FOREWORD 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 guoup when performing serveral differnt 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 deffernt 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” shoule be used. 4. Use of a separate warranty request form is required for each failure. 5. Use only one job code when servicing serveral 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 inclued 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 INDEX 1 INDEX 2
SECTIONAL GROUPING................................................................................................................................................. 7 SORTED BY GROUP NAME............................................................................................................................................ 15
INDEX 3 SORTED BY PART NAME................................................................................................................................................ 19 4A200LX-E010 CYLINDER BLOCK GROUP............................................................................................................................................ 46 3B183-E020 OIL PAN GROUP.............................................................................................................................................................. 48 4A200-E030 CYLINDER HEAD GROUP............................................................................................................................................... 50 4A220TLX-E040 GEAR CASE GROUP....................................................................................................................................................... 52 TD2200-E050 MAIN BEARING CASE GROUP....................................................................................................................................... 56 3B183-E080 VALVE ROCKER ARM GROUP........................................................................................................................................ 58 4A220-E090 CYLINDER HEAD COVER GROUP................................................................................................................................. 60 4A220A-E100 CAMSHAFT GROUP........................................................................................................................................................ 62 3B183-E110 PISTON, CRANKSHAFT GROUP.................................................................................................................................... 64 4A200-E110 PISTON, CRANKSHAFT GROUP.................................................................................................................................... 68 4A200B-E120 FLYWHEEL GROUP......................................................................................................................................................... 70 4A220-E130 NOZZLE HOLDER GROUP.............................................................................................................................................. 72 3B183-E140 FUEL CAMSHAFT GROUP.............................................................................................................................................. 74 4B243-E150 SPEED CONTROL PLATE GROUP................................................................................................................................. 76 4B243LX-E160 ENGINE STOP LEVER GROUP....................................................................................................................................... 78 3B183-E170 GOVERNOR GROUP....................................................................................................................................................... 82 3A165-E180 WATER PUMP GROUP.................................................................................................................................................... 84 3B183-E190 WATER HOSE GROUP.................................................................................................................................................... 86 3B183LX-E200 DYNAMO GROUP............................................................................................................................................................ 88 3A165-E220 MANIFOLD GROUP......................................................................................................................................................... 90 EX45H-T105A CLUTCH GROUP............................................................................................................................................................. 92 EX45H-T135A CLUTCH HOUSING 1 GROUP........................................................................................................................................ 94 EX45H-T145A CLUTCH HOUSING 2 GROUP........................................................................................................................................ 96 EX45H-T155A MID CASE GROUP.......................................................................................................................................................... 98 EX45H-T165A TRANSMISSION CASE GROUP...................................................................................................................................... 100 - -
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EX45H-T435A REAR DIFFERENTIAL SYSTEM GROUP........................................................................................................................ 102 EX45H-T285A PTO SHAFT GROUP........................................................................................................................................................ 104 EX35H-T455A BRAKE CASE GROUP..................................................................................................................................................... 108 D360-T610A HYDRAULIC CYLINDER BODY GROUP......................................................................................................................... 110 D360-T620A HYDRAULIC LIFT ARM GROUP...................................................................................................................................... 112 EX45H-T635A HYDRAULIC CYLINDER ASSEMBLY GROUP................................................................................................................ 114 D360-T640A HYDRAULIC CONTROL SYSTEM 2 GROUP.................................................................................................................. 116 EX45H-T685A TOP LINK BRACKET GROUP.......................................................................................................................................... 120 EX35H-T595A STEERING CYLINDER GROUP...................................................................................................................................... 122 EX35H-T725A GEAR PUMP GROUP...................................................................................................................................................... 124 DK45CHSE-T755A JOYSTICK VALVE GROUP.............................................................................................................................................. 126 DK45CHSE-T755A JOYSTICK VALVE GROUP.............................................................................................................................................. 128 D380L-T500A BEVEL PINION SHAFT GROUP...................................................................................................................................... 130 EX45H-T555A BEVEL GEAR SHAFT GROUP........................................................................................................................................ 132 EX45H-T545A BEVEL GEAR CASE GROUP.......................................................................................................................................... 134 EX45H-T565A FRONT AXLE CASE GROUP........................................................................................................................................... 138 EX35H-T575A FRONT AXLE GROUP...................................................................................................................................................... 140 EX45H-T485A REAR AXLE GROUP........................................................................................................................................................ 142 D380L-T560A PROPELLER SHAFT GROUP.......................................................................................................................................... 144 EX45H-T925B BATTERY GROUP............................................................................................................................................................ 146 EX45M-T935B ELECTRICAL SYSTEM 1 GROUP................................................................................................................................... 148 EX35M-T955B ELECTRICAL SYSTEM 3 GROUP................................................................................................................................... 150 DK45CHSE-T956A CRUISE CONTROL GROUP............................................................................................................................................ 152 DK45CHSE-T1235C CABIN LIGHT 1 GROUP.................................................................................................................................................. 156 DK45CHSE-T1215C CABIN ELECTRICAL 1 GROUP....................................................................................................................................... 158 DK45CHSE-T1225C CABIN ELECTRICAL 2 GROUP....................................................................................................................................... 162 DK45CHSE-T1125C WIPER MOTOR GROUP.................................................................................................................................................. 164 EX45H-T015A AIR CLEANER GROUP.................................................................................................................................................... 166 EX45H-T025A MUFFLLER GROUP ........................................................................................................................................................ 168 EX40H-T035A RADIATOR GROUP.......................................................................................................................................................... 170 - -
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DK45CHSE-T045A AIRCON BRACKET GROUP............................................................................................................................................ 174 EX35H-T825A BONNET 1 GROUP.......................................................................................................................................................... 176 EX45H-T735A SUCTION FILTER GROUP............................................................................................................................................... 178 D380L-T550A FRONT AXLE BRACKET GROUP.................................................................................................................................... 180 EX45H-T715A DOUBLE ACTING VALVE LEVER GROUP...................................................................................................................... 182 EX45H-T915A SEAT GROUP................................................................................................................................................................... 184 EX40-T1065B FRONT END WEIGHTS GROUP(OPTION) .................................................................................................................... 186 EX40-T1075B REAR WEIGHTS GROUP(OPTION) . ............................................................................................................................. 188 EX45H-T465A BRAKE PEDAL GROUP................................................................................................................................................... 190 EX45H-T785A POSITION DRAFT LEVER GROUP................................................................................................................................. 194 EX45H-T845A FRAME GROUP............................................................................................................................................................... 198 DK45CHSE-T835A DK45CHSE-T835A AIRCON, HEATER GROUP.......................................................................................................... 202 DK45CHSE-T1085C CABIN GROUP................................................................................................................................................................. 204 DK45CHSE-T1155C AIRCON GROUP.............................................................................................................................................................. 206 DK45CHSE-T1095C WINDSHIELD(CABIN)...................................................................................................................................................... 208 DK45CHSE-T1105C GATE GROUP(CABIN)..................................................................................................................................................... 212 DK45CHSE-T1115C REAR GLASS GROUP(CABIN)....................................................................................................................................... 218 DK45CHSE-T1135C ROOF GROUP(CABIN).................................................................................................................................................... 222 DK45CHSE-T1145C FENDER GROUP(CABIN)................................................................................................................................................ 226 DK35HSE-T585A FRONT WHEEL GROUP.................................................................................................................................................. 228 EX35H-T775A HST EXTERNAL HYDRAULIC LINE GROUP.................................................................................................................. 230 EX45H-T175A DRIVE SHAFT GROUP.................................................................................................................................................... 232 EX45H-T195A HST ASSEMBLY GROUP................................................................................................................................................ 234 EX45H-T205A COUNTER SHAFT GROUP............................................................................................................................................. 236 EX45H-T235A RANGE SHAFT GROUP.................................................................................................................................................. 238 EX45H-T255A SPIRAL BEVEL PINION GROUP..................................................................................................................................... 240 EX35H-T265A FRONT DRIVE SYSTEM GROUP.................................................................................................................................... 244 EX45H-T275A PTO COUNTER SHAFT GROUP..................................................................................................................................... 248 DK45CHSE-T2055B MID PTO GROUP(OPTION) . .......................................................................................................................................... 252 EX45M-T365A RANGE FORK GROUP.................................................................................................................................................... 256 - -
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EX45M-T445A DIFFERENTIAL LOCK FORK GROUP............................................................................................................................. 258 EX45H-T195B HST PARTS GROUP........................................................................................................................................................ 260 EX35H-T605A POWER STEERING UNIT GROUP.................................................................................................................................. 268 D360-T630A HYDRAULIC CONTROL SYSTEM 1 GROUP.................................................................................................................. 270 D360-T660A MAIN DISTRIBUTOR VALVE GROUP............................................................................................................................. 272 EX45CH-T705-1A EXTERNAL HYDRAULIC VALVE 1 GROUP.................................................................................................................... 274 EX45H-T736A INLET TUBE GROUP....................................................................................................................................................... 276 EX45H-T745A MODULATE VALVE GROUP............................................................................................................................................ 278 EX35H-T746A PTO HYDRAULIC TUBE GROUP.................................................................................................................................... 280 DK45CHSE-T785A RANGE LEVER GROUP.................................................................................................................................................. 282 EX45H-T790A DOWN SPEED CONTROL GROUP................................................................................................................................. 284 D380L-T480A FRONT AXLE SUPPORT GROUP................................................................................................................................... 286 EX45H-T525A FRONT DIFFERENTIAL GROUP..................................................................................................................................... 288 DK45CHSE-T965A LIGHT GROUP................................................................................................................................................................. 290 CK30M-T1020A 7 PIN SOCKET GROUP.................................................................................................................................................. 292 EX45H-T305A HST CONTROL GROUP.................................................................................................................................................. 294 EX45H-T375A CHANGE LEVER GROUP................................................................................................................................................ 296 EX45H-T505A FRONT AXLE FRAME GROUP........................................................................................................................................ 298 EX45H-T596A CYLINDER COVER GROUP............................................................................................................................................ 302 DK35-T785A THREE POINT CONNECTOR SYSTEM 1 GROUP......................................................................................................... 304 EX45H-T805A THREE POINT LINK SYSTEM 2 GROUP........................................................................................................................ 308 EX45H-T815A DRAWBAR GROUP.......................................................................................................................................................... 310 DK45CHSE-T825A BRAKE ROD GROUP...................................................................................................................................................... 312 EX45H-T855A OIL TANK GROUP............................................................................................................................................................ 314 EX45M-T865A THROTTLE GROUP......................................................................................................................................................... 318 EX45H-T875A INSTRUMENT METER COVER GROUP......................................................................................................................... 322 DK45CHSE-T865A STEP GROUP................................................................................................................................................................... 324 DK45CHSE-T895A HST PEDAL GROUP........................................................................................................................................................ 328 DK45CHSE-T1165C AIR CON DUCTOR GROUP(CABIN)............................................................................................................................... 330 DK45CHSE-T1175C SEAT SUPPORT GROUP(CABIN)................................................................................................................................... 332 - -
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4A200LX-E010 CYLINDER BLOCK GROUP
- 46 -
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REF. NO JOB CODE
DESCRIPTION
EX35CH
EX40CH
HOURS
EX45CH
EX50CH
*
E010099
COMPLETE ENGINE R&R
8.0
←
←
←
1
E010001
CYLINDER BLOCK ASSEMBLY
9.5
←
←
←
2
E010002
PLUG
5.5
←
←
←
3
E010003
PLUG
3.2
←
←
←
4
E010004
PLUG
3.0
←
←
←
5
E010005
PLUG
3.0
←
←
←
6
E010006
SEALING CAP
0.5
←
←
←
7
E010007
SEALING CAP
4.0
←
←
←
8
E010008
STRAIGHT PIN
4.0
←
←
←
9
E010009
STRAIGHT PIN
4.0
←
←
←
10
E010010
STRAIGHT PIN
3.2
←
←
←
11
E010011
STRAIGHT PIN
4.0
←
←
←
12
E010012
PIN
4.0
←
←
←
13
E010013
WATER RETURN PIPE
0.3
←
←
←
14
E010014
PLUG
0.5
←
←
←
15
E010015
GASKET
0.3
←
←
←
16
E010016
OIL PUMP ASSEMBLY
3.5
←
←
←
17
E010017
OIL PUMP GASKET
3.5
←
←
←
18
E010018
BOLT
-
-
-
-
19
E010019
OIL PUMP DRIVE GEAR
3.5
←
←
←
20
E010020
KEY
3.2
←
←
←
21
E010021
FLANGE NUT
-
-
-
-
22
E010022
OIL SWITCH
0.1
←
←
←
23
E010023
GUIDE
0.1
←
←
←
24
E010024
PIN
2.5
←
←
←
REMARK FAILED ENGINE INSPECTION TIME INCLUDED
- 47 -
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3B183-E020 OIL PAN GROUP
- 48 -
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REF. NO JOB CODE
DESCRIPTION
EX35CH
EX40CH
HOURS
EX45CH
EX50CH
1
E020001
OIL PAN ASSEMBLY
1.2
←
←
←
2
E020002
GASKET, OIL PAN
1.2
←
←
←
3
E020003
FLANGE BOLT
-
-
-
-
4
E020004
BOLT WITH WASHER
-
-
-
-
5
E020005
PLUG
0.5
←
←
←
6
E020006
WASHER, SEAL
0.5
←
←
←
7
E020007
FILTER1 OIL
1.3
←
←
←
8
E020008
FLANGE BOLT WITH PIN
-
-
-
-
9
E020009
O-RING
1.3
←
←
←
10
E020010
OIL GAUGE
0.1
←
←
←
11
E020011
OIL GAUGE GUIDE PIPE
0.5
←
←
←
12
E020012
PACKING
0.5
←
←
←
REMARK FAILED ENGINE INSPECTION TIME INCLUDED
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4A200-E030 CYLINDER HEAD GROUP
- 50 -
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REF. NO JOB CODE
DESCRIPTION
EX35CH
EX40CH
HOURS
EX45CH
EX50CH
1
E030001
CYLINDER HEAD ASSEMBLY
3.0
←
←
←
2
E030002
SEALING CAP
1.7
←
←
←
3
E030003
SEALING CAP
1.7
←
←
←
4
E030004
PLUG
-
-
-
-
5
E030005
INLET VALVE GUIDE(3)
3.2
←
←
←
6
E030006
EXHAUST VALVE GUIDE(3)
3.2
←
←
←
7
E030007
HOT PLUG
3.2
←
←
←
8
E030008
ENGINE HOLDER
0.1
←
←
←
9
E030009
ENGINE HOLDER
0.1
←
←
←
10
E030010
BOLT
0.1
←
←
←
11
E030011
HEAD BOLT
2.8
←
←
←
12
E030012
HEAD GASKET
2.8
←
←
←
13
E030013
TEMP SENSOR ASSEMBLY
0.5
←
←
←
14
E030014
STUD
0.2
←
←
←
15
E030015
NUT
-
-
-
-
16
E030016
SPRING WASHER
0.1
←
←
←
REMARK
- 51 -
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4A220TLX-E040 GEAR CASE GROUP
- 52 -
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REF. NO JOB CODE
DESCRIPTION
EX35CH
EX40CH
HOURS
EX45CH
EX50CH
1
E040001
GEARCASE ASSEMBLY
3.0
←
←
←
2
E040002
GEAR CASE
3.3
←
←
←
3
E040003
PLUG
0.5
←
←
←
4
E040004
O-RING
3.0
←
←
←
5
E040005
O-RING
3.0
←
←
←
6
E040006
O-RING
3.0
←
←
←
7
E040007
STRAIGHT PIN
2.5
←
←
←
8
E040008
OIL FILTER SUPPORT
0.5
←
←
←
9
E040009
O-RING
0.5
←
←
←
10
E040010
SCREW
-
-
-
-
11
E040011
BOLT WITH WASHER
-
-
-
-
12
E040012
BOLT
-
-
-
-
13
E040013
PLAIN WASHER
0.5
←
←
←
14
E040014
SPRING
0.5
←
←
←
15
E040015
VALVE SEAT
0.5
←
←
←
16
E040016
STEEL BALL
1.5
←
←
←
17
E040017
COVER
1.5
←
←
←
18
E040018
COVER BOLT
1.5
←
←
←
19
E040019
O-RING
1.5
←
←
←
20
E040020
O-RING
-
-
-
-
21
E040021
GEAR CASE GASKET
3.0
←
←
←
22
E040022
BOLT
-
-
-
-
23
E040023
BOLT
-
-
-
-
24
E040024
BOLT
-
-
-
-
25
E040025
BOLT
-
-
-
-
REMARK
- 53 -
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4A220TLX-E040 GEAR CASE GROUP
- 54 -
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REF. NO JOB CODE
DESCRIPTION
HOURS
EX45CH
EX50CH
-
-
-
EX35CH
EX40CH
-
26
E040026
BOLT
27
E040027
WATER RETURN FLANGE
0.3
←
←
←
28
E040028
CASKET
0.3
←
←
←
29
E040029
BOLT
-
-
-
-
30
E040030
STUD
-
-
-
-
31
E040031
NUT
-
-
-
-
32
E040032
WASHER, SPRING
0.5
←
←
←
33
E040033
OIL FILTER
0.6
←
←
←
REMARK
- 55 -
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TD2200-E050 MAIN BEARING CASE GROUP
- 56 -
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2008-10-18 오전 10:49:33
REF. NO JOB CODE
DESCRIPTION
EX35CH
EX40CH
HOURS
EX45CH
EX50CH
1
E050001
MAIN BEARING CASE ASSEMBLY
8.3
←
←
←
2
E050002
BEARING CASE BOLT 1
7.2
←
←
←
3
E050003
BEARING CASE GASKET
4.5
←
←
←
4
E050004
BEARING CASE COVER
4.5
←
←
←
5
E050005
GASKET, COVER
4.5
←
←
←
6
E050006
FLANGE BOLT
-
-
-
-
7
E050007
OIL SEAL
4.0
←
←
←
8
E050008
MAIN BEARING CASE ASSEMBLY
7.2
←
←
←
9
E050009
MAIN BEARING CASE ASSEMBLY
7.2
←
←
←
10
E050010
MAIN BEARING CASE ASSEMBLY
7.2
←
←
←
11
E050011
WASHER
-
-
-
-
12
E050012
BEARING CASE BOLT 2
7.5
←
←
←
13
E050013
STRAIGHT PIN
7.5
←
←
←
REMARK
- 57 -
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3B183-E080 VALVE ROCKER ARM GROUP
- 58 -
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REF. NO JOB CODE
DESCRIPTION
EX35CH
EX40CH
HOURS
EX45CH
EX50CH
1
E080001
INLET VALVE
3.5
←
←
←
2
E080002
EXHAUST VALVE
3.5
←
←
←
3
E080003
VALVE SPRING
3.5
←
←
←
4
E080004
RETAINER, VALVE SPRING
3.5
←
←
←
5
E080005
COLLET, VALVE SPRING
3.5
←
←
←
6
E080006
VALVE STEM SEAL
3.7
←
←
←
7
E080007
SHAFT ROCKER ARM ASSEMBLY
2.0
←
←
←
8
E080008
SHAFT, ROCKER ARM
2.5
←
←
←
9
E080009
SEALING CAP
-
-
-
-
10
E080010
ROCKER ARM BRACKET
2.3
←
←
←
11
E080011
PLAIN WASHER
-
-
-
-
12
E080012
ROCKER ARM SPRING
-
-
-
-
13
E080013
SNAP RING
2.0
←
←
←
14
E080014
ROCKERARM
2.3
←
←
←
15
E080015
ADJUSTING NUT
-
-
-
-
16
E080016
SCREW, ADJUSTING
2.3
←
←
←
17
E080017
BOLT, REAR AXLE SUPPORT
-
-
-
-
REMARK
- 59 -
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4A220-E090 CYLINDER HEAD COVER GROUP
- 60 -
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