FORWARD The labor hours specified in this manual are set by DAEDONG`s qualified service mechanics. The service hour for every service task was precisely measured based on the experience of our mechanics. Then, the labor hour was set by applying adjustment factors to this service hour so that this manual could be used by mechanics having different levels of expertise and servicing in various regions. The features of this manual are as follows; 1. Figures and reference numbers used in this manual are identical to those in the part manual to make searching easier. 2. As every individual part and component has its own code (except for hardware), it is easy to locate correct job codes faster. 3. The index attached to this manual serves as an additional measure for convenient searching of job codes. How to use this manual 1. The same job code should not be used more than once since the labor hour for one job code is for both disassembly and re-assembly jobs. 2. In most cases, only one code should be used in one group (page) at a time. However, * More than one job code can be used in one group when performing several different tasks. * One job code can be used two times in case when both LH and RH parts are serviced at the same time. 3. Do not use subordinate job codes even if they are in different groups. For example, “Bonnet R & R” and “Complete engine R & R should not be used at the same time since “Bonnet R & R” is included in “Complete engine R & R”. In this case, only “Complete engine R & R” should be used. 4. Use of a separate warranty request form is required for each failure.
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FORWARD 5. Use only one job code when servicing several adjacent or related parts. For example, if the bevel gear, its shaft and bearings are replaced the same time, use only the top level job code applicable. 6. Time taken for reconditioning, resealing, overhaul, related oil draining and refilling, part flushing and adjustment after replacing parts are included in the labor hours of these job codes. Therefore, there is no need to include other job codes for such services. 7. Labor hours for diagnosis and implement R & R are not included the job codes. Use the following extra job codes as needed with specific job descriptions on the warranty request form: * X999001: 0.5 hr. R & R of detachable main body of loaders, backhoes, mid-mount mowers, etc. * X999002: 1.0 hr. Diagnosis time * X999003: 2.0 hr. R & R of components used in the mounting of loaders, backhoes, mid-mount mowers, etc. 8. Failure to by the above instructions when drawing up the warranty request form (including on-line request) will result in rejection of your warranty claim. 9. If additional time is used for service, indicate details as to why and how many hours were needed in the description field of the form. Use of random job codes will result in your warranty being rejected.
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table of contents GROUP NO INDEX 1 INDEX 2 INDEX 3 4A220LX-E010 4A220-E020 4A220LW-E030 3B183-E040 TD2200-E050 4A220A-E080 4B243LX-E090 4A220LX-E100 4A200LW-E110 4A200B-E120 4A220-E130 4A220LX-E140 3B183-E150 4B243-E160 3A150LX-E170 4A200LX-E180 4A220LXM-E190 4A220LWE-E200 4A200-E220 DS4510-T480A
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GROUP NAME PAGE SECTIONAL GROUP...............................7 SORTED BY GROUP NAME.................11 SORTED BY PART NAME.....................15 CYLINDER BLOCK GROUP.................24 OIL PAN GROUP...................................26 CYLINDER HEAD GROUP....................28 GEAR CASE GROUP............................30 MAIN BEARING CASE GROUP............32 VALVE ROCKER ARM GROUP.............34 CYLINDER HEAD COVER GROUP......36 CAMSAFT GROUP................................38 PISTON & CRANK SHAFT GROUP......40 FLYWHEEL GROUP..............................42 NOZZLE HOLDER GROUP...................44 FUEL CAMSHAFT GROUP...................46 SPEED CONTROL PLATE GROUP......48 ENGINE STOP LEVER GROUP............50 GOVERNER GROUP............................52 WATER PUMP GROUP.........................54 WATER HOSE GROUP.........................56 DYNAMO GROUP.................................58 MANIFOLD GROUP..............................60 FRONT AXLE SUPPORT GROUP........62
GROUP NO D380L-T500A DS4510-T520A EX45H-T525A DS4510-T530A CT445B-T540A DS4510-T540A D360-T110A DS4510-T130A DS4510-T140A DS4510-T150A DS4510-T160A DS4510-T170A DS4510-T180A DK40-T195A D360-T200A DK40-T215A DS4510-T220A DS4510-T240A D360-T260A D360-T270A D43-T270A DS4510-T275A D360-T290A
GROUP NAME PAGE BEVEL PINION SHAFT GROUP...........64 BEVEL GEAR SHAFT GROUP.............66 FRONT DIFFERENTIAL GROUP..........68 FRONT AXLE CASE GROUP................70 BEVEL GEAR CASE GROUP...............72 FRONT AXLE GROUP..........................74 CLUTCH LEVER GROUP.....................76 CLUTCH HOUSING GROUP................78 MID CASE GROUP...............................80 TRANSMISSION CASE GROUP...........82 MAIN SHAFT GROUP...........................84 COUNTER SHAFT GROUP..................86 SHUTTLE SHAFT GROUP....................88 PTO COUNT SHAFT GROUP...............90 RANGE SHAFT GROUP.......................92 PTO CLUTCH GROUP..........................94 PTO SHAFT GROUP.............................96 SPIRAL BEVEL GEAR GROUP............98 FR. WH. DRIVING SHAFT GROUP....100 MAIN SHIFT FORK GROUP...............102 REAR DIFFERENTIAL GROUP..........104 SHIFT ROD GROUP...........................106 SHUTTLE FORK GROUP...................108
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table of contents GROUP NO DK40-T315A DS4510-T350A DS4510-T370A DS4510-T380A DS4510-T400A DS4510-T410A DS4510-T560A DS4510-T465A DS4510-T595A DS4510-T600-1A D360-T610B D360-T620A D360-T630B D360-T650B CK30M-T660A D360-T660A D360-T670A DK40-T705A DS4510-T710A DS4510-T720A DS4510-T730A DS4510-T740A DS4510-T750A
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GROUP NAME PAGE RANGE FORK GROUP.......................110 FRONT DRIVE FORK GROUP...........112 DIFF. LOCK FORK GROUP................114 BRAKE CASE GROUP........................116 BRAKE ROD GROUP..........................118 REAR AXLE GROUP...........................120 PROPELLER SHAFT GROUP............122 POWER STEERING UNIT GROUP....124 STEERING CYLINDER GROUP.........126 HYD. CYLINDER ASS`Y GROUP.......128 HYD. CYLINDER BODY GROUP........130 HYD. LIFT ARM GROUP.....................132 HYD. CONTROL SYSTEM GROUP 1....134 TOP LINK BRACKET GROUP.............136 HYD.CONTROL SYSTEM GROUP 2...138 MAIN DISTRIBUTOR VALVE GROUP..140 HYD. EXTERNAL VALVE 1 GROUP..................142 GEAR PUMP GROUP.........................144 PTO CLUTCH VALVE GROUP............146 HYDRAULIC BLACK GROUP.............148 HYDRAULIC FILTER GROUP.............150 HYDRAULIC TUBE GROUP...............152 INLET TUBE GROUP..........................154
GROUP NO LX480L-T010A DS4510-T020A DS4510-T030A DS4510-T100A DS4510-T325A DS4110-T430A DS4510-T550A EX45H-T596A DS4510-T770A DS4510-T780A D360-T790A DS4510-T805A LX480L-T810A DS4510-T820A DS4510-T830A LX480L-T840A DS4510-T915A DS4510-T935A DS4510-T995A DS4510-T1000A DS4510-T1015A DS4510-T1025A DS4510-T1035A
GROUP NAME PAGE AIR CLEANER GROUP.......................156 MUFFLER GROUP..............................158 RADIATOR GROUP.............................160 CLUTCH GROUP................................162 RANGE LEVER GROUP.....................164 FRONT AXLE FRAME GROUP...........166 FRONT AXLE BRACKET GROUP.......168 CYLINDER COVER GROUP...............170 POSITION CONTROL LEVER GROUP 172 3-POINT LINK SYSTEM 1GROUP......174 3-POINT CONNECTOR SYS. 2 GROUP... 176 DRAWBAR GROUP.............................178 BONNET 1 GROUP.............................180 BONNET 2 GROUP.............................182 FUEL TANK GROUP...........................184 FUEL FILTER GROUP.........................186 MAIN SHIFT LEVER GROUP..............188 FRONT WHEEL DRIVE LEVER GROUP 190 FENDER GROUP................................192 SEAT FLOOR GROUP........................194 SEAT GROUP......................................196 STEP GROUP.....................................198 HANDLE GROUP................................200
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table of contents GROUP NO DS4510-T1065A DS4510-T2000A DS4510-T2005A DS4510-T2015A DS4510-T2035A DS4510-T2055A DS4510-T2060A DS4510-T515A DS4510-T555A DS4510-T565A DS4510-T575A CT230-T1050A DS4510-T2085A CK30M-T1020A CK30M-T1040A CK30-T1065A DS4510-T3000-1A
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GROUP NAME PAGE ROPS GROUP.....................................202 CLUTCH PEDAL GROUP....................204 SHUTTLE LEVER GROUP..................206 BRAKE PEDAL GROUP......................208 FRAME GROUP..................................210 INSTRUMENT COVER GROUP.........212 THROTTLE GROUP............................214 BATTERY GROUP...............................216 ELECTRICAL SYSTEM 1 GROUP......218 ELECTRICAL SYSTEM 3 GROUP......220 LIGHT GROUP....................................222 WORKING LIGHT GROUP..................224 FRAME ELECTRONIC GROUP..........226 7 PIN SOCKET GROUP......................228 SUNSHADE GROUP...........................230 FRONT WEIGHT GROUP...................232 EXTERNAL HYDRAULIC VALVE GROUP......234
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4A220LX-E010
CYLINDER BLOCK GROUP
24
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REF NO JOB CODE
HOURS
DESCRIPTION
DS4510
DS4110
*
E010001
ENGINE ASSEMBLY, R & R
5.0
←
1
E010002
CYLINDER BLOCK ASSEMBLY
10.0
←
2
E010003
HOSE, WATER RETURN
0.5
←
3
E010004
OIL PUMP ASSEMBLY
5.0
←
4
E010005
GEAR, OIL PUMP DRIVING
5.0
←
5
E010006
OIL SWITCH
0.5
←
6
E010007
GUIDE
0.5
←
REMARK
25
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4A220-E020
OIL PAN GROUP
26
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REF NO JOB CODE
HOURS
DESCRIPTION
DS4510
DS4110
1
E020001
OIL PAN ASSEMBLY
1.5
←
2
E020002
GASKET, OIL PAN
1.5
←
3
E020003
FILTER 1, OIL
1.6
←
4
E020004
OIL GAUGE GUIDE PIPE
0.3
←
REMARK
27
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4A220LW-E030
CYLINDER HEAD GROUP
28
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REF NO JOB CODE
HOURS
DESCRIPTION
DS4510
DS4110
1
E030001
CYLINDER HEAD ASSEMBLY
3.0
←
2
E030002
COMBUSTION CHAMBER
2.5
←
3
E030003
GASKET, HEAD
2.5
←
REMARK
29
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3B183-E040
GEAR CASE GROUP
30
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REF NO JOB CODE
HOURS
DESCRIPTION
DS4510
DS4110
1
E040001
GEAR CASE ASSEMBLY
3.5
←
2
E040002
O-RING
3.5
←
3
E040003
O-RING
3.5
←
4
E040004
O-RING
3.5
←
5
E040005
GEAR CASE GASKET
3.5
←
REMARK
31
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TD2200-E050
MAIN BEARING CASE GROUP
32
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