KIOTI DAEDONG DK45 DK50 Tractor Workshop Repair Manual

CHAPTER 7 BRAKE

BRAKE 7-3 D569-W02 May-2003 25 ~ 40 mm 0.984 ~ 1.574 in. Less than 5 mm 0.20 in. 0.007 ~ 0.101 mm 0.00027 ~ 0.00397 in. 24.980 ~ 24.993 mm 0.9834 ~ 0.9839 in 25.000 ~ 25.081 mm 0.9842 ~ 0.9874 in. - 20.9 ~ 21.1 mm 0.8228 ~ 0.8307 in. 4.6 ~ 4.8 mm 0.181 ~ 0.189 in. 2.54 ~ 2.66 mm 0.100 ~ 0.1047 in. - - 0.4 mm 0.0197 in. - - 0.3 mm 0.012 in. 20.6 mm 0.8110 in. 4.0 mm 0.1574 in. 2.0 mm 0.0787 in. 2. SPECIFICATIONS Brake pedal Right and left Brake pedal shaft to bushing Brake pedal shaft Bushing (brake pedal) Cam plate 1 Cam plate 1 and ball Brake disc Plate Item Free play Difference Clearance O.D. I.D. Flatness Height Thickness Thickness Factory Specifications Allowable Limit 1. TROUBLESHOOTING Uneven braking force Brake drags Poor braking force Symptom - Brake pedal play unevenly adjusted - Brake disc worn - Cam Plate warped - Brake pedal play too small - Cam plate return spring weaken or broken - Brake pedal return spring weaken or broken - Brake camshaft rusted - Brake pedal play excessive - Brake disc worn - Cam plate warped - Brake camshaft or lever damaged - Brake camshaft or lever damaged Provable Causes Adjust Replace Replace Adjust Replace Replace Repair Adjust Replace Replace Replace Change Solution

CHAPTER 7 DK45/50 7-4 D569-W02 May-2003 3. TIGHTENING TORQUE Tightening torque Brake shaft Mounting bolt of parking brake shaft Mounting nut of brake cam lever Mounting bolt of brake case Mounting nut of brake case Mounting nut of brake rod 367.8 ~ 431.6 N·m 37.5 ~ 44.0 kgf·m 271.2 ~ 317.8 lbf·ft 23.5 ~ 27.4 N·m 2.4 ~ 2.8 kgf·m 17.3 ~ 20.2 lbf·ft 123.6 ~ 147.1 N·m 12.6 ~ 15.0 kgf·m 91.1 ~ 108.5 lbf·ft 77.5 ~ 90.2 N·m 7.9 ~ 9.2 kgf·m 57.1 ~ 66.5 lbf·ft 77.5 ~ 90.2 N·m 7.9 ~ 9.2 kgf·m 57.1 ~ 66.5 lbf·ft 48.0 ~ 55.9 N·m 4.9 ~ 5.7 kgf·m 35.4 ~ 41.2 lbf·ft

BRAKE 7-5 D569-W02 May-2003 4. STRUCTURE AND OPERATION 4.1 STRUCTURE (1) Brake Case (2) Packing (3) Guide Pin (4) Brake Cam (5) O-Ring (6) Cam Plate (RH) (7) Cam Plate (LH) (8) Steel Ball (9) Steel Ball Sheet (10) Brake Disc (11) Plate (12) Brake Cam Lever (RH) (13) Brake Cam Lever (LH) 569W701A

CHAPTER 7 DK45/50 7-6 D569-W02 May-2003 b. Parking Brake The parking brake is operated mechanically. If the hand lever located at the lower part of the instrument panel is pulled upward with brake pedal stepped powerfully, the parking brake lever holds the brake pedal as stepped down.The next application is as processed as the foot brake. a. Brake The brake is of mechanical wet-disc type with its two pedals left and right operated respectively. If the pedal (1) located at the front of the driver’s seat is stepped down, brake rods 3 (4) and brake cam lever (5) linked with brake lever by the hinge point are activated for- ward while brake rod (3) is pulled upward. The cam plate gets rotated, as the brake cam connected to the brake cam lever turns to the direction as arrowed. When the cam plate turns, the cam plate while being pushed toward the steel ball between the cam plate and the brake case compresses the brake disc. (1) Pedal (2) Shaft (3) Brake Rod (4) Brake Rod 3 (5) Brake Cam Lever (6) Cam Plate (7) Plate (8) Brake Disk (9) Brake Case 569W702A

BRAKE 7-7 D569-W02 May-2003 • If brake pedal (1) is stepped down, brake lever (5) is pulled to the direction as arrowed through connecting rods (2), (4) and link (3), and brake cam (6) is allowed to turn cam plate (7) to let it move as arrowed and apply braking with brake disc (8) as adhered closely to brake plate (9). • For parking, step the brake pedal completely and pull the parking brake lever (10) to hold the pedal. (1) Brake Pedal (2) Connecting Rod (3) Link (4) Connecting Rod (5) Brake Lever 4.2 OPERATION (6) Brake Cam (7) Cam Plate (8) Brake Disc (9) Brake Plate (10) Parking Brake Lever 569W704A

CHAPTER 7 DK45/50 7-8 D569-W02 May-2003 5. DISASSEMBLING AND ASSEMBLING 5.1 DRAINING THE TRANSMISSION FLUID Draining the Transmission Fluid 1. Place oil pans underneath the transmission case. 2. Remove the drain plugs. 3. Drain the transmission fluid. 4. Reinstall the drain plugs (When refilling) • Fill up from filling port after removing the filling plug (1) until reaching the gauge (2). • After running the engine for few minutes, stop it and check the oil level again, add the fluid to prescribed level if it is not correct level. IMPORTANT • Use only SAE 80, 90 gear oil. Use of other oils may damage the transmission or hydraulic system. Refer to “LUBRICANTS, FUEL AND COOLING WA- TER” (See page 1-13). • Do not mix different brands fluid together. Capacity Tansmission fluid 34.0 9.0 U.S.gal. (1) Drain Plugs (2) Gauge 569W705A 569W706A

BRAKE 7-9 D569-W02 May-2003 Preparation 2 1. Disconnect the brake rods (4), (10). 2. Disconnect the clutch rod (2). 3. Remove the accelerator rod (12). 4. Disconnect the foot accelerator rod (11). 5. Remove the panel frame cover (7) and disconnect the connectors (6). 6. Remove the shuttle shaft lever (5) after disconnector limit switch wire harness. 7. Disconnect the 2P connector of alternator (1), jumper for fuel level sensor (3) and starter (9). 8. Disconnect the meter cable (13) at the engine side. (1) 2P Connector for Alternator (2) Clutch Rod (3) Jumper Lead for Fuel Level Sensor (4) Brake Rod (LH) (5) Shuttle Shift Lever (6) Connectors (7) Panel Frame Cover (8) Jumper Lead for Oil Switch (9) Jumper Lead for Starter (10) Brake Rod (RH) (11) Food Accelerator Rod (12) Accelerator Rod (13) Meter Cable 569W710A 569W711A 5.2 SEPARATING PANEL FRAME ASSEMBLY Preparation 1 1. Removing the following parts. (1) Side Cover (RH, LH) (4) Side Skirt (RH, LH) (2) Bonnet (5) Battery Negative Code (3) Front Grille 569W707A

CHAPTER 7 DK45/50 7-10 D569-W02 May-2003 569W712A Hydraulic Pipes 1. Disconnect the main delivery hose (1), return hose (2), right turning delivery hose (3) and left turning delivery hose (4). (When reassembling) • In assembling the turning delivery hoses to the steering controller, connect the delivery hose with identification mark (tape) “A” to the L port of the steering controller. [A] Identification Mark (Tape) (1) Main Delivery Hose (2) Return Hose (3) Right Turning Delivery Hose (4) Left Turning Delivery Hose Tightening torque Main delivery hose retaining nut Turning delivery hoses retaining nut 46.6 ~ 50.9 N·m 4.8 ~ 5.2 kgf·m 34.4 ~ 37.6 lbf·ft 24.5 ~ 29.4 N·m 2.5 ~ 3.0 kgf·m 18.1 ~ 21.7 lbf·ft Panel Frame and Steering Assembly 1. Remove the panel frame mounting crews. (Two screws a upper part. Seven screws at lower part.) 2. Take out the panel frame and steering assembly as a unit. (When reassembling) • Do not get in the wiring harness between panel frame and platform. 569W713A

KIOTI DAEDONG DK45 DK50 Tractor Workshop Repair Manual

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