Branson TRACTOR Service manual

Service Manual

(00 series - Chassis)

KUKJE MACHINERY CO., LTD

GENERAL

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

KUKJE MACHINERY CO., LTD.

1

GENERAL

1. ABOUT WARRANTY

*. WARRANTY

You will need the “Warranty Registration” when your tractor requires warranty service. Read it and keep in

a safe place.

< Information you will need when contacting the dealer for service >

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

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2

2. OVERVIEW OF THE TRACTOR

<1> OVERVIEW

GENERAL

Steering Wheel

Fuel Tank

Hood

Head Lamp

Front Tire

ROPS

Direction Lamp

Seat

Rear Tire

Combination Lamp

Drawbar

Lower Link

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3

2. OVERVIEW OF THE TRACTOR

<2> OPERATION PART

1) Manual transmission

GENERAL

Emergency Stop S/W

Combination S/W

Side Lamp S/W

Clutch Pedal

Range Shift Lever

PTO Shift Lever

Instrument Panel

Steering Wheel

Accelerator Lever

Key Switch

Brake Pedal

Emergency Lamp S/W

Main Shift Lever

Accelerator Pedal

Position Lever

MFWD Lever

Slow Return Valve

Differential Lock Pedal

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4

2. OVERVIEW OF THE TRACTOR

2) HST transmission

GENERAL

Emergency Stop S/W

Combination S/W

Clutch Pedal

Side Lamp S/W

Parking Lever

Range Shift Lever

PTO Shift Lever

Instrument Panel

Cruise S/W

Steering Wheel

Accelerator Lever

Brake Pedal

Forward Pedal

Key Switch

Emergency Lamp S/W

Backward Pedal

MFWD Lever

Differential Lock Pedal

Position Lever

Slow Return Valve

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5

3. LOCATION OF SAFETY DECALS

LOCATION OF SAFETY DECALS

Safety decals are provided to ensure safe operation.

Keep the safety decals clean at all times and protect them from damage.

In case of loss or damage, replace with a new decal.

12. TZE5170000B4

GENERAL

6. NTE5270000A4

4.TZE4190000B4

10. TA00016518A 11.TA00016517A

9. NTE5150000C4

8. NTE5210000C4

5. TZE5130000B4

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7. TZE5110000B4

6

3. LOCATION OF SAFETY DECALS

LOCATION OF SAFETY DECALS

Safety decals are provided to ensure safe operation.

Keep the safety decals clean at all times and protect them from damage.

In case of loss or damage, replace with a new decal.

3. NTE6220000C4

GENERAL

1. TZE5180000B4

2. TZE4300000B4

No Part code Part description No Part code Part description

LABEL, FAN

1 TZE5180000B4

2 TZE4300000B4 LABEL, PTO CAUTION 8 NTE5210000C4 LABEL, PTO

3 NTE5220000C4 LABEL, SAFETY 9 NTE5150000C4 LABEL, DRAWBAR

4 TZE4190000B4

KUKJE MACHINERY CO., LTD.

WARNING 7 TZE5110000B4 LABEL, START CAUTION

LABEL, FILLER

CAUTION

10 TA00016518A LABEL, SAFETY

7

5 TZE5130000B4 LABEL, MUFFLER 11 TA0016517A LABEL, SAFETY

LABEL, START

GENERAL

6 NTE5270000A4

CAUTION 12 TZE5170000B4 LABEL, ROPS WARNING

4. SPECIFICATIONS

<1> SPECIFICATION

Items Unit

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)

Manual transmission HST transmission

2100 2400 2800 2400h 2800h

Rear Tread in 34.6 (880mm)

Ground Clearance in 12.4 (315mm)

Weight lbs.

1785

(810kg)

Engine Vertical 4 cycle. Water cooled, Diesel

Model

Combustion System Swirl Chamber

Aspiration N/A

Engine Horsepower

HP 20.5 24.0 28.0 24.0 28.0

(2600 rpm)

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

1805

(819kg)

1807

(820kg)

Turb o

Charger

1805

(819kg)

N/A

1807

(820kg)

Turb o

Charger

Compression Ratio 21.5:1 21:1 21:1

Fuel Consumption gal/hp.hr 0.067 (210 g/hp.hr)

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GENERAL

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

6F x 2R

(F x R)

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

Hydrostatic, high low gear shift

3 point hitch Category I

Lift capacity at lift

point

Pump Capacity gal/min 7.7 (29.0L/min)

lbs 1433 (650kg)

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4. SPECIFICATIONS

<2> TRAVELING SPEED

GENERAL

SHIFTING MODEL

LEVEL

MAIN RANGE

1 1 L 0.7(1.1Km/h)

2 2 L 1.1(1.8Km/h)

3 3 L 2.1(3.3Km/h)

Forward

4 1 H 2.7(4.4Km/h)

5 2 H 4.8(7.8Km/h)

6 3 H 8.8(14.1Km/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

Manual transmission HST transmission

2100, 2400, 2800 2400h,2800h

3.9(6.2Km/h)

9.6(15.5Km/h)

※ Theory speeds figured by rated engine rpm (mile/hr)

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5. PERIODIC MAINTENANCE SCHEDULE

< SCHEDULE >

GENERAL

Running hours

Check items

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 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

50 100 150 200 250 300 350 400 450 500 550 600

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 ○ ○ ○ ○

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GENERAL

※ 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

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,

Branson origin oil

Front axle fluid

Note) Use winter diesel when temperature is below 50’F.

Type Remarks

<2> FUEL, OIL AND COOLANT

Model

Type

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)

2100 2400 2800

-Texaco TDH oil, 1893

-Chevron Tractor HYD Fluid

Manual Transmission

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)

Model

Type

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)

KUKJE MACHINERY CO., LTD.

2400h 2800h

12

HST Transmission

GENERAL

Front axle oil 0.79 gal (3.0L) 0.79 gal (3.0L)

7. CHECK AND MAINTENANCE

▶ Be sure to check and service the tractor on a flat place with the engine shut off, the parking brake

on and chock the wheels.

<1> DAILY CHECK

To prevent trouble from occurring, it is important to know the condition of the tractor, Check the

following items before starting.

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GENERAL

< Checking >

▶ Check areas where previous trouble was experienced.

▶ Walk around the tractor.

1. Check the tire pressure, and check for wear and damage.

2. Check for oil and water leaks.

3. Check the engine oil level.

4. 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

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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.

GENERAL

Engine oil

2100

2400(h)

capacity

2800(h)

3.0 L

3.17 U.S.qts

0.79 gal

*. PART NAME

1) Drain plug 2) Oil inlet

3) Dipstick

(3)

7. DISASSEMBLING AND SERVICING

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15

< 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

GENERAL

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

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16

< 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.

(1)

(1)

GENERAL

◈ 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.

2100

2400

Transmission

2800

fluid capacity

2400h

2800h

Front case 3L (0.79gal)

Rear case 13L (3.43gal)

Front case 3L (0.79gal)

Rear case 15L (3.96gal)

*. PART NAME

1) Drain plug 2) Filling plug

(1)

(3)

3) Dipstick

7. DISASSEMBLING AND SERVICING

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< 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

GENERAL

(1)

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.

(2)

*. PART NAME

1) Hydraulic oil filter (HST) 2) Hydraulic oil filter

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

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18

< 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).

GENERAL

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”

Reference :

Clutch pedal free travel “L”

on top of clutch pedal.

Clearance “B”

Factor y

spec.

Factor y

spec.

7.0 to 9.0 mm

0.28 to 0.35 in.

25.0 to 35.0 mm

0.98 to 1.38 in.

1.5 to 2.0 mm

0.06 to 0.08 in.

L

*. PART NAME

1) Stopper bolt 2) Clutch pedal rod

3) Lock nut for stopper bolt 4) Clutch housing

5) Satety switch 6) Clutch rod

7. DISASSEMBLING AND SERVICING

<3> CHECK POINTS OF EVERY 50 HOURS

KUKJE MACHINERY CO., LTD.

19

GENERAL

< Checking engine start system >

▶ Do not allow anyone near the tractor while

testing.

▶ If the tractor does not pass the test do not

operate the tractor.

▷ Preparation before testing

1. Sit on operator’s seat.

2. 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.

*. PART NAME

1) Clutch pedal 2) Range shift

3) PTO gear shift 4) Speed control pedal

5) Main gear shift

7. DISASSEMBLING AND SERVICING

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20

▷ 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

GENERAL

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)

(1)

(2)

(4)

(3)

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.

7. DISASSEMBLING AND SERVICING

(5)

*. 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

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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.

GENERAL

▶ 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

Tightening

torque

Rear wheel mounting

Nut / bolt

77 to 90 Nm

7.9 to 9.2 kgfm

57.2 to 66.5 ft-lbs

108 to 125 Nm

11.0 to 12.8 kgfm

80 to 93 ft-lbs

<4> CHECK POINTS OF EVERY 100 HOURS

< Changing engine oil >

(2)
(3)

*. PART NAME

1) Front wheel mounting bolt

2) Rear wheel mounting bolt

3) Rear wheel mounting nut

-. 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

KUKJE MACHINERY CO., LTD.

22

▶ 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

GENERAL

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

*. PART NAME

1) Good 2) Charge

3) Change

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

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GENERAL

1. Make sure each electrolyte level is to the bottom

of vent wells, if necessary add distilled water in a

well-ventilated area.

2. The water in the electrolyte evaporates during

recharging. Liquid shortage damages the battery.

Excessive liquid spills over and damages the

tractor body.

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

BX50S 12 40 90 480 4.5

Vol t s

(V)

Capacity

at 5H.R

(A.H.)

Reserve

Capacity

(min.)

Cold

Cranking

Amps

Normal

Charging

Rate(A)

7. DISASSEMBLING AND SERVICING

KUKJE MACHINERY CO., LTD.

24

GENERAL

< Cleaning air cleaner element >

1. Remove the air cleaner cover(1) and primary

element(2).

2. Cleaning the primary element :

▷ When dry dust adheres to the element, blow

compressed air from the inside turning the

element. Pressure of compressed air must be

under 205kPa (2.1 kgf/㎠, 30 psi).

▷ 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

*. PART NAME

1) Cover 2) Primary element

3) Evacuator valve

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

KUKJE MACHINERY CO., LTD.

25

GENERAL

< Cleaning fuel filter >

This job should not be done in the field, but in a

clean place.

1. Loosen and remove the fuel filter bowl(2), and

rinse the inside with kerosene.

2. Take out the filter element(4) and dip it in the

kerosene to rinse.

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.

(2)

*. PART NAME

1) Filter bracket

2) Fuel filter bowl

3) O-ring

4) Filter element

5) O-ring

< 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.

A) Loosen

B) Tighten

*. PART NAME

1) Adjusting screw 2) Tension bolt

A) Check the belt tension B) To tighten

7. DISASSEMBLING AND SERVICING

KUKJE MACHINERY CO., LTD.

26

< 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

GENERAL

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

Factor y spec.

free travel (L)

▶ NOTE

30 to 40 mm

1.18 to 1.57 in.

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.

*. PART NAME

1) Brake pedal 2) Turnbuckle

3) Lock nut

L : Free travel

7. DISASSEMBLING AND SERVICING

KUKJE MACHINERY CO., LTD.

27

GENERAL

< Checking fuel line >

▶ Stop the engine when attempting the check and

change prescribed below.

▶ Remember to check the fuel line periodically.

The fuel line is subject to wear and aging, fuel

may leak out onto the running engine, causing

a fire.

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

*. PART NAME

1) Fuel hoses 2) Hose clamps

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

KUKJE MACHINERY CO., LTD.

28

< 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 >

GENERAL

▶ 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

*. PART NAME

1) Hose 2) Hose clamps

*. PART NAME

1) Hose 2) Clamp

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

KUKJE MACHINERY CO., LTD.

29

< Changing transmission fluid >

-. Reference the page 16.

< Cleaning transmission oil strainer >

-. Reference the page 17.

< Replace hydraulic oil filter cartridge >

-. Reference the page 17.

< Changing front axle case oil >

1. Place the oil pans underneath the front axle case.

2. Remove the both right and left hand side drain

plugs(2) and filling plug(1) to drain the oil.

3. After draining, reinstall the drain plugs(2).

4. Fill with new oil up to the upper notch on the

dipstick.

GENERAL

◈ Important

¾ After ten minutes, check the oil level again, add

oil to proper level.

¾ Use Branson genuine fluid.

Front axle case

2100

2400(h)

oil capacity

2800(h)

3.0 L

3.17 U.S.qts

0.79 gal

*. PART NAME

1) Filling plug with dipstick 2) Drain plug

A) Oil level is acceptable within this range

7. DISASSEMBLING AND SERVICING

<7> CHECK POINTS OF EVERY 400 HOURS

KUKJE MACHINERY CO., LTD.

30

< Front axle rocking force >

1. Jack up the front side of tractor.

2. Set a spring balance to the front axle flange.

3. Measure the front axle rocking force.

4. If the measurement is not within the factory

specifications, adjust by the adjusting screw(1).

5. Tighten the lock nut(2) firmly.

GENERAL

Front axle

Factor y spec.

rocking force

*. PART NAME

1) Adjusting screw 2) Lock nut

49.0 to 98.1 N

5.0 to 10.0 kgf

11.0 to 22.1 lbs

< Replace fuel filter element >

1. The fuel filter element should be replaced every

400 hours.

*. PART NAME

1) Filter bracket 2) Fuel filter bowl

3) O-ring 4) Filter element

5) O-ring

<8> CHECK POINTS OF EVERY 800 HOURS

< Checking valve clearance >

-. Reference the engine service manual.

<9> CHECK POINTS OF EVERY 1500 HOURS

< Checking fuel injection nozzle injection pressure >

-. Reference the engine service manual.

<10> CHECK POINTS OF EVERY 3000 HOURS

< Checking injection pump >

-. Reference the engine service manual.

<11> CHECK POINTS OF 1 YEAR

< Replace air cleaner primary element and secondary element >

-. Reference the page 24.

7. DISASSEMBLING AND SERVICING

<12> CHECK POINTS OF 2 YEARS

KUKJE MACHINERY CO., LTD.

31

GENERAL

< Replacing radiator hose (Water pipes) >

1. Replace the hoses and clamps.

-. Reference the page 28.

< Replacing fuel hose >

1. Replace the fuel hoses and clamps.

-. Reference the page 27.

< Replacing intake air line >

1. Replace the hoses and clamps, if necessary.

-. Reference the page 28.

< Flush cooling system and changing coolant >

▶ Do not remove the radiator cap when the engine

is hot. Then loosen cap slightly to the stop to

relieve any excess pressure before removing cap

completely.

1. Stop the engine and let cool down.

2. To drain the coolant, open the radiator drain

cock, and remove radiator cap. The radiator cap

must be removed to completely drain the

coolant.

3. After all coolant is drained, close the drain plug.

4. Fill with clean water and cooling system cleaner.

5. Follow directions of the cleaner instruction.

6. After flushing, fill with clean water and anti-

freeze until the coolant level is just below the

port.

7. Start and operate the engine for few minutes.

8. Stop the engine. Check coolant level and add

coolant if necessary.

9. Install the radiator cap securely.

*. PART NAME

1) Radiator cap 2) Recovery tank

3) Drain cock

7. DISASSEMBLING AND SERVICING

KUKJE MACHINERY CO., LTD.

32

GENERAL

◈ Important

¾ Do not start the engine without coolant.
¾ Use clean, fresh water and anti-freeze to fill the

radiator.

¾ When the anti-freeze is mixed with water, the

anti-freeze mixing ratio must be less than 50%.

¾ Securely tighten radiator cap. If the cap is loosen

or improperly fitted, water may leak out and the

engine could overheat.

Coolant

capacity(with

recover y tank)

2100

2400(h)

2800(h)

3.8 L

4.0 U.S.qts

1.0 gal

< Flush cooling system and changing coolant

(Continued) >

◆ Anti-freeze

If it freezes, cooling water can damage the

cylinders and radiator. When it may be necessary the

ambient temperature falls below 0℃(32℉) to remove

coolant water after operating or to add anti-freeze to

it.

1. There are two types of anti-freeze available; use

the permanent type for this engine.

2. Before adding anti-freeze for the first time, clean

the radiator interior by pouring fresh water and

draining it a few times.

3. The procedure for mixing the water and anti-

freeze differs according to the make of the anti-

freeze and the ambient temperature.

7. DISASSEMBLING AND SERVICING

KUKJE MACHINERY CO., LTD.

33

GENERAL

4. Mix the anti-freeze with water, and then fill in to

the radiator.

Freezing point Boiling point Vol %

Anti-freeze

40 -24 -12 106 222

50 -37 -34 108 226

℃ ℉ ℃ ℉

* At 760 mmHg pressure (atmospheric). A higher

boiling point is obtained by using a radiator

pressure cap which permits the development of

pressure within the cooling system.

▶ NOTE

1) The above data represents industry standards

that necessitate the minimum glycol content in

the concentrated anti-freeze.

2) When the coolant level drops due to

evaporation, add water only. In the case of

leakage, add anti-freeze and water in the

specified mixing ratio.

3) Anti-freeze absorbs moisture. Keep unused anti-

freeze in a tightly sealed container.

4) Do not use radiator cleaning agent when anti-

freeze had been added to the coolant. (Anti-

freeze contains an anti-corrosive agent, which

will react with the radiator cleaning agent

forming sludge which will affect the engine

parts.)

7. DISASSEMBLING AND SERVICING

<13> OTHERS

KUKJE MACHINERY CO., LTD.

34

GENERAL

< Bleeding fuel system >

Air must removed :

1. When the fuel filter or lines are removed.

2. When tank is completely empty.

3. After the tractor has not been used for a long

period of time.

Bleeding procedure is as follows :

1. Fill the fuel tank with fuel.

2. Start the engine and run for about 30 second,

and then stop the engine.

< Replacing fuse >

1. The tractor electrical system is protected from

potential damage by fuses. A blown fuse

indicates that there is an overload or short

somewhere in the electrical system.

2. If any of the fuses should blow, replace with a

new one of the same capacity.

◈ Important

¾ Before replacing a blown fuse, determine why

the fuse blew and make any necessary repairs.

Failure to follow this procedure may result in

serious damage to the tractor electrical system.

< Replacing light bulb >

1. Head light

Take the bulb out of the light body and replace

with a new one.

2. Other lights

Detach the lens and replace the bulb.

Light Capacity

Head light 55W

Tail light 10W

Turn signal / Hazard light 21W / 21W

Instrument panel light 1.7W

*. PART NAME

A) Fuse box B) Main fuse

Hazard light switch indicator 0.6W

KUKJE MACHINERY CO., LTD.

35

CLUTCH

CONTENTS 2. (CLUTCH)

1. LINKAGE MECHANISM …………………………………………………………………………………………….. 036

2. SERVICING SPECIFICATIONS …………………………………………………………………………………….. 037

3. TIGHTENING TORQUES ……………………………………………………………………………………………. 038

4. CHECKING, DISASSEMBLING AND SERVICING

<1> CHECKING AND ADJUSTING ……………………………………………………………………………. 039

<2> PREPARATION

1) SEPARATING ENGINE FROM CLUTCH HOUSING ……………………………………………… 040

<3> DISASSEMBLING AND ASSEMBLING ………………………………………………………………… 045

<4> SERVICING ……………………………………………………………………………………………………... 046

35

KUKJE MACHINERY CO., LTD.

1. LINKAGE MECHANISM

CLUTCH

1) Engine Flywheel 2) Clutch Disc 3) Clutch Cover

4) Pressure Plate 5) Diaphragm Spring 6) Clutch Rod

7) Clutch Release Fork 8) Clutch Adjusting Bolt 9) Clutch Pedal

10) Clutch Release Hub 11) Clutch Release Bearing 12) Clutch Shaft

13) Pressure Plate Assembly

Engine torque is transmitted to the pressure plate assembly(13) via the flywheel(1) which is connected to

the engine crankshaft. Therefore, the clutch cover constantly runs with the engine. The clutch disc(2) is

located between the flywheel(1) and the pressure plate(4) in the pressure plate assembly. Torque is

transmitted to the clutch disc(2) by the pressure created by the diaphragm spring(5) installed in the pressure

plate assembly. Then, the torque is transmitted to the transmission via the clutch shaft(12).

When the clutch pedal(9) is depressed, the clutch release hub(10) and the clutch release bearing(11) move

towards the flywheel and push the fingers of the diaphragm spring(5). In other words, this movement pulls

the pressure plate(4) up and disengages the clutch.

36

KUKJE MACHINERY CO., LTD.

2. SERVICING SPECIFICATIONS

Item Factory Specification Allowable Limit

CLUTCH

Clutch Pedal

Clutch pedal stopper bolt

Safety switch setting position

Clutch disc

Clutch disc boss to gear shaft

Pressure plate Flatness -

(Reference)

On Clutch Pedal

Clearance “A”

between Stopper Bolt

and Clutch Housing

Clearance “B” of

Safety Switch when

Clutch Pedal Released

Disc Surface to

Rivet Top (Depth)

Backlash

(Displacement

Around Disc Edge)

20.0 to 30.0 mm

0.8 to 1.2 in.

7.0 to 9.0 mm

0.28 to 0.35 in.

1.5 to 2.5 mm

0.059 to 0.098 in.

-

-

-

0.3 mm

-

0.012 in.

2.0 mm

-

0.079 in.

0.2 mm

0.008 in.

37

KUKJE MACHINERY CO., LTD.

CLUTCH

3. TIGHTENING TORQUES

Tightening torque of screws, bolts and nuts on the table below are especially specified.

Item N·m kgf·m ft-lbs

Steering wheel mounting nut 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2

Delivery pipe nut for HST 34.3 to 39.2 3.5 to 4.0 25 to 28

Oil cooler pipe nut 50.0 to 57.9 5.1 to 5.9 36.9 to 42.8

Delivery pipe nut for power steering 64.7 to 75.5 6.6 to 7.7 47.9 to 55.3

Clutch housing and engine mounting screw (M8) 25.5 to 27.5 2.4 to 2.8 17.4 to 20.2

Clutch housing and engine mounting screw (M10) 48.1 to 55.8 4.9 to 5.7 35.5 to 41.2

Clutch cover mounting screw 23.5 to 27.5 2.4 to 2.8 17.4 to 20.2

38

KUKJE MACHINERY CO., LTD.

4. CHECKING, DISASSEMBLEING AND SERVICING

<1> CHECKING AND ADJUSTING

CLUTCH

< Checking clutch pedal free travel >

When checking, park the tractor on flat ground,

apply the parking brake, stop the engine and

remove the key.

1. After adjusting it, measure total stroke “A”

between stopper bolt(1) and clutch housing(4).

2. If the measurement is not within the factory

specifications, adjust it with the clutch pedal

stopper bolt(1).

3. And at same the time, adjust the clearance “B”

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 “L” on top of

25 to 35 mm

clutch pedal.

Clutch pedal total stroke “A”

Clearance “B”

*. PART NAME

1) Stopper bolt

2) Clutch pedal rod

3) Lock nut for stopper bolt

4) Clutch housing

5) Safety switch

6) Clutch rod

Factor y

spec.

Factor y

spec.

0.98 to 1.38 in.

7.0 to 9.0 mm

0.31 to 0.35 in.

1.5 to 2.5 mm

0.06 to 0.08 in.

L

39

KUKJE MACHINERY CO., LTD.

4. CHECKING, DISASSEMBLEING AND SERVICING

<2> PREPARATION

1) Separating Engine From Clutch Housing.

< Draining transmission fluid >

1. Place and oil pan underneath the transmission

case, and remove the drain plugs(1).

2. Drain the transmission fluid.

3. Reinstall the drain plug.

▷ Refilling

9 Fill new oil from filling port after removing the

filling plug(2) up to the upper notch on the

dipstick(3).

9 After running the engine for a few minutes, stop

it and check the oil level again, if low, add oil to

(1)

CLUTCH

the proper level.

◈ Important

¾ Use only multi-grade transmission oil. Use of

other oils may damage the transmission or

hydraulic system.

¾ Never work the tractor immediately after

changing the transmission oil. Keep the engine

at medium speed for a few minutes to prevent

damage to the transmission.

¾ Do not mix different brands of oil together.

13.00 L

3.43 U.S.gals

2.90 lmp.gals

15.00 L

3.96 U.S.gals

3.30 lmp.gals

Transmission fluid

Capacity

2100

2400

2800

2100h

2400h

2800h

(2)

(1)

(1)

(3)

*. PART NAME

1) Drain plug

2) Filling plug

3) Dipstick

40

KUKJE MACHINERY CO., LTD.

4. CHECKING, DISASSEMBLING AND SERVICING

CLUTCH

< Hood and battery cord >

1. Open the hood(1).

2. Disconnect the battery grounding cord(2).

3. Disconnect the head light connectors and

remove the hood(1).

▶ NOTE

1) When disconnecting the battery cords,

disconnect the grounding cord first. When

connecting the battery cords, connect the

positive cord first.

*. PART NAME

1) Hood

2) Battery grounding cord

< Steering wheel >

1. Remove the steering wheel cap.

2. Remove the steering wheel mounting nut and

remove the steering wheel with a steering wheel

puller.

Tightening

Torq u e

Steering wheel

mounting nut

48.1 to 55.9 Nm

4.9 to 5.7 kgfm

35.1 to 41.2 ft-lbs

< Meter panel and panel under cover >

1. Tap out the spring pin and remove the hand

accelerator lever(7).

2. Remove the panel under cover(6).

3. Open the meter panel(1) and disconnect the

meter panel connector(2).

4. Disconnect the combination switch connector(3),

main switch connector(4), hazard switch

connector(5), light switch(8) and emergency stop

switch(9). And then remove the meter panel.

*. PART NAME

1) Meter panel 2) Meter panel connector

3) Combination switch connector

4) Main switch connector 5) Hazard switch connector

6) panel under cover 7) Hand accelerator lever

8) light switch 9) Emergency stop switch

41

KUKJE MACHINERY CO., LTD.

4. CHECKING, DISASSEMBLING AND SERVICING

CLUTCH

< Fuel tank >

1. Disconnect the fuel house(1) at the fuel filter

side, then drain fuel completely.

2. Disconnect the hazard unit, controller, starter

relay and regulator connectors and remove the

lead wire for fuel gauge.

3. Disconnect the overflow hoses(5) of fuel line.

4. Loosen the steering bracket(7).

5. Remove the tank frame(2) with fuel tank(3).

6. Remove the battery.

7. Disconnect the hydraulic pipes(6) and remove

the battery stay with oil cooler(4).

▶ NOTE

1) For fastening hydraulic pipe nut, use two

wrenches. Hold the fitting with a wrench, turn

the pipe nut with another wrench to avoid

damage at fitting installed part.

(7)

(2)

(3)

(5)

(6)

(1)

*. PART NAME

1) Fuel hose 2) Fuel tank frame

3) Fuel tank 4) Oil cooler

5) Overflow hose 6) Hydraulic hose

7) Steering bracket

(4)

34.3 to 39.2 Nm

3.5 to 4.0 kgfm

25.3 to 28.9 ft-lbs

50.0 to 57.9 Nm

5.1 to 5.9 kgfm

36.9 to 42.8 ft-lbs

64.7 to 75.5 Nm

6.6 to 7.7 kgfm

47.9 to 55.3 ft-lbs

Tightening

Torq u e

Delivery pipe

nut for HST

Oil cooler

pipe nut

Delivery pipe

nut for power

steering

< Propeller shaft cover and coupling >

1. Loosen the clamp and slide the propeller shaft

cover(1) to the rear.

2. Ta p o ut th e s pr in g p in (2) and then slide the

coupling(3) to the rear.

▷ Reassembling

Apply grease to the spline of the propeller shaft

and coupling.

*. PART NAME

1) Propeller shaft cover 2) Spring pin

3) Coupling

42

KUKJE MACHINERY CO., LTD.

4. CHECKING, DISASSEMBLEING AND SERVICING

< Universal joint and bearing holder >

1. Loosen the clamp and slide the universal joint

cover(1) to the rear.

2. Remove the bearing holder(4) with the propeller

shaft and universal joint.

3. Tap out the spring pins(3) and then slide the

universal joint(2) to the rear.

▷ Reassembling

9 Apply grease to the spline of the propeller shaft

and universal joint.

(4)

(3)

(2)

CLUTCH

(1)

9 When inserting the spring pins(3), face their

splits in the direction parallel to the universal

joint as shown in the figure.

9 Assemble the universal joint cover(1) so that the

water drain hole may become downward.

9 Arrange the position of the clamp at side as

shown in the figure.

< Hydraulic hose >

1. Remove the hydraulic hose(1) from the front

cylinder assy(2).

*. PART NAME

*. PART NAME

1) Universal joint cover

2) Universal joint

3) Spring pin

4) Bearing holder

1) Hydraulic hose 2) Front cylinder assy

43

KUKJE MACHINERY CO., LTD.

4. CHECKING, DISASSEMBLING AND SERVICING

CLUTCH

< Separating the engine from clutch housing >

1. Disconnect the connector for the engine stop

solenoid(4)

2. Disconnect the three point hitch delivery pipe(3),

suction house(2) and PST delivery pipe(1).

3. Disconnect the glow plug lead wire and thermo

sensor lead wire. And then disconnect the

connector for dynamo and starter motor lead

wire.

4. Disconnect the accelerator rod(5).

5. Place the jack under the center frame.

6. Hoist the engine by the chain at the engine

hook.

7. Remove the engine mounting screws and

separate the engine from the clutch housing.

▷ Reassembling

9 Apply liquid gasket to join face of the engine

(5)

(3)

(1)

*. PART NAME

1) Power steering delivery pipe

2) Suction hose

3) Delivery pipe

4) Engine stop solenoid

5) Accelerator rod

(2)

(4)

and clutch housing.

Tightening

Torq u e

Engine

mounting

screw

M8

M10

17.7 to 26.6 Nm

1.8 to 2.1 kgfm

13.0 to 15.2 ft-lbs

48.1 to 55.8 Nm

4.9 to 5.7 kgfm

35.5 to 41.2 ft-lbs

44

KUKJE MACHINERY CO., LTD.

4. CHECKING, DISASSEMBLEING AND SERVICING

<3> DISASSEMBLING AND ASSEMBLING

CLUTCH

< Separating the clutch assembly >

1. Remove the clutch assembly(2) from the

flywheel.

▷ Reassembling

9 Direct the shorter end of the clutch disc boss

toward the flywheel.

9 Apply molybdenum disulphide to the spline of

clutch disc boss.

9 Install the pressure plate, noting the position of

straight pins.

◈ Important

¾ Align the center of clutch disc and flywheel by

inserting the clutch center tool.

▶ NOTE

1) Do not allow grease and oil on the clutch disc

facing.

Tightening

Torq u e

Clutch mounting

screw

23.5 to 27.5 Nm

2.4 to 2.8 kgfm

17.4 to 20.2 ft-lbs

(1)

(3)

(2)

(4)

*. PART NAME

1) Clutch disc 2) Clutch assembly

< Clutch rod and clutch release fork >

1. Remove the clutch pedal rod.

2. Remove the external snap ring at the end of

clutch rod(1) and remove the clutch release

fork(2) and release bearing(3) with release hub.

▷ Reassembling

9 Set the clutch release fork and release hub with

set spring(4) in the correct direction.

*. PART NAME

1) Clutch rod

2) Clutch release fork

3) Release bearing 4) Set spring

3) Clutch cover 4) Clutch shaft

(2)

(1)

(3)

(4)

45

KUKJE MACHINERY CO., LTD.

4. CHECKING, DISASSEMBLEING AND SERVICING

<4>SERVICING

< Backlash between clutch disc and clutch shaft >

1. Mount the clutch disc onto the propeller shaft.

2. Hold the propeller shaft so that it does not

rotate.

3. Slightly move the disc and measure the

displacement around disc edge.

4. If the measurement exceeds the allowable limit,

replace clutch disc.

CLUTCH

Displacement around

disc edge

Allowable

limit

2.0 mm

0.079 in.

< Clutch disc wear >

1. Measure the depth from clutch disc surface to

the top of rivet at least 10 point with a depth

gauge.

2. If the depth is less than the allowable limit,

replace the disc.

3. If oil is sticking to the clutch disc, or disc surface

is carbonized, replace the clutch disc.

Disc surface to

rivet top (Depth)

Allowable

limit

0.3 mm

0.012 in.

< Clutch disc wear >

1. Place a straightedge on the pressure plate and

measure clearance with a feeler gauge at several

points.

2. If the clearance exceeds the allowable limit,

replace it.

3. When the pressure plate is worn around its

outside and its inside surface only is in contact

with the straightedge, replace even if the

clearance is within allowable limit.

Clearance between

pressure plate and

straightedge

Allowable limit

0.2 mm

0.008 in.

46

KUKJE MACHINERY CO., LTD.

4. CHECKING, DISASSEMBLEING AND SERVICING

< Checking pressure plate and diaphragm >

1. Check the pressure plate and if it is scratched

on its surface, correct with sandpaper or replace

it.

2. Check the diaphragm for crack and scratches. If

defects are found, replace it.

CLUTCH

< Checking clutch release bearing >

1. Check the clutch release bearing. If the surface

is worn excessively, or abnormal sounds occur,

replace it.

47

KUKJE MACHINERY CO., LTD.

FRONT AXLE

CONTENTS 3. (FRONT AXLE)

1. STRUCTURE ……………………………………………………………………………………………………………. 049

2. SERVICING SPECIFICATIONS …………………………………………………………………………………….. 050

3. TIGHTENING TORQUES ……………………………………………………………………………………………. 051

4. CHECKING, DISASSEMBLING AND SERVICING

<1> CHECKING AND ADJUSTING ……………………………………………………………………………. 052

<2> DISASSEMBLING AND ASSEMBLING

1) SEPARATING FRONT AXLE …………………………………………………………………………….. 053

2) DISASSEMBLING FRONT AXLE ………………………………………………………………………. 055

<3> SERVICING ……………………………………………………………………………………………………... 059

48

KUKJE MACHINERY CO., LTD.

1. STRUCTURE

FRONT AXLE

(20)

(21)

1) Axle 2) Axle Flange 3) Bevel Gear

4) Bevel Gear 5) Bevel Gear Case 6) Bevel Gear

7) Differential Yoke Shaft, LH 8) Front Axle Case 9) Differential Gear Assembly

10) Differential Pinion Gear 11) Spiral Bevel Gear 12) Collar

13) Front Axle Bracket, Front 14) Differential Yoke Shaft, RH 15) Front Axle Bracket, Rear

16) Coupling 17) Propeller Shaft 18) Spiral Bevel Pinion Shaft

19) Differential Side Gear 20) Bevel Gear Shaft 21) Bevel Gear Case

The front axle of the 4WD is constructed as shown above. Power is transmitted from the transmission case

through the propeller shaft(17) to the spiral bevel pinion shaft(18), then to the spiral bevel gear(11) and to

the differential side gear(19).

The power through the differential side gear is transmitted to the differential yoke shaft(7), (14), and to the

bevel gear shaft(20) through the bevel gears(4), (6) in the bevel gear case(5).

The revolution is greatly reduced by the bevel gears(21), (3), then the power is transmitted to the axle(1).

The differential system allows each wheel to rotate at a different speed to make turning easier.

49

KUKJE MACHINERY CO., LTD.

2. SERVICING SPECIFICATIONS

Item Factory Specification Allowable Limit

FRONT AXLE

Front wheel alignment Toe-in

Front axle Rocking force

Clearance

Differential case to differential

Differential case(I.D.)

pinion

Differential case(O.D.)

Spiral bevel pinion shaft Turning torque

Spiral bevel pinion shaft to spiral

Backlash

bevel gear

0.0 to 8.0 mm

0.0 to 0.315 in.

49.0 to 98.1 N

5.0 to 10.0 kgf

11.0 to 22.1 lbs

0.032 to 0.068 mm

0.00126 to 0.00268 in.

15.000 to 15.018 mm

0.59055 to 0.59126 in.

14.950 to 14.968 mm

0.5885 to 0.58929 in.

0.8 to 1.0 Nm

0.08 to 0.10 kgfm

0.59 to 0.73 ft-lbs

0.1 to 0.3 mm

0.004 to 0.012 in.

-

-

0.2 mm

0.0079 in.

-

-

-

-

10T Bevel gear to 16T Bevel gear Backlash

Clearance

Front axle case boss to bracket

bushing(Front)

Front axle case boss to bracket

bushing

Front axle case

boss(O.D.)

Bracket bushing(I.D.)

Clearance

Front axle case

boss(O.D.)

Bracket bushing(I.D.)

0.1 to 0.3 mm

0.004 to 0.012 in.

0.125 to 0.280 mm

0.0049 to 0.0110 in.

49.950 to 49.975 mm

1.9665 to 1.9675 in.

50.10 to 50.23 mm

1.9722 to 1.9774 in.

0.090 to 0.250 mm

0.0035 to 0.0098 in.

64.94 to 64.97 mm

2.5567 to 2.5579 in.

65.06 to 65.19 mm

2.5614 to 2.5665 in.

-

0.45 mm

0.018 in.

-

-

0.45 mm

0.018 in.

-

-

50

KUKJE MACHINERY CO., LTD.

FRONT AXLE

3. TIGHTENING TORQUES

Item N·m kgf·m ft-lbs

Drag link slotted nut 17.7 to 34.5 1.8 to 3.5 13.0 to 25.3

Front wheel bracket mounting screw 77.5 to 90.1 7.9 to 9.2 57.1 to 66.5

Front axle bracket mounting screw 124.0 to 147.0 12.6 to 15.0 91.0 to 108.0

Bevel gear case mounting screw 77.5 to 90.1 7.9 to 9.2 57.1 to 66.5

Knuckle arm mounting screw (M10) 48.0 to 56.0 4.9 to 5.7 35.5 to 41.2

Knuckle arm mounting screw (M12) 103.0 to 117.7 10.5 to 12.0 76.0 to 86.8

Axle flange mounting screw 48.1 to 55.9 4.9 to 5.7 35.5 to 41.2

51

KUKJE MACHINERY CO., LTD.

4. CHECKING, DISASSEMBLING AND SERVICING

<1> CHECKING AND ADJUSTING

FRONT AXLE

< Measuring toe-in >

1. Park the tractor on a flat surface.

2. Inflate the tires to the specified pressure.

3. Turn steering wheel so front wheels are in the

straight ahead position.

4. Lower the implement, lock the parking brake

and stop the engine.

5. Measure distance between tire beads at front of

tire hub height.

6. Measure distance between tire beads at rear of

tire hub height.

7. Front distance should be 0 to 8mm (0.0 to 0.315

in.) less than rear distance.

8. If the measurement is not within the factory

specifications correct the length(B-A) of tire rod

and correct toe-in to be in for factory spec.

A

B

(B-A) Length of tie rod

Toe-in(B-A) Factory spec.

0.0 to 8.0 mm

0.0 to 0.315 in.

< Front axle rocking force >

1. Jack up the front side of tractor.

2. Set a spring balance to the front axle flange.

3. Measure the front axle rocking force.

4. If the measurement is not within the factory

specifications, adjust with the adjusting screw(1).

5. Tighten the lock nut(2) firmly.

Front axle

rocking force

*. PART NAME

1) Adjusting screw 2) Lock nut

Factor y spec.

49.0 to 98.1 N

5.0 to 10.0 kgf

11.0 to 22.1 lbs

(2)

(1)

52

KUKJE MACHINERY CO., LTD.

4. CHECKING, DISASSEMBLING AND SERVICING

<2> DISASSEMBLING AND ASSEMBLING

1) Separating Front Axle

< Draining front axle case oil >

1. Place the oil pan underneath the front axle case.

2. Remove the both the right and left hand side

drain plugs(2) and filling plug(1) to drain the oil.

3. After draining, reinstall the drain plugs(2).

▷ Refilling

9 Fill with new oil up to the upper notch on the

dipstick.

FRONT AXLE

9 After fifteen minutes, check the oil level again,

add oil to proper level.

< Disconnecting propeller shaft >

1. Loosen the clamps and slide the propeller shaft

cover(1) to the rear.

2. Tap out the spring pin(2) and slide the

coupling(3) to the rear.

▷ Reassembling

9 Apply grease to the spline of the propeller shaft.

< Hydraulic hose >

1. Remove the hydraulic hose(1) from the front

cylinder assy(2).

*. PART NAME

1) Filling plug with dipstick 2) Drain plug

(3)

(2)

(1)

*. PART NAME

1) Propeller shaft cover 2) Spring pin

3) Coupling

*. PART NAME

1) Hydraulic hose 2) Front cylinder assy

53

KUKJE MACHINERY CO., LTD.

4. CHECKING, DISASSEMBLING AND SERVICING

< Front axle assembly >

1. Lift up the front side of tractor and place the

disassembling stand under the front axle frame.

2. Remove the front wheels.

3. Place the disassembling stand under the front

axle.

4. Remove the front axle brackets (Front and rear)

mounting screws.

5. Separate the front axle from the front axle frame.

▷ Reassembling

FRONT AXLE

9 After mounting the front axle assembly to the

front axle frame, be sure to adjust the front axle

rocking force.

Front wheel

mounting nut

Tightening

torque

Front axle bracket

mounting screw

77.5 to 90.1 Nm

7.9 to 9.2 kgfm

57.1 to 66.5 ft-lbs

124 to 147 Nm

12.6 to 15.0 kgfm

91 to 108 ft-lbs

54

KUKJE MACHINERY CO., LTD.

4. CHECKING, DISASSEMBLING AND SERVICING

2) Disassembling Front Axle

< Tie-rod and axle bracket >

1. Remove the slotted nut and remove the tie-

rod(3).

2. Remove the front axle brackets(1),(2).

▷ Reassembling

9 Apply grease to the thrust collars(4),(9), o-

FRONT AXLE

ring(6),(7) and oil seal(10).

9 After tightening the slotted nut to the specified

torque, install the cotter pin as shown in the

figure.

*. PART NAME

1) Assy holder(F) 2) Assy holder(R)

3) Tie-rod 4) Thrust collar

5) Bushing 6) O-ring

7) O-ring 8) Bush

9) Thrust collar 10) Oil seal

< Bevel gear case and front gear case >

1. Remove the bevel gear case mounting screws.

2. Remove the bevel gear case(1) and front gear

case(4) as a unit from the front axle case(3).

▷ Reassembling

9 Apply grease to the O-ring(2) and take care not

to damage it.

9 Do not interchange right and left bevel gear case

assemblies and right and left gear case

assemblies.

Tightening

torque

Bevel gear case

mounting screw

77.5 to 90.1 Nm

7.9 to 9.2 kgfm

57.1 to 66.5 ft-lbs

*. PART NAME

1) Bevel gear case 2) O-ring

3) Front axle case 4) Front gear case RH

55

KUKJE MACHINERY CO., LTD.

4. CHECKING, DISASSEMBLING AND SERVICING

< Front gear case >

1. Remove the knuckle arm(Left side only).

2. Remove the axle flange(2).

3. Remove the external snap ring(3).

4. Remove the bevel gear case(4) from front gear

case(1).

5. Remove the oil seal(5).

FRONT AXLE

6. Remove the ball bearing(6).

7. Remove the internal snap ring(7) and remove the

ball bearing(8).

8. Remove the bevel gear shaft(9) with ball bearing.

▷ Reassembling

9 Apply liquid gasket to joint face of the axle

flange(2) and front gear case(1) after removing

the water, oil and stuck liquid gasket.

9 Tighten the axle flange mounting screws and

nuts diagonally in several steps.

9 Install the oil seal(5) of bevel gear case, noting

its direction as shown in the figure.

(5)

(4)

(3)

Tightening

torque

Knuckle arm

M10

mounting

screw

M12

Axle flange mounting

screw

(6)

(1)

48.0 to 56.0 Nm

4.9 to 5.7 kgfm

35.5 to 41.2 ft-lbs

103.0 to 117.7 Nm

10.5 to 12.0 kgfm

76.0 to 86.8 ft-lbs

48.1 to 55.9 Nm

4.9 to 5.7 kgfm

35.5 to 41.2 ft-lbs

*. PART NAME

1) Front gear case 2) Cover gear case

3) External snap ring 4) Bevel gear case

5) Oil seal 6) Ball bearing

7) Internal snap ring 8) Ball bearing

9) Bevel gear shaft

56

KUKJE MACHINERY CO., LTD.

4. CHECKING, DISASSEMBLING AND SERVICING

< Bevel gear case and front gear case >

1. Remove the internal snap ring(1).

2. Take out the bevel gears(4),(5) with ball

FRONT AXLE

bearings(3),(6) and shims(2).

▷ Reassembling

9 Install the shims(2) to their original position.

▷ Reference

9 Thickness of adjusting shims:

0.8mm (0.031in.)

1.0mm (0.039in.)

1.2mm (0.47in.)

1.4mm (0.055in.)

< Axle >

1. Remove the bearing(1).

2. Take out the bevel gear(2).

3. Take out the collar(3).

4. Tap out the axle(4).

▷ Reassembling

9 Install the oil seal(7) of axle flange(6), noting its

(4)

*. PART NAME

1) Internal snap ring 2) Shim

3) Ball bearing 4) Bevel gear

5) Bevel gear 6) Ball bearing

7) Bevel gear case

(2)

(1)

(4)

(5)

(3)

(3)

(6)

direction as shown in the figure.

9 Install the shims(8),(9) to their original position.

▷ Reference

9 Thickness of adjusting shims(8) :

0.8mm (0.031in)

1.0mm (0.039in.)

1.2mm (0.47in.)

1.4mm (0.055in.)

9 Thickness of adjusting shims(9) :

0.8mm (0.031in)

1.0mm (0.039in.)

1.2mm (0.47in.)

(6)

(7)

(4)

(8)

*. PART NAME

1) Ball bearing 2) Bevel gear

3) Collar 4) Axle

5) Ball bearing 6) Axle flange

7) Oil seal 8) Shim

9) Shim

57

KUKJE MACHINERY CO., LTD.

(9)

4. CHECKING, DISASSEMBLING AND SERVICING

< Spiral bevel pinion shaft and differential gear

assembly >

1. Remove the internal snap ring(1).

2. Tap put the spiral bevel pinion shaft(2) by the

brass rod and hammer.

FRONT AXLE

3. Take out the differential gear assembly(3) with

differential yoke shafts, from right side of front

axle case(4).

4. Remove the lock nut(7).

5. Remove the taper roller bearings(6).

▷ Reassembling

9 Apply gear oil to the taper roller bearings(6) and

install them correctly, nothing their direction.

9 Replace the lock nut(7) with new ones.
9 After tightening the lock nut(7).
9 Install the adjusting collars(5) to their original

position.

▷ Reference

9 Thickness of adjusting collars :

3.4mm (0.134in.)

3.6mm (0.142in.)

(1)

(4)

(3)

(2)

(5)

3.8mm (0.150in.)

3.9mm (0.154in.)

4.0mm (0.157in.)

4.1mm (0.161in.)

4.2mm (0.165in.)

4.4mm (0.173in.)

4.5mm (0.177in.)

4.6mm (0.181in.)

*. PART NAME

1) Internal snap ring 2) Spiral bevel pinion shaft

3) Differential gear assembly

4) Front axle case 5) Adjusting collar

6) Taper roller bearing 7) Lock nut

8) Collar

58

KUKJE MACHINERY CO., LTD.

4. CHECKING, DISASSEMBLING AND SERVICING

FRONT AXLE

< Differential gear >

1. Tap out the spring pins(5) and remove the

external snap ring(2), and then pull out both of

the differential yoke shafts(1),(9).

2. Remove the differential side gears(4).

3. Remove the differential pinions(6).

4. Remove the spiral bevel gear(8), and

bearings(7),(11).

▶ NOTE

1) Arrange the parts to their original position.

▷ Reassembling

9 Apply molybdenum disulfide to the inner

circumferential surface of the differential side

gears(4) and differential pinions(6).

9 Be sure to install the spring pins(5) as shown in

the figure.

(8)

(1)

(11)

(2)

(10)

(3)

(4) (6)

(5)

(6)

(4)

(3)

(7)

(9)

(4)

(5)

*. PART NAME

1) Differential yoke shaft RH

2) External snap ring 3) Thrust collar

4) Differential side gear 5) Spring pin

6) Differential pinion 7) Ball bearing

<3> SERVICING

< Turning torque of spiral bevel pinion shaft >

1. Cramp the spiral bevel pinion shaft assembly to

the vise and tighten the lock nut.

2. Measure the turning torque of bevel pinion shaft.

3. If the turning torque is not within the factory

specifications, adjust with the lock nut.

Tightening

Factor y spec.

torque

▶ NOTE

0.8 to 1.0 Nm

0.08 to 0.10 kgfm

0.59 to 0.73 ft-lbs

8) Spiral bevel gear

9) Differential yoke shaft LH

10) Differential case 11) Ball bearing

1) After turning force adjustment, be sure tighten

the lock nut.

59

KUKJE MACHINERY CO., LTD.

4. CHECKING, DISASSEMBLING AND SERVICING

FRONT AXLE

< Clearance between differential case and

differential pinion >

1. Measure the differential pinion boss O.D. with an

outside micrometer.

2. Measure the differential case bore I.D. with a

cylinder gauge, calculate the clearance.

3. If the clearance exceeds the allowable limit,

replace faulty parts.

Clearance between

differential case and

differential pinion

Factor y spec.

Allowable

limit

0.032 to 0.068 mm

0.00126 to 0.00268 in.

0.2 mm

0.0079 in.

Differential case

Factor y spec.

bore I.D.

Differential

Factor y spec.

pinion O.D.

15.000 to 15.018 mm

0.59055 to 0.59126 in.

14.950 to 14.968 mm

0.58858 to 0.58929 in.

< Backlash between 10T bevel gear and 16T bevel

gear >

1. Stick a strip of fuse to three sports on the 16T

bevel gear(1) with grease.

2. Fix the front axle case, bevel gear case and front

gear case.

3. Turn the axle.

4. Remove the bevel gear case from front axle case

and measure the thickness of the fuses with an

outside micrometer.

5. If the backlash is not with in the factory

specifications, adjust with shim(3).

Backlash between

10T bevel gear and

16T bevel gear

Factor y spec.

0.1 to 0.3 mm

0.2 0.004 to 0.012 in.

9 Tooth contact : More than 35%

9 Thickness of adjusting shims (3) :

0.8mm(0.031in.), 1.0mm(0.039in.),

1.2mm(0.047in.), 1.4mm(0.055in.)

*. PART NAME

1) 16T Bevel gear 2) 10T Bevel gear

3) Shim

60

KUKJE MACHINERY CO., LTD.

4. CHECKING, DISASSEMBLING AND SERVICING

< Turning torque of spiral bevel pinion shaft >

1. Install the spiral bevel pinion shaft assembly only

to the front axle case.

2. Measure the turning torque of the spiral bevel

pinion shaft.

3. If the turning torque is not with in the factory

specifications, adjust with lock nut.

FRONT AXLE

Turning torque of

spiral bevel pinion

shaft

▶ NOTE

Factor y spec.

0.8 to 1.0 Nm

0.08 to 0.10 kgfm

0.59 to 0.74 ft-lbs

1) After turning torque adjustment, be sure tighten

the lock nut.

< Backlash between spiral bevel pinion shaft and

spiral bevel gear >

1. Set a dia gauge(lever type) with its finger on the

spline of spiral bevel pinion shaft.

2. Measure the backlash be moving the spiral bevel

pinion shaft by hand lightly.

3. If the backlash is not within the factory

specifications, select the adjusting collar(3).

4. Adjust the backlash properly by repeating the

*. PART NAME

1) Collar 2) Lock nut

above procedures.

Backlash between spiral

bevel pinion shaft and

spiral bevel gear

Factor y

spec.

0.1 to 0.3 mm

0.004 to 0.012 in.

▷ Reference

9 Above factory specification should be measured

on the tooth of spiral bevel pinion. When

measuring the backlash on the spline of its shaft,

factory specification will be 0.0571 to 0.1714mm

(0.00225 to 0.00675 in.)

9 Thickness of adjusting collars :

3.4mm(0.134in.), 3.6mm(0.142in.)

3.8mm(0.150in.), 3.9mm(0.154in.)

4.0mm(0.157in.), 4.1mm(0.161in.)

4.2mm(0.165in.), 4.4mm(0.173in.)

4.5mm(0.177in.), 4.6mm(0.181in.)

*. PART NAME

1) Spiral bevel gear 2) Spiral bevel pinion shaft

3) Adjusting collar

61

KUKJE MACHINERY CO., LTD.

4. CHECKING, DISASSEMBLING AND SERVICING

FRONT AXLE

< Clearance between front axle case bosses and

bracket bushing >

1. Measure the front axle case bosses O.D. with an

outside micrometer.

2. Measure the bracket bushing I.D. with a cylinder

gauge, and calculate the clearance.

3. If the clearance exceeds the allowable limit

replace the bracket bushing.

4. If the clearance still exceeds the allowable limit

replace the front axle case.

Clearance between

front axle case

boss(front) and

bracket bushing(front)

Factor y

spec.

Allowable

limit

0.125 to 0.280 mm

0.0049 to 0.0110 in.

0.45 mm

0.018 in.

Front axle case

Factor y

49.950 to 49.975 mm

boss(front) O.D.

Bracket

bushing(front) I.D.

spec.

Factor y

spec.

1.9665 to 1.9675 in.

50.10 to 50.23 mm

1.9722 to 1.9774 in.

Clearance between

front axle case

boss(rear) and

bracket bushing(rear)

Factor y

spec.

Allowable

limit

0.090 to 0.250 mm

0.0035 to 0.0098 in.

0.45 mm

0.018 in.

Front axle case

boss(rear) O.D.

Bracket

bushing(rear) I.D.

▶ Press-fitting bushing

Factor y

spec.

Factor y

spec.

64.94 to 64.97 mm

2.5567 to 2.5579 in.

65.06 to 65.19 mm

2.5614 to 2.5665 in.

z When replacing the bushing, press-fit it until

bushing contact to inside to front axle bracket.

62

KUKJE MACHINERY CO., LTD.

TRANSMISSION

CONTENTS 4. (TRANSMISSION)

1. POWER TRAIN FOR TRAVELING SYSTEM

<1> MAIN GEAR SHAFT SECTION (MANUAL TRANSMISSION TYPE) …………………………... 064

<2> HI-LO GEAR SHIFT SECTION …………………………………………………………………………….. 065

<3> FRONT WHEEL DRIVE SECTION ………………………………………………………………………… 065

2. POWER TRAIN FOR PTO GEAR

<1> REAR PTO SHIFT SECTION

1) MANUAL TRANSMISSION TYPE ………………………………………………………………………. 066

2) HST TYPE ……………………………………………………………………………………………………… 067

3. SERVICING SPECIFICATIONS …………………………………………………………………………………….. 068

4. TIGHTENING TORQUES ……………………………………………………………………………………………. 070

5. CHECKING, DISASSEMBLING AND SERVICING

<1> CHECKING AND ADJUSTING ……………………………………………………………………………. 072

<2> PREPARATION

1) SEPARATING HOUSING ………………………………………………………………………………….. 076

2) SEPARATING CENTER FRAME AND TRANSMISSION CASE …………………………………. 082

3) SEPARATING HST (HST TYPE) …………………………………………………………………………. 086

<3> DISASSEMBLING AND ASSEMBLING

1) DISASSEMBLING CLUTCH HOUSING ………………………………………………………………... 087

2) DISASSEMBLING HST (HST TYPE) ……………………………………………………………………. 088

3) DISASSEMBLING TRANSMISSION CASE (HST TYPE) ………………………………………….. 089

4) DISASSEMBLING TRANSMISSION CASE (MANUAL TRANSMISSION TYPE) …………... 092

5) DISASSEMBLING DIFFERENTIAL GEAR CASE …………………………………………………….. 096

<4> SERVICING

1) CLUTCH HOUSING …………………………………………………………………………………………. 098

2) TRANSMISSION CASE …………………………………………………………………………………….. 099

3) DIFFERENTIAL GEAR ………………………………………………………………………………………. 101

63

KUKJE MACHINERY CO., LTD.

1. POWER TRAIN FOR TRAVELING SYSTEM

<1> MAIN GEAR SHAFT SECTION (MANUAL TRANSMISSION TYPE)

TRANSMISSION

1) Gear shaft

2) Gear reverse

3) Gear

4) Gear shaft

A : Front cover

B : Transmission case

1) Ball joint shaft

2) Gear shaft

3) Gear shaft

4) Gear

5) Gear shaft

64

KUKJE MACHINERY CO., LTD.

1. POWER TRAIN FOR TRAVELING SYSTEM

<2> HI-LO GEAR SHIFT SECTION

TRANSMISSION

A

A

1

1

B

B

2

2

1) Gear shaft

2) 19T gear

3) 13T, 32T gear

4) Counter shaft

5) Front cover

4

4

A : Front cover

L

H

H

L

B : Transmission case

C : Diff. gear case

3

3

C

C

<3> FRONT WHEEL DRIVE SECTION

1) Counter Shaft

2) 4wd gear

3) 4wd gear

4) Front wheel drive shaft

65

KUKJE MACHINERY CO., LTD.

2. POWER TRAIN FOR PTO GEAR

<1> REAR PTO SHIFT SECTION

1) Manual Transmission Type

TRANSMISSION

1) Gear shaft 2) Gear 3) Cam, one way clutch

4) Gear shaft 5) Gear A : Rear cover

① : Low (540 rpm) ② : High (960 / 2500rpm)

66

KUKJE MACHINERY CO., LTD.

2. POWER TRAIN FOR PTO GEAR

2) HST Type

TRANSMISSION

1) HST pump shaft 2) Gear shaft 3) Shaft

4) Coupling 5) Gear shaft 6) Shaft PTO

① : Low (540 rpm) ② : High (960 / 2500 rpm)

67

KUKJE MACHINERY CO., LTD.

3. SERVICING SPECIFICATIONS

Item Factory Specification Allowable Limit

TRANSMISSION

Check and high pressure relief

valve

Charge relief valve Setting pressure

Shift fork to shift gear groove Clearance

16T-20T Gear to front wheel drive

shaft

Setting pressure

(Relief valve)

Clearance

Front wheel drive shaft

(O.D.)

16T-20T Gear (I.D.)

Needle (O.D.)

30.9 to 31.9 MPa

315.0 to 325.0 kgf/㎠

4480 to 4622 psi

392.0 to 490.0 MPa

4.0 to 5.0 kgf/㎠

56.9 to 71.1 psi

0.10 to 0.35 mm

0.004 to 0.014 in.

0.027 to 0.067 mm

0.0011 to 0.0025 in.

21.967 to 21.980 mm

0.8648 to 0.8654 in.

28.007 to 28.021 mm

1.1024 to 1.1032 in.

2.996 to 3.000 mm

0.1179 to 0.1181 in.

-

-

0.50 mm

0.020 in.

0.10 mm

0.0039 in.

-

-

-

Clearance

11T Gear, 0ne-way clutch cam

and Mid-PTO shaft

Spiral bevel pinion Side clearance

Spiral bevel pinion to spiral bevel

gear

Mid-PTO shaft (O.D.)

11T Gear and one-way

clutch (I.D.)

Needle (O.D.)

Backlash

Adjusting shim

(Thickness)

0.020 to 0.026 mm

0.0008 to 0.0010 in.

19.989 to 20.000 mm

0.7869 to 0.7874 in.

24.007 to 24.020 mm

0.9452 to 0.9457 in.

1.997 to 2.000 mm

0.0786 to 0.0787 in.

Less than 0.15 mm

Less than 0.0059 in.

0.10 to 0.30 mm

0.0039 to 0.012 in.

0.2 mm, 0.008 in. -

0.5 mm, 0.020 in. -

0.10 mm

0.0039 in.

-

-

-

-

0.4 mm

0.016 in.

68

KUKJE MACHINERY CO., LTD.

3. SERVICING SPECIFICATIONS

Item Factory Specification Allowable Limit

TRANSMISSION

Differential pinion to differential

side gear

Differential case to differential

side gear

Backlash

Adjusting shim

(Thickness)

Clearance

Differential case (I.D.)

Spiral bevel gear (I.D.)

Differential side gear

(O.D.)

Clearance

0.1 to 0.3 mm

0.004 to 0.012 in.

0.8 mm, 0.0315 in. -

1.0 mm, 0.0394 in. -

1.2 mm, 0.0472 in. -

0.025 to 0.066 mm

0.0016 to 0.0029 in.

32.000 to 32.025 mm

1.2598 to 1.2608 in.

32.000 to 32.025 mm

1.2598 to 1.2608 in.

31.959 to 31.975 mm

1.2598 to 1.2608 in.

0.016 to 0.045 mm

0.0006 to 0.0018 in.

0.4 mm

0.016 in.

0.30 mm

0.0118 in.

0.30 mm

0.0118 in.

-

-

-

Differential pinion shaft to

differential pinion

Differential pinion

shaft (O.D.)

Differential pinion (I.D.)

15.982 to 16.0 mm

-

0.6292 to 0.6299 in.

16.000 to 16.018 mm

-

0.6299 to 0.6306 in.

69

KUKJE MACHINERY CO., LTD.

TRANSMISSION

4. TIGHTENING TORQUES

Tightening torque of screws, bolts and nuts on the table below are especially specified.

Item N·m kgf·m ft-lbs

Rear wheel bolt and nut 108.0 to 125.0 11.0 to 12.7 79.0 to 92.2

3-Point hitch shaft setting screw 14.7 to 19.6 1.5 to 2.0 10.8 to 14.5

3-Point hitch shaft setting screw lock nut 43.0 to 47.0 4.4 to 4.8 31.7 to 35.4

Drawbar frame mounting screw 77.5 to 90.2 7.9 to 9.2 57.1 to 66.5

ROPS frame and frame top connecting bolt and nut 274.6 to 318.7 28.0 to 32.5 202.5 to 235.1

ROPS connecting plate mounting screw 123.6 to 147.0 12.6 to 15.0 91.1 to 108.5

ROPS frame mounting screw 77.5 to 90.1 7.9 to 9.2 57.2 to 66.5

Steering wheel mounting nut 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2

Delivery pipe nut for HST 34.3 to 39.2 3.5 to 4.0 25.3 to 28.9

Oil cooler pipe nut 50.0 to 57.9 5.1 to 5.9 36.9 to 42.8

Delivery pipe nut for power steering 64.7 to 75.5 6.6 to 7.7 47.9 to 55.3

Power steering assembly mounting screw 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2

Clutch housing and engines mounting screw (M8) 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3

Clutch housing and engines mounting screw (M10) 48.1 to 55.8 4.9 to 5.7 35.5 to 41.2

Clutch housing and center frame mounting screw and

nut

Clutch housing rear cover mounting screw 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3

Speed control rod screw 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3

3-Point hitch delivery pipe joint bolt 34.3 to 39.2 3.5 to 4.0 25.1 to 28.7

HST (Transmission case) and center frame mounting

screw and nut

Spring holder mounting screw 39.2 to 44.1 4.0 to 4.5 28.9 to 32.5

Connecting plate mounting screw 39.2 to 44.1 4.0 to 4.5 28.9 to 32.5

77.5 to 90.2 7.9 to 9.2 57.1 to 66.5

77.5 to 90.2 7.9 to 9.4 57.1 to 66.5

Top link bracket mounting screw 77.5 to 90.1 7.9 to 9.2 57.2 to 66.5

Hydraulic cylinder mounting screw and nut 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2

70

KUKJE MACHINERY CO., LTD.

TRANSMISSION

4. TIGHTENING TORQUES

Item N·m kgf·m ft-lbs

Rear axle case mounting screw 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2

Transmission case mounting screw and nut 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2

Mid-PTO case mounting screw 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2

Mid-PTO rear cover mounting screw 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3

Front case mounting screw 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2

Main shift cover mounting screw 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3

Neutral adjuster lock screw 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3

Neutral hold mounting screw 23.6 to 27.4 2.4 to 2.8 17.4 to 20.2

Change pump mounting screw 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3

Center section mounting hex. socket screw 48.1 to 55.8 4.9 to 5.7 35.5 to 41.2

Check and high pressure relief valve plug 118.0 to 147.0 12.0 to 15.0 86.8 to 108.5

Neutral valve cap screw 58.8 to 68.6 6.0 to 7.0 43.4 to 50.6

Bearing holder mounting screw 50.0 to 55.0 5.1 to 5.6 36.9 to 40.1

Rear PTO cover mounting screw 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2

Differential gears bearing holder mounting screw 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3

Spiral bevel gear UBS screw 29.4 to 34.3 3.0 to 3.5 21.7 to 25.3

71

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

<1> CHECKING AND ADJUSTING

TRANSMISSION

< Adjusting maximum speed (HST Type) >

1. Depress the speed control pedal(1) all the way

and measure the tractor speed.

2. If the measurement is not within factory

specification, loosen the lock nut(3) and adjust

with bolt(2).

15.5 to 17.0 km/h

9.6 to 10.6 mph

9.3 to 10.0 km/h

5.8 to 6.2 mph

Maximum speed

with AG tire

(at 2600 rpm)

2100h

2400h

2800h

Forward

Reverse

▷ Reference

9 Length “A” : 15 to 17 mm (0.59 to 0.67 in.)

< Adjusting neutral (HST Type) >

1. Disengage the front wheel drive lever. (Drive only rear

wheels.)

A

(2) (3)

*. PART NAME

1) Speed control pedal (HST pedal)

2) Adjusting bolt

3) Lock nut

(1)

2. Lift the rear of the tractor so that the rear wheels are

off the ground and run the engine at low idling and

drive only rear wheels.

3. Slightly loosen the neutral adjuster setting screw(1).

4. Rotate the neutral adjuster(2) clockwise so the rear

wheels turn reverse.

5. Then rotate it counterclockwise until wheels stop

completely.

6. Put a mark on the center frame aligning the

groove(3) on neutral adjuster.

7. Rotate the neutral adjuster(2) counterclockwise so the

rear wheels turn forward.

8. Then rotate it clockwise until wheels stop completely.

9. Put a mark on the center frame aligning the grove(3)

on neutral adjuster.

10. Hold the neutral adjuster so its groove is at the

middle of the marks and tighten the setting screw(1).

*. PART NAME

1) Neutral adjuster setting screw

2) Neutral adjuster

3) Groove

72

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

TRANSMISSION

▶ NOTE

1) When the wheels tend to turn forward, rotate

neutral adjuster clockwise.

2) When the wheels tend to turn reverse, rotate

neutral adjuster counterclockwise.

< Charge relief pressure and high relief pressure >

When checking, park the tractor on flat ground

and fully engage the parking brake.

1. Remove the lowering speed adjusting knob and

dipstick, then remove the seat under cover.

2. Assemble the HST adaptor (Tool for pressure

test) and threaded joint with O-ring and back

up ring.

◎ Charge relief pressure

1. Remove the neutral valve assembly one side

(forward(1) or reverse(2)) then install the

assembled HST adaptor (Tool for pressure test)

(2)

(1)

*. PART NAME

1) Neutral valve (Forward)

2) Neutral valve (Reverse)

to its neutral valve port.

2. Install the cable and low pressure gauge to HST

adaptor (Tool for pressure test).

3. Change the range gear shift lever to Low

position.

4. Start the engine and run it at the maximum

speed.

5. Read the low pressure gauge to measure the

charge relief pressure.

6. If the measurement is not the same as the

factory specification, check the charge relief

valve and related hydraulic components.

73

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

TRANSMISSION

◎ High relief pressure

1. Remove the neutral valve assembly forward(1),

then install the assembled HST adaptor (Tool for

pressure test) to its neutral valve port.

2. Install the cable and high pressure gauge to HST

adaptor (Tool for pressure test).

3. Change the range gear shift lever to High

position.

4. Start the engine and run it at the maximum speed.

5. Depress the speed control pedal forward and read

the high pressure gauge to measure the forward

high relief pressure.

6. Stop the engine. Change the installation of HST

adaptor (Tool for pressure test) and pressure

gauge from forward neutral valve port to reverse.

7. Start engine and repeat above method(4 and 5) to

measure the reverse high relief pressure.

8. If the measurement is not same as factory

specification, check the high pressure relief valve

and related hydraulic components.

Charge relief

Factor y spec.

(Oil temperature

pressure

at 50℃, 122℉)

Factor y spec.

High relief

(Oil temperature

pressure

at 50℃, 122℉)

392.0 to 490.0 kPa

4.0 to 5.0 kgf/㎠

56.9 to 71.1 psi

30.9 to 31.9 kPa

315.0 to 325 kgf/㎠

4480 to 4622 psi

Tightening

Torq u e

Neural valve

cap screw

58.8 to 68.6 kPa

6.0 to 7.0 kgf/㎠

43.4 to 50.6 psi

◈ Important

¾ Measure quickly so that the high pressure

relief valve is not be in operation more than

10 seconds.

▶ NOTE

1. High pressure gauge is 40 ㎫ (400 kgf/㎠,

5800 psi) full scale.

2. Low pressure gauge is 2 ㎫ (20 kgf/㎠, 290

psi) full scale.

3. When reinstalling the neutral valve, take care

not to damage the O-ring.

74

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

TRANSMISSION

< Neutral valve actuation test >

To avoid personal injury :

Do not operate if tractor moves on level ground

with foot off speed control pedal.

When checking, park the tractor on flat ground,

apply the parking brake.

1. Disengage the front wheel drive lever.

2. Disconnect the brake rod or one side.

3. Lift the rear of tractor, one side.

4. Set the engine speed to 1500 rpm.

5. Shift the range gear shift lever to High position.

(2)

(1)

*. PART NAME

1) Neutral valve (Forward)

2) Neutral valve (Reverse)

6. Move the HST pedal from the forward to the

neutral position make sure that the tire comes to

a stop. Check the same way for the movement

from rearward to the neutral potion. In this time,

make sure that the neutral range of HST.

7. If the tire fail to stop or neutral range is, check

the each neutral valve.

75

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

<2> PREPARATION

1) Separating Housing

< Draining transmission fluid >

1. Place an oil pan underneath the transmission

case, and remove the drain plugs(1).

2. Drain the transmission fluid.

3. Reinstall the drain plug.

▷ Refilling

9 Fill new oil from filling port after removing the

filling plug(2) up to the upper notch on the

dipstick(3).

9 After running the engine for few minutes, stop it

and check the oil level again, if low, add oil to

TRANSMISSION

(1)

proper level.

◈ Important

9 Use only multi-grade transmission oil. Use of

other oils may damage the transmission or

hydraulic system.

9 Never work the tractor immediately after

changing the transmission oil. Keep the engine

at medium speed for a few minutes to prevent

damage to the transmission.

9 Do not mix different brands oil together.

3.0 L

0.79 U.S.gals

0.66 lmp.gals

13.0 L

3.43 U.S.gals

2.86 lmp.gals

15.0 L

3.96 U.S.gals

3.3 lmp.gals

Transmission

Fluid capacity

2100

2400

2800

HST

Front

Case

Rear

case

Rear

case

(2)

(1)

(1)

(3)

*. PART NAME

1) Drain plug 2) Filling plug

3) Dipstick

76

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

< Hood, side cover and battery cord >

1. Open the hood(1) and remove.

2. Disconnect the battery grounding cable(2).

3. Disconnect the head light connectors and

remove the hood(1).

▶ NOTE

1) When disconnecting the battery cables,

disconnect the grounding cable(-) first.

TRANSMISSION

(1)

(2)

2) When connecting, positive cable(+) first.

< Steering wheel >

1. Remove the steering wheel cap.

2. Remove the steering wheel mounting nut and

remove the steering wheel.

▷ Reassembling

Tightening torque

Steering wheel

mounting nut

48.1 to 55.9 Nm

4.9 to 5.7 kgfm

35.4 to 41.2 ft-lbs

< Meter panel and panel under cover >

1. Tap out the spring pin and remove the hand

accelerator lever(7).

*. PART NAME

1) Hood

2) Battery grounding cord

(1)

(2)

(6)

(4)

(9)

(8)

(5)

(7)

(4)

2. Remove the panel under cover(6).

3. Open the meter panel(1) and disconnect the

meter panel connector(2).

4. Disconnect the combination switch connector(3),

main switch connector(4) and hazard switch

connector(5).

*. PART NAME

1) Meter panel 2) Meter panel connector

3) Combination switch connector

4) Main switch connector 5) Hazard switch connector

6) Panel under cover 7) Hand accelerator lever

8) Light switch 9) Emergency stop S/W

77

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

TRANSMISSION

< Fuel tank >

1. Disconnect the fuel hose(1) at the fuel filter side,

then drain fuel completely.

2. Disconnect the hazard unit, controller, starter

relay and regulator connectors and remove the

cable wire for fuel gauge.

3. Disconnect the overflow house(5) of fuel line.

4. Loosen the steering bracket(7).

5. Remove the tank frame(2) with fuel tank(3).

6. Remove the battery.

7. Disconnect the hydraulic hose(6) and remove

the battery stay with oil cooler(4).

▶ NOTE

1. For fastening hydraulic pipe nut, use two

wrenches. Hold the fitting with a wrench, turn

the pipe nut with another wrench to avoid

damage at fitting installed part.

(2)

(7)

(3) (5)

(6)

(1)

*. PART NAME

1) Fuel hose 2) Fuel tank frame

3) Fuel tank 4) Oil cooler

5) Overflow hose 6) Hydraulic hose

7) Steering bracket

(4)

Delivery pipe nut for

HST

Tightening

Oil cooler pipe nut

torque

Delivery pipe nut for

power steering

34.3 to 39.2 Nm

3.5 to 4.0 kgfm

25.3 to 28.9 ft-lbs

50.0 to 57.9 Nm

5.1 to 5.9 kgfm

36.9 to 42.8 ft-lbs

64.7 to 75.5 Nm

6.6 to 7.7 kgfm

47.9 to 55.3 ft-lbs

< Propeller shaft cover and coupling >

1. Loosen the clamp and slide the propeller shaft

cover(1) to the rear.

2. Tap out the spring pin(2) and then slide the

coupling(3) to the rear.

▷ Reassembling

9 Apply grease to the spline of the propeller shaft

and coupling.

(3)

(2)

(1)

*. PART NAME

1) Propeller shaft cover

2) Spring pin 3) Coupling

78

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

< Universal joint and bearing holder >

1. Loosen the clamp and slide the universal joint

cover(1) to the rear.

2. Remove the bearing holder(4) with propeller

shaft and universal joint.

3. Tap out the spring pins(2) and then slide the

universal joint(3) to the rear.

▷ Reassembling

9 Apply grease to the spline of the propeller shaft

and universal joint.

9 When inserting the spring pins(2), face their

splits in the direction parallel to the universal

joint as shown in the figure.

(4)

(2)

TRANSMISSION

(3) (1)

9 Assemble the universal joint cover(1) so that the

water drain hole may become downward.

9 Arrange the position of the clamp at side as

shown in figure.

< Hydraulic hose >

1. Remove the hydraulic hose(1) from the front

cylinder assy(2).

*. PART NAME

1) Hydraulic hose 2) Front cylinder assy

*. PART NAME

1) Universal joint cover 2) Spring pin

3) Universal joint 4) Bearing holder

79

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

TRANSMISSION

< Steering assembly >

1. Remove the seat under cover, rubber mat and

side step LH.

2. Disconnect the accelerator rod(4).

3. Disconnect the speed set rod(5) and parking

brake rod(2).

4. Remove the power steering delivery pipe(3) and

disconnect the power steering return pipe(6).

5. Remove the power steering assembly from the

center frame.

▶ NOTE

1) For fastening hydraulic pipe nut, use two

wrenches. Hold the fitting with a wrench, turn

the pipe nut with another wrench to avoid

damage at fitting installed part.

Delivery pipe nut

for power steering

Tightening

64.7 to 75.5 Nm

6.6 to 7.7 kgfm

47.9 to 55.3 ft-lbs

(5) (4)

(3) (2)

(1)

*. PART NAME

1) Power steering delivery pipe

2) Parking brake rod

3) Accelerator rod

4) Speed set rod

5) Power steering return pipe

torque

Power steering

assembly mounting

screw

77.5 to 90.1 Nm

7.9 to 9.2 kgfm

57.2 to 66.5 ft-lbs

80

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

TRANSMISSION

< Separating the engine from clutch housing >

1. Disconnect the three point hitch delivery pipe

and suction hose.

2. Disconnect the glow plug lead wire and heat

sensor lead for alternator connector and starter

motor cable.

3. Place the jack under the center frame.

4. Hoist the engine by the chain at the engine

hook.

5. Remove the engine mounting screws and

separate the engine from the clutch housing.

▷ Reassembling

9 Apply liquid gasket to joint face of the engine

and clutch housing.

23.5 to 27.5 Nm

M8

Tightening

Engine

mounting

torque

screw

2.4 to 2.8 kgfm

17.4 to 20.3 ft-lbs

48.1 to 55.8 Nm

M10

4.9 to 5.7 kgfm

35.5 to 41.2 ft-lbs

< Separating clutch housing >

1. Remove the clutch pedal rod(1).

2. Loosen the clamp and disconnect connecting

hose(2).

3. Separate the clutch housing from center frame.

4. Remove the hydraulic pipe(3).

▷ Reassembling

9 Apply grease to the spline of propeller shaft and

ball joint.

Tightening

Clutch housing

mounting screw

torque

and nut

*. PART NAME

1) Clutch pedal rod 2) Connecting hose

3) Hydraulic pipe

77.5 to 90.2 Nm

7.9 to 9.2 kgfm

57.1 to 66.5 ft-lbs

(3)

(1)

(2)

(2)

81

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

2) Separating Center Frame and Transmission Case

< Draining transmission fluid >

TRANSMISSION

-. Reference the page 76.

< Battery connector >

1. Open the hood(1).

2. Disconnect the battery ground cord(2).

3. Disconnect the head light connectors and

remove the hood(1).

▶ NOTE

1) When disconnecting the battery cords,

disconnect the grounding cord first.

When connecting, the positive cord first.

< Roll-Over protective structures (ROPS) and 3

Point hitch >

1. Disconnect the wire harness and remove the tail

(1)

(2)

*. PART NAME

1) Hood 2) Battery cord

(4)

(5)

(6)

lamps(6).

2. Remove the hazard lamps(5).

3. Remove the ROPS frame top mounting bolts and

nuts and remove the ROPS frame top(4).

4. Remove the lower link(1) and the collar from the

3-point hitch shaft(2).

5. Remove the ROPS frames(3) and 3-point hitch

shaft(2).

Connecting plate

mounting screw

ROPS frame and frame

Tightening

top mounting

torque

bolt and nut

ROPS frame mounting

screw

123.6 to 147.0 Nm

12.6 to 15.0 kgfm

91.1 to 108.5 ft-lbs

274.6 to 318.7 Nm

28.0 to 32.5 kgfm

202.5 to 235.1 ft-lbs

77.5 to 90.1 Nm

7.9 to 9.2 kgfm

57.2 to 66.5 ft-lbs

(3)

(7)

(2)

(1)

*. PART NAME

1) Lower link 2) 3-Point hitch shaft

3) ROPS frame 4) ROPS frame, Top

5) Direction lamp 6) Tail lamp

7) PTO shaft cover

23.5 to 27.5 Nm

2.4 to 2.8 kgfm

17.4 to 20.3 ft-lbs

43.0 to 47.0 Nm

4.4 to 4.8 kgfm

31.7 to 35.4 ft-lbs

torque

3-Point hitch shaft

setting screw

3-Point hitch shaft

setting screw lock nut

Tightening

82

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

< Seat, panel, step, rear wheel and others >

1. Remove the seat(2), seat under cover and rubber

mat(3).

2. Remove the tool box(7).

3. Disconnect the 2P connectors from the seat

switches, and then remove the seat stay(1).

4. Remove the steering wheel(4), panel(5) and panel

under cover(6). (Reference the page 77.)

5. Remove the fuel tank frame set screws and fuel

tank stay.

6. Disconnect the springs and rods from steps, and

then, remove the steps while lifting the fuel tank

frame.

TRANSMISSION

7. Place the jack under the transmission case and

remove the rear wheels, and then support the

both rear axles by stands.

◈ Important

¾ When refitting or adjusting a wheel, tighten the

bolts to the following torques then recheck after

driving the tractor 200m (200yards) and there

after daily check service.

▷ Reassembling

Tightening

torque

Rear wheel

bolt and nut

108.0 to 125.0 Nm

11.0 to 12.7 kgfm

79.0 to 92.2 ft-lbs

< Shaft levers and fenders >

1. Remove the all lever grips.

2. Remove the lever guide LH(3) and remove the

fender LH.

3. Remove the main shift lever(2) and remove the

*. PART NAME

1) Seat stay 2) Seat

3) Rubber mat 4) Steering wheel

5) Meter panel 6) Panel under cover

7) Tool box 8) Bolt

9) Nut

(1) (2)

*. PART NAME

1) Hydraulic control

lever

2) Main shift lever

3) Lever guide LH

lever guide RH (Manual transmission type only).

4. Remove the hydraulic control lever(1) and

remove the fender RH.

83

(3)

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

TRANSMISSION

< Propeller shaft cover and coupling >

-. Reference the page 78.

< Universal joint and bearing holder >

-. Reference the page 79.

< HST Pedal >

1. Remove the brake rod RH(1).

2. Remove the damper(4) and speed control rod

assembly(3).

3. Remove the HST pedal(5).

4. Remove the speed control rod screw(2) from the

neutral holder.

▷ Reassembling

9 Apply liquid lock to the speed control rod

screw(2).

Tightening

torque

Speed control

rod screw

39.2 to 44.1 Nm

4.0 to 4.5 kgfm

28.9 to 32.5 ft-lbs

*. PART NAME

1) Brake rod RH

2) Speed control rod screw

3) Speed control rod assembly

4) Damper

5) HST pedal

84

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

< Delivery pipes and HST safety switch holder >

TRANSMISSION

1. Remove the pipe clamps and delivery pipe joint

bolt(1).

2. Disconnect the differential lock rod.

3. Remove the accelerator rod and pedal, and then

remove the delivery pipe.

4. Remove the HST neutral bracket holder with

neutral rod(2).

5. Disconnect the HST delivery pipe(4)

◈ Important

¾ When HST safety switch(5) has been removed, be

sure to adjust the length A.

¾ Length A : 8 to 9 mm (0.31 to 0.35 in.)

Joint bolt (3P

delivery pipe)

Tightening

torque

HST delivery

pipe nut

23.5 to 27.5 Nm

2.4 to 2.8 kgfm

17.4 to 20.3 ft-lbs

34.3 to 39.2 Nm

3.5 to 4.0 kgfm

25.1 to 28.7 ft-lbs

(1)

(5)

*. PART NAME

1) Pipe joint bolt

(3)

(7)

(6)

(2)

(4)

< Hydraulic pipes and others >

1. Remove the brake rod LH(1).

2. Remove the connecting pipe(2).

3. Remove the HST suction pipe(3). (HST type only)

4. Remove the hydraulic oil filter assembly(4) and

pipe(5),(6). (HST type only)

*. PART NAME

1) Brake rod LH 2) Connecting pipe

3) HST suction pipe 4) Hydraulic oil filter assembly

5) Return pipe

(Oil cooler to filter)

6) Pipe

(Filter to HST)

2) HST safety switch with neutral rod

3) 3P delivery pipe 4) HST delivery pipe

5) HST safety switch 6) Neutral rod

7) Neutral bracket

(2) (3)

(1)

(5) (6)

(4)

85

KUKJE MACHINERY CO., LTD.

4. CHECKING, DISASSEMBLING AND SERVICING

TRANSMISSION

< Separating transmission assembly >

1. Disconnect the suction pipe at the transmission

case side.

2. Separate the transmission case from center

frame.

▷ Reassembling

Tightening

torque

HST and center

frame mounting bolt

77.5 to 90.2 Nm

7.9 to 9.4 kgfm

57.1 to 66.5 ft-lbs

3) Separating HST (HST Type)

< Separating transmission case and hydrostatic

transmission(HST) >

1. Tap out the spring pins and remove the universal

joint(4) with front wheel drive propeller shaft(5).

2. Remove the HST delivery pipe(3).

3. Remove the neutral spring(2) and remove the

(A)

(A) HST Type

(B) Manual transmission type

(1)

(B)

(2)

(3)

(4)

(5)

spring holder(1).

4. Separate the HST from transmission case.

▷ Reassembling

9 Apply gasket to joint face of the HST and

transmission case.

9 When inserting the spring pins, face their splits

in the direction at a right angle to the universal

joint and propeller shaft as shown in the figure.

9 Apply grease to the spline of the HST pump

shaft, front wheel propeller shaft, universal joint

and ball coupling.

▶ NOTE

1) When reassembling the spring holder, spring

hook(6) must be inside as shown in the figure.

Tightening

torque

Spring holder

mounting screw

39.2 to 44.1 Nm

4.0 to 4.5 kgfm

28.9 to 32.5 ft-lbs

(A)

(6)

(1)

*. PART NAME

1) Spring holder 2) Neutral spring

3) HST Delivery pipe 4) Universal joint

5) Front wheel driver propeller

6) Spring hook

A) HST Case side

86

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

<3> DISASSEMBLING AND ASSEMBLING

1) Disassembling Clutch Housing

TRANSMISSION

< Clutch rod and clutch release fork >

1. Remove the external snap ring at the end of

clutch rod.

2. Draw out the clutch rod(1) and remove the

clutch release fork(2).

3. Take out the release hub with release bearing(3).

▷ Reassembling

9 Set the clutch release fork and release hub with

set spring(4) in the correct direction.

< Clutch housing rear cover >

1. Remove the clutch housing rear cover(1).

▷ Reassembling

9 Apply the gasket to the joint face of clutch

housing and rear cover(1).

< Clutch shaft and others >

1. Pull out the clutch shaft assembly(1).

2. Pull out the 2

nd

gear shaft, front assembly(2)

(HST Type).

3. Pull out the 2

nd

shaft, front assembly(3)

(Manual transmission type).

4. Pull out the 3

rd

shaft, front assembly(4)

*. PART NAME

1) Clutch rod

2) Clutch release fork

3) Release bearing

4) Set spring

(4)

(2)

(3)

(1)

(A)

(B)

(1)

*. PART NAME

1) Clutch housing rear cover

A) HST Type B) Manual transmission type

(A)

(1)

(2)

(5)

(1)

(HST Type).

▷ Reassembling

9 Apply small amount of the grease to the oil

seal(5).

*. PART NAME

1) Clutch shaft assembly

2) 2nd gear shaft, front assembly

3) 2nd shaft, front assembly 4) 3rd shaft, front assembly

5) Oil seal

A) HST Type B) Manual transmission type

87

(B)

(4)

(1)

(3)

(5)

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

2) Disassembling HST (HST Type)

TRANSMISSION

< Neutral holder and neutral holder arm >

1. Place parting marks on the neutral adjuster(3)

and the neutral holder arm(2).

2. Remove the neutral holder arm(2) with neutral

adjuster(3).

3. Remove the screw and pull out the neutral

holder(1).

▷ Reassembling

9 Align the parting marks and install the neutral

adjuster and the neutral holder arm.

9 Be sure to install the spacer(4).

Neutral adjuster

lock screw

Tightening

torque

Neutral holder

mounting screw

23.6 to 27.4 Nm

2.4 to 2.8 kgfm

17.4 to 20.3 ft-lbs

23.6 to 27.4 Nm

2.4 to 2.8 kgfm

17.4 to 20.2 ft-lbs

(1)

(3)

(2)

(2)

(3)

(4)

*. PART NAME

1) Neutral holder 2) Neutral holder arm

3) Neutral adjuster 4) Spacer

< Charge pump >

1. Remove the charge pump mounting screws, and

remove the charge pump assembly(1) from the

HST housing.

▶ NOTE

1) Take care not to damage the O-ring.

Tightening

torque

Charge pump

mounting screw

23.5 to 27.5 Nm

2.4 to 2.8 kgfm

17.4 to 20.3 ft-lbs

(1)

*. PART NAME

1) Charge pump assembly

88

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

3) Disassembling Transmission Case (HST Type)

< Separating hydraulic cylinder, rear axle cases and

others >

1. Remove the external snap ring and remove the

PTO shift lever(7) and range gear shift lever(8).

2. Remove the front wheel driver lever(1).

3. Remove the differential lock pedal support(2).

4. Remove the top link bracket(3) and remove the

hydraulic cylinder(4).

5. Remove the rear axle case(5) and drawbar

frame(6).

▷ Reassembling

TRANSMISSION

1. Apply gasket to joint face of the differential case

to hydraulic cylinder and rear axle.

48.1 to 55.9 Nm

4.9 to 5.7 kgfm

35.4 to 41.2 ft-lbs

48.1 to 55.9 Nm

4.9 to 5.7 kgfm

35.4 to 41.2 ft-lbs

Tightening

torque

Hydraulic cylinder

mounting screw

and nut

Rear axle case

mounting screw

< Separating mid-PTO case, transmission case and

differential case >

1. Remove the mid-PTO case mounting screws and

separate the mid-PTO case(3) and transmission

case(1).

2. Remove the transmission case mounting screws

and nuts and separate the differential case(2)

and transmission case(1).

*. PART NAME

1) Front wheel drive lever

2) Differential lock pedal support

3) Top link bracket 4) Hydraulic cylinder

5) Rear axle case 6) Drawbar frame

7) PTO shift lever 8) Range gear shift lever

▷ Reassembling

9 Apply gasket to joint face of the transmission

case to differential case and mid-PTO case to

transmission case.

Tightening

torque

Transmission case

mounting screw

and nut

48.1 to 55.9 Nm

4.9 to 5.7 kgfm

38.4 to 41.2 ft-lbs

*. PART NAME

1) Transmission case 2) Differential case

3) Mid-PTO case

89

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

< 4th Gear shaft and spiral bevel pinion shaft >

1. Remove the spiral bevel pinion shaft(3) with 15T-

29T shifter gear(2), 13T gear(8) and shift fork(4).

2. Remove the 4

▷ Reassembling

9 When installing the spiral bevel pinion shaft, be

sure to install the shims(7).

9 Install the shift fork(4), so that the fork rod(9) of

the shift rod(5) faces rearward.

◈ Important

th

gear shaft(1) with 18T gear.

TRANSMISSION

¾ When disassembling the spiral bevel pinion

shaft(3), be sure to replace the external snap

ring(6) with new one.

*. PART NAME

1) Gear shaft 2) Shifter gear

3) Spiral bevel pinion shaft 4) Shift fork

5) Shift fork rod 6) External snap ring

7) Shim 8) 13T gear

9) Fork rod

A) Rear

< Bearing holder >

1. Remove the external snap ring and remove the

27T gear(1).

2. Remove the bearing holder mounting screws and

remove the bearing holder(2).

(5)

(4)

(9)

(3) (6)

(7)

(8) (2)

*. PART NAME

1) 27T Gear

2) Bearing holder

▷ Reassembling

Tightening

torque

Bearing holder

mounting screw

50 to 55 Nm

5.1 to 5.6 kgfm

36.9 to 40.1 ft-lbs

90

(1)

(2)

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

< 2nd Gear shaft and middle shaft >

1. Remove the 2

2. Remove the 3

fork(3) with shift rod.

3. Remove the middle shaft(4) and 19T gear with

nd

gear shaft(1) with bearings.

rd

shaft assembly(2) and shift

TRANSMISSION

(1)

(2)

bearing.

▷ Reassembling

9 When assembling the 19T gear(5), face the

chamber side to the front.

9 Install the shift fork(3), so that the snap ring(7) of

the shift rod(6) faces rearward.

*. PART NAME

1) 2nd gear shaft 2) 3rd shifter assembly

3) Shaft fork 4) Middle shift

5) 19T Gear 6) Shift fork rod

7) External snap ring

A) Rear

< Front wheel drive shaft >

1. Remove the external snap ring and remove the

20T shifter gear(1).

2. Draw out the front wheel drive shaft(2) to the

front.

(6) (7)

(3)

(3)

(4)

(5)

(6)

(1)

(2)

*. PART NAME

1) 20T Shifter gear 2) Front wheel drive shaft

< Mid-PTO shaft >

1. Remove the oil seal(1) and internal snap ring(2).

2. Remove the mid-PTO shaft(3) with bearing(4).

▷ Reassembling

9 Apply grease to lip and out of oil seal.

*. PART NAME

1) Oil seal 2) Internal snap ring

3) Mid-PTO Shaft 4) Bearing

91

(1)

(3)

(1)

(2)

(4)

(3) (4)

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

4) Disassembling Transmission Case (Manual transmission Type)

< Separating hydraulic cylinder and main shift

cover >

1. Remove the connecting pipe and propeller shaft.

2. Tap out the spring pins and remove the universal

joint(2) with front wheel drive propeller shaft.

3. Remove the external snap ring and remove the

PTO shift lever(4) with rod and range gear shift

lever(5).

4. Remove the top link bracket(8).

5. Remove the connecting plate(6) and hydraulic

cylinder mounting screws and remove the

hydraulic cylinder assembly(7).

6. Remove the main shift cover mounting screws

and remove the main shift cover(3) with

differential lock pedal.

(6)

(5)

TRANSMISSION

(4)

(7) (8)

▷ Reassembling

9 When inserting the spring pins, face their splits

in the direction parallel to the universal joint as

shown in the figure below.

9 Apply gasket to joint face of the main shift cover

to transmission case and differential case to the

hydraulic cylinder.

9 Apply grease to the spline of the front wheel

drive propeller shaft, universal joint and ball

coupling.

9 Reinstall the connecting pipe with O-ring and

back-up ring securely.

48.1 to 55.9 Nm

4.9 to 5.7 kgfm

35.4 to 41.2 ft-lbs

77.5 to 90.1 Nm

7.9 to 9.2 kgfm

57.2 to 66.5 ft-lbs

Tightening

torque

Connecting plate

mounting screw

Top link bracket

mounting screw

Tightening

torque

*. PART NAME

1) Front wheel drive propeller shaft

2) Universal joint

Main shift cover

mounting screw

23.5 to 27.5 Nm

2.4 to 2.8 kgfm

17.4 to 20.3 ft-lbs

Hydraulic cylinder

mounting screw

48.1 to 55.9 Nm

4.9 to 5.7 kgfm

35.4 to 41.2 ft-lbs

3) Main shift cover 4) PTO Shift lever

5) Range gear shift lever 6) Connecting plate

7) Hydraulic cylinder assembly 8) Top link bracket

92

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

< Separating rear axle case, mid-PTO case,

drawbar frame and transmission case >

1. Remove the front wheel drive lever(3).

2. Remove the rear axle cases(5) from differential

case.

3. Remove the mid-PTO case(1) from transmission

case.

4. Remove the drawbar frame(6).

5. Separate the transmission case(2) and differential

case(4).

▷ Reassembling

9 Apply gasket to the face of the rear axle cases,

mid-PTO case and transmission case to

TRANSMISSION

differential case.

77.5 to 90.2 Nm

7.9 to 9.2 kgfm

57.1 to 66.5 ft-lbs

48.1 to 55.9 Nm

4.9 to 5.7 kgfm

35.4 to 41.2 ft-lbs

48.1 to 55.9 Nm

4.9 to 5.7 kgfm

35.4 to 41.2 ft-lbs

48.1 to 55.9 Nm

4.9 to 5.7 kgfm

35.4 to 41.2 ft-lbs

Tightening

torque

Drawbar frame

mounting screw

Mid-PTO case

mounting screw

Transmission case

mounting screw

and nut

Rear axle case

mounting screw

< Front cover >

1. Remove the front cover mounting screw and

*. PART NAME

1) Mid-PTO case 2) Transmission case

3) Front wheel drive lever 4) Differential case

5) Rear axle case 6) Drawbar frame

remove the front cover(1).

▷ Reassembling

9 Apply liquid gasket to joint face of the front

cover to transmission case.

Tightening

torque

Front case

mounting screw

48.1 to 55.9 Nm

4.9 to 5.7 kgfm

35.4 to 41.2 ft-lbs

*. PART NAME

1) Front cover

93

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

< 4th gear shaft >

1. Remove the bearing, 30T shifter gear and 13T-

17T shifter gear.

2. Draw out the 4

rearward.

*. PART NAME

1) 4th Gear shaft

th

gear shaft(1) with 19T gear

TRANSMISSION

(1)

< Spiral bevel pinion shaft and 20T shifter gear >

1. Remove the external snap ring(1) and one-way

clutch cam(2).

2. Remove the spiral bevel pinion shaft(3) with 13T-

32T shifter gear(4), 13T gear(5), and shift fork

with shift rod.

3. Remove the external snap ring and remove the

20T shifter gear(6).

▷ Reassembling

9 When installing the spiral bevel pinion shaft, be

sure to install the shim(7).

*. PART NAME

1) External snap ring 2) One-way clutch cam

3) Spiral bevel pinion shaft 4) 13T-32T Shifter gear

5) 13T Gear 6) 20T Shifter gear

7) Shim (1.8T)

< 2nd gear shaft and front wheel drive shaft >

1. Remove the 2

nd

gear shaft(1) with bearing.

2. Draw out the front wheel drive shaft(2) with 16T-

20T gear(3).

▷ Reassembling

9 When installing the needle bearing into the 16T-

20T gear, apply transmission oil to the needle

bearings.

*. PART NAME

nd

Gear shaft 2) Front wheel drive shaft

1) 2

3) 16T-20T Gear

94

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

< Middle shaft and 3rd shaft >

1. Tap out the middle shaft(1) and remove the 19T

gear with bearing.

2. Draw out the 3

rd

shaft(2) with 13T-17T shifter

(3)

(2)

TRANSMISSION

gear(3) and shift fork(4) with shift rod.

▷ Reassembling

9 Install the shift fork(4) and shift rod(5) as shown

in the figure.

*. PART NAME

1) Middle shaft 2) 3rd Shaft

3) 13T-17T Shifter gear 4) PTO Shifter fork

5) Shifter fork rod

A) Front B) Rear

< Mid-PTO shaft and one-way clutch >

1. Remove the mid-PTO case rear cover mounting

screws and separate the rear cover(1).

2. Remove the bearing(2) and remove the friction

plates, brake discs(10) and spring(9).

3. Remove the external snap ring and remove the

(1)

A B

(3)

(4) (5)

(4)

(6)

(4)

(5)

(5)

(2) (1)

(7)

(8)

(9) (2)

spring(11) and one-way clutch cam(8).

4. Remove the oil seal(4) and internal snap ring(5).

5. Remove the mid-PTO shaft(3) with bearing(13),

11T gear(6) and coupling(7).

▷ Reassembling

9 Apply grease to lip and outer of oil seal.
9 When installing the needle bearings(12) into the

11T gear and one-way clutch cam, apply

transmission oil to the needle bearings.

9 Install the longer needle bearing to front side.

Tightening

torque

Mid-PTO rear

cover mounting

screw

23.5 to 27.5 Nm

2.4 to 2.8 kgfm

17.4 to 27.3 ft-lbs

(12) (11) (10)

*. PART NAME

1) Mid-PTO case rear cover 2) Bearing

3) Mid-PTO Shaft 4) Oil seal

5) Internal snap ring 6) 11T Gear

7) Coupling 8) One-way clutch cam

9) Spring

10) Friction plate and brake disc

11) Spring 12) Needle spring

13) Bearing

95

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

< Main gear shift fork >

1. Remove the cotter pin(1) and remove the

spring(2) and ball(3).

2. Draw out the shift rod(4) and remove the 1

reverse gear shift fork(5).

3. Remove the 2

way as the 1

nd-3rd

gear shift fork(6), in the same

st

-reverse shift fork removing

procedure.

4. Take out the interlocker(7) and slide the shift arm

stopper(8) and then remove the shift arm(9).

5. Remove the shift shaft(10).

6. When remove the differential lock pedal

shaft(11) draw out the dowel pin(12) first.

st

-

TRANSMISSION

*. PART NAME

1) Cotter pin 2) Spring

3) Ball 4) Shift rod

5) 1st-Reverse gear shift fork 6) 2nd-3rd Gear shift fork

7) Interlocker 8) Shift arm stopper

9) Shift arm 10) Shift shaft

11) Differential lock pedal shaft

12) Dowel pin

5) Disassembling Differential Gear Case

< PTO shaft >

1. Remove the PTO cover mounting screws and

remove the PTO cover assembly.

▷ Reassembling

9 Apply gasket to joint face of differential gear

case and PTO cover.

Tightening

torque

PTO cover

mounting screw

48.1 to 55.9 Nm

4.9 to 5.7 kgfm

35.4 to 41.2 ft-lbs

96

KUKJE MACHINERY CO., LTD.

4. CHECKING, DISASSEMBLING AND SERVICING

TRANSMISSION

< Differential gear assembly >

1. Remove the bearing holder mounting screws and

remove the bearing holder(1).

2. Take out the differential gear assembly(3).

▷ Reassembling

9 Install the differential gear assembly, noting the

number of shims(2) in the differential case left

side and bearing holder side.

Tightening

Differential gears

bearing holder

torque

mounting screw

23.5 to 27.5 Nm

2.4 to 2.8 kgfm

17.4 to 27.3 ft-lbs

< Bearing >

1. Remove the right and left bearings from in the

differential case.

< Spiral bevel gear >

1. Remove the spiral bevel gear UBS screws(1).

2. Remove the spiral bevel gear(2) from differential

case(3).

▷ Reassembling

9 Apply liquid lock to the spiral bevel gear UBS

screws.

(2)

(3)

(2)

(1)

*. PART NAME

1) Bearing holder 2) Adjusting shim

3) Differential gear assembly

*. PART NAME

(1)

(2)

(3)

1) Spiral bevel

gear UBS screw

2) Spiral bevel gear

3) Differential case

Tightening

torque

Spiral bevel gear

UBS screw

29.4 to 34.3 Nm

3.0 to 3.5 kgfm

21.7 to 25.3 ft-lbs

< Differential side gear and differential pinion >

1. Put parting marks on the differential

pinion(1) and the differential side gear(2).

2. Tap out the dowel pin(3).

3. Remove the differential pinion shaft.

4. Remove the differential pinion(4), differential

side gear(2) and shim(5).

▷ Reassembling

9 Install the differential pinion and differential side

gear, aligning the parting marks.

*. PART NAME

1) Differential pinion 2) Differential side gear

3) Dowel pin 4) Differential pinion

5) Shim

97

KUKJE MACHINERY CO., LTD.

5. CHECKING, DISASSEMBLING AND SERVICING

<4> SERVICING

1) Clutch Housing

TRANSMISSION

< Checking bearing >

1. Hold the inner race, and push and pull the outer

race in all directions to check for wear and

roughness.

2. Apply transmission fluid to the bearing, and hold

the inner race. Then turn the outer race to check

rotation.

3. If there is any defect, replace it.

< Checking propeller shaft ball coupling >

1. Hold the ball coupling outer, and push and pull,

and rotate the ball coupling inner in all

directions to check for wear and roughness.

2. If there is any defect, replace it.

▷ Reassembling

9 Apply grease to the inner parts of ball coupling

and spline of ball coupling inner.

9 When replacing the ball coupling assembly,

install the ball coupling inner(1) with balls so that

its ball position inside of ball coupling outer(2)

as shown in the figure.

*. PART NAME

1) Inner, Coupling 2) Outer, Coupling

98

KUKJE MACHINERY CO., LTD.