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.
DC45-WOO Nov. 2004
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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
2
DC45-WOO Nov. 2004
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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DC45-WOO Nov. 2004
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
6
DC45-WOO Nov. 2004
TO THE READER
CABIN
C45W011A
(1) Parts No. : T4625-52191
DC45-WOO Nov. 2004
(2) Parts No. : T4837-51181
7
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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DC45-WOO Nov. 2004
TO THE READER (9) Parts No. : T2241-50702
(10) Parts No. : T2445-50724
(11) Parts No. : T4837-51093
(12) Parts No. : T2615-54112
(13) Parts No. : T4818-52132
(14) Parts No. : T2615-55112
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DK45S(DK451) (15) Parts No. : T4817-52201
(16) Parts No. : T2615-53561
CARE OF DANGER, WARNING AND CAUTION LABELS 1. Keep danger, warning and caution labels clean and free from obstructing material. 2. Clean danger, warning and caution labels with soap and water, dry with a soft cloth. 3. Replace damaged or missing danger, warning and caution labels with new labels. 4. If a component with danger, warning or caution label(s) is replaced, make sure new label(s) is (are) attached in the same locations(s) as the replaced component. 5. Mount new labels by applying on a clean dry surface and pressing any bubbles to outside edge.
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DC45-WOO Nov. 2004
CHAPTER 1
GENERAL
GENERAL
1. TRACTOR IDENTIFICATION When contacting your local KIOTI distributor, always specify engine serial number, tractor serial number and hour meter reading.
C45W102A
C45W101A
(1) Statutory Plate
(2) Identification Plate
(3) Engine Serial Number
C45W103A
(4) Hour Meter
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CHAPTER 1
DK45S(DK451)
2. TRACTOR VIEW
C45W104A
1-4
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GENERAL
3. GENERAL PRECAUTIONS 3.1 ASSEMBLY AND DISASSEMBLY
C45W105A
(1) Grease
(4) Assemble Towards to be Forced
(2) Snap Ring for Shaft
(5) Reciprocating
(3) Snap Ring for Hole
(6) Rotating
1. Place the tractor on firm and level ground prior to any service or adjustment. 2. Work with the engine stopped whenever possible. Be careful when doing any testing that requires the engine to be running. 3. Use only DAEDONG approved special tools. Servicin g d eal ers ma y m ach ine to ols to DE ADO NG specifications, if the tool will not be used often. 4. Keep your work area and the tractor clean during all p h as e s o f t he di s a ss e m b ly a n d r e a ss e m b ly process.
11. When assembling an outside snap ring, on a shaft, or an inside snap ring, in a hole, assemble with the head in the direction of force. Reference the above figure. 12.When replacing a new part also replace the associated packing (gasket), bearing(s), and o-ring(s). Apply grease properly for O-rings and oil seals before assembly. 13.Locate the split portion of any spring pin by referencing the direction of force, like the above figure. 14.Replace any split pin with a new one.
5. After removal, keep parts clean and organized. Tighten nuts to m ating bolts by hand to keep matched sets together. 6. Be careful during disassembly, assembly, and storage of hydraulic parts. Dust and metal chips can contaminate the whole hydraulic system. Keep parts covered whenever possible. 7. Use only approved manufactures cleaning agents fo r p arts cl ean ing . H yd rau lic par ts sho uld be cleaned with an approved cleaning oil. Diesel fuel should never be used for cleaning. 8. Remove all oil and contaminates before performing any measurement of parts. 9. Disconnect the battery negative (-) cable before removing or installing any live electrical components.
IMPORTANT •
Use packing bond, gasket sealer, equivalent to three bond 1208D.
•
Remove all existing sealer before applying new sealer to the part.
•
Apply the bond, sealer, in a bead centered on the sealing flange area. If a bolt hole is encountered, continue bead to the center of the inner sealing surface.
•
Assemble the parts within 10 minutes of bond, sealer, application. Wait 30 minutes before adding oil to the sealed parts, if applicable.
10.Use only DAEDONG ( KIOTI) genuine parts to maintain the performance and safety of your KIOTI tractor.
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CHAPTER 1
DK45S(DK451)
3.2 ELECTRICAL SYSTEM 1. Check all electrical connectors daily for any damage or short circuit at their junctions. In addition, annually schedule a complete electrical system inspection with your local KIOTI dealer. 2. Do not modify or reorganize the wiring harness or the electric field parts. 3. When disconnecting battery cables, disconnect the negative cable first. Reinstall the positive cable first when reinstalling.
NOTE: •
Be sure to turn the starting key OFF when connecting or disconnecting the cable.
4. When disconnecting a connector, grasp the plastic section, not the wiring.
C45W106A
5. When reconnecting the connector, Insert it until it snaps.
C45W107A
6. When replacing a broken fuse with a new one, be sure to use the fuse with the correct amperage capacity. Use your owner’s manual to establish the correct capacity. 7. Be sure not to drop sensors and relays. They are fragile.
C45W108A
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GENERAL
3.3 TUBES AND RUBBERS Keep the tubes (hoses) and rubber parts free from oil and other petroleum products. This may cause a change in quality in these parts, and may shorten product life.
C45W109A
3.4 LUBRICANT During assembly and repair, apply designated lubricant where specified in accordance with this repair manual.
C45W110A
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CHAPTER 1
DK45S(DK451)
4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING To ensure safety and prevent damage to the machine and surrounding equipment, heed the following precautions in handling electrical parts and wiring.
IMPORTANT •
Check electrical wiring for damage and loosened connection every year. To this end, educate the customer to do his or her own check. At the same time recommend that the dealer performs a periodic check during regular maintenance.
•
Do not attempt to modify or remodel any electrical parts and/ or wiring.
• When removing the battery cables, disconnect the negative cable first. When installing the battery cables, connect the positive cable first.
1-8
C45W111A
DC45-WOO Nov. 2004
GENERAL
5. SPECIFICATIONS
Model
DK45S
DK451
Model
4A220B
Type Engine
Liquid-cooled, 4-cylinder diesel
Engine gross
HP (kW)
45 (33.6)
P.T.O
HP (kW)
38 (28.3)
cc (cu.in)
2,197 (134.1)
Displacement Rated revolution
r.p.m min-1
Fuel tank capacity
(gal.)
Clutch
Drive train
2,600 58 (15.32) Dry type single stage
Transm ission
Synchro
Speeds
12F 12R
Differential lock
Standard
Brake
Wet disc type
P.T.O
Trans
Rear
(rpm)
Pump capacity (Max. flow rate)
/min (gpm)
1 speed (540 rpm at
3 speed (560/728/1040
2,600 engine rpm)
rpm at 2,600 engine rpm)
Main pump 37.4 (9.88) Power steering pump 16.4 (4.33)
Hydraulic system
3-point hitch
Cat.I
Maximum lifting capacity
kgf (lbs.)
Hydraulic lift control system
1,204 (2,654) Position, draft and Mixed control
Steering Standard tire size
Hydrostatic
Front Rear (AG, TURF, INDUSTRIAL) Forward (At rated engine rpm)
Traveling sp ee ds
Dimensio ns
Reverse (At rated engine rpm)
km/h (mph)
km/h (mph)
9.5 - 16, 6PR
9.5 - 16, 6PR
14.9 - 24, 6PR
13.6 - 26, 6PR
0.39 ~ 25.90
0.38 ~ 25.67
(0.24 ~ 16.09)
(0.236 ~ 15.95)
0.32 ~ 21.44
0.32 ~ 21.25
(0.20 ~ 13.32)
(0.20 ~ 13.20)
Overall length (with 3p)
mm (in.)
3,243 (126.8)
Overall width (minimum tread)
mm (in.)
1,564 (61.6)
Overall height (Top of Cabin)
mm (in.)
Wheel base
mm (in.)
1,880 (74.0)
Min. ground clearance
mm (in.)
370 (14.6)
Tread
Front
mm (in.)
1,265 (49.8)
Rear
mm (in.)
1,208 ~ 1,490 (47.6 ~ 58.7)
Min. turning radius (with brake) Weight (with Cabin)
2,333 (91.9)
2,325 (91.5)
m (Ft.)
2,865 (112.8)
kgf (lbs.)
2,030 (4,475)
NOTE: The specifications are subject to change for the purpose of improvement without any notice.
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CHAPTER 1
DK45S(DK451)
6. LUBRICANTS, FUEL AND COOLANT No.
Locations
Capacities
Lubricants No.2-D diesel fuel
1
Fuel
2
Coolant
58.0
(15.32 U.S.gal.)
No.1-D diesel fuel if temperature is below -10°C (14°F)
8.6
(2.30 U.S.gal.)
Fresh clean water with anti-freeze Engine oil: API Service Classification CC or CD
3
Engine crankcase
8.0
(2.1 U.S.gal.)
Above 25°C (77°F)
SAE30, SAE10W-30 or 10W-40
0 to 25°C (32 to 77°F)
SAE20, SAE10W-30 or 10W-40
Below 0°C (32°F)
SAE10W, SAE10W-30 or 10W-40
Multi-gradetransmission fluid the fluid listed below or equivalent are recommended. 4
5
Transmission case
Front axle case
38.0
8.2
(10.04 U.S.gal)
(2.17 U.S.gal.)
Applying grease Hydraulic control lever shaft section 3 point link section 6
Exxonmobil
Mobilfluid 423 or 424 Exxon hydraul 560
Shell
DONAX-TD/TD Plus
BP
Tractran UTH
SAE 90 gear oil Capacity Small quantity Until grease exits
Type of grease SAE multi-purpose type grease
Brake pedal link section Bracket section in front and rear of the front axle Clutch release hub
1-10
Supply when removed
DC45-WOO Nov. 2004
GENERAL
7. TIGHTENING TORQUES 7.1 GENERAL USE SCREWS, BOLTS AND NUTS Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be tightened according to the table below. Indication on top of bolt
4
Material of bolt Material of opponent part Unit Diameter
No-grade or 4T
7
SS400, S20C
7T
9
9T
SCr435, SCM435
S43C, S48C
Ordinariness
Aluminum
Ordinariness
Aluminum
Ordinariness
N·m kgf·m lbf·ft
N·m kgf·m lbf·ft
N·m kgf·m lbf·ft
N·m kgf·m lbf·ft
N·m kgf·m lbf·ft
7.85 M6 ~ (6 mm, 0.24 in.) 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
17.7 M8 ~ (8 mm, 0.31 in.) 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
39.3 M10 ~ (10 mm, 0.39 in.) 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
62.8 M12 ~ (12 mm, 0.47 in.) 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
108 M14 ~ (14 mm, 0.55 in.) 125
11.0 ~ 12.8
79.6 ~ 92.5
124 ~ 147
12.6 ~ 15.0
91.2 ~ 108
167 ~ 196
17.0 ~ 20.0
123 ~ 144
167 M16 ~ (16 mm, 0.63 in.) 191
17.0 ~ 19.5
123 ~ 141
197 ~ 225
20.0 ~ 23.0
145 ~ 166
260 ~ 304
26.5 ~ 31.0
192 ~ 224
246 M18 ~ (18 mm, 0.71 in.) 284
25.0 ~ 29.0
181 ~ 209
275 ~ 318
28.0 ~ 32.5
203 ~ 235
344 ~ 402
35.0 ~ 41.0
254 ~ 296
334 M20 ~ (20 mm, 0.79 in.) 392
34.0 ~ 40.0
246 ~ 289
368 ~ 431
37.5 ~ 44.0
272 ~ 318
491 ~ 568
50.0 ~ 58.0
362 ~ 419
7.2 STUD BOLTS Material of opponent part Unit
Ordinariness
Aluminum
N·m
kgf·m
lbf·ft
N·m
kgf·m
lbf·ft
M8 (8 mm, 0.31 in.)
11.8 ~ 15.6
1.2 ~ 1.6
8.68 ~ 11.5
8.82 ~ 11.8
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
Diameter
DC45-WOO Nov. 2004
1-11
CHAPTER 1
DK45S(DK451)
7.3 AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS Grade
SAE GR.5
SAE GR.8
Unit
Nominal diameter
N·m
kgf·m
lbf·ft
N·m
kgf·m
lbf·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 ~ 18.27
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
1-12
DC45-WOO Nov. 2004
GENERAL
8. MAINTENANCE CHECK LIST Period
Indication On Hour Meter
After Purchase Important
No. 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1500 3000
Item 1
Engine oil
Change
2
Engine oil filter
Replace
3
Transmission oil filter
Replace
4
Transmission fluid
Change
5
Front axle case oil
Change
6
Front axle pivot
Adjust
7
Engine start system
Check
8
Greasing
9
Wheel bolt torque
Check
10
Battery condition
Check
11
Air cleaner element
12
Fuel filter element
13
Fan belt
Adjust
14
Clutch
Adjust
15
Brake
Adjust
Radiator hose and clamp
Check
16 17
Power steering oil line
18
Fuel line
19
Intake air line
20
Toe-in
Adjust
21
Engine valve clearance
Adjust
22
Fuel injection nozzle injection pressure
Check
23
Injection pump
Check
24
Cooling system
25
Coolant
26
Fuel system
27
Fuse
Replace
28
Light bulb
Replace
1
2
year years
-
Clean Replace Check Replace
Replace Check Replace Check Replace Check
DC45-WOO Nov. 2004
Replace
Flush Change Bleed
Service as required
1-13
CHAPTER 1
DK45S(DK451) Period
After Purchase
Indication On Hour Meter
Important
No. 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1500 3000
Item 29
Air conditioner condenser net
30
Air conditioner belt Replace tension
31
Air conditioner filter
Clean
32
Condensor blocked
Check
33
Air conditioner hose and pipe
Check
34
Cabin rubber
Check
35
Lubrication system
Check
36
Washer liquid
Check
37
Refrigerant capacity
Check
1
2
year years
Daily
Clean
Service as required
IMPORTANT •
The jobs indicated by
must be done after the first 50 hours of operation.
*1 Air cleaner should be cleaned more often in dusty conditions than in normal conditions. *2 Every year or every 6 times of cleaning. *3 Replace only if necessary. *4 When the battery is used for less than 100 hours per year, check the fluid level annually. •
The items listed above (@ marked) are registered as emission related critical parts by DAEDONG in the US.EPA 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 instruction. Please see the Warranty Statement in detail.
1-14
DC45-WOO Nov. 2004
GENERAL
9. CHECK AND MAINIENANCE 9.1 DAILY CHECK Walk Around Inspection
For your own safety and maximum service life of the machine, make a thorough daily inspection before operating the machine to start the engine.
Look around and under the tractor for such items as loose bolts, trash build-up, oil or coolant leaks, broken or worn parts.
CAUTION To avoid personal injury: • Be sure to check and service the tractor on a flat place with the engine shut off and the parking brake “ON”.
A. CHECKING AND REFUELING Fuel tank capacity
58.0 (15.32 U.S.gal.)
CAUTION To avoid personal injury: • Do not smoke while refueling. • Be sure to stop the engine before refueling. 1. Turn the key switch to “ON”, check the amount of fuel showing on the fuel gauge. 2. Fill fuel tank when the fuel gauge shows 1/4 or less fuel in the tank.
C45W112A
3. Use grade No.2-Diesel fuel at all temperatures above -10°C (14°F).
(1) Fuel Tank Cap
IMPORTANT
NOTE:
•
Do not permit dirt or trash to get into the fuel system.
•
Be careful not to let the fuel tank become empty, otherwise air will enter the fuel system, requiring the fuel system to be bled before next engine start.
•
Be careful not to spill during refueling. If a spill should occur, wipe it off at once. Fuel on the tractor may cause a fire.
•
To prevent condensation( water) accumulation in the fuel tank, fill the tank before parking the tractor overnight.
•
No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE J313 JUN 87)
•
Grade of Diesel Fuel Oil According to ASTM D975
Flash Point °C (°F)
Water and Sediment, Volume %
Carbon Residue On, 10 Percent Residuum, %
Ash, Weight %
Min
Max
Max
Max
52 (125)
0.05
0.35
0.01
Distillation Temperatures, °C (°F) 90% Point
Viscosity Kinematic cSt or mm²/s at 40°C
Viscosity Saybolt, SUS at 100°F
Sulfur, Weight %
Copper Strip Corrosion
Cetane Number
Min
Max
Min
Max
Min
Max
Max
Max
Min
282 (540)
338 (640)
1.9
4.1
32.6
40.1
0.50
No.3
40
DC45-WOO Nov. 2004
1-15
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