rocker arm bushings 13.000 ~ 13.025 mm 0.5118 ~ 0.5128 in. Clearance between rocker arm shafts and 0.02 ~ 0.07 mm...

  • Page 62: Pistons

    ENGINE - SPECIFICATIONS CK22/CK22H 2.4.7 PISTONS Reference Value Allowable Limit Item 20.03 mm I.D. of piston bosses 20.000 ~ 20.013 mm 0.7885 in. 0.7874 ~ 0.7879 in. 20.002 ~ 20.011 mm O.D. of piston pin 0.7875 ~ 0.7878 in. 20.025 ~ 20.040 mm I.D.

  • Page 63: Injection Pump

    ENGINE - SPECIFICATIONS CK22/CK22H 2.4.10 INJECTION PUMP Item Reference Value Allowable Limit Tightness of plunger More than 60 seconds; initial pres- 30 seconds sure from 34.32 ~ 39.23 MPa 350 ~ 400 kgf/cm , 4,978 ~ 5,689 psi. Tightness of delivery valve More than 10 seconds;...

  • Page 64: Tightening Torque

    ENGINE - SPECIFICATIONS CK22/CK22H 2.4.15 TIGHTENING TORQUE Indicate the bolts with mark and manually tighten first. Item kgf-m lb-ft Head bolt, nut 58.8 ~ 63.7 6.0 ~ 6.5 43.4 ~ 47.0 29.4 ~ 34.3 21.7 ~ 25.3 Bearing case bolt 1 3.0 ~ 3.5...

  • Page 65: Operating Principle

    The com- bustion chamber is of DAEDONG’s select circular com- bustion chamber type. Suction air is combustion and reduces fuel consumption. Throttle type injection nozzles and rapid heating enclosed glow plugs are installed in the combustion.

  • Page 66: Crankshaft

    ENGINE - OPERATING PRINCIPLE CK22/CK22H 3.1.3 CRANKSHAFT The crankshaft drives the pistons and connecting rods, and transfers its reciprocating movement to a circular camshaft. Six counterweights are integrated into one unit to minimize bearing wear and lubricating oil tem- perature rise.

  • Page 67: Camshaft And Fuel Camshaft

    ENGINE - OPERATING PRINCIPLE CK22/CK22H 3.1.6 CAMSHAFT AND FUEL CAMSHAFT The camshaft is made of special cast iron; the journal and cam sections are chromed to resist wear. The jour- nal sections are force-lubricated. The fuel camshaft controls the reciprocating movement of the injection pump, and is also equipped with a ball to control the governor.

  • Page 68: Inlet And Exhaust Valves

    ENGINE - OPERATING PRINCIPLE CK22/CK22H 3.1.8 INLET AND EXHAUST VALVES The inlet and exhaust valves and their guides are dif- ferent from each other. Other parts, such as valve springs, spring retainers, valve spring collets, valve stem seals, and valves all contact or sliding parts, which are covered and tempered to resist, wear.

  • Page 69: Lubrication System

    ENGINE - OPERATING PRINCIPLE CK22/CK22H 3.2 LUBRICATION SYSTEM 196W200B A. Oil filter 1 C. Oil filter cartridge and relief D. Camshaft valve B. Oil pump E. Rocker arm rocker arm shaft 3. To rocker arm shaft and 1. Inlet hole F.

  • Page 70: Engine Oil Flow

    ENGINE - OPERATING PRINCIPLE CK22/CK22H 3.2.1 ENGINE OIL FLOW Rocker arm shaft Rocker arm Rocker arm Rocker arm Engine oil pressure sensor Valve Valve cam shaft Valve cam shaft Valve cam shaft Valve cam shaft shaft Valve cam shaft Valve cam shaft...

  • Page 71: Relief Valve

    ENGINE - OPERATING PRINCIPLE CK22/CK22H 3.2.2 RELIEF VALVE The relief valve prevents damage to the lubrication sys- tem due to high oil pressure. Control range of the relief valve is 196 to 441 Kpa (2.0 to 4.5 kgh/cm², 28 to 64 psi).

  • Page 72: Cooling System

    ENGINE - OPERATING PRINCIPLE CK22/CK22H 3.3 COOLING SYSTEM The cooling system consists of a radiator, centrifugal water pump, suction fan and thermostat. The water is cooled through the radiator core, and the fan set behind the radiator pulls cooling air through the core to improve cooling.

  • Page 73: Thermostat

    ENGINE - OPERATING PRINCIPLE CK22/CK22H 3.3.2 THERMOSTAT The thermostat is wax pellet type, which controls the flow of the cooling water to the radiator to keep the proper temperature. The case has a seat (1) and the pellet has a valve (2). The spindle attached to the case is inserted into the synthetic rubber in the pellet.

  • Page 74: Fuel System

    ENGINE - OPERATING PRINCIPLE CK22/CK22H 3.4 FUEL SYSTEM 3.4.1 FLOW OF FUEL The fuel is feed from the fuel tank (1) through the fuel filter (2) to the injection pump (4) by the fuel feed pump (3). The injection pump force-feeds the fuel through the injection nozzles (6), which inject the fuel into the cylinders for combustion.

  • Page 75: Fuel Feed Pump

    ENGINE - OPERATING PRINCIPLE CK22/CK22H 3.4.4 FUEL FEED PUMP From fuel tank To fuel filter The diaphragm (6) is linked to the tappet (3) with the push rod (2). The tappet is reciprocated by the eccen- tric cam on the fuel camshaft (7).
  • Page 76 ENGINE - OPERATING PRINCIPLE CK22/CK22H A. PUMP ELEMENT The pump element (1) consists of a plunger (3) and cylinder (2) which their sliding surfaces are finely ma- chined to maintain the fuel tightness. The plunger (3) is installed in the control sleeve (5) and the sleeve is engaged with the control rack that rotates the plunger in the cylinder to control the amount of fuel delivered.
  • Page 77 ENGINE - OPERATING PRINCIPLE CK22/CK22H C. AMOUNT OF FUEL DELIVERY a . No fuel delivery When the control rack (3) is at the engine stop position, the lengthwise slot (1) on the plunger (2) aligns with the feed hole (5). The pressure in the delivery chamber...
  • Page 78 (9) Packing This injection nozzle is throttle type nozzle. It features the low fuel consumption and works well with DAEDONG combustion chamber. The nozzle valve opening pressure is about 14.7 MPa (150 kgf/cm², 2134 psi). When the pressure overcomes the counterforce...

  • Page 79: Governor System

    ENGINE - OPERATING PRINCIPLE CK22/CK22H 3.5 GOVERNOR SYSTEM 3.5.1 DISASSEMBLED VIEW 196W239B (1) Start spring (6) Fork lever shaft (11) Steel ball (2) Governor spring 1 (7) Fork lever holder (12) Governor sleeve (3) Governor spring 2 (8) Governor lever...

  • Page 80: Basic Principle Of Governor System

    ENGINE - OPERATING PRINCIPLE CK22/CK22H 3.5.2 BASIC PRINCIPLE OF GOVERNOR SYSTEM 15 14 Torque Spring Torque control screw T46W246B (1) Governor spring 1, 2 (6) Steel ball (11) Governor sleeve (2) Solenoid guide (7) Governor lever (12) Fork lever 2...

  • Page 81: Operation Of Governor

    Therefore, never adjust them without permission from DAEDONG. Such action violates the EPA regula- tion and also can void the warranty. F. WHEN STOPPED When the key switch is moved to the “OFF” position, the stop solenoid power is cut off to release the electromagnet.

  • Page 82: Intake And Exhaust System

    ENGINE - OPERATING PRINCIPLE CK22/CK22H 3.6 INTAKE AND EXHAUST SYSTEM 3.6.1 FLOW OF INTAKE AIR AND EXHAUST 196W244B (A) Inlet air (3) Cylinder head (B) Exhaust gas (4) Muffler (1) Inlet manifold (5) Exhaust manifold (2) Air cleaner 3.6.2 AIR CLEANER The air cleaner is dry-cyclone type and easy to maintain.

  • Page 83: Pcv Valve

    ENGINE - OPERATING PRINCIPLE CK22/CK22H 3.6.4 PCV VALVE A. PCV (POSITIVE CRANKCASES VENTILATION) The PCV system is a system that prevents air pollution by returning the blow-by gas to the intake manifold through the bleeding pipe of the cylinder head cover for recirculation of the gas.

  • Page 84: Troubleshooting

    ENGINE - TROUBLESHOOTING CK22/CK22H 4. TROUBLESHOOTING ENGINE DOES NOT START. Crankshaft and camshaft have seized up. Crankshaft Frictional resis- does not turn tance of moving Piston and cylinder liner have seized up. parts is too much Bearings are oil-stuck. Lubrication system not working property.
  • Page 85 ENGINE - TROUBLESHOOTING CK22/CK22H Engine does not turn normally. Fuel filter clogged. Fuel pipes broken or loose. Air in pump. Revolution is Injection not smooth at pump wrong. Pump capacity not constant. high speeds. Tappet roller and pin worn. Delivery valve not completely oil-tight.
  • Page 86 ENGINE - TROUBLESHOOTING CK22/CK22H Color of exhaust fumes not normal. Piston ring stuck. Piston ring worn. Excessive gap between cylinder liner and Lubricant piston. White or blue rises through smoke. piston gap. Too much oil. Injection delayed. Compression pressure insufficient.

  • Page 87: Measurement And Adjustment

    ENGINE - MEASUREMENT AND ADJUSTMENT CK22/CK22H 5. MEASUREMENT AND ADJUSTMENT 5.1 FAN BELT 1. Measure the deflection, depressing the belt half- way between the fan drive pulley and the alternator pulley at 78.5 N (8 kgf, 17.6 lbs) of force.

  • Page 88: Valve Clearance

    ENGINE - MEASUREMENT AND ADJUSTMENT CK22/CK22H 5.3 VALVE CLEARANCE 1. Remove the cylinder head cover and the timing win- dow cover on the flywheel housing and all glow plugs. 2. Turn the flywheel and align the 1TC to mark with the...

  • Page 89: Injection Timing Measurement And Adjust- Ment

    - When turning the crankshaft, use a socket for turn- ing the crankshaft. NOTE: • How to use the crankshaft turning socket T46W258A T46W259A You can use DAEDONG special tool kit (part No.: G0611-B0010) for spline socket. DS35-W00 May. 2007 2-37...
  • Page 90 ENGINE - MEASUREMENT AND ADJUSTMENT CK22/CK22H 4. Remove the No. 1 high pressure pipe. 5. Unscrew the nozzle holder (1) slightly and tighten it when it is filled with fuel. T46W260C 6. Remove the fuel in the nozzle holder with clean cloth and leave only small amount of fuel.

  • Page 91: Engine Oil Pressure

    ENGINE - MEASUREMENT AND ADJUSTMENT CK22/CK22H 5.5 ENGINE OIL PRESSURE 1. Remove the oil pressure switch and install adap- tors and pressure tester. 2. Start the engine and run it until it is warmed up, and measure the oil pressure both at idling and rated speed.

  • Page 93: Exploded View (Ck22/Ck22H)

    ENGINE - EXPLODED VIEW (CK22/CK22H) CK22/CK22H 6. EXPLODED VIEW (CK22/CK22H) 196W247B (1) Cylinder Block (7) Cylinder Head (12) Bearing Case Bolt 1 (18) Push Rod (24) Connecting Rod (30) Glow Plug (36) Engine Stop Solenoid (41) Alternator (46) Idle Limit System...

  • Page 95: Servicing

    ENGINE - SERVICING CK22/CK22H 7. SERVICING 7.1 REMOVAL AND REASSEMBLE 7.1.1 ENGINE ASSEMBLY Drain the oil and the water, if disassemble the engine body. 1. Remove the muffler and exhaust manifold (7). 2. Remove the oil pressure switch (8). 3. Pull out the dipstick (6).

  • Page 96: Intake Manifold And Fuel Hoses

    ENGINE - SERVICING CK22/CK22H 7.1.3 INTAKE MANIFOLD AND FUEL HOSES 1. Disconnect the fuel hose (3). 2. Loosen the injection pipe fittings with two wrenches and remove the injection pipes (2). 3. Remove the inlet manifold (1) and the fuel feed pump (4).
  • Page 97 ENGINE - SERVICING CK22/CK22H C. REMOVING NOZZLE HOLDER ASSEMBLIES 1. Remove the pipe clips holding the fuel overflow pipes, and detach the pipes. 2. Detach the nozzle holders using a 27 mm (1.0630 in.) nozzle holder socket wrench, after loosening the lock nuts.

  • Page 98: Rocker Arm And Push-Rods

    ENGINE - SERVICING CK22/CK22H 7.1.5 ROCKER ARM AND PUSH-RODS A. ROCKER ARM ASSEMBLY 1. Loosen the nuts in several steps and the specified sequence shown in the figure and remove them. • To loosen (3) to (1). • To tighten (1) to (3).

  • Page 99: Cylinder Heads And Valves

    ENGINE - SERVICING CK22/CK22H 7.1.6 CYLINDER HEADS AND VALVES A. REMOVING CYLINDER HEADS AND GASKET. 1. Remove the fourteen cylinder head set bolts and two nuts. • To loosen (14) to (1) • To tighten (1) to (14) 2. Lift up the cylinder head to detach.
  • Page 100 ENGINE - SERVICING CK22/CK22H B. REMOVING TAPPETS 1. Remove the six tappets from the crankcase. (Note for reassembling) • Visually check the contact between tappets and cams for proper rotation. If a defect is found, re- place tappets. • Before installing the tappets, apply a thin coat of oil around them.

  • Page 101: Fuel Feed Pump And Injection Pump

    ENGINE - SERVICING CK22/CK22H 7.1.7 FUEL FEED PUMP AND INJECTION PUMP A. FUEL FEED PUMP REMOVING FUEL FEED PUMP 1. Remove the two fuel feed pump mounting nuts. 2. Detach the fuel feed pump. 3. Remove the injection pump cover(2).
  • Page 102 ENGINE - SERVICING CK22/CK22H 4. Remove the idle limit system (3). 5. Remove the injection pump mounting bolts and nuts (A). 6. Align the control rack pin (4) with the slot (5) on the cylinder and remove the injection pump.

  • Page 103: Crank Case

    ENGINE - SERVICING CK22/CK22H 7.1.8 CRANK CASE A. DETACH THE GOVERNOR SPRING 1. Detach the governor spring 1, 2 and speed control plate from governor lever. 2. Remove the manual stop lever plate (4). (Note for reassembling) • Be careful not to drop the governor spring 1, 2 in the gear case.
  • Page 104 ENGINE - SERVICING CK22/CK22H B. REMOVING FAN DRIVE PULLEY 1. Flatten the crankshaft washer. 2. Loosen and remove the crankshaft nut. 3. Draw out the pulley with a puller. (Note for reassembling) • Bend the crankshaft washer against one side of the nut.

  • Page 105: Timing Gears, Cam Shafts And Oil Pump

    ENGINE - SERVICING CK22/CK22H 7.1.9 TIMING GEARS, CAM SHAFTS AND OIL PUMP A. REMOVING CRANKSHAFT OIL SLINGER 1. Remove the crankshaft collar. 2. Remove the O-ring. 3. Detach the crankshaft oil slinger. 196W280A (1) Crankshaft oil slinger (2) O-ring (3) Crankshaft collar B.
  • Page 106 ENGINE - SERVICING CK22/CK22H C. REMOVING CAMSHAFT STOPPER 1. Align the round hole on the cam gear with the cam- shaft stopper mounting bolt position. 2. Remove the camshaft stopper mounting bolt. 3. Detach the camshaft stopper. 196W283A (1) Camshaft stopper D.
  • Page 107 ENGINE - SERVICING CK22/CK22H F. REMOVING OIL PUMP DRIVE GEAR 1. Remove the nut from oil pump. 2. Draw out the oil pump drive gear with gear puller. (Note for reassembling) • Ensure there is a feather key. 196W287A (1) Crank gear (2) Oil pump drive gear G.

  • Page 108: Piston

    ENGINE - SERVICING CK22/CK22H 7.1.10 PISTON A. REMOVING OIL PAN 1. Lay the engine on the engine cradle on its side. 2. Remove the eighteen oil pan mounting bolts. 3. Detach the oil pan by lightly tapping the groove of the pan with a wooden hammer.
  • Page 109 ENGINE - SERVICING CK22/CK22H D. REMOVING PISTONS 1. Turn the crankshaft and bring the piston to top dead center. 2. Draw out the piston upward by lightly tapping it from the bottom of the crankcase with the grip of a hammer.
  • Page 110 ENGINE - SERVICING CK22/CK22H E. PISTON RING AND PISTON PIN 1. Remove the piston rings with a piston ring replac- ing tool. 2. Remove the piston pin. (When reassembling) • Clean all the parts before assembling. • Heat the piston in approx. 80°C (176°F) of oil for 10 ~ 15 minutes, when inserting the piston pin into the piston.

  • Page 111: Flywheel And Main Bearing Case Cover

    ENGINE - SERVICING CK22/CK22H 7.1.11 FLYWHEEL AND MAIN BEARING CASE COVER A. FLYWHEEL AND REAR PLATE 1. Loosen the flywheel bolt and remove the flywheel. 2. Loosen the bolt and remove the rear plate. (When reassembling) • Check the end of crankshaft any uneven wear, lack or crack of teeth.

  • Page 112: Crankshaft And Journal Bearing

    ENGINE - SERVICING CK22/CK22H 7.1.12 CRANKSHAFT AND JOURNAL BEARING A. REMOVING BEARING CASE BOLT 2 Detach the bearing case bolts. (Note for reassembling) • When tightening the main bearing case bolts, align the direction of the holes so that the crankshaft can be easily installed.

  • Page 113: Inspection For Overhaul

    ENGINE - SERVICING CK22/CK22H 7.2 INSPECTION FOR OVERHAUL 7.2.1 CYLINDER HEAD A. CYLINDER HEAD SURFACE FLATNESS 1. Thoroughly clean the cylinder head surface. 2. Place a straightedge on the cylinder head and mea- sure the clearance with a feeler gage as shown in the figure.
  • Page 114 ENGINE - SERVICING CK22/CK22H C. VALVE STEM CLEARANCE 1. Remove the carbon from the valve guide. 2. Measure the valve stem O.D. with an outside micrometer. 3. Measure the valve guide I.D. of cylinder head, and calculate the clearance. 4. If the measurement exceeds the allowable limit, replace the valve guide or the valve.

  • Page 115: Valve Spring

    ENGINE - SERVICING CK22/CK22H 7.2.2 VALVE SPRING A. CHECKING VALVE SPRING FREE LENGTH 1. Measure the spring with a set of vernier calipers. 2. If the measurement exceeds the allowable limit, replace. 35.1 ~ 35.6 mm Reference value 1.382 ~ 1.402 in.

  • Page 116: Checking Oil Clearance Between Rocker Arm Shaft And Bushing

    ENGINE - SERVICING CK22/CK22H 7.2.3 CHECKING OIL CLEARANCE BE- TWEEN ROCKER ARM SHAFT AND BUSHING 1. Measure the rocker arm I.D. 2. Measure the rocker arm O.D. 3. If the clearance exceeds the allowable limit, replace. 0.02 ~ 0.08 mm Reference value 0.0008 ~ 0.0031 in.

  • Page 117: Timing Gears And Camshafts

    ENGINE - SERVICING CK22/CK22H 7.2.5 TIMING GEARS AND CAMSHAFTS A. TIMING GEAR BACKLASH 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Clamp one gear, rotate the other and measure the backlash. 3. If the backlash exceeds the allowable limit, replace.
  • Page 118 ENGINE - SERVICING CK22/CK22H D. INJECTION PUMP GEAR SIDE CLEARANCE 1. Pull the fuel camshaft and pull the injection pump gear (1) to each end. 2. Measure the clearance A between the injection pump gear (1) and the snap ring (2) on the fuel camshaft.
  • Page 119 ENGINE - SERVICING CK22/CK22H G. 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 outside micrometer. 3. If the clearance exceeds the allowable limit, replace the shaft.

  • Page 120: Connecting Rod And Piston

    ENGINE - SERVICING CK22/CK22H 7.2.6 CONNECTING ROD AND PISTON A. PISTON PIN BORE 1. Measure the I.D. of piston pin bore in piston (lengthwise and widthwise of the piston) with a cyl- inder gauge. 2. If the measurement exceeds the allowable limit, replace the piston.
  • Page 121 ENGINE - SERVICING CK22/CK22H D. PISTON RING GAP 1. Push down the ring into the cylinder to the lower limit of ring travel in the assembled engine with a piston. 2. Measure the ring gap with a feeler gauge. 3. If the gap exceeds the allowable limit, replace the piston ring.
  • Page 122 ENGINE - SERVICING CK22/CK22H F. CONNECTING ROD ALIGNMENT 1. Remove the connecting rod bearing and install the bearing cap. 2. Install the piston pin in the connecting rod. 3. Install the connecting rod on the connecting rod alignment tool. 4. Put a gauge over the piston pin and move it against the face plate.

  • Page 123: Crankshaft

    ENGINE - SERVICING CK22/CK22H 7.2.7 CRANKSHAFT A. FLYWHEEL DEFLECTION AND CRANK- SHAFT END PLAY 1. Set a dial indicator with its tip on the rear friction face of the flywheel near the edge. 2. Turn the flywheel and measure the deflection or the uneven wear.
  • Page 124 ENGINE - SERVICING CK22/CK22H D. REPLACING CRANKSHAFT BEARING 1 1. Press out the bearing 1 with crankshaft replacing tool. 2. Clean a new bearing 1 and bore, and apply engine oil to them. 3. Press fit a new bearing 1 using a inserting tool, taking due care to see that the seam of bearing 1 faces the exhaust manifold side.
  • Page 125 ENGINE - SERVICING CK22/CK22H F. CRANKPIN AND CONNECTING ROD BEAR- ING OIL CLEARANCE 1. Paste a press gauge onto the crank pin bearing with grease. 2. Install the connecting rod cap and tighten the screws to the specified torque once, and remove the cap again.

  • Page 126: Lubricating System

    ENGINE - SERVICING CK22/CK22H 7.2.8 LUBRICATING SYSTEM A.ENGINE OIL PRESSURE 1. Remove the oil pressure switch and install adap- tors and pressure tester. 2. Start the engine and run it until it is warmed up, and measure the oil pressure both at idling and rated speed.
  • Page 127 ENGINE - SERVICING CK22/CK22H C. ROTOR AND LOBE CLEARANCE OF OIL PUMP 1. Measure the clearance between the outer and in- ner rotor with a feeler gauge. 2. Measure the clearance between the outer and the housing with a feeler gauge.

  • Page 128: Cooling System

    ENGINE - SERVICING CK22/CK22H 7.2.9 COOLING SYSTEM A. CHECKING AND ADJUSTING Fan Belt 1. Measure the deflection, depressing the belt half- way between the fan drive pulley and the alternator pulley at 78.5 N (8 kgf, 17.6 lbs.) of force.

  • Page 129: Disassembling And Assembling

    ENGINE - SERVICING CK22/CK22H B. DISASSEMBLING AND ASSEMBLING THERMOSTAT 1. Remove the thermostat cover (2). 2. Take out the thermostat (1). (When reassembling) • Apply liquid gasket (Three Bond 1,215 or equivalent) to the gasket. 196W2G2A (1) Thermostat (2) Thermostat Cover WATER PUMP 1.

  • Page 130: Fuel System

    ENGINE - SERVICING CK22/CK22H 7.2.10 FUEL SYSTEM A. DELIVERY VALVES FUEL TIGHTNESS 1. Remove the injection pipes, glow plugs and the in- let manifold, and install the pressure tester. 2. With the speed control lever at the fuel injection position, turn the crankshaft counterclockwise (facing the flywheel) until the pressure build up to the fuel injection pressure.
  • Page 131 ENGINE - SERVICING CK22/CK22H C. FUEL TIGHTNESS OF NEEDLE VALVE SEAT TIGHTNESS 1. Set the injection nozzle to the nozzle tester. 2. Apply a pressure 130 kgf/cm² (12.75 MPa, 1,849 psi). After keeping the nozzle under this pressure for 10 seconds.
  • Page 132 MEMO ...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 133 CK22/CK22H CLUTCH TABLE OF CONTENTS 1. SPECIFICATIONS ..............3-2 2. OPERATION PRINCIPLE ............3-3 3. TROUBLESHOOTING .............. 3-4 4. CHECKING AND ADJUSTMENT ..........3-5 4.1 Clutch pedal play adjustment .......... 3-5 4.2 Adjustment of clutch pedal stopper bolt ......3-5 4.3 Adjustment of safety switch ..........

  • Page 134: Specifications

    CLUTCH - SPECIFICATIONS CK22/CK22H 1. SPECIFICATIONS Item Reference Value Allowable Limit Clutch pedal free play 20 ~ 30 mm 0.79 ~ 1.18 in. 3.5 ~ 4.5 mm Safety switch pedal movement (When depressing clutch pedal to the stroke end) 0.14 ~ 0.18 in.

  • Page 135: Operation Principle

    CK22/CK22H 2. OPERATION PRINCIPLE A single disc clutch is standard equipment on the model CK22 tractor and the model CK22H tractor equipped with the hydrostatic drive transmission. The clutch assembly consists of the clutch pressure plate (1), clutch disc (2), flywheel (3), release bearing (4), and hub assembly (5).

  • Page 136: Troubleshooting

    CLUTCH - TROUBLESHOOTING CK22/CK22H 3. TROUBLESHOOTING Symptom Probable Cause Solution Clutch drags • Clutch pedal free play excessive Adjust • Clutch release lever improperly adjusted Adjust • Clutch disc boss spline sticking or rusted Replace or remove rust • Dust on clutch disc generated from clutch disc facing Remove rust •...

  • Page 137: Checking And Adjustment

    CLUTCH - CHECKING AND ADJUSTMENT CK22/CK22H 4. CHECKING AND ADJUSTMENT 4.1 CLUTCH PEDAL PLAY ADJUST- MENT 1. Press clutch pedal (1) by hand and measure (A) at the end of pedal. 2. If the measurement is not within the factory specifications, loosen lock nut (3), (4) of clutch rod (2), adjust the clutch rod (2) length.

  • Page 138: Servicing

    2. After draining reinstall the drain plug. 3. Fill with the new DAEDONG TF65 fluid up to the up- 196W320A per line of the gauge. (See “LUBRICANTS” in maintenance section) 4.

  • Page 139: Bonnet

    2. Remove the parking brake lever grip (2) and the speed set lever grip (3). 3. Remove the transmission cover (4). (CK22) 4. Remove the instrument panel cover (down) (5). 5. Remove the engine stop wire & rotation cable from the engine side.

  • Page 140: Propeller Shaft

    CLUTCH - SERVICING CK22/CK22H (When reassembling) • Make sure to connect each hose to the correct loca- tion by identifying its tag. • Hose identification - Steering hose P: A red tag attachment - Steering hose R: A white tag attachment...

  • Page 141: Hydraulic Pipes

    CLUTCH - SERVICING CK22/CK22H 5.1.7 HYDRAULIC PIPES 1. Remove the suction pipe 3 (1), hydraulic pipe (3), cooling pipe 4 (2), fuel pipe 2 (4), fuel pipe 3 (6) and cooling pipe 3 (5). (When reassembling) • Make sure to clamp connecting rubber pipe of in- take pipe to prevent air entered.

  • Page 142: Removing Clutch

    CLUTCH - SERVICING CK22/CK22H 5.1.9 REMOVING CLUTCH 1. Remove the clutch from the flywheel. 196W312A (When reassembling) • Take care of assembly direction. The shorter spline boss (A) should be located toward flywheel when assembling clutch disc. • Take care to treat clutch disc and clean each fiction surface of flywheel and clutch pressure plate.

  • Page 143: Inspection For Overhaul

    CLUTCH - SERVICING CK22/CK22H 5.2 INSPECTION FOR OVERHAUL 5.2.1 SPLINE BACKLASH BETWEEN CLUTCH DISC BOSS AND MAIN SHAFT 1. Mount the clutch disc to the main shaft. 2. Hold the main shaft so that it does not turn. 3. Rotate disc lightly and measure the displacement around the disc edge.

  • Page 144: Thrust Ball Bearing

    CLUTCH - SERVICING CK22/CK22H 5.2.4 THRUST BALL BEARING 1. Check the contact area for excessive wear. 2. With inner wheel seized and outer wheel loaded, check for abnormal noise or operation. 3. If faulty, replace it. CAUTION • When assembling the bearing, make sure not to apply force to the bearing ball or taper roller.
  • Page 145 4.9 Hand brake (CK22-EU) ...... 4-25 2.2 Power train ..........4-5 4.10 Fender ..........4-26 2.2.1 Main gear shift section (CK22) 4-5 4.11 Fuel tank ..........4-26 2.2.2 Reverse shift (CK22) ....4-7 4.12 Front wheel driving lever ....4-26 2.2.3 High-Low shift ......

  • Page 146: Specifications

    TRANSMISSION - SPECIFICATIONS CK22/CK22H 1. SPECIFICATIONS Item Reference Value Allowable Limit Spiral bevel gear pinion turning torque 0.98 ~ 1.28 Nm 0.1 ~ 0.13 kgf-m 0.72 ~ 0.94 lb-ft PTO shaft lock nut tightening torque 147.1 ~ 196.1 Nm 15 ~ 20 kgf-m 108.5 ~ 144.7 lb-ft...
  • Page 147 INDEX INDEX INDEX ELECTRIC ELECTRIC ELECTRIC HYDRAULIC HYDRAULIC HYDRAULIC STEERING STEERING STEERING FRONT AXLE FRONT AXLE FRONT AXLE BARKE BARKE BARKE REAR AXLE REAR AXLE REAR AXLE TRANSMISSION TRANSMISSION TRANSMISSION CLUTCH CLUTCH CLUTCH ENGINE ENGINE ENGINE GENERAL GENERAL GENERAL INDEX INDEX ELECTRIC ELECTRIC...
  • Page 148 INDEX INDEX INDEX INDEX INDEX ELECTRIC ELECTRIC ELECTRIC ELECTRIC ELECTRIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC STEERING STEERING STEERING STEERING STEERING FRONT AXLE FRONT AXLE FRONT AXLE FRONT AXLE FRONT AXLE BARKE BARKE BARKE BARKE BARKE REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE TRANSMISSION...

  • Page 149: Operating Principle

    The transmission consists of a series of gears and shaft shown previously. It offers the most suitable speed for traveling and operation by combination of these gears. It transmits power to the front axle, rear axle and PTO shaft. CK22 is equipped a transmission with 6 forwards and 2 reverses. 2.2.1 MAIN GEAR SHIFT SECTION (CK22)
  • Page 150 TRANSMISSION - OPERATING PRINCIPLE CK22/CK22H B. SYNCHRO OPERATION 1ST STAGE • By shift of main transmission shift lever, shifter (3) and key (2) are moved and the end of key contacted with cone of gear (6) with synchronizer ring (5) pushed.

  • Page 151: Reverse Shift (Ck22)

    TRANSMISSION - OPERATING PRINCIPLE CK22/CK22H 2.2.2 REVERSE SHIFT (CK22) 196W406A (1) Main Shaft (4) 24T gear (7) Shifter (2) 22T gear (5) 16T gear (8) Synchro hub (3) 34T gear (6) 40T gear (9) Connecter shaft The standard 6 x 2 gear transmission (1), consists of...

  • Page 152: High-Low Shift

    CK22/CK22H 2.2.3 HIGH-LOW SHIFT 196W407A (1) Counter shaft (4) 34T gear (CK22), 36T gear (CK22H) (2) 14T gear (CK22), 23T gear (CK22H) (5) 22T gear (CK22), 20T gear (CK22H) (3) 42T gear (CK22), 33T gear (CK22H) (6) Spiral bevel pinion...

  • Page 153: Transmission Pto Section

    CK22/CK22H 2.2.4 TRANSMISSION PTO SECTION 6204 196W408B (1) Main shaft (8) PTO shaft (2) PTO drive shaft 1 (CK22), HST shaft (CK22H) (9) 17T gear (3) Overrunning clutch (10) 42T gear (4) PTO drive shaft 2 (11) 37T gear (5) PTO drive shaft 3...
  • Page 154 (3) 17T gear (7) Mid PTO shaft (4) 42T gear B. REAR PTO The rear power take-off is available on the CK22, CK22H model tractors equipped with either the 6 x 2 mechanical gear transmission or the hydrostatic transmission. REAR PTO ENGAGEMENT PTO drive shaft 2 (1) →...

  • Page 155: Front Wheel Drive

    (14) Front wheel shaft (7) 23T (36T) gear (15) Front wheel drive shaft 2 (8) 20-33T gear A. CK22 B. CK22H Four wheel drive or two wheel drive is selected by op- Four wheel drive or two wheel drive is selected by op-...

  • Page 156: Transmission Shift Linkage Structure

    TRANSMISSION - OPERATING PRINCIPLE CK22/CK22H 2.3 TRANSMISSION SHIFT LINKAGE STRUCTURE 2.3.1 MAIN SHIFT (CK22) A. MAIN GEAR SHIFT (1ST, 2ND & 3RD) 196W413A (1) Main shift arm (5) Connecter shaft (2) Main shift fork 1 (6) Main shift fork (3) Shifter...

  • Page 157: Reverse Shift (Ck22)

    TRANSMISSION - OPERATING PRINCIPLE CK22/CK22H 2.3.2 REVERSE SHIFT (CK22) 196W414A (1) Main shift arm (3) Shifter (5) 40T gear (2) Main shift fork 1 (4) 16T gear (6) Counter shaft • If the transmission shift lever moved to right, main shift arm (1) will be engaged with main shift fork 1 (2) in 1st stage.

  • Page 158: High-Low Range Shift

    TRANSMISSION - OPERATING PRINCIPLE CK22/CK22H 2.3.3 HIGH-LOW RANGE SHIFT 196W416A (1) High-Low shift lever (4) High-Low shift arm (2) Connecting plate (5) 42T - 22T gear (3) High-Low shift connecting arm • The high-low shift lever (1) is located at left side of driver’s seat and connected to connecting plate (2),...

  • Page 159: Mid, Rear Pto Shift

    TRANSMISSION - OPERATING PRINCIPLE CK22/CK22H 2.3.4 MID, REAR PTO SHIFT 196W418A (1) Mid PTO lever (5) Mid PTO lever 1 (9) Shifter (2) Rear PTO lever (6) PTO shift arm (10) Shifter (3) Mid PTO rod (7) Mid PTO shift arm...

  • Page 160: Front Wheel Drive Shift

    TRANSMISSION - OPERATING PRINCIPLE CK22/CK22H 2.3.5 FRONT WHEEL DRIVE SHIFT 196W422A (1) Front wheel drive lever (4) Front wheel drive shaft Engaged (2) Front wheel rod (5) Front wheel drive arm Disengage (3) Front wheel drive arm 2 (6) Front wheel shifter •...

  • Page 161: Differential Gear

    TRANSMISSION - OPERATING PRINCIPLE CK22/CK22H 2.4 DIFFERENTIAL GEAR 2.4.1 STRUCTURE 196W424A (1) 11 gear shaft (RH) (5) Rear differential case (8) Differential side gear (2) Spiral bevel pinion (6) 11 gear shaft (LH) (9) Differential pinion (3) Differential bearing case (RH)
  • Page 162 TRANSMISSION - OPERATING PRINCIPLE CK22/CK22H A. DURING STRAIGHT RUNNING Rotation of the spiral bevel pinion (2) is transmitted to the spiral bevel gear (1) and differential case (4). When road resistance to right and left wheels are equal, differential pinions (3) and differential side gears (5) are all rotates as a unit.
  • Page 163 TRANSMISSION - OPERATING PRINCIPLE CK22/CK22H C. DIFFERENTIAL LOCK When resistance to the right and left tires is different due to ground conditions or type of work, the wheel with less resistance slips and prevents the tractor moving ahead. To compensate for this, the differential lock restricts the differential action and causes both rear axles to rotate as a unit.

  • Page 164: Troubleshooting

    TRANSMISSION - TROUBLESHOOTING CK22/CK22H 3. TROUBLESHOOTING 3.1 MECHANICAL TRANSMISSION (MANUAL) Symptom Probable Cause Solution Noise from trans- • Transmission oil insufficient Refill mission • Gear worn or broken Replace • Improper backlash between ring gear and spiral Adjust bevel pinion shaft •...

  • Page 165: Servicing

    TRANSMISSION - SERVICING CK22/CK22H 4. SERVICING 4.1 DRAINING THE TRANSMISSION MANUAL FLUID CAUTION To avoid personal injury: • Allow engine to cool down sufficiently, oil can be hot and can burn. 1. To drain the used oil, remove the drain plug at the bottom of the transmission case and drain the oil completely into the oil pan.

  • Page 166: Bonnet

    2. Remove the parking brake lever grip (2) and the speed set lever grip (3). 3. Remove the transmission cover (4). (CK22) 4. Remove the instrument panel cover (down) (5). 5. Remove the engine stop wire & rotation cable from the engine side.

  • Page 167: Power Steering Unit

    TRANSMISSION - SERVICING CK22/CK22H 4.4 POWER STEERING UNIT 1. Disconnect the steering hose assembly (1) (L.R.P). 2. Disconnect the hose band. 3. Remove the mounting bolts in the power steering unit (2) and remove the steering hose T and then remove the power steering unit assembly slowly.

  • Page 168: Step

    TRANSMISSION - SERVICING CK22/CK22H 4.6 STEP 1. Remove the step mat (LH/RH) (1). 2. Remove the joystick mounting bolts and disconnect the cover (2). 3. Remove the frame (3). 4. Remove the step (LH/RH) (4). 196W4D1A (1) Step mat (3) Frame...

  • Page 169: Hand Brake (Ck22-Eu)

    TRANSMISSION - SERVICING CK22/CK22H 4.9 HAND BRAKE (CK22-EU) 196W4D6A (1) Split pin (5) Grommet (8) Parking brake wire 1 (2) Plain washer (6) Parking brake bracket (9) Parking brake wire 3 (3) Joint pin (7) Parking brake bracket 1 (10) Bolt (4) Parking brake wire 1.

  • Page 170: Fender

    TRANSMISSION - SERVICING CK22/CK22H 4.10 FENDER 1. Rmove the connect of the rear combi lamp, turn sigal lamp and working lamp. 2. Remove the ROPS mounting bracket (1). 3. Remove the grip (2) from the levers and then re- move the lever guide (3).

  • Page 171: Hydraulic Tubes

    TRANSMISSION - SERVICING CK22/CK22H 4.13 HYDRAULIC TUBES 1. Remove the suction tube 3 (1), hydraulic tube (3), cooling tube 4 (2), fuel hose 2 (4), fuel hose 3 (6) and cooling tube 3 (5). (When reassembling) • Make sure to clamp connecting rubber hose of in- take tube to prevent air entered.

  • Page 172: Joy-Stick Valve

    TRANSMISSION - SERVICING CK22/CK22H 4.15 JOY-STICK VALVE 1. Remove the hydraulic tube P1 (1), hydraulic tube P2 (2), and return tube (3). 2. Remove the bolts and the valve. 3. Remove the valve support (4). Tightening torque Item Joint bolt 39.2 ~ 44.1 Nm...

  • Page 173: Hst Damper Assembly (Ck22H)

    TRANSMISSION - SERVICING CK22/CK22H 4.16 HST DAMPER ASSEMBLY (CK22H) 1. Remove the split pin (1), cir-clip (2), plain washer (3), damper cylinder (4), spacers (5)(6), damper (7), spacer (11), split pin (8), plain washer (9) and con- nector plate (12).

  • Page 174: Disassembling The Clutch Housing And Middle Case

    TRANSMISSION - SERVICING CK22/CK22H 4.18 DISASSEMBLING THE CLUTCH HOUSING AND MIDDLE CASE [CK22H] 1. Place the jack under the HST case. 2. Hoist the clutch housing by the nylon lift strap. 3. Remove the bolts (3) and nuts (6). (When reassembling) •...

  • Page 175: Disassembling The Hst Assembly And Front Wheel Drive Assembly

    (4) Middle case (9) Drain tube (5) Joint Bolt (10) Joint bolt B. DISASSEMBLING THE FRONT WHEEL DRIVE ASSEMBLY (CK22) 1. Remove the bolts (1). 2. Take out the front wheel drive assembly (2). 196W456A (1) Bolt (2) Front wheel drive assembly DS35-W00 May.

  • Page 176: Disassembling The Front Wheel Drive Shaft

    TRANSMISSION - SERVICING CK22/CK22H 4.20 DISASSEMBLING THE FRONT WHEEL DRIVE SHAFT [CK22H] 1. Separate the front wheel drive case from the HST case. 2. Draw out the front wheel shift (7), ball (9) and spring (8). 3. Remove the cir-clip (6) and draw out the front wheel drive shaft 2 with the bearing and cir-clip (4) on it.

  • Page 177: Hst Output Shaft Group (Ck22H)

    TRANSMISSION - SERVICING CK22/CK22H A. FRONT WHEEL DRIVE LEVER 1. Tap out the spring pin (6). 2. Remove the front wheel drive arm 2 (5), bolt (8), front wheel drive stopper (7), front wheel drive shaft (2) and O-ring (4).

  • Page 178: Counter Shaft Group (Ck22)

    (7) 23T gear (14) Front wheel drive shaft 1 4.22 COUNTER SHAFT GROUP (CK22) A. SEPARATING THE MIDDLE CASE ASSEMBLY 1. Remove the bolt (1), nut (2) and spring washer (3). 2. Tap out the middle case assembly to the front side.
  • Page 179 TRANSMISSION - SERVICING CK22/CK22H B. SEPARATING THE PTO DRIVE SHAFT 1 1. Remove the bolts (11) and bearing case (12). 2. Tap out the PTO drive shaft 1 with spacer 1 (2), O-ring (3), ball bearing (6), 22T gear (7), Cir- clip (8), Cir-clip (9), ball bearing (10) to the rear side.
  • Page 180 TRANSMISSION - SERVICING CK22/CK22H D. SEPARATING THE COUNTER SHAFT 196W465 A (1) Cir-clip (8) Synchronize ring (15) Spacer (22) Stopper (2) Ball bearing (9) Synchro hub (16) 22T-32T gear (23) Bolt (3) Counter shaft (10) Spring (17) Reverse shaft (24) Coupling...

  • Page 181: Disassembling Spiral Bevel Gear

    TRANSMISSION - SERVICING CK22/CK22H 4.23 DISASSEMBLING SPIRAL BEVEL GEAR 1. Tap out the spring pin (1), and remove the differen- tial lock arm. 2. Remove the differential lock pedal assembly (3, 4, 5) from the transmission case. 196W472A (1) Spring pin...
  • Page 182 TRANSMISSION - SERVICING CK22/CK22H [CK22H] 5. Straighten locking tab of lock nut (1) and remove the nut (1). 6. Remove the 20T gear (2) and tap out the spiral bevel gear (3) to the rear. 7. Remove the 33T-20T gear (4).

  • Page 183: Pto Lever And Mid Pto Lever

    TRANSMISSION - SERVICING CK22/CK22H 4.24 PTO LEVER AND MID PTO LEVER 1. Tap out the spring pin (18). 2. Remove the mid PTO lever 1 (17). 3. Remove the nut (5), screw (4). 4. Remove the items (13 ~ 16).

  • Page 184: Rear Pto

    TRANSMISSION - SERVICING CK22/CK22H 4.25 REAR PTO 1. Remove the seal cap (1), snap ring (2). 2. Use a soft-faced hammer and PTO drive shaft 3 (4) rearwards out of bearing (6) and remove the PTO drive shaft assembly out of housing.

  • Page 185: Mid Pto

    TRANSMISSION - SERVICING CK22/CK22H 4.26 MID PTO 1. Place a container under the transmission drain plug (20). Remove the drain plug (20) and drain the oil. Install and tighten the drain plug. 2. Support the mid PTO assembly, remove the bolts (1) and remove the assembly.
  • Page 186 MEMO ...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 187 CK22/CK22H TABLE OF CONTENTS 1. SPECIFICATIONS ..............5-2 2. OPERATING PRINCIPLE ............5-3 2.1 Power train diagram ............5-3 2.2 Structure ................5-5 2.2.1 Features ..............5-5 2.2.2 Appearance of hydraulic transmission and circuit ................. 5-5 2.2.3 Cross sectional drawing of the hydrostatic trans- mission ..............

  • Page 188: Specifications

    HST - SPECIFICATIONS CK22/CK22H 1. SPECIFICATIONS Item Reference Value Allowable Limit Displacement Pump Motor 0 ~ 16.4 cc/rev 16.4 cc/rev Angle of swash plate 0 ~ 16 Pump Motor 16° Charge pump displacement 4.1 cc/rev Maximum working pressure 280 kgf/cm (Relief setting pressure) 3982.5 psi...
  • Page 189 INDEX INDEX INDEX ELECTRIC ELECTRIC ELECTRIC HYDRAULIC HYDRAULIC HYDRAULIC STEERING STEERING STEERING FRONT AXLE FRONT AXLE FRONT AXLE BARKE BARKE BARKE REAR AXLE REAR AXLE REAR AXLE TRANSMISSION TRANSMISSION TRANSMISSION CLUTCH CLUTCH CLUTCH ENGINE ENGINE ENGINE GENERAL GENERAL GENERAL INDEX INDEX ELECTRIC ELECTRIC...

  • Page 191: Operating Principle

    HST - OPERATING PRINCIPLE CK22/CK22H 2.2 STRUCTURE 2.2.1 FEATURES 1. HST (Hydraulic Transmission) • The pump converts the input rotation from engine to hydraulic pressure that lets the motor operate; • HST is directly linked to transmission case, and it accordingly the motor produces the output rotation.

  • Page 192: Cross Sectional Drawing Of The Hydrostatic Transmission

    HST - OPERATING PRINCIPLE CK22/CK22H 2.2.3 CROSS SECTIONAL DRAWING OF THE HYDROSTATIC TRANSMISSION 196W4B8A (2) Pump shaft (17) Cylinder block (7) Motor drive shaft (25) Rear cover (8) Swash plate (pump) (51) Charge pump casing (15) Swash plate (motor) DS35-W00 May. 2007...

  • Page 193: Functions Of Each Component

    HST - OPERATING PRINCIPLE CK22/CK22H 2.3 FUNCTIONS OF EACH COMPONENT 2.3.1 HYDRAULIC PUMP This is an axial piston pump with rotating swash plate (variable displacement type). The cylinder block with swash plate is rotated by the drive shaft. The angle of the swash plate determines...

  • Page 194: Charge Pump

    HST - OPERATING PRINCIPLE CK22/CK22H 2.3.3 CHARGE PUMP Some internal leaks exist in pump and motor even though they are connected each other with closed circuit. The trochoid pump is installed as a charge pump to compensate the leaks. The oil filter is installed at outlet side of the pump.

  • Page 195: Neutral Valve

    HST - OPERATING PRINCIPLE CK22/CK22H 2.3.5 NEUTRAL VALVE Neutral valve is a valve that secures neutral position during starting. When the swash plate’s angle and discharge volume become smaller, the motor does not rotate because the oil flows into the inner passage of case (passage B-drain circuit) via orifice.

  • Page 196: Operation Control

    HST - OPERATING PRINCIPLE CK22/CK22H 2.4 OPERATION CONTROL 2.4.1 NEUTRAL (HST PEDAL: STOP) When the swash plate control lever is at neutral position, the sliding surface of the swash plate will have vertical position against piston. Then the cylinder block rotates with input shaft but the piston stroke becomes zero.

  • Page 197: Forward

    HST - OPERATING PRINCIPLE CK22/CK22H 2.4.2 FORWARD Move the swash plate control lever to the left, the run- ning swash plate will be angled as illustrated. As the cylinder block is connected with the input shaft, it ro- tates with the input shaft. When the cylinder block ro-...

  • Page 198: Reverse

    HST - OPERATING PRINCIPLE CK22/CK22H 2.4.3 REVERSE Move the swash plate control lever to the right, the run- ning swash plate will be angled as illustrated. As the cylinder block is connected with the input shaft, it ro- tates with the input shaft. When the cylinder block ro- tates by passing the pump port B, oil comes in through piston port.

  • Page 199: Troubleshooting

    HST - TROUBLESHOOTING CK22/CK22H 3. TROUBLESHOOTING 3.1 HYDROSTATIC TRANSMISSION System will not operate Vibration Loss of power in either direction and noise turn good good good Check oil Check linkage Check Check Check input shaft lever (speed control pedal (charge pressure)
  • Page 200 HST - TROUBLESHOOTING CK22/CK22H (CONTINUED) Reduce Oil heat over machine load good good good good Check oil Inspect radiator net Check (charge Check level and oil cooler pressure) - high relief (case pressure) pressure l o w defective High above...
  • Page 201 HST - TROUBLESHOOTING CK22/CK22H (CONTINUED) Tractor jerks Tractor will not when traveling stop in neutral slowly. position Check linkage (speed good control pedal speed to Can’t adjust Adjust neutral Inspect neutral neutral holder and adjuster valve speed set device) defective...

  • Page 203: Servicing

    HST - SERVICING CK22/CK22H 4. SERVICING 4.1 EXPLODED VIEW 196W401B (1) Body (8) Plate, swash (pump) (15) Plate, swash (motor) (22) Guide, ball (29) Holder, spring (36) Spring (43) Bolt (50) Plate (57) Plug (64) Bearing (2) Shaft (pump) (9) Cover, swash (lever)

  • Page 205: Disassembly

    HST - SERVICING CK22/CK22H 4.2 DISASSEMBLY 1. Remove the wrench bolts (55) and remove the charge pump. Remove items (48, 54, 53, 33) from the charge pump casing (51). 2. Remove the wrench bolts (47) and remove the rear cover (25) and gasket (44).

  • Page 206: Assembly

    HST - SERVICING CK22/CK22H 4.3 ASSEMBLY 1. Install the swash plate (8) into the housing. 2. Using bushing, bearing and seal drive set, install a new oil seal (10) up to the shoulder of the swash cover (14). Install bearing (11) and a new O-ring.
  • Page 207 HST - SERVICING CK22/CK22H 8. Install the swash plate (15) into the housing, match- ing the dowel in the housing with the hole in the swash plate (15). Install the shoe plate (16) as shown in the figure. Then, assemble items (17 ~ 24) and install them onto the swash plate (16).

  • Page 208: Hst Pedal

    HST - SERVICING CK22/CK22H 4.4 HST PEDAL 12 13 196W486A (1) Rod (5) Adjust rod (9) Damper assembly (13) Lock shoe (2) Nut (6) Joint (10) Connector lever 2 (14) Lock shaft (3) Lever (7) Plate (11) Lock arm (15) Connector...
  • Page 209 CK22/CK22H REAR AXLE TABLE OF CONTENTS 1. SPECIFICATIONS ..............6-2 2. OPERATING PRINCIPLE ............6-3 2.1 Power train ................. 6-3 2.2 Principle of differential system ........6-4 2.3 Differential lock system ............ 6-6 3. TROUBLESHOOTING .............. 6-7 4. SERVICING ................6-8 4.1 Draining the transmission fluid ........

  • Page 210: Specifications

    REAR AXLE - SPECIFICATIONS CK22/CK22H 1. SPECIFICATIONS Application Specified Limit 0.060 ~ 0.102 mm Differential pinion shaft to differential pinion clearance 0.0023 ~ 0.0040 in. Differential pinion to differential side gear 0.15 ~ 0.20 mm backlash 0.0059 ~ 0.0079 in.

  • Page 211: Operating Principle

    REAR AXLE - OPERATING PRINCIPLE CK22/CK22H 2. OPERATING PRINCIPLE 2.1 POWER TRAIN 196W501A (1) Spiral bevel pinion (4) 72T spur gear (2) Spiral bevel gear (5) Rear axle (3) 11 gear shaft (6) Rear axle case The rear axle is the final mechanism which transmits power from the transmission to the rear wheels.

  • Page 212: Principle Of Differential System

    REAR AXLE - OPERATING PRINCIPLE CK22/CK22H 2.2 PRINCIPLE OF DIFFERENTIAL SYSTEM If two racks with same weight are set between the pin- ion as shown in the figure (A) and the pinion is lifted by pulling up the string attached to it as shown in the fig- ure (B), the pinion does not rotate and the pinion and both racks are lifted in the same height (H).
  • Page 213 REAR AXLE - OPERATING PRINCIPLE CK22/CK22H However, if the wheels on one side are on the slippery road, the load difference between both differential side gears remarkably increases and the self-rotating speed of differential pinion (3) considerably increases too. Therefore, the side gear (5) with very low load rotates at twice the speed and the side gear (6) with compara- tively high load does not rotate at all.

  • Page 214: Differential Lock System

    REAR AXLE - OPERATING PRINCIPLE CK22/CK22H 2.3 DIFFERENTIAL LOCK SYSTEM T46W606A The differential lock system is to solve such problems as described on the previous page. When the differen- tial lock lever is depressed, the differential fork shaft (1) rotates and the differential fork (2) moves to lock the differential system.

  • Page 215: Troubleshooting

    REAR AXLE - TROUBLESHOOTING CK22/CK22H 3. TROUBLESHOOTING Symptom Items Solution Excessive or unusual • Improper backlash between 7T spiral bevel pinion and Adjust noise at all times bevel gear. • Improper backlash between differential pinion and Adjust differential side gear.

  • Page 216: Servicing

    2. After draining reinstall the drain plug. 3. Fill with the new DAEDONG TF65 fluid up to the up- per line of the gauge. 196W502A (See “LUBRICANTS” in Maintenance Section) 4.

  • Page 217: Hand Brake (Eu)

    REAR AXLE - SERVICING CK22/CK22H 4.2 HAND BRAKE (EU) 196W513A (1) Split pin (5) Grommet (8) Parking brake wire 1 (2) Plain washer (6) Parking brake bracket (9) Parking brake wire 3 (3) Joint pin (7) Parking brake bracket 1...

  • Page 218: Separating Rops And Tires

    REAR AXLE - SERVICING CK22/CK22H 4.3 SEPARATING ROPS AND TIRES 1. Remove the lynch pin (2) and the lock pin (1) from the ROPS frame. 2. Loosen the lock nuts (3) and remove the pin (4). 3. Place to fix the jacket to the bottom of the rear axle.

  • Page 219: Link

    REAR AXLE - SERVICING CK22/CK22H 4.5 LINK 1. Remove the lifting rod (1). 2. Remove the check chain (2). 3. Remove the lower link (3). 4. Remove the check chain bracket (4). 5. Disconnect the brake rod (5). 196W505A (1) Lifting rod...

  • Page 220: Rear Axle

    REAR AXLE - SERVICING CK22/CK22H 4.7 REAR AXLE 196W510A (1) Bolt (6) 72T bear (10) Oil seal (2) Spring washer (7) Spacer (11) Cir-clip (3) Bolt (8) Collar (12) Ball bearing (4) Cir-clip (9) Rear axle (13) Hitch bracket (5) Ball bearing 1.
  • Page 221 4. SERVICING ................7-6 4.1 Disassembling and assembling ........7-6 4.1.1 Draining the transmission fluid ......7-6 4.1.2 Hand brake (CK22-EU) ........... 7-7 4.1.3 Separating rops and tires ........7-8 4.1.4 Fender ..............7-8 4.1.5 Disassembling and assembling ......7-9 4.1.6 Disassembling brake assembly ......

  • Page 222: Specifications

    BRAKE - SPECIFICATIONS CK22/CK22H 1. SPECIFICATIONS Item Reference Value Allowable Limit Brake pedal free play 20 ~ 30 mm 0.8 ~ 1.2 in. Brake disc thickness 4.6 ~ 4.8 mm 0.1811 ~ 0.1889 in. Disc facing surface to steel plate 0.25 mm...

  • Page 223: Operating Principle

    BRAKE - OPERATING PRINCIPLE CK22/CK22H 2. OPERATING PRINCIPLE 2.1 STRUCTURE Independent mechanical wet disc brakes are used for the right and left traveling brakes. They are operated by the brake pedals through the mechanical linkages, provide stable braking and require little adjustment.

  • Page 224: Features Of Wet Disc Brakes

    BRAKE - OPERATING PRINCIPLE CK22/CK22H 2.2 FEATURES OF WET DISC BRAKES A. REDUCED DISC WEAR Although wet discs are worn by approximately several tens of microns depending on the initial contact in ini- tial period (50 hours or so) of use, almost no wear occurs afterwards.

  • Page 225: Troubleshooting

    BRAKE - TROUBLESHOOTING CK22/CK22H 3. TROUBLESHOOTING Symptom Items Solution Uneven braking force • Brake pedal play unevenly adjusted. Adjust • Brake disc worn. Replace • Cam plate warped. Replace Brake drags • Brake pedal play too small. Adjust • Brake pedal return spring weaken or broken.

  • Page 226: Servicing

    2. After draining reinstall the drain plug. 3. Fill with the new DAEDONG TF65 fluid up to the up- per line of the gauge. 196W604A (See “LUBRICANTS” in Maintenance Section) CK22H 4.

  • Page 227: Hand Brake (Ck22-Eu)

    BRAKE - SERVICING CK22/CK22H 4.1.2 HAND BRAKE (CK22-EU) 196W622A (1) Sprit pin (5) Grommet (8) Parking brake wire 1 (2) Plain washer (6) Parking brake bracket (9) Parking brake wire 3 (3) Joint pin (7) Parking brake bracket 1 (10) Bolt (4) Parking brake wire 1.

  • Page 228: Separating Rops And Tires

    BRAKE - SERVICING CK22/CK22H 4.1.3 SEPARATING ROPS AND TIRES 1. Remove the lynch pin (2) and the lock pin (1) from the ROPS frame. 2. Loosen the lock nuts (3) and remove the pin (4). 3. Place to fix the jacket to the bottom of the rear axle.

  • Page 229: Disassembling And Assembling

    BRAKE - SERVICING CK22/CK22H 4.1.5 DISASSEMBLING AND ASSEMBLING A. SEPARATING BRAKE ASSEMBLY 1. Remove the brake rod (1). 2. Remove the mounting bolts and remove the brake assembly (2). (When reassembling) • When assembling, note left or right positions. Tightening torque Item 24.5 ~ 29.4 Nm...

  • Page 230: Inspection For Overhaul

    BRAKE - SERVICING CK22/CK22H 4.2 INSPECTION FOR OVERHAUL 4.2.1 CHECKING DISASSEMBLING AND SERVICING A .BRAKE PEDAL FREE PLAY 1. Press the center of the pedal with a force of ap- proximately 39 ~ 59 N (4 ~ 6 kgf, 9 ~ 13 lbs.), and measure the free play of the brake pedal edge.
  • Page 231 CK22/CK22H FRONT AXLE TABLE OF CONTENTS 1. SPECIFICATIONS ........8-2 5.1.8 Disassembling bevel gear case gears ........8-15 1.1 General specifications ......8-2 5.1.9 Disassembling axle ....8-15 1.2 Service specifications ......8-3 5.1.10 Disassembling spiral bevel pinion 2. OPERATING PRINCIPLE ......8-5 shaft and differential gear assem- bly ..........

  • Page 232: Specifications

    Shell (DONAX-TD/TD Plus) IMPORTANT • The same DAEDONG transmission fluid is filled in the front axle in the factory for easy manufacturing process. The SAE90 gear oil mentioned above cannot be used in the transmission or any hydraulic system. If such oil is used in the transmission, it can cause the abnormal noise and damage the hydraulic system components.

  • Page 233: Service Specifications

    FRONT AXLE - SPECIFICATIONS CK22/CK22H 1.2 SERVICE SPECIFICATIONS Item Factory Specification Allowable Limit Front wheel alignment Toe-in 2 ~ 8 mm 0.08 ~ 0.31 in. Front wheel Axial sway Less than 5 mm 0.20 in. Front axle Rocking force 49.0 ~ 117.7 N 5.0 ~ 12.0 kgf...
  • Page 234 FRONT AXLE - SPECIFICATIONS CK22/CK22H Item Factory Specification Allowable Limit Spiral bevel pinion shaft (Pinion shaft only) Turning force 98.1 ~ 117.7 N 10 ~ 12 kgf 22.0 ~ 26.5 lbs Spiral bevel pinion shaft to spiral bevel gear Backlash 0.2 ~ 0.3 mm...

  • Page 235: Operating Principle

    FRONT AXLE - OPERATING PRINCIPLE CK22/CK22H 2. OPERATING PRINCIPLE 2.1 FRONT AXLE STRUCTURE 196W701A (1) Front bracket (7) Front differential cover (13) Bevel gear (2) Rear bracket (8) Front axle (14) Bevel gear (3) Center pin (9) Spiral bevel pinion shaft...

  • Page 236: Wheel Alignment

    FRONT AXLE - OPERATING PRINCIPLE CK22/CK22H 2.2 WHEEL ALIGNMENT To improve control and safety running, front wheel is applied with adequate inclination in the direction of left, right and forward. 1. Camber reduces bending or twisting of the front axle caused by vertical load or running resistance, and also maintains the stability in running.

  • Page 237: Differential System

    FRONT AXLE - OPERATING PRINCIPLE CK22/CK22H 4. The front wheels tend to roll outward due to the camber, but toe-in offsets it and ensures parallel rolling of the front wheels. Another purpose of toe- in is to prevent excessive and uneven wear of tires.

  • Page 238: Troubleshooting

    FRONT AXLE - TROUBLESHOOTING CK22/CK22H 3. TROUBLESHOOTING Symptom Provable Causes Solution • Tire pressure uneven Adjust Front wheels wander to right or left • Improper toe-in adjustment (improper alignment) Adjust • Clearance between front axle case boss and front axle Replace bracket (front, rear) bushing excessive.

  • Page 239: Measurment And Adjusting

    FRONT AXLE - MEASURMENT AND ADJUSTING CK22/CK22H 4. MEASURMENT AND ADJUSTING 4.1 TOE-IN 1. Apply air pressure as specified to tires. 2. Measure the front width (A) and the rear width (b) between the front wheels while straightened to ob- tain the difference (toe-in).

  • Page 240: Axial Sway Of Front Wheel

    FRONT AXLE - MEASURMENT AND ADJUSTING CK22/CK22H 4.3 AXIAL SWAY OF FRONT WHEEL 1. Jack up the front side of tractor. 2. Set a dial gauge on the outside of rim. 3. Turn the wheel slowly and read the runout of rim.

  • Page 241: Servicing

    FRONT AXLE - SERVICING CK22/CK22H 5. SERVICING 5.1 DISASSEMBLING AND ASSEM- BLING 5.1.1 DRAINING FRONT AXLE CASE OIL 1. Place oil pans underneath the front axle case. 2. Remove the drain plug (3) both sides and filling port plug (2) to drain the oil.

  • Page 242: Disconnecting Propeller Shaft

    FRONT AXLE - SERVICING CK22/CK22H 5.1.3 DISCONNECTING PROPELLER SHAFT 1. Slide the propeller shaft cover (5), (4) after remov- ing the bolts (10). 2. Tap out the spring pin (8), and then slide the cou- pling (2) to the rear.

  • Page 243: Disassembling Front Axle

    FRONT AXLE - SERVICING CK22/CK22H 5.1.5 DISASSEMBLING FRONT AXLE 1. Place the jacks under the front axle, and hang up the bumper by the hoist to support it. 2. Remove the shaft bracket 1 mounting screws and shaft bracket 2 mounting screws.

  • Page 244: Disassembling Bevel Gear Case, Front Differential Case And 40 Bevel Gear

    FRONT AXLE - SERVICING CK22/CK22H 5.1.7 DISASSEMBLING BEVEL GEAR CASE, FRONT DIFFERENTIAL CASE AND 40 BEVEL GEAR 196W721A (1) 40T bevel Gear (7) 9T bevel gear (2) Shim (8) Bevel gear shaft (3) Snap ring (9) Bevel gear case (4) Plug...

  • Page 245: Disassembling Bevel Gear Case Gears

    FRONT AXLE - SERVICING CK22/CK22H 5.1.8 DISASSEMBLING BEVEL GEAR CASE GEARS 1. Remove the internal snap ring (1). 2. Take out the bevel gears (5), (7) with ball bearings (4), (6), collar (2) and shims (3). (When reassembling) • Install the same shims (3) before they are removed.

  • Page 246: Disassembling Spiral Bevel Pinion Shaft And Differential Gear Assembly

    FRONT AXLE - SERVICING CK22/CK22H 5.1.10 DISASSEMBLING SPIRAL BEVEL PINION SHAFT AND DIFFERENTIAL GEAR ASSEMBLY 1. Take out the differential yoke shaft (12), (13) both sides. 2. Remove the oil seal (7) and internal snap ring (6). 3. Remove the plug (11), and then tap out the spiral bevel pinion shaft (3) by the brass rod and hammer.

  • Page 247: Disassembling Differential Gear

    FRONT AXLE - SERVICING CK22/CK22H 5.1.11 DISASSEMBLING DIFFERENTIAL GEAR 1. Remove the differential case cover mounting bolts (9) and then take out the differential case cover (5), ball bearing (6) and spiral bevel gear (7) as a unit. 2. Remove the external snap ring (8), and then remove the ball bearing (6) and spiral bevel gear (7) as a unit with a puller.

  • Page 248: Inspection For Overhaul

    FRONT AXLE - SERVICING CK22/CK22H 5.2 INSPECTION FOR OVERHAUL 5.2.1 CLEARANCE BETWEEN DIFFEREN- TIAL CASE AND DIFFERENTIAL SIDE GEAR 1. Measure the differential side gear boss O.D. 2. Measure the differential case bore I.D. and calcu- late the clearance. 3. Measure the differential case cover bore I.D. and calculate the clearance.

  • Page 249: Backlash Between Differential Pinion And Differential Side Gear

    FRONT AXLE - SERVICING CK22/CK22H 5.2.3 BACKLASH BETWEEN DIFFEREN- TIAL PINION AND DIFFERENTIAL SIDE GEAR 1. Set a dial gauge (lever type) on a tooth of the differ- ential pinion. 2. Fix the differential side gear and move the differen- tial pinion to measure the backlash.

  • Page 250: Backlash Between Spiral Bevel Pinion Shaft And Spiral Bevel Gear

    FRONT AXLE - SERVICING CK22/CK22H 5.2.5 BACKLASH BETWEEN SPIRAL BEVEL PINION SHAFT AND SPIRAL BEVEL GEAR 1. Set a dial gauge (lever type) with its finger on the spline of spiral bevel pinion shaft. 2. Measure the backlash by moving the spiral bevel pinion shaft by hand lightly.

  • Page 251: Backlash Between 11T Bevel Gear And 16T Bevel Gear

    FRONT AXLE - SERVICING CK22/CK22H 5.2.6 BACKLASH BETWEEN 11T BEVEL GEAR AND 16T BEVEL GEAR 1. Stick a strip of fuse to three spots on the 16T bevel gear (1) with grease. 2. Fix the front axle case, bevel gear case and front gear case.

  • Page 252: Clearance Between Front Axle Case Bosses And Bracket Bushings

    FRONT AXLE - SERVICING CK22/CK22H 5.2.8 CLEARANCE BETWEEN FRONT AXLE CASE BOSSES AND BRACKET BUSHINGS 1. Measure the front axle case bosses O.D. with an outside micrometer. 2. Measure the bracket bushing I.D. with an inside mi- crometer and calculate the clearance.
  • Page 253 CK22/CK22H STEERING SYSTEM TABLE OF CONTENTS 1. SPECIFICATIONS ........9-2 4. SERVICING ..........9-12 4.1 Hydraulic pump ........9-12 2. OPERATING PRINCIPLE ......9-3 4.1.1 Bonnet ........9-12 2.1 Hydraulic schematic ......9-3 4.1.2 Disassembly the hydraulic pump 2.2 Hydraulic circuit diagram ....9-4 ass’y .........

  • Page 254: Specifications

    STEERING SYSTEM - SPECIFICATIONS CK22/CK22H 1. SPECIFICATIONS Item Reference Value Type Gear Hydraulic pump Pump capacity /min 7.66 GPM Pump gear ratio 1/0.8056 Power steering unit volume 40 cc/rev Power steering unit Relief pressure 110 kgf/cm 10.8 MPa Tube O.D...

  • Page 255: Operating Principle

    STEERING SYSTEM - OPERATING PRINCIPLE CK22/CK22H 2. OPERATING PRINCIPLE 2.1 HYDRAULIC SCHEMATIC 196W801A (1) Oil tank (transmission case) (5) Steering unit (2) Oil filter (6) Steering hose (3) Gear pump (7) Steering cylinder (4) Priority valve The steering system is hydrostatic and includes a The power steering motor has a relief valve for protect- power steering motor, hydraulic relief ass’y and steer-...

  • Page 256: Hydraulic Circuit Diagram

    STEERING SYSTEM - OPERATING PRINCIPLE CK22/CK22H 2.2 HYDRAULIC CIRCUIT DIAGRAM 196W802B (1) Oil tank (transmission case) (4) Priority valve (2) Oil filter (5) Steering unit (3) Gear pump (6) Steering cylinder • With engine started, the hydraulic pump is driven to pass oil in transmission case through valve to power steering unit.

  • Page 257: Operation

    STEERING SYSTEM - OPERATING PRINCIPLE CK22/CK22H 2.3 OPERATION 2.3.1 IN NEUTRAL If the steering wheel is not rotated, control valve (3) keeps in neutral by centering spring (4). This time oil flow will be formed between port p (from pump) of control valve and port T of transmission case and all oil supplied from gear pump will be drained to port.

  • Page 258: Turning To Left

    STEERING SYSTEM - OPERATING PRINCIPLE CK22/CK22H 2.3.3 TURNING TO LEFT The operation for the left turn is same as that of right turn except for the oil flow direction. 196W810B (1) Steering controller (4) Centering spring (2) Steering wheel (5) Gerotor...

  • Page 259: Operating Of Steering Unit

    STEERING SYSTEM - OPERATING PRINCIPLE CK22/CK22H 2.4 OPERATING OF STEERING UNIT T46W912A (1) Steering case assembly (9) Control valve assembly (16) Gerotor (2) Dust seal (9a) Relief valve (17) Star seal assembly (3) Retainer ring (10) Centering spring (18) Endcap...

  • Page 260: Power Steering Control Motor

    STEERING SYSTEM - OPERATING PRINCIPLE CK22/CK22H 2.4.1 POWER STEERING CONTROL MOTOR D. CHECK VALVE A. SPOOL AND SLEEVE The check valve normally remains closed, which pre- 1. The spool (22) and sleeve (23) are the rotary valve vents the fluid from flowing from its inlet side to its to select the fluid passage as well as the direction outlet side directly.

  • Page 261: Steering Cylinder

    STEERING SYSTEM - OPERATING PRINCIPLE CK22/CK22H 2.5 STEERING CYLINDER A. STRUCTURE 196W807B (1) Tube (6) Ring (A) Rod O.D (2) Packing (7) Housing (B) Tube I.D (3) Bush (8) Bearing (C) Tube O.D (4) Dust seal (9) Snap ring (D) Stroke (5) Rod B.

  • Page 262: Gear Pump

    STEERING SYSTEM - OPERATING PRINCIPLE CK22/CK22H 2.6 GEAR PUMP A. PUMP CHARACTERISTICS Power steering hydraulic pumps have superior volume efficiency and mechanical efficiency and extracts power from the engine right cam shaft gear. B. PUMP PERFORMANCE Flow rate at rated...

  • Page 263: Troubleshooting

    STEERING SYSTEM - TROUBLESHOOTING CK22/CK22H 3. TROUBLESHOOTING Symptom Provable Causes Solution Excessive • Steering shaft gear worn Replace steering wheel play • Centering spring weaken or broken Replace Tractor pulls to right or left • Tire pressure uneven Adjust • Steering wheel play too small Adjust •...

  • Page 264: Servicing

    STEERING SYSTEM - SERVICING CK22/CK22H 4. SERVICING 3.2 DISASSEMBLY AND ASSEMBLY 4.1 HYDRAULIC PUMP 4.1.1 BONNET 1. After opening the bonnet (1), disconnect the con- nector (2), remove the bolts and the bonnet. 2. Remove the side cover (LH/RH) (3).
  • Page 265 STEERING SYSTEM - SERVICING CK22/CK22H 4.1.3 DISASSEMBLY THE HYDRAULIC PUMP 196W811A (1) Housing (4) Drive gear (7) Seal (10) Snap ring (2) Cover (5) Driven gear (8) Seal (11) Dowel pin (3) Busing (6) Thrust plate (9) Oil seal (12) Bolt 1.
  • Page 266 STEERING SYSTEM - SERVICING CK22/CK22H 4. Remove the drive gear (4) and the driven gear (5). (When reassembling) • Install the driven gear, noting its direction. 196W816A (4) Drive gear (5) Driven gear 5. Remove the thrust plate (6). IMPORTANT •...

  • Page 267: Power Steering Unit

    STEERING SYSTEM - SERVICING CK22/CK22H 4.2 POWER STEERING UNIT 4.2.1 BONNET 1. After opening the bonnet (1), disconnect the con- nector (2), remove the bolts and the bonnet. 2. Remove the side cover (LH/RH) (3). 3. Disconnect the negative battery terminal (-) (4).
  • Page 268 STEERING SYSTEM - SERVICING CK22/CK22H (When reassembling) • When tightening a hose band of steering hose T, check the direction of the pipe band. - A pipe band can interfere with a bolt. • A hose classification - Steering hose P: A red tag attachment...

  • Page 269: Disassembly The Power Steering

    STEERING SYSTEM - SERVICING CK22/CK22H 4.2.4 DISASSEMBLY THE POWER STEERING UNIT 1. Place the control motor (2), upside down in a vice. Use soft-faced jaws and tighten the vise just enough to hold the motor. Otherwise, the pressure could jam components against one another.
  • Page 270 STEERING SYSTEM - SERVICING CK22/CK22H 6. Using a screwdriver, remove the retaining ring (2), from the upper end of the steering housing (3). Then remove the gland bushing (1). 196W827A (1) Gland bushing (3) Steering housing (2) Retaining ring 7. Remove the oil seal, dust seal, and O-ring seal, from the gland.
  • Page 271 STEERING SYSTEM - SERVICING CK22/CK22H 9. Pull the sleeve and spool (2), from the bottom of the motor housing (1). The sleeve is a close fit in the steering motor housing and should be rotated slightly during removal. While rotating the sleeve...

  • Page 272: Inspection

    STEERING SYSTEM - SERVICING CK22/CK22H 4.2.5 INSPECTION 1. Inspection the spool and sleeve for evidence of sticking, scuff marks, and any other damage. If found defective, replace the spool and sleeve as a matched marked set. 2. Check the pin to make sure it is not bent or cracked and check the internal teeth on the spool for damage.
  • Page 273 STEERING SYSTEM - SERVICING CK22/CK22H 5. Position the spool and sleeve so that their ends are flush and insert the pin (1), through the assembly until its ends are below the surfaces of the sleeve. 196W835A (1) Pin 6. Orient the spool and sleeve (2), so that the pin is...
  • Page 274 STEERING SYSTEM - SERVICING CK22/CK22H 8. Install a new O-ring, dust seal, and oil seal, in the gland bushing, then insert the bushing into the hous- ing while rotating it. 9. Install the retaining ring in the housing groove. 196W738A 10.Position the steering motor housing in a vise with...
  • Page 275 STEERING SYSTEM - SERVICING CK22/CK22H 13.Position the spool and sleeve so that the pin (1), is parallel with the port face of the steering motor hous- ing (3). 196W841A (1) Pin (2) Spacer plate motor (3) Port face of steering 14.Insert the drive shaft (1), into the motor so that its...
  • Page 276 STEERING SYSTEM - SERVICING CK22/CK22H 16.Position the rotor and stator on the steering motor with the seal side up. Visually align the holes in the spacer plate and stator while doing so. Before en- gaging the drive shaft splines with the rotor, align...
  • Page 277 STEERING SYSTEM - SERVICING CK22/CK22H 19.Tighten the end cap retainer bolts (1), in the se- quence shown in Figure in two stages, first to about 10.8 Nm (1.1 kgf-m, 8 lb-ft), and then to 20.6 Nm (2.1 kgf-m, 15 lb-ft). After torquing the bolts, check that the spool turns freely in the motor.

  • Page 278: Steering Cylinder

    STEERING SYSTEM - SERVICING CK22/CK22H 4.3 STEERING CYLINDER 4.3.1 DISASSEMBLING, ASSEMBLING AND SERVICING 1. Disconnect the steering hoses (1, 2) 2. Pull out the split pin (5) and remove the nut (6). 3. With tapping the end of support pin using a plastics hammer, pull out support pin from the front axle case.

  • Page 279: Servicing

    STEERING SYSTEM - SERVICING CK22/CK22H 4.3.2 SERVICING A. STEERING WHEEL CLEARANCE IMPORTANT • Before disassembling the power steering system, check the performance of hydraulic relief assem- bly and power steering motor using a hydraulic tester. • Do not disassemble the power steering motor needlessly.
  • Page 280 MEMO ...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 281 2.1 Hydraulic scheme ......10-4 4.2.2 Joy-stick valve disassembly . 10-31 2.2 Hydraulic circuit diagram 4.2.3 Joy-stick valve assembly ..10-32 (CK22/CK22H) ........10-5 4.3 Hydraulic lift cylinder ....... 10-34 2.3 Oil filter ..........10-7 4.3.1 Draining the transmission fluid 2.3.1 Structure of oil filter ....

  • Page 283: Specification

    HYDRAULIC SYSTME - SPECIFICATION CK22/CK22H 1. SPECIFICATION Item Reference Dimension Hydraulic pump Type Gear Pump capacity 29 /min (7.66 gpm) Pump gear ratio 1/0.805 Main hydraulic filter Micron rating (micron) Max. Pore Dia: 110 ± 8 Min Pore Dia: 92 ± 4 Area 2,772 cm²...

  • Page 284: Operating Principle

    HYDRAULIC SYSTME - OPERATING PRINCIPLE CK22/CK22H 2. OPERATING PRINCIPLE 2.1 HYDRAULIC SCHEME 196W902B (1) Oil filter (8) Hydraulic cylinder (2) Gear pump (9) Charge pump (CK22H) (3) Priority valve control flow (10) Oil cooler (CK22H) (4) Power steering unit (11) HST filter (CK22H)
  • Page 285 INDEX INDEX INDEX INDEX INDEX ELECTRIC ELECTRIC ELECTRIC ELECTRIC ELECTRIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC STEERING STEERING STEERING STEERING STEERING FRONT AXLE FRONT AXLE FRONT AXLE FRONT AXLE FRONT AXLE BARKE BARKE BARKE BARKE BARKE REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE TRANSMISSION...

  • Page 287: Oil Filter

    HYDRAULIC SYSTME - OPERATING PRINCIPLE CK22/CK22H 2.3 OIL FILTER 2.3.1 STRUCTURE OF OIL FILTER The suction filter (1) is a canister-type filter and should be replace after 200 hour of use. 196W904B (1) Hydraulic filter (2) Filter bracket 2.3.2 FUNCTION AND OPERATION A.

  • Page 288: Hydraulic Block

    HYDRAULIC SYSTME - OPERATING PRINCIPLE CK22/CK22H 2.4 HYDRAULIC BLOCK When implement is not attached When implement is attached 196W906A (1) To hydraulic control valve (3-point hitch) (1) Flow priority valve (2) To sower steering (PS type only) (2) Inlet from implements (PS 3/8″) (3) From gear pump (3) Outlet to implements (PS 3/8″)

  • Page 289: Flow Priority Valve

    HYDRAULIC SYSTME - OPERATING PRINCIPLE CK22/CK22H 2.4.1 FLOW PRIORITY VALVE A. STANDARD OIL CIRCUIT The total flow of oil (29 /min, 7.66 U.S. GPM), pres- sure-fed from the hydraulic pump, enters into the “IN” port through the route as shown in diagram.
  • Page 290 HYDRAULIC SYSTME - OPERATING PRINCIPLE CK22/CK22H C. WHEN USING IMPLEMENTS When using the front loader or other implements, re- move the plugs. Connect the implement’s inlet line to port A. The outlet line to the port B, then turn the directional valve coun- terclockwise to the end.

  • Page 291: Joystick Valve

    HYDRAULIC SYSTME - OPERATING PRINCIPLE CK22/CK22H 2.5 JOYSTICK VALVE 196W917B (1) Lever knob (12) End cap (23) Plug (2) Rubber (13) Spool control kit (24) Spool (3) Nut (14) Ring (25) Spool (4) Selector (15) O-ring (26) Rod pin (5) Pin...

  • Page 292: Description And Operation

    HYDRAULIC SYSTME - OPERATING PRINCIPLE CK22/CK22H 2.5.1 DESCRIPTION AND OPERATION The Joystick valve is mounted on the right fender. 196W916A (1) Joystick valve The double-spool remote valve also contains a spring- loaded detent mechanism to provide a float position for loader operation. In float position, fluid is free to flow between piston and rod sides or the loader lift cylinder allowing the lift arms to float over uneven terrain.
  • Page 293 HYDRAULIC SYSTME - OPERATING PRINCIPLE CK22/CK22H A. DUMP POSITION 196W919A (1) Lift control valve spool (4) Bucket cylinder (2) Bucket control spool (5) Lift cylinder (3) Control lever When the control lever (3) is moved to the dumping The fluid contained in the rod side of the bucket cylin- position, the bucket control spool (2) is moved inward.
  • Page 294 HYDRAULIC SYSTME - OPERATING PRINCIPLE CK22/CK22H B. ROLL BACK POSITION 196W921A (1) Lift control valve spool (4) Bucket cylinder (2) Bucket control spool (5) Lift cylinder (3) Control lever When the control lever (3) is moved to the roll back...
  • Page 295 HYDRAULIC SYSTME - OPERATING PRINCIPLE CK22/CK22H C. RAISING POSITION 196W922A (1) Lift control valve spool (4) Bucket cylinder (2) Bucket control spool (5) Lift cylinder (3) Control lever When the control lever (3) is moved to the raising posi- Because the bucket control spool (2) is in the neutral tion the lift control valve spool (2) is moved outward.
  • Page 296 HYDRAULIC SYSTME - OPERATING PRINCIPLE CK22/CK22H D. LOWERING POSITION 196W923A (1) Lift control valve spool (4) Bucket cylinder (2) Bucket control spool (5) Lift cylinder (3) Control lever When the control lever (3) is moved to the lowering position, the lift control valve spool (1) is moved inward.
  • Page 297 HYDRAULIC SYSTME - OPERATING PRINCIPLE CK22/CK22H E. FLOATING POSITION 196W924A (1) Lift control valve spool (4) Bucket cylinder (2) Bucket control spool (5) Lift cylinder (3) Control lever When the lift control lever (3) is moved to the detent The loader lift arms then move up and down as the position (float), the control valve spool is moved in- loader passes over uneven terrain.

  • Page 298: Auxiliary Control Valve (If Equipped)

    HYDRAULIC SYSTME - OPERATING PRINCIPLE CK22/CK22H 2.6 AUXILIARY CONTROL VALVE (IF EQUIPPED) A double acting detent type control valve is used. When the control valve operating lever is moved to the imple- ment cylinder actuating position, the spool is moved and the oil from the pump port flows through A or B, causing the implement cylinder to operate.

  • Page 299: Point Hitch Lifting System

    HYDRAULIC SYSTME - OPERATING PRINCIPLE CK22/CK22H 2.7 3 POINT HITCH LIFTING SYSTEM 2.7.1 OPERATING OF MLS (MITA LOAD SENSING VALVE) 196W932B (A) Charge (C) Neutral position 109 ± 0.15 (B) Discharge A. OPERATION OF MLS CONTROL VALVE The Control Valve has three distinct functioning phases: DS35-W00 May.
  • Page 300 HYDRAULIC SYSTME - OPERATING PRINCIPLE CK22/CK22H B. NEUTRAL T46WA29A (1) Control spool (5) Safety valve (9) Spring (12) Pilot valve (2) Regulator piston (6) Drain hole (10) Lift cylinder (13) Pilot drain hole (3) Check valve (7) Cylinder duct (11) Upper chamber...
  • Page 301 HYDRAULIC SYSTME - OPERATING PRINCIPLE CK22/CK22H C. LIFTING T46WA31A Lifting: When the control spool (1) is pushed up and starts to open, the fluid drawn through the (b) port passes the spool and then joins the fluid drawn through the (a) port.
  • Page 302 HYDRAULIC SYSTME - OPERATING PRINCIPLE CK22/CK22H D. LOWERING T46WA32A Lowering: Control sensitivity adjustment: When the control spool (1) moves downward, the fluid The opening timing of the spool (1) can be adjusted by passage between (a) and (b) ports are blocked as adjusting the position of the spool with unscrewing the same as when the valve is in the neutral position.

  • Page 303: Link Mechanism In The Lifting System

    HYDRAULIC SYSTME - OPERATING PRINCIPLE CK22/CK22H 2.7.2 LINK MECHANISM IN THE LIFTING SYSTEM A. OPERATION OF INTERNAL LEVERS IN CONTROLLED POSITION Moving the control lever “L” (In the direction of the arrow) The roller cam bowl “4” remains in contact with the one can raise the arms and the internal levers affect lever by effect of the springs of the shaft “1”, so the...
  • Page 304 HYDRAULIC SYSTME - OPERATING PRINCIPLE CK22/CK22H B. ROCKSHAFT ADJUSTMENT In case of revision of the Rockshaft or Control Valve it is opportune to do again the adjustments in the sequence found below. 1. SENSITIVITY ADJUSTMENT OF THE CON- TROL VALVE.
  • Page 305 HYDRAULIC SYSTME - OPERATING PRINCIPLE CK22/CK22H C. ASSEMBLY MEASUREMENT OF PUSH ROD This is an important measurement of the good func- tioning of the rockshaft. If the rockshaft is adjusted and if the hydraulic group in the drawing is disassembled one must always restore the measurement of 19 mm.

  • Page 306: Troubleshooting

    HYDRAULIC SYSTME - TROUBLESHOOTING CK22/CK22H 3. TROUBLESHOOTING 3.1 POWER LIFT ASSEMBLY Symptom Provable Causes Solution The rockshaft lifts • Insufficient oil level in the tank. Top up the level. jerkily. • Pump inlet filter clogged. Clean or replace the filter.

  • Page 307: Joystick Valve

    HYDRAULIC SYSTME - TROUBLESHOOTING CK22/CK22H 3.2 JOYSTICK VALVE Symptom Provable Causes Solution External leakage • Worn spool seal due to mechanical actuation or Locate the leakage and control kit or opposite high back pressure. replace the seal. side. Check back pressure level.

  • Page 308: Servicing

    HYDRAULIC SYSTME - SERVICING CK22/CK22H 4. SERVICING 4.1 FLOW CONTROL VALVE 4.1.1 BONNET 1. After open the bonnet (1) and disconnect the connector, remove the bolt (2) and the bonnet. 2. Remove the side cover (LH/RH) (3). 3. Disconnect the negative battery terminal (-) (4).

  • Page 309: Relief Valve Assembly

    HYDRAULIC SYSTME - SERVICING CK22/CK22H 4.1.3 RELIEF VALVE ASSEMBLY 1. Separate the relief valve assembly (1). (When reassembling) • Install the relief valve assembly to the outlet, taking care not to damage the O-ring Item Tightening torque Relief valve assembly 49.0 ~ 58.8 Nm...

  • Page 310: Joy-Stick Valve Disassembly, Inspection And Assembly

    HYDRAULIC SYSTME - SERVICING CK22/CK22H 4.2 JOY-STICK VALVE DISASSEMBLY, INSPECTION AND ASSEMBLY 4.2.1 JOY-STICK VALVE REMOVAL 1. Remove the step mat (1). 2. Loosen the joy-stick bolts and remove the cover (2). 3. Remove the frame (3) and push the joy-stick down.

  • Page 311: Joy-Stick Valve Disassembly

    HYDRAULIC SYSTME - SERVICING CK22/CK22H 4.2.2 JOY-STICK VALVE DISASSEMBLY 196W944B (1) Lever knob (7) Ring (13) Spool control kit (18) Body (23) Plug (28) O-ring (2) Rubber (8) Washer (14) Ring (19) Plug (24) Spool (29) Flange (3) Nut (9) Screw...

  • Page 312: Joy-Stick Valve Assembly

    HYDRAULIC SYSTME - SERVICING CK22/CK22H 4.2.3 JOY-STICK VALVE ASSEMBLY 1. Install the plug (19). Item Tightening torque Blocking plug 42 Nm 4.3 kgf-m 31 lb-ft 196W946A (1) Plug 2. Install the load check poppets: with O-rings, springs and check plugs (17).
  • Page 313 HYDRAULIC SYSTME - SERVICING CK22/CK22H 6. Install the cables (10, 11), pins (26) and screws (30) into the assembly and tighten its locknut. Waterproof cap prearranged for remote control with flexible cable. Item Tightening torque Socket head cap screw 6.6 Nm 0.7 kgf-m...

  • Page 314: Hydraulic Lift Cylinder

    HYDRAULIC SYSTME - SERVICING CK22/CK22H 4.3 HYDRAULIC LIFT CYLINDER CK22 4.3.1 DRAINING THE TRANSMISSION FLUID CAUTION To avoid personal injury: Allow engine to cool down sufficiently, oil can be • hot and can burn. 1. To drain the used oil, remove the drain plug at the bottom of the transmission case and drain the oil completely into the oil pan.

  • Page 315: Platform

    HYDRAULIC SYSTME - SERVICING CK22/CK22H 4.3.2 PLATFORM 1. Remove the step mat (LH/RH) (1). 2. Remove the joystick mounting bolts and disconnect the cover (2). 3. Remove the frame (3). 4. Remove the platform (LH/RH) (4). 196W9A5A (1) Step mat...

  • Page 316: Fender

    HYDRAULIC SYSTME - SERVICING CK22/CK22H 4.3.5 FENDER 1. Rmove the connectors to the rear combi lamp, turn sigal lamp and working lamp. 2. Remove the ROPS mounting bracket (1). 3. Remove the grip (2) from the levers and then re- move the lever guide (3).

  • Page 317: Fuel Tank

    HYDRAULIC SYSTME - SERVICING CK22/CK22H 4.3.7 FUEL TANK 1. Drain the fuel tank. 2. Disconnect the fuel hose from the engine. 3. Disconnect the fender wire harness. 4. Remove the fuel filter (1). 5. Remove the nuts (2). 6. Remove the fuel tank assembly (3) & the socket fixture.

  • Page 318: Lift Arms Removal And Installation

    HYDRAULIC SYSTME - SERVICING CK22/CK22H 4.4 LIFT ARMS REMOVAL AND IN- STALLATION 1. Remove external snap ring (1) from end splined shaft. 2. Use wire brush to clean paint and any dirt from end of splined shaft. 3. Mark end of splined shaft and lift arm (2) for ease of reassembly.

  • Page 319: Power Lift Assy Assembly, Dissembly And Installation

    HYDRAULIC SYSTME - SERVICING CK22/CK22H 4.5 POWER LIFT ASSY ASSEMBLY, DISSEMBLY AND INSTALLATION 4.5.1 CYLINDER REMOVAL 1. Remove socket head cap screw (1) securing cylin- der to body. 2. Support cylinder and remove cylinder joint bolt (2) securing front of cylinder to body.

  • Page 320: Depth Control Mechanism Removal

    HYDRAULIC SYSTME - SERVICING CK22/CK22H 4.5.2 DEPTH CONTROL MECHANISM REMOVAL 1. Remove lock nut and socket head cap screw (1) from bracket (2). 2. Remove two socket head cap screw (3) securing plate to housing. Remove plate (4). 3. Remove bracket from end of eccentric actuator.
  • Page 321 HYDRAULIC SYSTME - SERVICING CK22/CK22H 8. Remove E-clips retaining plunger assembly. 9. Unscrew pins from outside of body making sure that plunger assembly does not bind on shaft of pin during removal. 10.Remove the plunger assembly from the body. 196W968B...
  • Page 322 HYDRAULIC SYSTME - SERVICING CK22/CK22H 16.Remove cir-clip retaining cap plate to shaft. 196W971A (1) Shaft (2) Cir-clip 17.Remove stopper screw. 196W972A (1) Shaft (2) Stopper 18.Remove shaft (1) from outside of housing and lever from inside of housing. 196W973A (1) Shaft...
  • Page 323 HYDRAULIC SYSTME - SERVICING CK22/CK22H 19.Measure shaft (1) outside diameter and bore in housing. Replace if not in specifications. Shaft (1) Specifications: O.D. 21.95 mm (0.864 in.) Bore I.D. 22.00 mm (0.866 in.) 20.Inspect shaft (1), O-ring, stopper screw and lever for damage or wear.

  • Page 324: Rockshaft Removal

    HYDRAULIC SYSTME - SERVICING CK22/CK22H 4.5.3 ROCKSHAFT REMOVAL 1. Remove set screw securing arm to shaft. IMPORTANT Rockshaft can only be removed from one side of • housing due to stepped bearing surfaces. Be sure to determine correct orientation of rockshaft be- fore attempting to remove rockshaft from housing.
  • Page 325 HYDRAULIC SYSTME - SERVICING CK22/CK22H 8. If bushings require replacement use appropriate REMOVAL bushings driver to remove shaft bushings. Drive busing out from inside of housing. Replace by driv- ing in from outside of housing. NOTE: • THE FOLLOWING MESURMENTS ARE FOR NEW COMPONENTS, AND DO NOT REFLECT WEAR SPECIFICATIONS.

  • Page 326: Control(Mls) Valve Removal And Installation

    HYDRAULIC SYSTME - SERVICING CK22/CK22H 4.5.4 CONTROL(MLS) VALVE REMOVAL AND INSTALLATION A. REMOVE 1. Remove the snap ring (1) from the universal joint (2) on the Hydraulic control shaft. 2. Remove the pin (3) from the universal Joint (2). 050W981A...

  • Page 327: Mls Valve Removal And Reassembly

    HYDRAULIC SYSTME - SERVICING CK22/CK22H 4.5.5 MLS VALVE REMOVAL AND REAS- SEMBLY A. DISASSEMBLY 1. Remove the socket head bolt (1). T46WAC9A 2. Remove the cap (1). T46WAD0A 3. Remove the check valve and lowering speed con- trol valve. T46WAD1A 4.
  • Page 328 HYDRAULIC SYSTME - SERVICING CK22/CK22H 5. Unscrew the socket head bolt (1) and remove the end plate (2), control spool (3), spring (4) and spacer behind the end plate. T46WAD3A 6. Disassemble each valve. (refer to the figure) 7. Refer to the installation procedure for the removal of each valve.
  • Page 329 HYDRAULIC SYSTME - SERVICING CK22/CK22H B. REASSEMBLY Apply sufficient amount of oil to each part to prevent any damage when installing them. 1. Be careful with the location of valves. T46WAD5A (1) Safety valve hole (4) Pilot valve hole (2) Regulator piston hole (5) Drain hole...
  • Page 330 HYDRAULIC SYSTME - SERVICING CK22/CK22H 4. Install the pilot valve. T46WAD8A 5. Put three spacers (1) and insert the end plate, spring and control spool as a unit. Coat the spacer with grease to hold them. 6. Fix the socket head bolt.
  • Page 331 HYDRAULIC SYSTME - SERVICING CK22/CK22H 9. Install the valve cap (1). T46WAE2A 10. Install the brass orifice (1) completely (if removed). 11. Apply oil on the O-ring (2) to prevent any damage when installing the valve assembly to the cylinder body.
  • Page 332 MEMO ...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 333 3.7 Trouble shooting enigne tachometer circuit ............11-19 1.1 Circuit diagram ........11-3 3.8 Trouble shooting charging system . 11-19 1.2 Electric component location (CK22) ..11-4 4. SERVICING ..........11-20 1.3 Legend for circuit diagram ....11-5 4.1 Battery ..........11-20 1.3.1 Symbols for electric components...

  • Page 335: Circuit And Component Location

    ELECTRIC SYSTEM - CIRCUIT AND COMPONENT LOCATION CK22/CK22H 1. CIRCUIT AND COMPONENT LOCATION 1.1 CIRCUIT DIAGRAM 3 R 5.0 3 R 3.0 ALTERNATOR (+14.5V) AM ACC ON GL ST TIMER RELAY 66 RL 0.85 1.25 Lg COMBINATION SWITCH TER. TER.

  • Page 336: Electric Component Location (Ck22)

    ELECTRIC SYSTEM - CIRCUIT AND COMPONENT LOCATION CK22/CK22H 1.2 ELECTRIC COMPONENT LOCATION (CK22) Engine (RH) Lamp Switch, Sensor, Sender Relay, Solenoid Other Components 20.Fuse box 32.Head Lamp Interior Electric Components 16.Horn 7.Starter relay 21.Preheating relay 22.Brake switch 17.Diode 1.Battery 18.Engine stop solenoid 2.Coolant temperature...

  • Page 337: Legend For Circuit Diagram

    ELECTRIC SYSTEM - CIRCUIT AND COMPONENT LOCATION CK22/CK22H 1.3 LEGEND FOR CIRCUIT DIAGRAM 1.3.1 SYMBOLS FOR ELECTRIC COMPONENTS Symbol Description Symbol Description Single bulb Fuse Lamp Slow-blow fuse Double bulb Diode Motor Zener-diode Switch (Normally Open Type) (Light Emitting Diode)

  • Page 338: Wiring Color Identification

    ELECTRIC SYSTEM - CIRCUIT AND COMPONENT LOCATION CK22/CK22H 1.3.2 WIRING COLOR IDENTIFICATION Code Color Code Color Black Yellow Blue Light Green White Gray Brown Orange Green Pink Black/Yellow Black / White Light Green / Red Black / Red Light Green / White...

  • Page 339: Wire Identification

    ELECTRIC SYSTEM - CIRCUIT AND COMPONENT LOCATION CK22/CK22H 1.3.3 WIRE IDENTIFICATION A. WIRE CODE The codes used in wiring diagram represent the size of wire and the color of insulating cover. Example) AVS(SS, X) 0.85GR A: Low-tension cables for automobiles...

  • Page 340: Operation Principle

    ELECTRIC SYSTEM - OPERATION PRINCIPLE CK22/CK22H 2. OPERATION PRINCIPLE 2.1 PREHEATING 3 R 5.0 3 R 3.0 ALTERNATOR (+14.5V) AM ACC ON GL ST TIMER RELAY 66 RL 0.85 RERAY+ 73 YL 0.5 To Hour meter IC REG 71WR 0.5 PREHEAT CONT 62 LR 0.5...

  • Page 341: Starting

    ELECTRIC SYSTEM - OPERATION PRINCIPLE CK22/CK22H 2.2 STARTING 3 R 5.0 3 R 3.0 ALTERNATOR (+14.5V) AM ACC ON GL ST TIMER RELAY 66 RL 0.85 RERAY+ 73 YL 0.5 To Hour meter IC REG 71WR 0.5 PREHEAT CONT 62 LR 0.5...

  • Page 342: Charging

    ELECTRIC SYSTEM - OPERATION PRINCIPLE CK22/CK22H 2.3 CHARGING 3 R 5.0 3 R 3.0 ALTERNATOR (+14.5V) AM ACC ON GL ST TIMER RELAY 66 RL 0.85 RERAY+ 73 YL 0.5 To Hour meter IC REG 71WR 0.5 PREHEAT CONT 62 LR 0.5...

  • Page 343: Lighting

    ELECTRIC SYSTEM - OPERATION PRINCIPLE CK22/CK22H 2.4 LIGHTING From Battery From ON 1.25 Lg COMBINATION SWITCH FLASHER UNIT TER. TER. TER. POS. POS. POS. HORN FREE PUSH 0.85 BW HAZARD SWITCH 0.85 B REAR COMBI REAR COMBI T/SIGNA T/SIGNAL HEAD...

  • Page 344: Hazard Warning Switch

    ELECTRIC SYSTEM - OPERATION PRINCIPLE CK22/CK22H 2.4.2 HAZARD WARNING SWITCH The hazard light switch is a rocker switch located on the left-hand side of the dash. When the hazard light switch is in the “ON” position, both turn signal symbols located in combination meter will illuminate green and flash.

  • Page 345: Brake

    196WA09A (1) Tail lamp cover (LH) (3) Tail light (2) Brake light C. TAIL LIGHT (ONLY CK22-USA) The tail lights only operate while the main light switch is ON. 196WA10A DS35-W00 May. 2007 11-13...
  • Page 346 ELECTRIC SYSTEM - OPERATION PRINCIPLE CK22/CK22H D. HEAD LIGHTS CK22-USA CK22-USA The head lights have 12 V 35 / 35 W bulbs. Only use replacement bulbs with the correct ratings. CK22-EU The head lights have 12 V 55 / 60 W bulbs.

  • Page 347: Instrument Cluster

    ELECTRIC SYSTEM - OPERATION PRINCIPLE CK22/CK22H 2.5 INSTRUMENT CLUSTER 196WA12B Appearance High speed Low speed Mid speed Trnasmission High Quck One-side Differential Name Neutral Parking Charge ENG oil Glow Cruise Turn/L Turn/R beam turn brake Lock shift shift shift filter Lamp 1.4W...

  • Page 348: Gauges And Indicators

    OFF immediately. Never operate the tractor cause. while the gauge is in the red zone. (And contact the nearest DAEDONG Dealer.) D. HOUR METER 1 Hz signal (1 wave for 1 second) is sent to the hour meter on the instrument panel as 14 V of voltage is supplied to the ON terminal of the preheat controller while the alternator operates.

  • Page 349: Circuit Diagram

    ELECTRIC SYSTEM - OPERATION PRINCIPLE CK22/CK22H 2.5.2 CIRCUIT DIAGRAM 3 R 5.0 3 R 3.0 ALTERNATOR (+14.5V) AM ACC ON GL ST 66 RL 0.85 TIMER RELAY ‘ON’ 73 YL 0.5 IC REG 71WR 0.5 PREHEAT CONT 62 LR 0.5...

  • Page 350: Troubleshooting

    ELECTRIC SYSTEM - TROUBLESHOOTING CK22/CK22H 3. TROUBLESHOOTING 3.1 TRUOUBLE SHOOTING STARTING CIRCUIT Condition Possible Cause Remedy • Insufficient battery charge • Recharge or replace the battery Start motor will not energize • Blown 60 amp fuse • Replace the 60 amp fuse •...

  • Page 351: Trouble Shooting Fuel Level Circuit

    ELECTRIC SYSTEM - TROUBLESHOOTING CK22/CK22H 3.4 TROUBLE SHOOTING FUEL LEVEL CIRCUIT Condition Possible Cause Remedy Inoperative fuel • Blown 5 amp fuse • Replace the 5 amp fuse gauge • Malfunctioning sending unit • Test the sending unit and replace if necessary •...

  • Page 352: Servicing

    ELECTRIC SYSTEM - SERVICING CK22/CK22H 4. SERVICING 4.1 BATTERY CAUTION • To avoid accidental short circuit, “be sure to at- tach the positive cable to the positive terminal before the negative cable is attached to the nega- tive terminal. •...

  • Page 353: Battery Removal

    ELECTRIC SYSTEM - SERVICING CK22/CK22H 4.1.2 BATTERY REMOVAL 1. Raise the tractor hood by moving the latch release to the right and lifting the hood to its fully raised position. 2. Disconnect the negative (-) battery cable 3. 3. Disconnect the positive (+) battery cable 2.

  • Page 354: Starting System

    ELECTRIC SYSTEM - SERVICING CK22/CK22H 4.2 STARTING SYSTEM 4.2.1 KEY SWITCH The key switch is located on the right side of the operator’s console. The five positions of the switch are: ..Off (1) ..Accessory (2) ..Key On (3) ..

  • Page 355: Start Relay And Preheat Relay

    ELECTRIC SYSTEM - SERVICING CK22/CK22H 4.2.2 START RELAY AND PREHEAT RELAY If they have the same number of poles and the same capacity, they are interchangeable. 196WA21A (1) Start Relay (4P) (2) Preheat Relay (5P) (3) Pull-Coil Relay (4P) A. RELAY TESTING To test a relay, disconnect it from the circuit.

  • Page 356: Engine Stop Solenoid

    ELECTRIC SYSTEM - SERVICING CK22/CK22H 4.2.3 ENGINE STOP SOLENOID The Engine Stop Solenoid Is Installed On The Engine Gear Case. The resistance of the engine stop solenoid should be measured when the wiring connector is disconnected. The voltage values should be measured when turning the key switch to ON position when the wiring connec- tor is installed.

  • Page 357: Preheating System

    ELECTRIC SYSTEM - SERVICING CK22/CK22H 4.2.4 PREHEATING SYSTEM The pre-heat controller is fixed on left side of the steer- ing column assembly. This controller limits the length of time that the glow plugs operate. A. PRE-HEAT CONTROLLER TESTING NOTES: •...

  • Page 358: Starter Motor

    ELECTRIC SYSTEM - SERVICING CK22/CK22H 4.2.6 STARTER MOTOR 196WA27B A. VOLTAGE TEST (B+ TERMINAL) B. MOTOR OPERATING TEST 1. Measure the voltage with a voltmeter across the B CAUTION terminal and chassis. • Secure the starter motor in a vise to prevent it 2.
  • Page 359 ELECTRIC SYSTEM - SERVICING CK22/CK22H C. HOLD IN TEST OF MAGNETIC SWITCH 1. Disconnect M terminal of the starter. 2. Connect battery negative terminal to M terminal of the starter motor. 3. Connect Battery positive terminal to S terminal with a switch placed in the circuit.

  • Page 360: Lighting System

    ELECTRIC SYSTEM - SERVICING CK22/CK22H 4.3 LIGHTING SYSTEM 4.3.1 HEADLAMP SWITCH When operating the switch to the 1st position, the headlamps (low beam) and tail lamps are turned on. When operating the switch to the 2nd position, the headlamps (high beam) and tail lamps are turned on.

  • Page 361: Flasher Warning Light(Ck22-Usa)

    (8) Bulb (12 V 21 / 5 W) (4) Screw (9) Bulb (12 V 21 W) (5) Screw 4.3.6 BRAKE AND TAIL LIGHTS(CK22-EU) To replace a faulty taillight bulb. 1. Release the rear lens (3). 2. Push in on the bulb (8) and rotate counterclockwise in the socket to remove the old bulb.

  • Page 362: Headlights

    ELECTRIC SYSTEM - SERVICING CK22/CK22H 4.3.7 HEADLIGHTS To replace a failed head light bulb: 1. Open the tractor hood. 196WA63A 2. Remove the connector connected to the bulb 196WA64A 3. Remove the rubber cap, then remove the spring retainer from the headlamp housing.

  • Page 363: Brake And Tail Lights (Inside: Brake Light, Outside: Tail Light) (Ck22-Usa)

    ELECTRIC SYSTEM - SERVICING CK22/CK22H 4.3.8 BRAKE AND TAIL LIGHTS (INSIDE: BRAKE LIGHT, OUTSIDE: TAIL LIGHT) (CK22-USA) To replace a faulty taillight bulb. 1. Twist socket counterclockwise to remove from lens. 2. Push in on the bulb and rotate counterclockwise in the socket to remove the old bulb.

  • Page 364: Combination Meter

    ELECTRIC SYSTEM - SERVICING CK22/CK22H 4.4 COMBINATION METER ASS'Y COMBI-METER 196WA44B A: From key ON 3: From main SW “AM” 11: From comtroller 1Hz terminal 8: From combination switch for tail light 7: From combination switch for left turn P2: From preheat controller lamp terminal...

  • Page 365: Sensors

    ELECTRIC SYSTEM - SERVICING CK22/CK22H 4.4.1 SENSORS 196WA70A A. ENGINE OIL PRESSURE SWITCH B. ENGINE COOLANT TEMPERATURE SEN- The oil pressure switch is located on the rear left side of the engine. The switch opens under normal oil The coolant temperature sensor is located at the left pressure(above 0.5 ±...
  • Page 366 ELECTRIC SYSTEM - SERVICING CK22/CK22H C. FUEL LEVEL SENDER The fuel level sensor, 1, is mounted on the top of the fuel tank. The sensor float moves up and down with the fuel in the tank, while changing the resistance to the ground circuit of the fuel gauge.
  • Page 367 CONTENTS CHAPTER 0. SAFETY FIRST ......................0-1 1. FOR SAFETY ..............................0-2 1.1 ALERT SYMBOLS ..........................0-2 2. SAFETY TIPS ..............................0-3 2.1 SAFETY GEAR ............................0-3 2.2 WORK PLACE ............................0-3 2.3 SAFETY INSTRUCTIONS WHEN PREPARING TRACTOR ............. 0-4 2.4 FIRE HAZARDS .............................
  • Page 368 5.3 VALVE CLEARANCE ........................... 2-36 5.4 INJECTION TIMING MEASUREMENT AND ADJUSTMENT ............2-37 5.5 ENGINE OIL PRESSURE ........................2-39 6. EXPLODED VIEW (CK22/CK22H) ......................2-41 7. SERVICING ..............................2-43 7.1 REMOVAL AND REASSEMBLE ......................2-43 7.2 INSPECTION FOR OVERHAUL ......................2-61 CHAPTER 3.
  • Page 369 4.20 DISASSEMBLING THE FRONT WHEEL DRIVE SHAFT ..............4-32 4.21 HST OUTPUT SHAFT GROUP (CK22H) ..................4-33 4.22 COUNTER SHAFT GROUP (CK22) ....................4-34 4.23 DISASSEMBLING SPIRAL BEVEL GEAR ..................4-37 4.24 PTO LEVER AND MID PTO LEVER ....................4-39 4.25 REAR PTO ............................
  • Page 370 CHAPTER 5. HST ..........................5-1 1. SPECIFICATIONS ............................5-2 2. OPERATING PRINCIPLE ..........................5-3 2.1 POWER TRAIN DIAGRAM ........................5-3 2.2 STRUCTURE ............................5-5 2.3 FUNCTIONS OF EACH COMPONENT ....................5-7 2.4 OPERATION CONTROL ........................5-10 3. TROUBLESHOOTING ..........................5-13 3.1 HYDROSTATIC TRANSMISSION .......................
  • Page 371 1. SPECIFICATION ............................10-3 1.1 CONTROL (MLS) VALVE ........................10-3 2. OPERATING PRINCIPLE ..........................10-4 2.1 HYDRAULIC SCHEME ........................10-4 2.2 HYDRAULIC CIRCUIT DIAGRAM (CK22/CK22H) ................. 10-5 2.3 OIL FILTER ............................10-7 2.4 HYDRAULIC BLOCK ........................... 10-8 2.5 JOYSTICK VALVE ..........................10-11 2.6 AUXILIARY CONTROL VALVE (IF EQUIPPED) ................
  • Page 372 3. TROUBLESHOOTING ..........................10-26 3.1 POWER LIFT ASSEMBLY ........................ 10-26 3.2 JOYSTICK VALVE ..........................10-27 4. SERVICING ..............................10-28 4.1 FLOW CONTROL VALVE ......................... 10-28 4.2 JOY-STICK VALVE DISASSEMBLY, INSPECTION AND ASSEMBLY .......... 10-30 4.3 HYDRAULIC LIFT CYLINDER ......................10-34 4.4 LIFT ARMS REMOVAL AND INSTALLATION ..................

This manual is also suitable for:

Ck22h

Table of Contents

Save PDF