Branson 2000 series, 2100, 2800, 2400h, 2800h Service Manual
...
Service Manual
(00 series - Chassis)
KUKJE MACHINERY CO., LTD
GENERAL
KUKJE MACHINERY CO., LTD.
1
CONTENTS 1. (GENERAL)
1. ABOUT WARRANTY ………………………………………………………………………………………………… 002
2. OVERVIEW OF THE TRACTOR
<1> OVERVIEW ……………………………………………………………………………………………............. 003
<2> OPERATION PART
1) MANUAL TRANSMISSION ……………………………………………………………………............ 004
2) HST TRANSMISSION …………………………………………………………………………………….. 005
3. LOCATION OF SAFETY DECALS …………………………………………………………………………………. 006
4. SPECIFICATIONS
<1> SPECIFICATION ………………………………………………………………………………………............ 008
<2> TRAVELING SPEED …………………………………………………………………………………............. 010
5. PERIODIC MAINTENANCE SCHEDULE ………………………………………………………………............ 011
6. OIL, GREASE, ANTI-FREEZE, FUEL AND COOLANT CHART
<1> OIL, GREASE AND ANTI FREEZE ………………………………………………………………............ 012
<2> FUEL, OIL AND COOLANT ………………………………………………………………………............. 012
7. CHECK AND MAINTENANCE
<1> DAILY CHECK …………………………………………………………………………………………............ 013
<2> CHECK POINTS OF INITIAL 50 HOURS ………………………………………………………………. 014
<3> CHECK POINTS OF EVERY 50 HOURS ………………………………………………………............. 019
<4> CHECK POINTS OF EVERY 100 HOURS ……………………………………………………………… 021
<5> CHECK POINTS OF EVERY 200 HOURS ……………………………………………………………… 028
<6> CHECK POINTS OF EVERY 300 HOURS ……………………………………………………………… 029
<7> CHECK POINTS OF EVERY 400 HOURS ……………………………………………………………… 030
<8> CHECK POINTS OF EVERY 800 HOURS ……………………………………………………………… 030
<9> CHECK POINTS OF EVERY 1500 HOURS …………………………………………………………….. 030
<10> CHECK POINTS OF EVERY 3000 HOURS …………………………………………………............. 030
<11> CHECK POINTS OF EVERY 1 YEAR …………………………………………………………………… 030
<12> CHECK POINTS OF EVERY 2 YEARS …………………………………………………………………. 031
<13> OTHERS ……………………………………………………………………………………………………….. 034
GENERAL
KUKJE MACHINERY CO., LTD.
2
1. ABOUT WARRANTY
*. WARRANTY
You will need the “Warranty Registration” when your tractor requires warranty service. Read it and keep in
a safe place.
< Information you will need when contacting the dealer for service >
x Type of model and machine s/n number.
x In case of engine, the engine s/n number.
x Circumstances of breakdown.
(What kind of work, gear position, etc)
x Amount of work done.
(Square footage or number of hours)
x Other information in as much detail as possible
surrounding the circumstanced of the
breakdown.
Chassis S/N
Engine S/N
GENERAL
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2. OVERVIEW OF THE TRACTOR
<1> OVERVIEW
ROPS
Direction Lamp
Rear Tire
Combination Lamp
Lower Link
Front Tire
Seat
Drawbar
Steering Wheel
Fuel Tank
Hood
Head Lamp
GENERAL
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2. OVERVIEW OF THE TRACTOR
<2> OPERATION PART
1) Manual transmission
Emergency Stop S/W
Clutch Pedal
Range Shift Lever
PTO Shift Lever
MFWD Lever
Slow Return Valve
Differential Lock Pedal
Position Lever
Brake Pedal
Accelerator Pedal
Key Switch
Accelerator Lever
Steering Wheel
Instrument Panel
Main Shift Lever
Emergency Lamp S/W
Combination S/W
Side Lamp S/W
GENERAL
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2. OVERVIEW OF THE TRACTOR
2) HST transmission
Emergency Stop S/W
Clutch Pedal
Range Shift Lever
PTO Shift Lever
MFWD Lever
Slow Return Valve
Differential Lock Pedal
Position Lever
Brake Pedal
Backward Pedal
Key Switch
Accelerator Lever
Steering Wheel
Instrument Panel
Forward Pedal
Emergency Lamp S/W
Side Lamp S/W
Combination S/W
Parking Lever
Cruise S/W
GENERAL
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3. LOCATION OF SAFETY DECALS
LOCATION OF SAFETY DECALS
Safety decals are provided to ensure safe operation.
Keep the safety decals clean at all times and protect them from damage.
In case of loss or damage, replace with a new decal.
6. NTE5270000A4
10. TA00016518A 11.TA00016517A
12. TZE5170000B4
9. NTE5150000C4
8. NTE5210000C4
4.TZE4190000B4
5. TZE5130000B4
7. TZE5110000B4
GENERAL
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3. LOCATION OF SAFETY DECALS
LOCATION OF SAFETY DECALS
Safety decals are provided to ensure safe operation.
Keep the safety decals clean at all times and protect them from damage.
In case of loss or damage, replace with a new decal.
No Part code Part description No Part code Part description
1 TZE5180000B4
LABEL, FAN
WARNING 7 TZE5110000B4 LABEL, START CAUTION
2 TZE4300000B4 LABEL, PTO CAUTION 8 NTE5210000C4 LABEL, PTO
3 NTE5220000C4 LABEL, SAFETY 9 NTE5150000C4 LABEL, DRAWBAR
4 TZE4190000B4
LABEL, FILLER
CAUTION
10 TA00016518A LABEL, SAFETY
3. NTE6220000C4
2. TZE4300000B4
1. TZE5180000B4
GENERAL
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5 TZE5130000B4 LABEL, MUFFLER 11 TA0016517A LABEL, SAFETY
6 NTE5270000A4
LABEL, START
CAUTION 12 TZE5170000B4 LABEL, ROPS WARNING
4. SPECIFICATIONS
<1> SPECIFICATION
Manual transmission HST transmission
Items Unit
2100 2400 2800 2400h 2800h
Drive System 4 Wheel Drive
Main Dimensions
Overall Length in 106 (2692mm)
Overall Width in 44.3 (1124mm)
Overall Height in 87.2 (2216mm)
Wheel Base in 59.1 (1502mm)
Front Tread in 33.6 (853mm)
Rear Tread in 34.6 (880mm)
Ground Clearance in 12.4 (315mm)
Weight lbs.
1785
(810kg)
1805
(819kg)
1807
(820kg)
1805
(819kg)
1807
(820kg)
Engine Vertical 4 cycle. Water cooled, Diesel
Model
Combustion System Swirl Chamber
Aspiration N/A
Turb o
Charger
N/A
Turb o
Charger
Engine Horsepower
(2600 rpm)
HP 20.5 24.0 28.0 24.0 28.0
No. of Cylinders 3
Bore x Stroke mm 74 X 82 78 X 82 78 X 82 78 X 82
Displacement cc 1058 1175 1175 1175
Compression Ratio 21.5:1 21:1 21:1
Fuel Consumption gal/hp.hr 0.067 (210 g/hp.hr)
GENERAL
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Type of Air Cleaner Dry, element
Fuel Tank Capacity gal 6.08 (23L)
4. SPECIFICATION
Manual transmission HST transmission
Items Unit
2100 2400 2800 2400h 2800h
Battery Volt 12
Steering Hydrostatic
Clutch Dry, single stage
Brake Wet disc
Transmission
Gear Shifting
(F x R)
6F x 2R
Hydrostatic, high low gear shift
Tires (Agricultural) Turf and Industrial tires Available
Front 6 - 12
Rear 9.5 - 16
Rear PTO 6 spline shaft
Type Live
Speed 540 rpm, 960 rpm, 2500rpm(mid) @2600 engine rpm
MID PTO 14 spline shaft
Type Live
Speed 2500 rpm @ 2600 engine rpm
Hydraulic System Control / Position
3 point hitch Category I
Lift capacity at lift
point
lbs 1433 (650kg)
Pump Capacity gal/min 7.7 (29.0L/min)
GENERAL
KUKJE MACHINERY CO., LTD.
10
4. SPECIFICATIONS
<2> TRAVELING SPEED
SHIFTING MODEL
Manual transmission HST transmission
LEVEL
MAIN RANGE
2100, 2400, 2800 2400h,2800h
1 1 L 0.7(1.1Km/h)
2 2 L 1.1(1.8Km/h)
3 3 L 2.1(3.3Km/h)
3.9(6.2Km/h)
4 1 H 2.7(4.4Km/h)
5 2 H 4.8(7.8Km/h)
Forward
6 3 H 8.8(14.1Km/h)
9.6(15.5Km/h)
1 R L 0.8(1.3Km/h) 2.3(3.7Km/h)
Reverse
2 R H 3.4(5.5Km/h) 5.8(9.3Km/h)
◎ Rated Engine rpm: 2600 rpm
Tire: agri 9.5-16 (423mm)
※ This specification will be changed without prior notice for improvement of quality
※ Theory speeds figured by rated engine rpm (mile/hr)
GENERAL
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5. PERIODIC MAINTENANCE SCHEDULE
< SCHEDULE >
Running hours
Check items
50 100 150 200 250 300 350 400 450 500 550 600
Engine oil R R R R R R R
Transmission fluid R ○ ○ ○ ○ R ○ ○ ○ ○ ○ R
Front axle fluid R ○ ○ ○ ○ R ○ ○ ○ ○ ○ R
Engine oil filter R R R
Transmission fluid filter R R R
Radiator cleaning At the time the coolant is replaced
Fuel oil filter and element ○ ○ R ○ ○ R
Coolant Check before every use (Replace every year)
Air cleaner element ○ ○ ○ ○ ○ ○ ○ ○ ○ R ○ ○
Fan and radiator cleaning ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Battery solution Replace every two years
Battery (specific gravity) ○ ○ ○ ○ ○ ○
Fuel pipe and connection ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Steering wheel hose ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Radiator hose
Hydraulic fluid hose
Fuel hose, electric cables
Electric cables ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Greasing ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Tightening handles ○ ○ ○ ○ ○ ○
Tightening bolts ○ ○ ○ ○ ○ ○ ○
Cooling fan belt ○ ○ ○ ○ ○ ○ ○
Engine breed pipe ○ ○ ○ ○ ○ ○ ○
Engine crankcase cleaning ○ ○
Intake/Exhaust gas valves ○
Fuel injection valve ○
Generator motor ○ ○ ○ ○
Hydraulic system ○ ○ ○ ○
GENERAL
KUKJE MACHINERY CO., LTD.
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※ Inspection should be done every 50 hours. If the tractor is not used much, inspect every year.
※ Replace parts every two years regardless of running hours.
※ Replace the steering wheel hose every two years.
6. OIL, GREASE, ANTI-FREEZE, FUEL AND COOLANT CHART
<1> OIL, GREASE AND ANTI-FREEZE
Type
Item
Type Remarks
Fuel Diesel(KS # 2) Summer: S，Winter：W
Engine oil SAE 10W-40 CG Above
Grease NO.2 of KSM2130 Multi purpose
Anti - Freeze International genuine product No.2 of KSM 2142,permanent type
Transmission, Steering,
Front axle fluid
Branson origin oil
-Texaco TDH oil, 1893
-Chevron Tractor HYD Fluid
Note) Use winter diesel when temperature is below 50’F.
<2> FUEL, OIL AND COOLANT
Manual Transmission
Model
Type
2100 2400 2800
Fuel 6.08 gal (23L) 6.08 gal (23L) 6.08 gal (23L)
Radiator 1.00 gal (3.8L) 1.00 gal (3.8L) 1.00 gal (3.8L)
Coolant
Sub tank 0.21 gal (0.8L) 0.21 gal (0.8L) 0.21 gal (0.8L)
Engine oil 0.79 gal (3L) 0.79 gal (3L) 0.79 gal (3L)
Transmission oil 3.43 gal (13L) 3.43 gal (13L) 3.43 gal (13L)
Front axle oil 0.79 gal (3.0L) 0.79 gal (3.0L) 0.79 gal (3.0L)
HST Transmission
Model
Type
2400h 2800h
Fuel 6.08 gal (23L) 6.08 gal (23L)
Radiator 1.00 gal (3.8L) 1.00 gal (3.8L)
Coolant
Sub tank 0.21 gal (0.8L) 0.21 gal (0.8L)
Engine oil 0.79 gal (3L) 0.79 gal (3L)
Transmission oil 3.96 gal (15L) 3.96 gal (15L)
GENERAL
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Front axle oil 0.79 gal (3.0L) 0.79 gal (3.0L)
7. CHECK AND MAINTENANCE
▶ Be sure to check and service the tractor on a flat place with the engine shut off, the parking brake
on and chock the wheels.
<1> DAILY CHECK
To prevent trouble from occurring, it is important to know the condition of the tractor, Check the
following items before starting.
GENERAL
KUKJE MACHINERY CO., LTD.
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< Checking >
▶ Check areas where previous trouble was experienced.
▶ Walk around the tractor.
1. Check the tire pressure, and check for wear and damage.
2. Check for oil and water leaks.
3. Check the engine oil level.
4. Check the transmission fluid level.
5. Check the coolant level.
6. Check the condition of seat belt and ROPS attaching hardware.
7. Check and clean the radiator screen and grill.
8. Check that the bolts and nuts of the tires are tight.
9. Check the number plate or SMV emblem for damage and clean, replace as necessary of equipped.
10. Care of danger, warning, and caution labels.
11. Clean around the exhaust manifold and the muffler of the engine.
▶ While sitting in the operator’s seat.
1. Check the HST pedal, brake pedal and clutch pedal.
2. Check the parking brake.
3. Check the steering wheel.
▶ Turning the key switch.
1. Check the performance of the instrument panel lights.
2. Check the head lights, tail lights and hazard lights. Clean if necessary.
3. Check the performance of the meters and gauges.
▶ Starting the engine.
1. Check to see that the lights on the easy checker go off.
2. Check the color of the exhaust gas.
3. Check the brakes for proper operation.
7. DISASSEMBLING AND SERVICING
<2> CHECK POINTS OF INITIAL 50 HOURS
GENERAL
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< Changing engine oil >
▶ Be sure to stop the engine.
▶ Allow engine to cool down sufficiently,
oil can be hot and can burn.
1. Place an oil pan underneath the engine.
2. To drain the used oil, remove the drain plug(1) at
the bottom of the engine and drain the oil
completely.
3. Screw in the drain plug(1).
4. Fill with the new oil up to the upper notch on
the dipstick.
◈ Important
¾ Never mix two different types of oil.
Engine oil
capacity
2100
2400(h)
2800(h)
3.0 L
3.17 U.S.qts
0.79 gal
*. PART NAME
1) Drain plug 2) Oil inlet
3) Dipstick
7. DISASSEMBLING AND SERVICING
(3)
GENERAL
KUKJE MACHINERY CO., LTD.
16
< Replacing engine oil filter cartridge >
▶ Be sure to stop the engine before changing oil
filter cartridge.
1. Remove the oil filter cartridge with the filter
wrench.
2. Apply a slight coat of oil onto the cartridge
gasket.
3. To install the new cartridge, screw it in by hand.
Over tightening may cause deformation of
rubber gasket.
4. After the new cartridge has been replaced, the
engine oil normally decrease a little. Thus see
that the engine oil does not leak through the
seal and be sure to read the oil level on the
dipstick. Then, replenish the engine oil up to the
specified level.
◈ Important
¾ To prevent serious damage to the engine,
replacement element must be highly efficient.
Use only a Branson genuine filter.
*. PART NAME
1) Engine oil filter
7. DISASSEMBLING AND SERVICING
GENERAL
KUKJE MACHINERY CO., LTD.
17
< Changing transmission fluid >
▶ Be sure to stop the engine before checking and
changing the transmission fluid.
1. Place an oil pan under the tractor.
2. Remove the drain plugs(1) at the bottom of the
rear axle cases, transmission case and front
transmission case.
3. Drain the transmission fluid.
4. After draining, screw in the four drain plugs.
5. Fill new oil from filling port after removing the
filling plug(2), up to the upper notch on the
dipstick.
6. After running the engine for a few minuets, stop
it and check the oil level again, if low, add oil to
proper level.
◈ Important
¾ Use only multi-grade transmission oil. Use of
other oils may damage the transmission of
hydraulic system.
¾ Never work the tractor immediately after
changing the transmission oil. Keep the engine
at medium speed for a few minutes to prevents
damage to the transmission.
Front case 3L (0.79gal)
2100
2400
2800
Rear case 13L (3.43gal)
Front case 3L (0.79gal)
Transmission
fluid capacity
2400h
2800h
Rear case 15L (3.96gal)
*. PART NAME
1) Drain plug 2) Filling plug
3) Dipstick
7. DISASSEMBLING AND SERVICING
(1)
(1)
(1)
(3)
GENERAL
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18
*. PART NAME
1) Hydraulic oil filter (HST) 2) Hydraulic oil filter
< Replacing hydraulic oil filter cartridge >
▶ Be sure to stop the engine before changing the
oil filters.
1. Drain the transmission fluid.
2. Remove the oil filter cartridge by using a filter
wrench.
3. Apply a slight coat of oil onto the cartridge
gasket.
4. To install the new cartridge, screw it in by hand.
Over tightening may cause deformation of
rubber gasket.
5. After the new cartridge has been replaced, the
transmission fluid level will normally decrease
slightly. Make sure that the transmission fluid
does not leak through the seal. Check the fluid
level.
◈ Important
¾ To prevent serious damage to the hydraulic
system. Use only a genuine Branson filter.
< Cleaning transmission oil strainer (HST) >
1. Clean the strainer with nonflammable solvent.
▶ NOTE
1) When changing the transmission fluid,
disassemble and rinse the strainer with
nonflammable solvent to completely clean off
filings. When reassembling, be careful not to
damage the parts.
2) Since the fine filings in the oil could impair the
component parts of the hydraulic system which
is precision built to withstand high pressure, the
suction line end is provided with an oil strainer.
3) Please do the replacing, of the oil filter cartridge
and the cleaning oil strainer at the same time.
And when replacing, reinstall the oil strainer first.
7. DISASSEMBLING AND SERVICING
(1)
(2)
GENERAL
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19
*. PART NAME
1) Stopper bolt 2) Clutch pedal rod
3) Lock nut for stopper bolt 4) Clutch housing
5) Satety switch 6) Clutch rod
< Checking clutch pedal free travel >
▶ When checking, park the tractor on flat ground,
apply the parking brake, stop the engine and
remove the key.
1. Slightly depress the clutch pedal and measure
stroke “A” at top of stopper bolt(1).
2. If the measurement is not within the factory
specifications, loosen the lock nut and adjust the
clutch pedal rod(2) length.
3. After adjusting it, measure total stroke “B”
between stopper bolt(1) and clutch housing(4).
4. If the measurement is not within the factory
specifications, adjust it with the clutch pedal
stopper bolt(1).
5. And at the same time, adjust the clearance “C”
between safety switch(5) and clutch rod(6).
▶ NOTE
1) After adjustment, secure the stopper bolt with
the lock nut(3).
Clutch pedal free travel on
stopper bolt stroke “A”
Factor y
spec.
7.0 to 9.0 mm
0.28 to 0.35 in.
Reference :
Clutch pedal free travel “L”
on top of clutch pedal.
25.0 to 35.0 mm
0.98 to 1.38 in.
Clearance “B”
Factor y
spec.
1.5 to 2.0 mm
0.06 to 0.08 in.
7. DISASSEMBLING AND SERVICING
<3> CHECK POINTS OF EVERY 50 HOURS
L
GENERAL
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*. PART NAME
1) Clutch pedal 2) Range shift
3) PTO gear shift 4) Speed control pedal
5) Main gear shift
< Checking engine start system >
▶ Do not allow anyone near the tractor while
testing.
▶ If the tractor does not pass the test do not
operate the tractor.
▷ Preparation before testing
1. Sit on operator’s seat.
2. Set the parking brake and stop the engine.
3. HST type
-. Shift the range gear shift lever to “Neutral”
position.
-. Place the speed control pedal in “Neutral”
position.
Manual transmission type
-. Shift the main gear shift lever in “Neutral”
position.
4. Shift the PTO gear shift lever to “Neutral”
position.
5. Fully depress the clutch pedal.
▷ Test 1 : Safety switch for clutch pedal
1. Place the speed control pedal in “Neutral”
position for a HST type or shift the main gear
shift lever for a Manual transmission type to
“Neutral” position.
2. Release the clutch pedal.
3. Turn the key to “Start” position.
4. The engine must not crank.
7. DISASSEMBLING AND SERVICING
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▷ Test 2 : Safety switch for HST of main gear
1. Fully depress the clutch pedal.
2. Depress the speed control pedal HST type or
shift the main gear shift lever Manual
transmission type to “Desired” position.
3. Turn the key to “Start” position.
4. The engine must not crank.
▷ Test 3 : Safety switch for PTO
1. Fully depress the clutch pedal.
2. Place the speed control pedal in “Neutral”
position HST type or shift the main gear shift
lever Manual transmission type to “Neutral”
position.
3. Shift the PTO gear shift lever to “On”(Engaged)
position.
4. Turn the key to “Start” position.
5. The engine must mot crank.
▷ Test 4 : Seat switch
1. Sit on operator’s seat.
2. Start the engine.
3. Fully depress the clutch pedal.
4. Shift the PTO gear shift lever to “On”(Engaged)
position.
5. Stand up. (Do not get off the machine.)
6. The engine must shut off after approximately 1
second.
7. If it does not stop, consult your local Branson
Dealer for this service.
▶ NOTE
1) If the engine cranks during nay of these tests,
adjust or replace the required safety switch.
< Greasing >
1. Apply the grease to the following position as
figures.
*. PART NAME
1) Grease fitting(HST pedal) 2) Battery terminals
3) Grease fitting (Lifting rod RH)
4) Grease fitting (Top link)
5) Front axle tie rod
7. DISASSEMBLING AND SERVICING
(4)
(3)
(5)
(2)
(1)
GENERAL
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< Checking wheel mounting screws and nuts
tightening torque >
▶ Never operate tractor with a loose rim, wheel,
or axle.
▶ Any time bolts and nuts are loosened,
retighten to specified torque.
▶ Check all bolts and nuts frequently
and keep them tight.
1. Check wheel bolts and nuts regularly especially
when new. If there are loosened, tighten as
follows.
Front wheel mounting
bolt
77 to 90 Nm
7.9 to 9.2 kgfm
57.2 to 66.5 ft-lbs
Tightening
torque
Rear wheel mounting
Nut / bolt
108 to 125 Nm
11.0 to 12.8 kgfm
80 to 93 ft-lbs
*. PART NAME
1) Front wheel mounting bolt
2) Rear wheel mounting bolt
3) Rear wheel mounting nut
<4> CHECK POINTS OF EVERY 100 HOURS
< Changing engine oil >
-. Reference the page. 14.
< Checking clutch pedal free travel >
-. Reference the page. 18.
< Checking battery condition >
▶ Never remove the vent plugs
while the engine is running.
7. DISASSEMBLING AND SERVICING
(2)
(3)
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*. PART NAME
1) Good 2) Charge
3) Change
▶ Keep electrolyte away from eyes, hands and
clothes. If you are spattered with it, wash it
away completely with water immediately
and get medical attention.
▶ Wear eye protection and rubber gloves
when working around battery.
1. Mishandling the battery shortens the service life
and adds to maintenance costs.
2. The original battery is a maintenance free type,
but stills needs some servicing. If the battery is
weak, the engine is difficult to start and the
lights become dim. It is important check the
battery periodically.
< Battery charging >
▶ When the battery is being activated, hydrogen
and oxygen gases in the battery are extremely
explosive. Keep open sparks and flames away
from the battery at all times, especially when
charging the battery.
▶ When charging battery, remove battery vent
plugs.
▶ When disconnecting the cable from the battery,
start with the negative terminal first. When
connecting the cable to the battery, start with the
positive terminal first.
▶ Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
7. DISASSEMBLING AND SERVICING
GENERAL
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1. Make sure each electrolyte level is to the bottom
of vent wells, if necessary add distilled water in a
well-ventilated area.
2. The water in the electrolyte evaporates during
recharging. Liquid shortage damages the battery.
Excessive liquid spills over and damages the
tractor body.
3. To slow charge the battery, connect the battery
positive terminal to the charger positive terminal
and the negative to the negative, then recharge
in the standard fashion.
4. A boost charge is only for emergencies. It will
partially charges the battery at a high rate and in
a short time. When using a boost-charged
battery, it is necessary to recharge the battery as
early as possible. Failure to do this will shorten
the battery’s service life.
5. When the specific gravity of electrolyte become
between 1.27 and 1.29 charge has completed.
6. When exchanging an old battery for a new one,
use battery of equal specification.
◆ Direction for storage
1. When storing the tractor for long periods of
time, remove the battery from tractor, adjust the
electrolyte to the proper level and store in a dry
place out of direct sunlight.
2. The battery self-discharges while it is stored.
Recharge it once every three months in hot
seasons and once every six months in cold
seasons.
Battery
Type
Vol ts
(V)
Capacity
at 5H.R
(A.H.)
Reserve
Capacity
(min.)
Cold
Cranking
Amps
Normal
Charging
Rate(A)
BX50S 12 40 90 480 4.5
7. DISASSEMBLING AND SERVICING
GENERAL
KUKJE MACHINERY CO., LTD.
25
*. PART NAME
1) Cover 2) Primary element
3) Evacuator valve
< Cleaning air cleaner element >
1. Remove the air cleaner cover(1) and primary
element(2).
2. Cleaning the primary element :
▷ When dry dust adheres to the element, blow
compressed air from the inside turning the
element. Pressure of compressed air must be
under 205kPa (2.1 kgf/㎠, 30 psi).
▷ When carbon or oil adheres to the element,
soak the element in detergent for 15 minutes
then wash it several times in water, rinse with
clean water and dry it naturally. After the
element is fully dried, inspect inside of the
element with a light and check if it is damaged
or not.
3. When to replace the air cleaner primary
element(2) : Once a year or after every six times
of cleaning, whichever comes first.
◈ Important
¾ The air cleaner uses a dry element, never apply
oil.
¾ Do not run the engine with the filter element
removed.
¾ Be sure to refit the dust cup with the arrow↑(on
the rear of cup) upright. If the dust cup is
improperly fitted, evacuator valve will not
function and dust will adhere to the element.
¾ Do not touch the secondary element except in
cases where replacing is required.
◆ Evacuator valve
Open the evacuator valve once a week under
ordinary conditions or daily when used in a dusty
place to get rid of large particles of dust and dirt.
7. DISASSEMBLING AND SERVICING
GENERAL
KUKJE MACHINERY CO., LTD.
26
*. PART NAME
1) Filter bracket
2) Fuel filter bowl
3) O-ring
4) Filter element
5) O-ring
A) Loosen
B) Tighten
< Cleaning fuel filter >
This job should not be done in the field, but in a
clean place.
1. Loosen and remove the fuel filter bowl(2), and
rinse the inside with kerosene.
2. Take out the filter element(4) and dip it in the
kerosene to rinse.
3. After cleaning, reassemble the fuel filter, keeping
out dust and dirt.
4. Bleed the fuel system.
▶ NOTE
1) When the fuel filter bowl has been removed, fuel
stops flowing from the fuel tank. If the fuel tank
is almost full, however, the fuel will flow back
from the fuel return pipe to the fuel filter. Before
checking the above, mark sure the fuel tank is
less than half-full.
< Checking fan belt tension >
▶ Be sure to stop engine before checking belt
tension.
1. Stop the engine and remove the key.
2. Apply moderate thumb pressure to the belt
between pulleys.
3. If the tension is incorrect, loosen the alternator
mounting bolts and, using a lever placed
between the alternator and the engine block,
pull the alternator out until the deflection of the
belt falls within acceptable limits.
4. Replace fan belt if it is damaged.
Fan belt
tension
Factor y
spec.
A deflection of between 7 to 9mm
(0.28 to 0.34 in.) when the belt is
pressed in the middle of the span.
*. PART NAME
1) Adjusting screw 2) Tension bolt
A) Check the belt tension B) To tighten
7. DISASSEMBLING AND SERVICING
(2)
GENERAL
KUKJE MACHINERY CO., LTD.
27
*. PART NAME
1) Brake pedal 2) Turnbuckle
3) Lock nut
L : Free travel
< Adjusting brake pedal free travel >
▶ Stop the engine and chock the wheels before
checking the brake pedal.
▶ The difference between the right and left pedal
free travel must be less than 4.0 mm (0.16 in.).
1. Release the parking brake.
2. Slightly depress the brake pedals and measure
the free travel at the top of the pedal stroke.
3. If the measurement is not within the factory
specifications, loosen the lock nut and turn the
turnbuckle to adjust the brake rod length.
4. Retighten the lock nut securely.
5. Keep the free travel in the right and left brake
pedals equal.
Brake pedal
free travel (L)
Factor y spec.
30 to 40 mm
1.18 to 1.57 in.
▶ NOTE
1) After checking brake pedal free travel, be sure to
engage the parking brake lever fully and check
to see that the brake pedals are securely locked.
7. DISASSEMBLING AND SERVICING
GENERAL
KUKJE MACHINERY CO., LTD.
28
*. PART NAME
1) Fuel hoses 2) Hose clamps
< Checking fuel line >
▶ Stop the engine when attempting the check and
change prescribed below.
▶ Remember to check the fuel line periodically.
The fuel line is subject to wear and aging, fuel
may leak out onto the running engine, causing
a fire.
1. Check to see that all line and hose clamps are
tight and not damaged.
2. If hoses and clamps are found worn or damaged,
replace or repair them at once.
3. The fuel line is made of rubber and ages
regardless of period of service. Replace the fuel
pipe together with the clamp every two years
and securely tighten.
4. However if the fuel pipe and clamp are found
damaged or deteriorated earlier than two years,
then change or repair.
5. After the fuel line and clamp have been
changed, bleed the fuel system.
◈ Important
¾ When the fuel line is disconnected for change,
close both ends of the fuel line with a piece of
clean cloth of paper to prevent dust and dirt
from entering. Entrance of dust and dirt causes
malfunction of the fuel injection pump. In
addition, particular care must be taken not to
admit dust and dirt into the fuel pump.
7. DISASSEMBLING AND SERVICING
<5> CHECK POINTS OF EVERY 200 HOURS
GENERAL
KUKJE MACHINERY CO., LTD.
29
*. PART NAME
1) Hose 2) Hose clamps
*. PART NAME
1) Hose 2) Clamp
< Replacing engine oil filter cartridge >
-. Reference the page 15.
< Checking intake air line >
1. Check to see that hoses and hose clamps are
tight and not damaged.
2. If hoses and clamps are found worn or damaged,
replace or repair them at once.
< Checking radiator hose and hose clamp >
▶ Check to see if radiator hoses are properly fixed
every 200 hours of operation or six months,
whichever comes first.
1. If hose clamps are loose or water leaks, tighten
bands securely.
2. Replace hoses and tighten hose clamps securely,
if the radiator hoses are swollen, hardened or
cracked. Replace hoses and hose clamps every 2
years or earlier if checked and found that hoses
are swollen, hardened or cracked.
◆ Precaution at overheating
Take the following actions in the event the coolant
temperature is near or more than the boiling point,
which is called “Overheating”.
1. Stop the machine operation in a safe place and
keep the engine unloaded idling.
2. Don’t stop the engine suddenly, but stop it after
about 5 minutes of unloaded idling.
3. Keep yourself well away from the machine for
another 10 minutes or while the steam has
blown out.
4. Checking that there gets on danger such as
burn, get rid of the causes of overheating
according to the manual and start again the
engine.
7. DISASSEMBLING AND SERVICING
<6> CHECK POINTS OF EVERY 300 HOURS
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