KIOTI DAEDONG DK DK45S DK451 Tractor Workshop Repair Manual

CHAPTER 6 BRAKE

6-3 DC45-W00 Nov. 2004 BRAKE 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) C45W601A

6-4 DC45-W00 Nov. 2004 CHAPTER 6 DK45S(DK451) • 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. • 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 C45W602A

6-5 DC45-W00 Nov. 2004 BRAKE 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 - 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. 3. SPECIFICATIONS Brake pedal Right and left Brake pedal shaft to bushing Brake pedal shaft Cam plate 1 Cam plate 1 and ball Brake disc Plate Item Free play Difference Clearance O.D. Flatness Height Thickness Thickness Factory Specifications Allowable Limit 2. 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

6-6 DC45-W00 Nov. 2004 CHAPTER 6 DK45S(DK451) 4. 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

6-7 DC45-W00 Nov. 2004 BRAKE 5. CHECK, DISASSEMBLYING AND MAINTENANCE Brake Pedal Free Play 1. Press the center of the pedal with a force of approx. 39.2 ~ 58.8 N (4 ~ 6 kgf, 8.8 ~ 13.2 lbs), and mea- sure the free play of the brake pedal edge. 2. If the measurement is not within the factory specifications, turn the turnbuckle of brake rod to adjust. 3. After adjustment, tighten the turnbuckle lock nut firmly. NOTE: • After checking brake pedal free play, be sure to engage the parking brake lever fully and check to see that the brake pedals are securely locked. (1) Brake Pedal (2) Brake Rod (3) Parking Brake Lever (4) Brake Lever Brake pedal free play (A) Factory spec. 25 ~ 40 mm 0.984 ~ 1.574 in. C45W603A Clearance between the stop switch and the brake pedal (B) Factory spec. 0 ~ 1.0 mm 0 ~ 0.0393 in. (5) Brake Rod (6) Brake Cam Lever (7) Stop Switch (8) Nut 3. After the adjustment of the clearance, surely tighten the stop switch with its mounting nut (8). Adjustment of the Brake Stop Switch 1. Install the stop switch on the bracket. 2. Adjust the position of the switch (7) installed, to al- low the clearance between the stop switch and the brake pedal to be 0 to 1 mm. 5.1 ADJUSTMENT OF THE BRAKE • The difference between the right and left pedal plays must be less than 5 mm (0.20 in.). CAUTION

6-8 DC45-W00 Nov. 2004 CHAPTER 6 DK45S(DK451) (1) Drain Plug C45W604A (1) Oil Inlet (2) Oil Filling Plug (A) Oil Level is Acceptable Within the Range C45W605A 5.2 DISASSEMBLING AND ASSEMBLY A. DRAINING TRANSMISSION OIL 1. Underlay oil pan under transmission. 2. Remove the drain plug and drain the oil. 3. After draining, install the plug. (Assembling) • When filling oil, remove the oil tap and fill the tank with oil up to the maximum of gauge. • Stop the engine after running for a few minutes, and check the quantity to replenish with oil if required. Transmission oil capacity 38.0 (10.04 U.S.gal) • DAEDONG genuine oil should be used. • For engine oil specification, refer to 1-10 page. • Never mix with other oil. IMPORTANT

6-9 DC45-W00 Nov. 2004 BRAKE 1 2 3 C45W606A C45W607A c. Disassembling Rear Wheels, 3 Point Link (1) Rear Wheel (2) Lift Cylinder (3) Lower Link Tightening torque of the rear wheel assembly nut 274.6 ~ 318.7 N·m 28.0 ~ 32.5 kgf·m 202.5 ~ 235.1 lbf·ft 6. Disconnect the brake rod. 7. Loosen the cabin assembly bolt. 8. Support the cabin with a hoist. 9. Loosen the bolt and remove the rear axle case from the brake case. (When Assembling) • When assembling the rear axle take care that the O-ring does not impress. Tightening torque of the assembly bolt, nut 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 Tightening torque of the stud bolt 1. The support jack is installed under the transmission to support it. 2. Remove the rear wheels. 3. After removing the rear wheels, install the support ack on the rear axle case. 4. Remove the lift cylinder from the lower link. 5. The lower link, bracket, and stabilizer are removed together at the same time. (When Assembling)

6-10 DC45-W00 Nov. 2004 CHAPTER 6 DK45S(DK451) It is Possible to Disassemble as Shown in the Figure Above. (When reassembling) • Place the brake discs (9) so that the hole “A” of the second disc should be overlapped 70% or more. • Apply grease to the O-ring (12) and take care not to damage them. Brake Case 1. Loosen and remove the nut (1), spring washer (2), plain washer (3), brake can lever (4), bolt (5) and spring washer (6). 2. Separate the brake case (7), tapping the brake case lightly. (When reassembling) • Apply grease to the brake ball seats (16). (Do not grease excessively.) • Before installing the brake case (7) to the transmission case, install the cam plate (14) to the transmission case. (1) Nut (9) Disc (2) Spring Washer (10) Plate (3) Plain Washer (11) Snap Ring (4) Brake Cam Lever (12) O-Ring (5) Bolt (13) Brake Cam (6) Spring Washer (14) Cam Plate (7) Brake Case (15) Ball (8) Gasket (16) Ball Seat B. DISASSEMBLING BRAKE CASE Tightening torque Brake case mounting bolt, nut Brake cam lever mounting nut 77.5 ~ 90.2 N·m 7.9 ~ 9.2 kgf·m 57.1 ~ 66.5 lbf·ft 123.6 ~ 147.1 N·m 12.6 ~ 15.0 kgf·m 91.1 ~ 108.5 lbf·ft C45W608A C45W609A

KIOTI DAEDONG DK DK45S DK451 Tractor Workshop Repair Manual

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