MECHRON 2200 WORKSHOP MANUAL UTV_01_.indd 1 2010-05-07 6:26:20 We reserve the right to make changes throughout the entire manual at any time without notice. REMARK Using unspecified parts, fuel and lubricants other than DAEDONG's genuine parts can damage the UTV and such damage will not be covered by warranty. IMpORTANT PREFACE This manual is to provide servicing personnel with information on the general speci- fications, service, operating principle, troubleshooting, exploded view including part name, removing and installing procedures for MECHRON 2200 UTV (Utility Vehicle) with high-end technology. All information in this manual is based on the latest product information available at the time of publication. Therefore, some of the information in this manual may differ from the machine you have. KIOTI has a principle to apply update to the next edition of the manual if there is any. However, KIOTI has no obligation to modify the contents in this manual, especially the contents in the manual which is already distributed or published. The modified information is available in KIOTI's online electronic manual system (DEMSS). This manual is ultimately to satisfy customers with best performance of this UTV. If there is any typo, wrong information or question for this manual, feel free to contact KIOTI. Nov. 2009 service division DAEDONG INDUSTRIAL Co., Ltd. UTV_01_.indd 3 2010-05-07 6:26:20 CHAPTER 1 SAFETY FIRST CHAPTER 2 GENERAL CHAPTER 3 ENGINE CHAPTER 5 TRANSMISSION CHAPTER 6 CHASSIS CHAPTER 7 REAR AXLE CHAPTER 8 BRAKE CHAPTER 10 STEERING CHAPTER 9 FRONT AXLE CHAPTER 11 HYDRAULIC SYSTEM CHAPTER 4 CVT CHAPTER 12 ELECTRIC SYSTEM TABLE OF CONTENTS CHAPTER 13 INDEX UTV_01_.indd 5 2010-05-07 6:26:20 1. SAFETY DECALS ................................... 1-2 1.1 Alert symbols ..........................................1-2 2. SAFETY TIpS .......................................... 1-3 2.1 Safety gear .............................................1-3 2.2 Workplace .............................................1-3 2.2.1 Ventilating system .........................1-3 2.2.2 Safe workplace .............................1-3 2.2.3 Illumination ...................................1-3 2.2.4 Safety equipment ..........................1-3 2.2.5 Keeping your work area clean ...... 1-3 2.3 Safety instructions when preparing UTV ....... 1-4 2.4 Fire .........................................................1-4 2.5 Cautions when handling the battery ....... 1-5 2.6 Cautions for high pressure hoses ................1-5 2.7 Use of appropriate tools and equipment 1-6 2.8 Handling of hazardous materials ............... 1-6 2.9 Handling of rotating shaft and driving belt ....... 1-7 2.10 Scald prevention ....................................1-7 2.11 Disposal of environmental waste .................1-8 2.12 Cautions when handling tires ................. 1-8 3. SAFETY DECALS ................................... 1-9 3.1 The location of safety decal ..................1-9 MECHRON 2200 CHAPTER 1 TABLE OF CONTENTS SAFETY FIRST UTV_01_.indd 1 2010-05-07 6:26:21 1-2 SUUV-W00 Nov. 2009 MECHRON 2200 SAFETY FIRSTGENERALENGINECVTTRANSMISSION CHASSISREAR AXLEBRAKEFRONT AXLESTEERINGHYDRAULIC ELECTRIC ! S76W001A S76W004A 1. SAFETY DECALS Most accidents can be avoided if basic safety in- structions and regulations are followed. Always fol- low the safety regulations and avoid any dangerous situation to prevent an accident. You can be unexpectedly injured if inspecting or servicing the UTV without full knowledge of it. Read the manual carefully before starting service, and follow the instructions on service, maintenance and inspection to prevent any injury. A. REMARK S76W003A B. IMpORTANT This mark indicates emphasis on information which can be confused when servicing. If this information is not carefully read and observed, the UTV cannot fully function or may be damaged. C. CAUTION This mark indicates potentially hazardous situation which, if not observed, may result in serious injury. D. WARNING This mark indicates hazardous situation which, if not observed, may result in death or injury. 1.1 ALERT SYMBOLS The meanings of the safety-alert symbols used in this manual are as follows: S76W002A Broaden your knowledge with additionally supplied service information for optimal service. REMARK CAUTION S76W005A WARNING READ MANUAL! SAFETY FIRST - SAFETY DECALS UTV_01_.indd 2 2010-05-07 6:26:22 SUUV-W00 Nov. 2009 MECHRON 2200 1-3 SAFETY FIRSTGENERALENGINECVTTRANSMISSION CHASSISREAR AXLEBRAKEFRONT AXLESTEERINGHYDRAULIC ELECTRIC S76W007A S76W008A 2. SAFETY TIpS 2.1 SAFETY GEAR 2.2.1 VENTILATING SYSTEM The service should be performed in a well-ventilated area. If the engine should be started in an enclosed place, an exhaust gas vent pipe should be installed. 2.2.2 SAFE WORKpLACE California proposition 65 Warning Inhaling exhaust gas can cause cancer or damage the generative function leading to infertility. WARNING S76W006A When operating on the vehicle, wear safety gloves, safety shoes, ear plugs, safety goggles, safety helmet, working clothes, etc. appropriate for your working envi- ronment. Never wear loose fitting clothing or a tie which can be caught by rotating part. According to the statistics, most accidents occurred with rotating parts are due to this inappropriate manner of wearing clothes. 2.2 WORKpLACE The work should be done in a wide, level and safe place to prevent slip and fall accident. 2.2.3 ILLUMINATION The work place should be well illuminated. If working in a dark place or under the vehicle, use the work lamp. The work lamp should be covered with the safety cov- er. The bulb can start a fire due to the leaked fuel when it is broken. 2.2.4 SAFETY EqUIpMENT Be sure to keep a first aid kit and fire extinguisher han- dy at all times. 2.2.5 KEEpING YOUR WORK AREA CLEAN Keep the working area clean before and during work. If any oil or fuel is spilled, it should be cleaned up immediately. SAFETY FIRST - SAFETY TIPS UTV_01_.indd 3 2010-05-07 6:26:23 1-4 SUUV-W00 Nov. 2009 MECHRON 2200 SAFETY FIRSTGENERALENGINECVTTRANSMISSION CHASSISREAR AXLEBRAKEFRONT AXLESTEERINGHYDRAULIC ELECTRICS76W010A S76W013A S76W011A S76W012A S76W014A 2.3 SAFETY INSTRUCTIONS WHEN pREpARING TRACTOR Stop the engine and remove the key. Put "No Operation" label on the tractor if necessary. 2.4 FIRE Never smoke or allow flames or sparks in your work area when maintaining the fuel system. Keep flames or sparks away from the fuel container, spray paint, etc. and be careful of leaks. Disconnect the negative battery cable. Always disconnect the battery cable for fire preven- tion before wiring service. Be extra cautious of fire when welding. Always keep a fire extinguisher in workplace. SAFETY FIRST - SAFETY TIPS UTV_01_.indd 4 2010-05-07 6:26:24 SUUV-W00 Nov. 2009 MECHRON 2200 1-5 SAFETY FIRSTGENERALENGINECVTTRANSMISSION CHASSISREAR AXLEBRAKEFRONT AXLESTEERINGHYDRAULIC ELECTRIC2.5 CAUTIONS WHEN HANDLING THE BATTERY Always disconnect the negative battery cable first and reconnect it last to avoid sparks from an acci- dental short circuit. Otherwise, it could result in fire or injury. The battery can be very hazardous because it con- tains sulfuric acid. It can damage your cloth, and even burn your skin when directly contacted. If it contacts with your eyes, you may lose your sight. 2.6 CAUTIONS FOR HIGH pRESSURE HOSES Do not charge the frozen battery. Charging the fro- zen battery can cause explosion. Let the battery warm up to ambient temperature (16C, 60F) be- fore charging. Keep sparks and flames (match, lighter) away from the battery. The battery can explode due to hy- drogen gasses inside the case.Never connect the battery's negative and positive cables with metal for test. Use only tester when checking. the battery voltage. S76W015A S76W018A The hydraulic fluid leaks from high pressure hoses or pipes can penetrate your skin. S76W019A Before connecting a high pressure hose or pipe, stop the engine and depressurize it by valve. Check the bolts for tightness before starting the engine af- ter the hydraulic system service. Use a cardboard or plank when checking leakage. S76W020A Never weld the high pressure pipe or the surround- ing area. The pipe or hose can be heated and ex- plode which can lead to fire or burn. S76W021A S76W017A S76W016A SAFETY FIRST - SAFETY TIPS UTV_01_.indd 5 2010-05-07 6:26:25 1-6 SUUV-W00 Nov. 2009 MECHRON 2200 SAFETY FIRSTGENERALENGINECVTTRANSMISSION CHASSISREAR AXLEBRAKEFRONT AXLESTEERINGHYDRAULIC ELECTRIC2.7 USE OF AppROpRIATE TOOLS AND EqUIpMENT When lifting the tractor with a hydraulic jack or a hoist, fix it firmly and install the auxiliary support. Never work under the tractor if the support and the hydraulic jack (hoist) are not installed. When using a hydraulic jack or a hoist, do not use it over the limit of the equipment and the conveying belt. Make sure that the hydraulic lock operates properly before used. Improper use of lock can cause a seri- ous accident. Check the buttons and operating direction of the hoist before using it. Improper operation can cause a serious accident. Do not use wooden blocks or bricks as support un- der the tractor. As the tractor's weight is continuous- ly applied to them, they can be broken or collapsed. 2.8 HANDLING OF HAzARDOUS MATERIALS All DAEDONG's genuine parts do not contain asbestos. REMARK Do not blow out hazardous materials, such as clutch dust, with compressed air. Inhaling such hazardous materials can damage your health. S76W022A These materials should be rinsed or wiped away after sprayed with oil. Use the standard tools in proper size. If an inap- propriate tool is used, it can slip which can damage parts or injure you. Do not confuse units (mm, inch, etc.). Use the air impact wrench only when unscrewing the bolts or nuts. Such wrench should not be used especially when assembling precisely machined parts which its tightening torque should be strictly followed. It can cause malfunctions. Be careful of a socket popped out due to the turning force when using the air impact wrench. Especially, be extra cautious when working on connection or socket with joint. SAFETY FIRST - SAFETY TIPS UTV_01_.indd 6 2010-05-07 6:26:25 SUUV-W00 Nov. 2009 MECHRON 2200 1-7 SAFETY FIRSTGENERALENGINECVTTRANSMISSION CHASSISREAR AXLEBRAKEFRONT AXLESTEERINGHYDRAULIC ELECTRIC2.9 HANDLING OF ROTATING SHAFT AND DRIVING BELT Do not open the radiator cap when the radiator is hot. Hot coolant or steam can be surged leading to a serious scald. 2.10 SCALD pREVENTION S76W027A Be careful not to get caught by the rotating engine cooling fan. S76W025A You can be seriously injured if your hand or clothes is caught by the rotating fan belt or A/C belt. S76W026A Check the surface temperature of the container be- fore draining the engine oil, transmission fluid, cool- ant, etc. If it is hot, let it cool down before draining it. There is a high risk of burning. Perform any service on the engine parts (muffler, exhaust manifold, etc.) only when they are not hot. S76W028A SAFETY FIRST - SAFETY TIPS Do not set a hand or a foot into the vehicle's rotat- ing shaft or belt. Be extra careful when you are in loose clothes. S76W024A UTV_01_.indd 7 2010-05-07 6:26:26 1-8 SUUV-W00 Nov. 2009 MECHRON 2200 SAFETY FIRSTGENERALENGINECVTTRANSMISSION CHASSISREAR AXLEBRAKEFRONT AXLESTEERINGHYDRAULIC ELECTRICS76W029A S76W030A S76W031A Observe relevant environmental protection regula- tions when disposing used oil, transmission fluid, coolant, oil filter, etc. Otherwise, they can pollute the environment seriously and you could be charged in violation of regulations. Do not weld or apply heat to the tire rim or disc. The tire can explode due to the rapidly increased pres- sure in the tire. Check tires for inflation pressure, damage, deforma- tion, extended wear on lug and damage of rim and disc. Also check if wheel nuts are loose. The tire rims can fall out of the tires. Therefore, stay out of its way when checking or inflating tires. 2.11 DISpOSAL OF ENVIRONMENTAL WASTE 2.12 CAUTIONS WHEN HANDLING TIRES SAFETY FIRST - SAFETY TIPS UTV_01_.indd 8 2010-05-07 6:26:27 SUUV-W00 Nov. 2009 MECHRON 2200 1-9 SAFETY FIRSTGENERALENGINECVTTRANSMISSION CHASSISREAR AXLEBRAKEFRONT AXLESTEERINGHYDRAULIC ELECTRIC3. SAFETY DECALS When replacing the existing part with a new one, attach the same safety decal to the new part. Otherwise, the customer's safety will be threatened. If a decal is damaged or detached, attach the same decal to the part. The decals and their attaching locations are as follows. There is part number on the bottom of decals. 3.1 THE LOCATION OF SAFETY DECAL UUVW001A SAFETY FIRST - SAFETY DECALS UTV_01_.indd 9 2010-05-07 6:26:35 1-10 SUUV-W00 Nov. 2009 MECHRON 2200 SAFETY FIRSTGENERALENGINECVTTRANSMISSION CHASSISREAR AXLEBRAKEFRONT AXLESTEERINGHYDRAULIC ELECTRIC (2) Part No. : U3215-85081 (6) Part No. : U3215-85071 (4) Part No. : T2615-54112 (1) Part No. : U3215-85011 (5) Part No. : U3215-85101 (3) Part No. : T4625-52351 (7) Part No. : T4625-52361 SAFETY FIRST - SAFETY DECALS UTV_01_.indd 10 2010-05-07 6:26:37 SUUV-W00 Nov. 2009 MECHRON 2200 1-11 SAFETY FIRSTGENERALENGINECVTTRANSMISSION CHASSISREAR AXLEBRAKEFRONT AXLESTEERINGHYDRAULIC ELECTRIC (8) Part No. : U3215-85091 (12) Part No. : U3215-85111 (11) Part No. : U3215-85041 (9) Part No. : U3215-85021 (10) Part No. : U3215-85031 (14) Part No. : U3215-85061 (15) Part No. : U3215-85121 (13) Part No. : U3215-85051 SAFETY FIRST - SAFETY DECALS UTV_01_.indd 11 2010-05-07 6:26:39 1-12 SUUV-W00 Nov. 2009 MECHRON 2200 SAFETY FIRSTGENERALENGINECVTTRANSMISSION CHASSISREAR AXLEBRAKEFRONT AXLESTEERINGHYDRAULIC ELECTRIC (17) Part No. : U3215-85161 (16) Part No. : U3215-85131 U3215-85131 TO AVOID PERSONAL INJURY FROM LOSS OF STEERING CONTROL: Do not lock differential or turn with differential locked while operating machine at high speed or on slopes UTV_01_.indd 12 2010-05-07 6:26:41 1. DESCRIPTION FOR SYMBOLS AND ABBREVIATIONS ................................... 2-2 2. UTV APPEARANCE ................................ 2-3 3. SERIAL NUMBER ................................... 2-3 3.1 UTV serial number location ....................2-3 3.2 Engine serial number location ................ 2-4 3.3 Others location .......................................2-4 4. DIMENSIONS .......................................... 2-5 5. SPECIFICATIONS ................................... 2-6 6. GEAR ARRANGEMENT AND DRIVING SPEED ..................................................... 2-7 6.1 Gear arrangement of transmission ......... 2-7 6.2 Gear arrangement of rear axle ............... 2-8 6.3 Gear arrangement of front axle .............. 2-8 6.4 Driving speed .........................................2-9 7. MAINTENANCE .................................... 2-10 7.1 Maintenance schedule chart ................2-10 7.2 Lubrication and replenishment ............. 2-12 8. TIRE MAINTENANCE ........................... 2-13 8.1 Specified inflation pressure ..................2-13 8.2 Tightening torque for wheel ..................2-13 9. TIGhTENING TORqUES ...................... 2-14 9.1 General use screws, bolts and nuts ..... 2-14 9.2 Studs ...................................................2-14 9.3 American standard screws, bolts and nuts with unc or unf threads .........................2-15 10. PART NUMBER ASSIGNMENT STANDARD FOR DAEDONG BOLTS AND NUTS .................. 2-16 10.1 Bolts ....................................................2-16 10.2 Nuts .....................................................2-17 11. hOw TO INSTALL SPRING PIN AND SNAP RING ........................................... 2-18 11.1 Spring pin installation ...........................2-18 11.2 Snap ring assembly ..............................2-18 12. UNIT CONVERSION TABLE ............... 2-19 TABLE OF CONTENTS MECHRON 2200 CHAPTER 2 GENERAL UTV_02_.indd 1 2010-05-07 3:28:36 2-2 MECHRON 2200 SUUV-w00 Nov. 2009 SAFETY FIRSTGENERALENGINECVTTRANSMISSION ChASSISREAR AXLEBRAKEFRONT AXLESTEERINGhYDRAULIC ELECTRICFuel-level Headlamp - low beam Engine coolant- temperature Headlamp - high beam Parking brake Front wheel drive- engage Battery not charged Neutral position Engine oil pressure Preheat Turn signal lamp High travel light Differential lock Low travel light Hazard warning lamp 4wD .......Four Wheel Drive API ......... American Petroleum Institute hI-LO .....High speed-Low speed Rh/Lh .... Right Hand side and Left Hand side (Determined based on driving direction) ROPS ..... Roll Over Protection Structure RPM .......Revolutions Per Minute SAE ........Society of Automotive Engineers SMV .......Slow Moving Vehicle CVT ........Continuously Variable Transmission UTV ........ Utility Vehicle Symbols Abbreviations 1. DESCRIPTION FOR SYMBOLS AND ABBREVIATIONS There are various symbols used in this manual. Their design and meanings are as follows: GENERAL - DESCRIPTION FOR SYMBOLS AND ABBREVIATIONS UTV_02_.indd 2 2010-05-07 3:28:38 2-3 MECHRON 2200 SUUV-w00 Nov. 2009 SAFETY FIRSTGENERALENGINECVTTRANSMISSION ChASSISREAR AXLEBRAKEFRONT AXLESTEERINGhYDRAULIC ELECTRIC3. SERIAL NUMBER 3.1 UTV SERIAL NUMBER LOCATION 2. UTV APPEARANCE UUVW101A UTV serial number assignment standard This vehicle serial number(1) is located on the struc- ture frame where the battery is installed. Model Example) Year of manufacturing Example) 2 2002 3 2003 D 2004 E 2005 F 2006 G 2007 H 2008 J 2009 K 2010 J Z01 00001 Production serial number Example) 0 0 0 0 1: The first chassis manu- factured in that year Z01 MECHRON 2200 UUVO201A GENERAL - UTV APPEARANCE / SERIAL NUMBER UTV_02_.indd 3 2010-05-07 3:28:41 2-4 MECHRON 2200 SUUV-w00 Nov. 2009 SAFETY FIRSTGENERALENGINECVTTRANSMISSION ChASSISREAR AXLEBRAKEFRONT AXLESTEERINGhYDRAULIC ELECTRICThe engine number(1) is stamped on the machined front surface below the fuel injection pump. UUVW102A 3.2 ENGINE SERIAL NUMBER LOCATION J K 1 9 0 0 0 0 6 Production serial number Engine model (3C100LWU) Year of manufacturing Engine number assignment standard 3.3 OThERS LOCATION UUVW2F5A UUVW2F3A UUVW2F4A Front axle case serial number It is marked on the flat surface on the lower section of the spiral bevel pinion shaft of the front axle case. Transmission serial number It is marked on the side of the bleeding pipe on top of the transmission case. Rear axle case serial number It is marked on the right side of the mating surface of the rear axle case and cover. For detailed information on how the engine number is assigned, refer to chapter "Engine". REMARKS GENERAL - SERIAL NUMBER UTV_02_.indd 4 2010-05-07 3:28:45 2-5 MECHRON 2200 SUUV-w00 Nov. 2009 SAFETY FIRSTGENERALENGINECVTTRANSMISSION ChASSISREAR AXLEBRAKEFRONT AXLESTEERINGhYDRAULIC ELECTRIC4. DIMENSIONS mm (inch) Item MEChRON 2200 REMARKS A : Overall length 2,852 (112.3) - B : Overall width 1,543 (60.7) - C : Overall height 1,940 (76.4) - D : Wheel base 1,940 (76.4) - E : Tread E1 : Front 25 x 10 - 12 1,262 (49.7) - E2 : Rear 25 x 11 - 12 1,228 (48.3) - F : Min. ground clearance 304 (12.0) - CE1 B D A E2 FUUVW104A GENERAL - DIMENSIONS UTV_02_.indd 5 2010-05-07 3:28:47 2-6 MECHRON 2200 SUUV-w00 Nov. 2009 SAFETY FIRSTGENERALENGINECVTTRANSMISSION ChASSISREAR AXLEBRAKEFRONT AXLESTEERINGhYDRAULIC ELECTRIC5. SPECIFICATIONS NOTE: The specifications are subject to change without notice. Model MEChRON 2200 Engine Model 3C100LWU Type 4Cyl., In-line Vertical, Water-cooled, Indirect injection, diesel Max. power HP (Kw)/rpm 22 (16.2) / 2,800 Number of cylinders 3 Bore x stroke mm (in.) 75 X 76 (2.95 X 2.99) Displacement cc (cu in.) 1,007 (61.45) Rated revolution (rpm) 2,800 Injection timing BTDC 18 Injection sequence 1 - 2 - 3 Compression ratio 21.5 : 1 Capacity Fuel tank (U.S.gal) 28 (7.39) Engine crankcase (U.S.gal) 3.2 (0.85) Engine coolant (U.S.gal) 6.3 (1.66) Transmission case (U.S.gal) 0.9 (0.24) Front axle case (U.S.gal) 0.5 (0.13) Rear axle case (U.S.gal) 0.8 (0.2) Drive train Type Belt CVT Transmission Forward 2 (High/Low), Reverse 1, Mechanical Brake Front / Rear hyd. dry caliper disc 4WD system Manual Differential lock Front Limit slip Rear Manual Tire size Front 25 x 10 - 12 6PR Rear 25 x 11 - 12 6PR Suspension Front Independent, McPherson strut Rear Independent, Double A-arm (Wishbone) Steering Type Rack & Pinion Cargo bed Size mm (in.) 980 x 1,427 x 293 (38.6 x 56.2 x 11.5) Capacity kg (lbs) 500 (1,102) Driving speed Forward Km/h(mile/h) 0 ~ 40 (0 ~ 25.0) Reverse Km/h(mile/h) 0 ~ 25 (0 ~ 15.5) Turning radius m (ft.) 4.0 (13.1) Weight kg (lbs) 765 (1,687) Towing capacity kg (lbs) 590 (1,300) Payload capacity (include driver) kg (lbs) 726 (1,600) GENERAL - SPECIFICATIONS UTV_02_.indd 6 2010-05-07 3:28:47 2-7 MECHRON 2200 SUUV-w00 Nov. 2009 SAFETY FIRSTGENERALENGINECVTTRANSMISSION ChASSISREAR AXLEBRAKEFRONT AXLESTEERINGhYDRAULIC ELECTRIC6. GEAR ARRANGEMENT AND DRIVING SPEED 6.1 GEAR ARRANGEMENT OF TRANSMISSION 25x30x176204R52T46T03014-508206305R6305R T2610-22661620420x24x1325x29x1362046205620425x29x1331T19 HEX25x30x1362056304K5400-1457-10 3 0 1 4 -5 0 8 2 0 62046 3 0 5 R T 2 6 1 0 -2 2 6 6 1 63053 4 1 5 0 -2 1 5 6 -1 62056205311026151730341022T19521931102615173034102252Rear Wheel DriveFront Wheel Drive315246315246UUVW105A GENERAL - GEAR ARRANGEMENT AND DRIVING SPEED UTV_02_.indd 7 2010-05-07 3:28:48 2-8 MECHRON 2200 SUUV-w00 Nov. 2009 SAFETY FIRSTGENERALENGINECVTTRANSMISSION ChASSISREAR AXLEBRAKEFRONT AXLESTEERINGhYDRAULIC ELECTRIC37300-2817-2 32207J32207J4T-32009X 10 37 20 #RII #RQ 12 UUVW106A 6.2 GEAR ARRANGEMENT OF REAR AXLE 6.3 GEAR ARRANGEMENT OF FRONT AXLE UUVW107A 14T 12T 34T 8T 6005 6005 6010 6010 LSD (Limit Slip Device) 14 2 34 8 Diff. Lock OFF Diff. Lock ON GENERAL - GEAR ARRANGEMENT AND DRIVING SPEED UTV_02_.indd 8 2010-05-07 3:28:49 2-9 MECHRON 2200 SUUV-w00 Nov. 2009 SAFETY FIRSTGENERALENGINECVTTRANSMISSION ChASSISREAR AXLEBRAKEFRONT AXLESTEERINGhYDRAULIC ELECTRIC6.4 DRIVING SPEED Model MEChRON 2200 Rear tire size 25 x 11 - 12 Forward / Low km/h (MPH) 17 (10.6) Forward / High 40 (24.9) Reverse 25 (15.5) 1. Forward / Low : 2800 rpm x 1 0.68 x 15 34 x 46 52 x 10 31 x 10 37 = 140 rpm 140 x 0.635 x x 60 1000 = 17 2. Forward / High : 2800 rpm x 1 0.68 x 31 30 x 46 52 x 10 31 x 10 37 = 328 rpm 328 x 0.635 x x 60 1000 = 40 3. Reverse : 2800 rpm x 1 0.68 x 17 26 x 46 52 x 10 31 x 10 37 = 207 rpm 207 x 0.635 x x 60 1000 = 25 Calculation of driving speed Where ; 140 : Rear axle rpm, Forward / Low at engine rated speed (2,800 rpm) 328 : Rear axle rpm, Forward / High at engine rated speed (2,800 rpm) 207 : Rear axle rpm, Reverse at engine rated speed (2,800 rpm) 0.635 : Rear tire rolling diameter : Engine rpm x CVT Pulley reduction ratio x Rotating speed ratio x Tire rolling circumference GENERAL - GEAR ARRANGEMENT AND DRIVING SPEED UTV_02_.indd 9 2010-05-07 3:28:49 2-10 MECHRON 2200 SUUV-w00 Nov. 2009 SAFETY FIRSTGENERALENGINECVTTRANSMISSION ChASSISREAR AXLEBRAKEFRONT AXLESTEERINGhYDRAULIC ELECTRIC7. MAINTENANCE 7.1 MAINTENANCE SChEDULE ChART No. Maintenance interval Item Run hour Run age Remarks 10 50 100 200 400 800 1000 1 year 2 year 1 Engine oil and filter Replace 2 Fuel filter Replace # 3 Fuel line and hose connection Check 4 Fuel tank and its filler cap Check # 5 Air cleaner filter Check *1 # Replace *2 6 Air intake hose connection and filter body anti-dust valve Check *3 7 Valve clearance Check 8 Injection nozzle Check # 9 Spark arrester Check # 10 Coolant Replace 11 Cooling system (radiator grill, coolant hose, cooling fan) Check 12 CVT belt Check Replace 13 CVT pulley and system Check 14 Gearbox and front/rear axle oil Check Replace 15 Hydraulic oil (if equipped with hydraulic kit) Replace 16 Pump, cylinder, levers, oil tank and hoses related to hydraulic kit (if equipped) Check 17 Brake fluid level Check 18 Front/rear wheel and parking brake pads Check 19 Suspension mounting bushing play and mounting rubber Check 20 Leakage from shock absorber Check 21 Wheel hub bearing clearance Check 22 Wheel hub bolt tightness Check 23 Other bolt tightness Check 24 Battery Check *3 25 Steering rack and pinion, ball joint Check 26 Drive shaft and CV boots Check 27 ROPS and safety belt Check 28 Greasing drive shaft Check GENERAL - MAINTENANCE UTV_02_.indd 10 2010-05-07 3:28:50 2-11 MECHRON 2200 SUUV-w00 Nov. 2009 SAFETY FIRSTGENERALENGINECVTTRANSMISSION ChASSISREAR AXLEBRAKEFRONT AXLESTEERINGhYDRAULIC ELECTRICmust be performed only 1 time after the initial of operation. *1 The air cleaner should be cleaned more frequently in dusty conditions than in normal conditions. *2 Every year or every 5 times of cleaning, whichever comes first. *3 Replace only if necessary. The items listed above (# marked) are registered as emission related critical parts by DAEDONG in the U.S.EPA exhaust emission standards non-road emission regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the above instructions. IMPORTANT GENERAL - MAINTENANCE UTV_02_.indd 11 2010-05-07 3:28:50 2-12 MECHRON 2200 SUUV-w00 Nov. 2009 SAFETY FIRSTGENERALENGINECVTTRANSMISSION ChASSISREAR AXLEBRAKEFRONT AXLESTEERINGhYDRAULIC ELECTRIC7.2 LUBRICATION AND REPLENIShMENT To prevent serious equipment damage, use only genuine DAEDONG oils or equivalents. No Item Capacity Lubricants 1 Fuel tank 28 (7.39 U.S.gal.) Diesel fuel 2 Radiator & water tank 6.3 (1.66 U.S.gal.) Fresh clean water with Ethylene glycol (50:50) 3 Engine crankcase 3.2 (0.85 U.S.gal.) Engine oil: API Service Classification CC or CD, SAE 15W-40 4 Transmission case 0.9 (0.24 U.S.gal.) SAE gear oil No. 90 or DAEDONG: UTF55 Shell: DONAX-TD Exxonmobil: Mobilfluid 423 or 424 BP: Tractran UTH 5 Front axle case 0.5 (0.13 U.S.gal.) 6 Rear axle case 0.8 (0.2 U.S.gal.) 7 Brake fluid tank Max level after bleeding DOT3 or equivalent 8 Front axle knuckle case Rear universal joint Apply until grease leaks out from a gap other than grease nipple. SAE multi-purpose grease. 9 Hydraulic oil tank (Option) 15 (3.97 U.S.gal.) DAEDONG: UTF55 Shell: DONAX-TD Exxonmobil: Mobilfluid 423 or 424 BP: Tractran UTH GENERAL - MAINTENANCE UTV_02_.indd 12 2010-05-07 3:28:50 2-13 MECHRON 2200 SUUV-w00 Nov. 2009 SAFETY FIRSTGENERALENGINECVTTRANSMISSION ChASSISREAR AXLEBRAKEFRONT AXLESTEERINGhYDRAULIC ELECTRIC8. TIRE MAINTENANCE 8.1 SPECIFIED INFLATION PRESSURE Items Tightening torque Front Wheel nut (1) 39.2 ~ 45.1 Nm 4.0 ~ 4.6 kgf-m 28.8 ~ 33.1 lb-ft Rear Wheel nut (2) Tires Front Rear Size Inflation pressure Size Inflation pressure Standard 25 x 10 - 12 6PR 0.84 kg/cm 82.7 Kpa 12 psi 25 x 11 - 12 6PR 1.27 kg/cm 124 Kpa 18 psi 8.2 TIGhTENING TORqUE FOR whEEL Tightening Torque UUVW108A UUVW110A UUVW109A Front Rear GENERAL - TIRE MAINTENANCE UTV_02_.indd 13 2010-05-07 3:28:52 2-14 MECHRON 2200 SUUV-w00 Nov. 2009 SAFETY FIRSTGENERALENGINECVTTRANSMISSION ChASSISREAR AXLEBRAKEFRONT AXLESTEERINGhYDRAULIC ELECTRIC9. TIGhTENING TORqUES 9.1 GENERAL USE SCREwS, BOLTS AND NUTS Screws, bolts and nuts whose tightening torques are not specified in this workshop manual should be tight- ened according to the table below. Mark on bolt head No-grade or 4T 7T 9T Material of bolt SS400, S20C S43C, S48C SCr435, SCM435 Material of steel or gray iron part Steel or gray iron Aluminum Steel or gray iron Aluminum Steel or gray iron Unit Code Nm kgf-m lb-ft Nm kgf-m lb-ft Nm kgf-m lb-ft Nm kgf-m lb-ft Nm kgf-m lb-ft M6 (6 mm, 0.24 in.) 7.85 ~ 9.31 0.80 ~ 0.95 5.79 ~ 6.87 7.85 ~ 8.82 0.80 ~ 0.90 5.79 ~ 6.50 9.81 ~ 11.2 1.00 ~ 1.15 7.24 ~ 8.31 7.85 ~ 8.82 0.80 ~ 0.90 5.79 ~ 6.50 12.3 ~ 14.2 1.25 ~ 1.45 9.05 ~ 10.4 M8 (8 mm, 0.31 in.) 17.7 ~ 20.5 1.8 ~ 2.1 13.1 ~ 15.1 16.7 ~ 19.6 1.7 ~ 2.0 12.3 ~ 14.4 23.6 ~ 27.4 2.4 ~ 2.8 17.4 ~ 20.2 17.7 ~ 20.5 1.8 ~ 2.1 13.1 ~ 15.1 29.5 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3 M10 (10 mm, 0.39 in.) 39.3 ~ 45.1 4.0 ~ 4.6 29.0 ~ 33.2 31.4 ~ 34.3 3.2 ~ 3.5 23.2 ~ 25.3 48.1 ~ 55.8 4.9 ~ 5.7 35.5 ~ 41.2 39.3 ~ 44.1 4.0 ~ 4.5 29.0 ~ 32.5 60.9 ~ 70.6 6.2 ~ 7.2 44.9 ~ 52.0 M12 (12 mm, 0.47 in.) 62.8 ~ 72.5 6.4 ~ 7.4 46.3 ~ 53.5 77.5 ~ 90.2 7.9 ~ 9.2 57.2 ~ 66.5 62.8 ~ 72.5 6.4 ~ 7.4 46.3 ~ 53.5 103 ~ 117 10.5 ~ 12.0 76.0 ~ 86.7 M14 (14 mm, 0.55 in.) 108 ~ 125 11.0 ~ 12.8 79.6 ~ 92.5 124 ~ 147 12.6 ~ 15.0 91.2 ~ 108 167 ~ 704 17.0 ~ 20.0 123 ~ 144 M16 (16 mm, 0.63 in.) 167 ~ 191 17.0 ~ 19.5 123 ~ 141 197 ~ 225 20.0 ~ 23.0 145 ~ 166 260 ~ 304 26.5 ~ 31.0 192 ~ 224 M18 (18 mm, 0.71 in.) 246 ~ 284 25.0 ~ 29.0 181 ~ 209 275 ~ 318 28.0 ~ 32.5 203 ~ 235 344 ~ 402 35.0 ~ 41.0 254 ~ 296 M20 (20 mm, 0.79 in.) 334 ~ 392 34.0 ~ 40.0 246 ~ 289 368 ~ 431 37.5 ~ 44.0 272 ~ 318 491 ~ 568 50.0 ~ 58.0 362 ~ 419 Material of component part Steel or gray iron Aluminum Unit Diameter Nm kgf-m lb-ft Nm kgf-m lb-ft M8 (8 mm, 0.31 in.) 11.6 ~ 15.6 1.2 ~ 1.6 8.68 ~ 11.5 8.82 ~ 11.6 0.90 ~ 1.2 6.51 ~ 8.67 M10 (10 mm, 0.39 in.) 24.6 ~ 31.3 2.5 ~ 3.2 18.1 ~ 23.1 19.7 ~ 25.4 2.0 ~ 2.6 14.5 ~ 18.8 M12 (12 mm, 0.47 in.) 29.5 ~ 49.0 3.0 ~ 5.0 21.7 ~ 36.1 31.4 3.2 23.1 9.2 STUD 4 7 9 GENERAL - TIGHTENING TORQUE UTV_02_.indd 14 2010-05-07 3:28:52 2-15 MECHRON 2200 SUUV-w00 Nov. 2009 SAFETY FIRSTGENERALENGINECVTTRANSMISSION ChASSISREAR AXLEBRAKEFRONT AXLESTEERINGhYDRAULIC ELECTRIC9.3 AMERICAN STANDARD SCREwS, BOLTS AND NUTS wITh UNC OR UNF ThREADS Grade Unit Diameter SAE GR.5 SAE GR.5 Nm kgf-m lb-ft Nm kgf-m lb-ft 5/16 23.1 ~ 27.8 2.35 ~ 2.84 17.0 ~ 20.5 32.5 ~ 39.3 3.31 ~ 4.01 24.0 ~ 29.0 3/8 47.5 ~ 57.0 4.84 ~ 5.82 35.0 ~ 42.0 61.0 ~ 73.2 6.22 ~ 7.47 45.0 ~ 54.0 1/2 108.5 ~ 130.2 11.07 ~ 13.29 80.0 ~ 96.0 149.2 ~ 179.0 15.22 ~ 16.27 110.0 ~ 132.0 9/16 149.2 ~ 179.0 15.22 ~ 18.27 110.0 ~ 132.0 217.0 ~ 260.4 22.14 ~ 26.57 160.0 ~ 192.0 5/8 203.4 ~ 244.1 20.75 ~ 24.91 150.0 ~ 180.0 298.3 ~ 358.0 30.44 ~ 36.53 220.0 ~ 264.0 GENERAL - TIGHTENING TORQUE UTV_02_.indd 15 2010-05-07 3:28:53 2-16 MECHRON 2200 SUUV-w00 Nov. 2009 SAFETY FIRSTGENERALENGINECVTTRANSMISSION ChASSISREAR AXLEBRAKEFRONT AXLESTEERINGhYDRAULIC ELECTRIC10. PART NUMBER ASSIGNMENT STANDARD FOR DAEDONG BOLTS AND NUTS 10.1 BOLTS GENERAL - PART NUMBER ASSIGNMENT STANDARD FOR DAEDONG BOLTS AND NUTS 0 1 1 3 3 - 5 1 0 5 5 Length: 55 mm In case the bolt length is over 100 mm, its length is identified by the last number. 5 MFZn5-C (Electric zinc) 6 MFZn5-G (Green chromate) 0 No plating Bolt size: M10 Plating 0 4T Partial thread (bolt) * Hardness is shown on the head of bolt. (with number or punching) 2 4T Full thread (set screw) 3 7T Partial thread (bolt) 5 7T Full thread (set screw) 6 9T Partial thread (bolt) Hardness and thread No. Spring washer Pitch M5 M6 M8 M10 M12 M14 M16 M18 M20 2 Yes Regular 0.8 1 1.25 1.5 1.75 2 2 2.5 2.5 3 Yes Fine - - 1 1.25 1.25 1.5 1.5 1.5 1.5 5 No Regular 0.8 1 1.25 1.5 1.75 2 2 2.5 2.5 7 No Fine - - 1 1.25 1.25 1.5 1.5 1.5 1.5 Spring washer and pitch No. Type M5 M6 M8 M10 M12 M14 M16 M18 M20 0 Regular 8 10 13 17 19 22 24 27 30 1 Small - - 12 14 17 19 22 24 27 Head size (mm) Part name (bolt) Example) 01120-50850 This is a zinc-plated 4T partial thread screw which its spring washer thread pitch is 1.25 mm, head size is 12 mm, diameter is 8 mm and length is 50 mm. UTV_02_.indd 16 2010-05-07 3:28:53 2-17 MECHRON 2200 SUUV-w00 Nov. 2009 SAFETY FIRSTGENERALENGINECVTTRANSMISSION ChASSISREAR AXLEBRAKEFRONT AXLESTEERINGhYDRAULIC ELECTRIC10.2 NUTS 0 2 1 1 4 - 5 0 0 8 0 Nut size: M8 5 MFzn5-C (Electric zinc plated) 6 MFzn5-GR (Electric flat chrome plated) 0 No plating Plating number Item hardness Thread height Remarks 54 4T Regular Type 2 Height - Type 2: longer - Type 3: shorter Hardness - For 6T nut, its hardness is indicated in number or chro- nometric method. - For 4T nut, its hardness is not usually indicated. 52 4T Regular Type 3 74 4T Fine Type 2 72 4T Fine Type 3 14 4T Regular Type 2 12 4T Regular Type 3 56 6T Regular Type 2 18 4T Fine Type 2 16 4T Fine Type 3 76 6T Fine Type 2 Cross distance Part name: nut Hardness, pitch, width 0 Regular 1 Small Nut specification standard table Item No. M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 Pitch Regular - 1 1 1.25 1.5 1.75 2 2 2.5 2.5 2.5 Fine - - - 1 1.25 1.25 1.5 1.5 1.5 1.5 1.5 Cross distance Regular 0 8 10 13 17 19 22 24 27 30 32 Small 1 - - 12 14 17 19 22 24 27 30 Height Type 2 - 4 5 6.5 8 10 11 13 15 16 18 Type 3 - 3 3.6 5 6 7 8 10 11 12 13 GENERAL - PART NUMBER ASSIGNMENT STANDARD FOR DAEDONG BOLTS AND NUTS UTV_02_.indd 17 2010-05-07 3:28:53 2-18 MECHRON 2200 SUUV-w00 Nov. 2009 SAFETY FIRSTGENERALENGINECVTTRANSMISSION ChASSISREAR AXLEBRAKEFRONT AXLESTEERINGhYDRAULIC ELECTRIC11. hOw TO INSTALL SPRING PIN AND SNAP RING 11.1 SPRING PIN INSTALLATION 11.2 SNAP RING ASSEMBLY F F F S76W111A In order to prevent displacement of a snap ring, as- semble its rounded area (R) against the opponent part as seen in the picture below. S76W112A Since a spring pin can be displaced depending on its direction that may cause shaking, it should be assem- bled, its split groove face the directin from which a force is applied. Spring pin Spring pin Snap ring GENERAL - HOW TO INSTALL SPRING PIN AND SNAP RING UTV_02_.indd 18 2010-05-07 3:28:54 Thank you very much for your reading. Please Click Here Then Get More Information.