CONTENTS CHAPTER 1GENERAL ........................................................................................................................ 1-1 1.TRACTOR INDENTIFICATION ......................................................................................................................... 1-3 2.TRACTOR VIEW ................................................................................................................................................. 1-4 3.GENERTAL PRECATIONS ................................................................................................................................ 1-5 3.1 ASSEMBLY AND DISASSEMBLY ............................................................................................................ 1-5 3.2 ELECTRICAL SYSTEM ........................................................................................................................... 1-6 3.3 TUBE AND RUBBERS ............................................................................................................................ 1-7
3.4 LUBICANT ................................................................................................................................................ 1-7 4.HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING ..................................................... 1-8 5.SPECIFICATION ................................................................................................................................................. 1-9 6.LUBRICANTS,FUEL AND COOLANT ............................................................................................................. 1-10 7.TIGHTENING TORQUE .................................................................................................................................... 1-11
7.1 GENERAL USE SCREW,BOLTS AND NUTS ...................................................................................... 1-11 7.2 STUD BOLTS ............................................................................................................................................ 1-11 7.3 AMERICAN STANDARD SCREW,BOLTS AND NUTS WITH UNC OR UNF THREADS ................. 1-12 8.MAINTENANCE CHECK LIST ......................................................................................................................... 1-13 9.CHECK AND MAINTENANCE .......................................................................................................................... 1-15 9.1DAILY CHECK ............................................................................................................................................ 1-15 9.2EVERY 50 HOURS ................................................................................................................................... 1-19 9.3EVERY 100 HOURS ................................................................................................................................. 1-21 9.4EVERY 200 HOURS ................................................................................................................................. 1-26
CHAPTER 2.ENGINE .......................................................................................................................... 2-1 1.FEATURE ............................................................................................................................................................ 2-3 2.LUBRICATING SYSTEM .................................................................................................................................... 2-4 3.COOLING SYSTEM ............................................................................................................................................ 2-5 4.FUEL SYSTEM ................................................................................................................................................... 2-6 5.TROUBLESHOOTING ....................................................................................................................................... 2-7 6.SERVICING SPECIFICATION .......................................................................................................................... 2-10 6.1ENGINE BODY .......................................................................................................................................... 2-10 6.2LUBRICATING SYSTEM ........................................................................................................................... 2-13 6.3COOLING SYSTEM ................................................................................................................................... 2-14 6.4FUEL SYSTEM ........................................................................................................................................... 2-14 6.5TIGHTENING TORQUE ............................................................................................................................ 2-15 7.DISASSEMBLING AND MAINTENANCE ........................................................................................................ 2-16 7.1SEAPRATING THE ENGINE .................................................................................................................... 2-16 7.2ENGINE DISASSEMBLED VIEW ............................................................................................................ 2-17 7.3ENGINE BODY .......................................................................................................................................... 2-29
7.4LUBRICATING SYSTEM ........................................................................................................................... 2-54 7.5COOLING SYSTEM ................................................................................................................................... 2-54 7.6FUEL SYSTEM ........................................................................................................................................... 2-56
CHAPTER 3.CLUTCH ......................................................................................................................... 3-1 1.FEATURES .......................................................................................................................................................... 3-3 2.TROBLESHOOTING .......................................................................................................................................... 3-4 3.SPECIFICATIONS,TIGHTENING TROQUES AND SPECIAL TOOLS ......................................................... 3-5 3.1SPECIFICATIONS ...................................................................................................................................... 3-5 3.2TIGHTENING TORQUES .......................................................................................................................... 3-5 3.3SPECIAL TOOLS ....................................................................................................................................... 3-5
CHAPTER 4.TRANSMISSION SYSTEM ...................................................................................................................... 4-1 1.STRUCTURE ...................................................................................................................................................... 4-3 1.1POWER TRAIN DIAGRAM ......................................................................................................................... 4-3 1.2POWER TRAIN ........................................................................................................................................... 4-4 1.3TRANSMISSION SHIFT LINKAGE STRUCTURE ................................................................................ 4- 10 2.TROUBLESHOOTING ..................................................................................................................................... 4-11 2.1TROUBLESHOOTING FOR SHUTTLE SHIFT ..................................................................................... 4- 15 2.2TROUBLESHOOTING FOR MAIN SHIFTS SECTION IN OPERATION ERROR ............................. 4- 15 2.3TROUBLESHOOTING FOR AUXILIARY AND CREEP SHIFTS IN OPERATION ERROR .............. 4- 16 2.4TROUBLESHOOTING FOR REAR DIFFERENTIAL GEAR IN OPERATION ERROR .................... 4- 16 2.5TROUBLESHOOTING FOR FRONT WHEEL DRIVE IN OPERATION ERROR .............................. 4- 17 2.6TROUBLESHOOTING FOR PTO CLUTCH IN OPERATION ERROR .............................................. 4- 17 2.7TROUBLESHOOTING FOR PTO IN OPERATION ERROR ................................................................ 4- 17 2.8TROUBLESHOOTING FOR PARKING BRAKE IN OPERATION ERROR ........................................ 4- 17 3.SPECIFICATIONS ............................................................................................................................................ 4- 18 3.1TIGHTENING TORQUES ........................................................................................................................ 4- 18 4.DISASSEMBLING AND MAINTENANCE ....................................................................................................... 4- 19 4.1DISASSEMBLING TRANSMISSION ....................................................................................................... 4- 19
CHAPTER 5.REAR AXLE ................................................................................................................... 5-1 1.STRUCTURE ...................................................................................................................................................... 5-2 2.TROUBLESHOOTING ....................................................................................................................................... 5-4 3.TIGHTENING TORQUE ..................................................................................................................................... 5-5 4.DISASSEMBLING AND MAINTENANCE ......................................................................................................... 5-6 4.1DISASSEMBLING REAR AXLE ................................................................................................................. 5-6 4.2MAINTENANCE ......................................................................................................................................... 5-10
CHAPTER 6.BRAKE ........................................................................................................................... 6-1 1.STRUCTURE ...................................................................................................................................................... 6-2 2.TROUBLESHOOTING ....................................................................................................................................... 6-5 3.TIGHTENING TORQUE ..................................................................................................................................... 6-5
4.TIGHTENING TORQUE MAINTENANCE ........................................................................................................ 6-7 5.CHECK,DISASSEMBLING AND MAINTENANCE .......................................................................................... 6-7 5.1ADJUSTMENT OF THE BRAKE ............................................................................................................... 6-7 5.2DISASSEMBLING AND ASSEMBLY ......................................................................................................... 6-8 5.3SERVICING ................................................................................................................................................ 6-11
CHAPTER 7.FRONT AXLE ................................................................................................................. 7-1 1.STRUCTURE ...................................................................................................................................................... 7-3 2.TROUBLESHOOTING ....................................................................................................................................... 7-4 3.SPECIFICATIONS .............................................................................................................................................. 7-5 4.TIGHTENING TORQUE ..................................................................................................................................... 7-7 5. CHECK,DISASSEMBLING AND MAINTENANCE ......................................................................................... 7-8 5.1CHECK AND MAINTENANCE .................................................................................................................. 7-8 5.2SEPARATING FRONT AXLE .................................................................................................................... 7-10 5.3DISASSEMBLING THE FRONT AXLE .................................................................................................... 7-12 5.4SERVICING ................................................................................................................................................ 7-22
CHAPTER 8 STEERING SYSTEM .................................................................................................... 8-1 1.STRUCTURE ...................................................................................................................................................... 8-2 1.1CHARACTERISTICS ................................................................................................................................. 8-3 1.2HYDRAULIC CIRCUIT OF POWER STEERING SYSTEM ................................................................... 8-4 1.3GEAR PUMP ............................................................................................................................................... 8-5 1.4POWER STEERING UNIT ........................................................................................................................ 8-6 1.5STEERING CYLINDER ............................................................................................................................. 8-7 1.6OIL FLOW .................................................................................................................................................... 8-8 2.TROUBELSHOOTING ...................................................................................................................................... 8-10 3.SPECIFICATIONS ............................................................................................................................................. 8-11 4.DISASSEMBLING AND MAINTENANCE ........................................................................................................ 8-12 4.1DISASSEMBLING TRANSMISSION ........................................................................................................ 4-19 4.1SEPARATING THE HYDRAULIC PUMP ................................................................................................. 8-12 4.2SEPARATING THE STEERING UNIT ..................................................................................................... 8-14 4.3DISASSEMBLING OF THE STEERING CYLINDER ............................................................................. 4-22 4.4SERVICING ................................................................................................................................................ 4-24
CHAPTER 9 HYDRAULIC SYSTEM .............................................................................................................................. 9-1 1.STRUCTURE ...................................................................................................................................................... 9-2 1.1HYDRAULIC OIL FLOW SHEMATIC ........................................................................................................ 9-3 1.2HYDRAULIC CIRCUIT SHEMATIC .......................................................................................................... 9-4 1.3HYDRAULIC FILTER SHEMATIC ............................................................................................................. 9-5 1.4HYDRAULICPUMP SHEMATIC ................................................................................................................ 9-5 1.5POWER STEERING SYSTEM .................................................................................................................. 9-6 1.6PTO CLUTCH VALVE SYSTEM ................................................................................................................ 9-8
1.74WD,Q/T AND Q/T(AB) SYSTEM ............................................................................................................... 9-9 1.8JOYSTICK VALVE ....................................................................................................................................... 9- 10 1.9HORIZONTAL CONTROL SYSTEM(ONLY JP) ...................................................................................... 9- 13 1.10HYDRAULIC POWER LIFT SYSTEM .................................................................................................... 9- 12 1.11AUXILIARY CONTROL VALVE(ONLY EQUIPPED) .............................................................................. 9- 13 2.TROUBLINGSHOOTING .................................................................................................................................. 9-14 2.1JOYSTICK VALVE ....................................................................................................................................... 9- 14 2.2HYDRAULIC LIFT SYSTEM ...................................................................................................................... 9- 15 3.CHECKING,DISASSEMBLING AND MAINTENANCE .................................................................................. 9- 16 3.1HYDRAULIC FILTER ................................................................................................................................. 9 -16 3.2HYDRAULIC PUMP ................................................................................................................................... 9- 16 3.3 POWER STEERING UNIT ....................................................................................................................... 9- 18 3.4PTO CLUTCH VALVE ................................................................................................................................. 9 -19 3.5 4WA,Q/T AND Q/T(AB) VALVE ................................................................................................................. 9- 23 3.6JOYSTICK VALV ......................................................................................................................................... 9- 27 3.7HORIZONTAL CONTROL VALVE ............................................................................................................. 9- 28 3.8HYDRAULIC LIFT SYSTEM ...................................................................................................................... 9- 30
CHAPTER 10 CABIN SYSTEM .................................................................................................................................. 10-1 1.STRUCTURE ..................................................................................................................................................... 10 -3 1.1HEATER ...................................................................................................................................................... 10 -3 1.2AIR-CONDITIONER ................................................................................................................................... 10 -4 2.TROUBLESHOOTING ...................................................................................................................................... 10 -6 3.INSPECTION AND ADJUSTMENTS ............................................................................................................... 10 -4
CHAPTER11 ELECTRIC SYSTEM .............................................................................................................................. 11-1 1.HOW TO WIRING DIAGRAM ............................................................................................................................ 11-3 1.1WIRE CODE ............................................................................................................................................... 11-3 1.2WIRE SIZE .................................................................................................................................................. 11-3 1.3INSTRUMENT PANEL BULBS ................................................................................................................. 11-4 1.4RELAY AND SWITCH ................................................................................................................................. 11-5 1.5MULTIPLE SWITCH ................................................................................................................................... 11-5 1.6RELAY BOX ................................................................................................................................................. 11-6 1.7FUSE CHECK ............................................................................................................................................ 11-7 1.8WIRING DIAGRAM ..................................................................................................................................... 11-9 2.INSTRMENT PANEL ........................................................................................................................................ 11-11 2.1SYMBOL DESCRIPTION ......................................................................................................................... 11-11 2.2CIRCUIT DIAGRAM OF INSTRUMENT(USA) ....................................................................................... 11 -14 3.STSRTING SYSTEM ........................................................................................................................................ 11 -15 3.1IGNITION CIRCUIT(WITHOUT THE INSTALLATION OF HORIZONTAL CONTROLLER ............... 11 -15 3.2IGNITION CIRCUIT(HORIZONTAL CONTROL INSTALLATION EXPECTATION ONLY JP ............. 11 -16 3.3MAJOR COMPONENTS ........................................................................................................................... 11 -17
4.CHARGING SYSTEM ....................................................................................................................................... 11 -22 4.1CIRCUIT DIAGRAM .................................................................................................................................. 11 -22 4.2AC (ALTERNATING CURRENT)ALTERNATOR .................................................................................... 11 -23 5.ENGINE GLOW PLUG SYSTEM .................................................................................................................... 11 -25 5.1CIRCUIT DIAGRAM .................................................................................................................................. 11 -25 5.2MAJOR COMPONENTS ........................................................................................................................... 11- 26 6.PTO SYSTEM(ONLY USA) .............................................................................................................................. 11 -28 6.1CIRCUIT DIAGRAM .................................................................................................................................. 11 -28 6.2CIRCUIT DESCRIPTION ........................................................................................................................ 11 -30 6.3TROUBLESHOOTING ............................................................................................................................. 11-3 0 7.ROTARY LEVEL CONTROL INSTALLATION(ONLY JP) ............................................................................. 11 -31 7.1SYSTEM COMPOSITION PARTS ........................................................................................................... 11 -31 7.2OUTLINE ................................................................................................................................................... 11 -32 7.3LEVEL CONTROL INSTALLATION FUCTION ...................................................................................... 11 -34 7.4TERMINAL ARRANGEMENT TABLE ...................................................................................................... 11 -37 8.QUECK TURN(ONLY JP) ................................................................................................................................ 11- 38 8.1ELECTRIC CIRCUIT ................................................................................................................................ 11- 38 8.2MAIN PARTS COMPOSITION .................................................................................................................. 11 -40 8.3REPAIRS FOR QUECK TURN1 MALFUCTION ................................................................................... 11 -42 9.AIR CONDITIONING SYTEM .......................................................................................................................... 11 -43 9.1CIRCUIT DIAGRAM .................................................................................................................................. 11 -43 9.2MAJPR COMPONENTS ........................................................................................................................... 11- 44 10.HEATER SYSTEM .......................................................................................................................................... 11 -46
TO THE READER
TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of DAEDONG tractors DK45S(DK451). It is divided into two parts, “Mechanism” and “Servicing”.
MECHANISM Information on the construction and functions are included. The part should be completely understood before proceeding with troubleshooting, disassembling or servicing.
SERVICING In this section you will find general precautions, maintenance and special tools. The are other sections which include troubleshooting, servicing, specifications lists, disassembling, assembling and servicing that explains in detail procedures, precautions, factory specifications and acceptable limits.
This manual contains the latest production information on illustrations and specifications based on the most up to date production information available at the time of publication. We reserve the right to make changes throughout the entire manual at any time without notice.
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DK45S(DK451)
SAFETY FIRST This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and the decals on the machine itself to warn of the possibility of personal injury. It is essential that you read the instructions and safety regulations before you attempt to repair or operate this unit. Read these instructions carefully. SIGNS
DESCRIPTION
DANGER
This mark indicates hazardous situation which, if not observed, may result in death or fatal injury. This mark should be indicated for most dangerous situations only.
WARNING
This mark indicates potentially hazardous situation which, if not observed, may result in death or moderate injury.
CAUTION
This mark indicates potentially hazardous situation which, if not observed, may result in minor or moderate injury. And this mark can be used as a warning against unsafe activities.
IMPORTANT
This mark indicates emphasis on notable characteristics in working procedures or information on working procedures and technology for convenient use.
NOTE
Gives helpful information.
BEFORE SERVICING AND REPAIRING 1. Read all safety instructions in this manual and be aware of the safety decals on your machine itself. 2. Thoroughly clean your work area and the machine. 3. Make sure the machine is on firm and level ground and that the parking brake is set. 4. Lower the implement to the ground. 5. Stop the engine and remove the key. 6. Disconnect the negative battery cable. 7. Place a “DO NOT OPERATE” tag in operator station.
C45W001A
SAFETY STARTING 1. Always use the safety start switch to start the engine and never by any other means. 2. Do not alter or remove any part of machine safety system. 3. Before starting the engine, make sure that all shift levers are in neutral positions or in the disengaged positions. 4. N eve r s tart the en gin e u nle ss y ou are in the operator’s seat.
C45W002A
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TO THE READER SAFETY WORKING 1. Do not operate or service the machine while under the influen ce of alcoho l, med ication , or o ther substances. 2. Never wear loose fitting clothing and always use safety equipment appropriate to the job. 3. Never use improvised tools, parts or procedures. Use only recommended tools appropriate to the work. 4. Be careful to perform all work safely when servicing is done by two or more people. 5. Always support the machine by safety stands. Never work under the machine that is supported solely by a jack.
C45W003A
6. Do not touch any rotating or hot parts while the engine is running. 7. Never remove the radiator cap while the engine is running, or immediately after stopping. Only remove radiator cap when it is cool enough to touch with bare hands. Slowly loosen the cap to relieve pressure before removing completely. 8. Escaping fluid (fuel or hydraulic oil) under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or fuel lines. Tighten all connections before applying pressure. C45W004A
AVOID FIRES 1. Never smoke or allow flames or sparks in your work area, as fuel is extremely flammable and explosive under certain conditions. 2. Always disconnect the negative battery cable first and reconnect it last to avoid sparks from an accidental short circuit. 3. Battery gas will ignite. Keep sparks and open flame away from the top of battery, especially while charging. 4. Be careful not to spill fuel on the engine.
C45W005A
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DK45S(DK451) VENTILATE WORK AREA 1. Exhaust contains poisonous carbon monoxide, so you should never run the engine in a closed area. If th e en gin e m ust be runn ing wh ile p erf ormi ng maintenance, make sure the area is well ventilated.
C45W006A
PREVENT ACID BURNS 1. Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, clothing and cause blindness if splashed into eyes. Keep electrolyte away from eyes, hands and clothing. If you spill electrolyte on yourself, flush with water, and get medical attention immediately.
C45W007A
DISPOSE OF FLUIDS PROPERLY 1. Observe relevant environmental protection regulations when disposing of oil, fuel, coolant, electrolyte and other harmful waste. Never pour fluids into the ground, down a drain, or into a stream, pond, or lake.
C45W008A
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TO THE READER PREPARE FOR EMERGENCIES 1. Be sure to keep a first aid kit and fire extinguisher handy at all times. 2. Keep emergency numbers for the nearest fire d e pa r t m en t , ho s p it a l , d o c to r a n d a m b u la n c e service, near your telephone in case of emergency.
C45W009A
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DK45S(DK451)
SAFETY DECALS The following safety decals are installed on the machine. If a decal becomes damaged, illegible or is not on the machine, replace it. The decal part number is listed in the parts list.
ROPS
C45W010A
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TO THE READER
CABIN
C45W011A
(1) Parts No. : T4625-52191
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(2) Parts No. : T4837-51181
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DK45S(DK451) (3) Parts No. : T4685-52311
(4) Parts No. : T4818-52142
(5) Parts No. : T2325-50743
(6) Parts No. : T4625-52351
(7) Parts No. : T4625-52361
(8) Parts No. : T4625-53191
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