service repair manual

1. DK752C/DK902C
TRACTORS
WORKSHOP MANUAL
M39_AU.indb 1
M39_AU.indb 1 2007-10-29 오후 8:21:41
2007-10-29 오후 8:21:41

2. We reserve the right to make changes
throughout the entire manual at any time
without notice.
•
NOTE
Using unspecified parts, fuel and lubricants
other than DAEDONG’s genuine parts can
damage the tractor and such damage will not
be covered by warranty.
•
IMPORTANT
PREFACE
The purpose of this manual is to provide service technicians in the field with the gen-
eral specifications, service, operating principles, trouble shooting, exploded views with
part names, removing and installation procedures for all DK752C/DK902C tractors.
All information in this manual is based on the latest product information and pro-
cesses available at the time of publication. Therefore, some of the information in this
manual may differ from the machine you are working with. The specifications are pro-
cesses contained in this manual are subject to change without notice.
DAEDONG periodically updates each new edition of its manuals to improve the qual-
ity of information provided. However, DAEDONG has no obligation to modify the con-
tents in this manual which has been already published and distributed. All updated
information can be accessed by using the DAEDONG electronic manual system
(DEMSS)
All information contained herein is intended to help customer receive the best perfor-
mance out of their tractor. If there is any typo, incorrect information or question about
this manual, feel free to contact DAEDONG.
2007. 11
Overseas service team
DAEDONG INDUSTRIAL Co., Ltd.
M39_AU.indb 3
M39_AU.indb 3 2007-10-29 오후 8:22:08
2007-10-29 오후 8:22:08

3. TABLE OF CONTENTS
CHAPTER 0 SAFETY FIRST
CHAPTER 1 GENERAL
CHAPTER 2 ENGINE
CHAPTER 3 CLUTCH
CHAPTER 4 TRANSMISSION
CHAPTER 6 REAR AXLE
CHAPTER 7 BRAKE
CHAPTER 8 FRONT AXLE
CHAPTER 10 HYDRAULIC SYSTEM
CHAPTER 11 ELECTRIC SYSTEM
CHAPTER 9 STEERING SYSTEM
CHAPTER 12 CABIN
CHAPTER 14 INDEX
CHAPTER 13 AIR CONDITIONING
M39_AU.indb 5
M39_AU.indb 5 2007-10-29 오후 8:22:11
2007-10-29 오후 8:22:11

4. 1. FOR SAFETY .......................................... 0-2
1.1 Alert symbols..........................................0-2
2. SAFETY TIPS.......................................... 0-3
2.1 Safety gear.............................................0-3
2.2 Work place ............................................0-3
2.2.1 Ventilating system.........................0-3
2.2.2 Safe working place .......................0-3
2.2.3 Illumination ...................................0-3
2.2.4 Safety equipment..........................0-3
2.2.5 Clean working area.......................0-3
2.3 Safety instructions when preparing
tractor.....................................................0-4
2.4 Avoid fires...............................................0-4
2.5 Cautions when handling the battery.......0-5
2.6 Cautions for high pressure hoses................0-5
2.7 Use of appropriate tools and equipment
...............................................................0-6
2.8 Handling of hazardous materials............0-6
2.9 Handling of rotating blade, shaft and
driving belt..............................................0-7
2.10 Prevention of scald.................................0-7
2.11 Disposal of environmental waste ...........0-8
2.12 Cautions when handling tires.................0-8
3. SAFETY DECALS................................... 0-9
3.1 Location of decals ..................................0-9
CHAPTER 0
SAFETY FIRST
TABLE OF CONTENTS
DK752C/DK902C
M39_AU.indb 섹션1:1
M39_AU.indb 섹션1:1 2007-10-29 오후 8:22:14
2007-10-29 오후 8:22:14

5. 0-2 DS42-W00 Nov. 2007
DK752C/DK902C
SAFETY
FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
REAR
AXLE
BRAKE
FRONT
AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C
SYSTEM
1. FOR SAFETY
Most accidents can be avoided if basic safety in-
structions and regulations are followed. Always fol-
low the safety regulations and avoid any dangerous
situation to prevent an accident.
You can be unexpectedly injured if inspecting or
servicing the tractor without full knowledge of it.
Read the service manual carefully before starting
servicing and follow the instructions for servicing,
maintenance and inspection to prevent any injury.
•
•
A. REMARK
Broaden your knowledge with additionally supplied
service information for optimal service.
•
B. IMPORTANT
This mark indicates emphasis on information which
can be confused when servicing. If this information
is not carefully read and observed, the tractor can-
not fully function or may be damaged.
•
ᴯᖿ⤇#╤ⴋ#$
T46W001A
T46W002A
T46W003A
C. CAUTION
ⱇ#⪣
This mark indicates potentially hazardous situation
which, if not observed, may result in serious injury.
•
D. WARNING
This mark indicates hazardous situation which, if
not observed, may result in death or injury.
•
T46W004A
T46W005A
1.1 ALERT SYMBOLS
In this manual, the following safety-alert symbols are used. Their meanings are as follows:
REMARK CAUTION
WARNING
READ MANUAL!
SAFETY FIRST - FOR SAFETY
M39_AU.indb 섹션1:2
M39_AU.indb 섹션1:2 2007-10-29 오후 8:22:17
2007-10-29 오후 8:22:17

6. SAFETY
FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
REAR
AXLE
BRAKE
FRONT
AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C
SYSTEM
DS42-W00 Nov. 2007 0-3
DK752C/DK902C
2. SAFETY TIPS
2.1 SAFETY GEAR
2.2.1 VENTILATING SYSTEM
The service should be performed in well-ventilated
area. If the engine should be started in an enclosed
place, the exhaust gas vent pipe should be installed.
2.2.2 SAFE WORKING PLACE
T46W006A
California Proposition 65 Warning
Inhaling exhaust gas can cause cancer or damage
the generative function leading to infertility.
•
WARNING
When working on the tractor, wear safety gloves, safety
shoes, ear plugs, safety goggles, safety helmet, work-
ing clothes, etc. appropriate for your working environ-
ment.
Never wear loose fitting clothing or a tie which can be
caught by a rotating part. According to the statistics,
most accidents that occurred with rotating parts are
due to this inappropriate manner of wearing clothes.
2.2 WORK PLACE
T46W007A
T46W008A
The work should be done in a wide, level and safe
place to prevent slip and fall accident.
2.2.3 ILLUMINATION
The work place should be well illuminated. If working
in a dark place or under the tractor, use the work lamp.
The work lamp should be covered by the safety
cover. Light bulbs can cause fire if exposed to fuel
leaks.
2.2.4 SAFETY EQUIPMENT
Be sure to keep a first aid kit and fire extinguisher han-
dy at all times.
2.2.5 CLEAN WORKING AREA
Keep the working area clean before and during work. If
any oil or fuel is spilled, it should be cleaned up imme-
diately.
SAFETY FIRST - SAFETY TIPS
M39_AU.indb 섹션1:3
M39_AU.indb 섹션1:3 2007-10-29 오후 8:22:23
2007-10-29 오후 8:22:23

7. 0-4 DS42-W00 Nov. 2007
DK752C/DK902C
SAFETY
FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
REAR
AXLE
BRAKE
FRONT
AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C
SYSTEM
Lower the implement on to the ground.
Never stand under the bucket.
•
•
T46W009A
2.3 SAFETY INSTRUCTIONS WHEN
PREPARING TRACTOR
T46W010A
Stop the engine and remove the key.
Put “Do not operate” label on the tractor if neces-
sary.
•
•
2.4 AVOID FIRES
Never smoke or allow flames in your work area
when servicing the fuel system.
•
T46W011A
T46W012A
Keep flames or sparks away from the spray paint or
fuel containers and be careful of leaks.
•
T46W013A
Disconnect the negative battery cable.
Always disconnect the battery cable before servic-
ing the wiring to prevent fire.
Be extra cautious of fire when welding.
•
•
•
T46W014A
Always keep a fire extinguisher in the work area.
•
SAFETY FIRST - SAFETY TIPS
M39_AU.indb 섹션1:4
M39_AU.indb 섹션1:4 2007-10-29 오후 8:22:28
2007-10-29 오후 8:22:28

8. SAFETY
FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
REAR
AXLE
BRAKE
FRONT
AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C
SYSTEM
DS42-W00 Nov. 2007 0-5
DK752C/DK902C
2.5 CAUTIONS WHEN HANDLING THE
BATTERY
Always disconnect the negative battery cable first
and reconnect it last to avoid sparks from an acci-
dental short circuit. You could be injured or fire may
break out.
•
The battery contains the acid that can burn you.
When it contact skin, it causes burns. If it contacts
with your eyes, you may lose your sight.
•
T46W015A
T46W017A
T46W018A
T46W019A
2.6 CAUTIONS FOR HIGH PRESSURE HOSES
T46W020A
T46W021A
The hydraulic fluid leaks from high pressure
hoses or pipes can penetrate your skin.
•
Before connecting a high pressure hose or pipe,
stop the engine and depressurize it by valve.
Check the bolts for tightness before starting the en-
gine after servicing the hydraulic system.
Use a cardboard or plank when checking leakage.
•
•
•
Never weld the high pressure pipe or the surround-
ing area. The pipe or hose can be heated and ex-
plode which can lead to fire or burn.
•
T46W016A
Do not charge the frozen battery. Charging the fro-
zen battery can cause explosion. Let the battery
warmed up to ambient temperature (16°C, 60°F)
before charging.
Keep sparks and flames (match, lighter) away from
the battery. The battery can explode due to the bat-
tery fluid.
Never connect the battery’s negative and positive
cables with metal for test. Use only tester when
checking the battery voltage.
•
•
•
SAFETY FIRST - SAFETY TIPS
M39_AU.indb 섹션1:5
M39_AU.indb 섹션1:5 2007-10-29 오후 8:22:34
2007-10-29 오후 8:22:34

9. 0-6 DS42-W00 Nov. 2007
DK752C/DK902C
SAFETY
FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
REAR
AXLE
BRAKE
FRONT
AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C
SYSTEM
2.7 USE OF APPROPRIATE TOOLS AND
EQUIPMENT
Use the appropriate tools and proper size. If an in-
appropriate tool is used, it can slip which can dam-
age parts or injure you.
Do not confuse units (mm, inch, etc.).
Use the air impact wrench only when unscrewing
the bolts or nuts. Such wrench should not be used
when assembly precisely machined parts which its
tightening torque should be strictly observed. It can
cause malfunctions.
Be careful of a socket popped out due to the turning
force when using the air impact wrench. Especially,
be extra cautious when working on connection or
socket with joint.
•
•
•
•
When lifting the tractor with a hydraulic jack or a
hoist, fix it firmly and install the auxiliary support.
Never work under the tractor if the support and the
hydraulic jack (hoist) are not installed.
When using a hydraulic jack or a hoist, do not use
it over the limit of the equipment and the conveying
belt.
Make sure that the hydraulic lock operates properly
before using the hydraulic jack. Improper use of
lock can cause a serious accident.
Check the buttons and operating direction of the
hoist before using it. Improper operation can cause
a serious accident.
Do not use wooden blocks or bricks as support un-
der the tractor. As the tractor’s weight is continuous-
ly applied to them, they can be broken or collapsed.
•
•
•
•
•
2.8 HANDLING OF HAZARDOUS MATERIALS
Do not blow out hazardous materials, such as clutch
dust, with compressed air. Inhaling such hazardous
materials can damage your health.
•
T46W022A
No genuine DAEDONG part contains asbestos.
REMARK
These materials should be rinsed or wiped away
after spraying with oil.
•
SAFETY FIRST - SAFETY TIPS
M39_AU.indb 섹션1:6
M39_AU.indb 섹션1:6 2007-10-29 오후 8:22:40
2007-10-29 오후 8:22:40

10. CHAPTER 2
ENGINE
TABLE OF CONTENTS
1. GENERAL INFORMATION ..................... 2-3
1.1 Introduction............................................2-3
1.2 Engine views and engine identification..2-4
1.2.1 Engine views..............................2-4
1.2.2 Engine Identification...................2-5
1.3 Safety precautions.................................2-6
1.3.1 Engine lift equipment .................2-7
1.3.2 Viton seals .................................2-7
1.3.3 Safety cautions when an engine is
cleaned ......................................2-7
1.3.4 Powerpart recommended
consumable products.................2-8
2. SPECIFICATIONS................................... 2-9
2.1 Engine performance curve.....................2-9
2.1.1 Engine performance curve....... 2-11
2.2 Engine Specification and Data.............2-12
2.2.1 Engine specifications ...............2-12
2.2.2 Cylinder head...........................2-13
2.2.3 Intake and exhaust valves .......2-13
2.2.4 Dimensions of recesses
for valve seat inserts................2-14
2.2.5 Valve seat insert tool................2-14
2.2.6 Valve guides and valve
springs .....................................2-15
2.2.7 Tappets, rocker shaft,
rocker levers ............................2-15
2.2.8 Pistons and piston
cooling jets...............................2-15
2.2.9 Piston rings ..............................2-16
2.2.10 Connecting rods and
big end bearings ......................2-16
2.2.11 Gudgeon pins and
small end bushes.....................2-17
2.2.12 Crankshaft................................2-17
2.2.13 Crankshaft overhaul.................2-18
2.2.14 Main bearings ..........................2-19
2.2.15 Crankshaft thrust washers .......2-19
2.2.16 Timing case and drive
assembly..................................2-20
2.2.17 Cylinder block assembly ..........2-21
2.2.18 Turbocharger............................2-21
2.2.19 Lubrication system...................2-22
2.2.20 Cooling system ........................2-23
2.2.21 Thermostat...............................2-23
2.2.22 Fuel system..............................2-23
2.2.23 Atomiser service settings.........2-24
2.2.24 Flywheel and housing ..............2-24
2.2.25 Electrical equipment.................2-24
3. TIGHTENING TORQUE ........................ 2-25
3.1 Thread sealant.....................................2-25
3.2 Standard torque values........................2-25
3.2.1 Specific torque values..............2-26
4 COMPRESSION TEST DATA ............... 2-28
4.1 How to do a compression test .............2-28
5. TROUBLESHOOTING .......................... 2-29
6. EXPLODED VIEW................................. 2-31
6.1 E010 cylinder block..............................2-31
6.2 E020 piston crankshaft ........................2-32
6.3 E030 cylinder head..............................2-33
6.4 E040 rocker arm ..................................2-34
6.5 E050 timing case .................................2-35
6.6 E060 water pump.................................2-36
6.7 E070 balancer......................................2-37
6.8 E080 fuel injection pump .....................2-38
6.9 E090 oil pan.........................................2-39
6.10 E100 cylinder head cover ....................2-40
6.11 E110 bleeder........................................2-41
6.12 E120 oil hose.......................................2-42
6.13 E130 oil cooler.....................................2-43
DK752C/DK902C
M39_AU.indb 1
M39_AU.indb 1 2007-10-29 오후 8:25:44
2007-10-29 오후 8:25:44

11. 6.14 E140 oil filter........................................2-44
6.15 E150 cooling fan..................................2-45
6.16 E160 alternator ....................................2-46
6.17 E170 manifold......................................2-47
6.18 E180 fuel feed pump............................2-48
6.19 E190 free filter .....................................2-49
6.20 E200 glow plug ....................................2-50
6.21 E210 flywheel ......................................2-51
6.22 T030A radiator .....................................2-52
6.23 T415A front axle frame ........................2-53
6.24 T020A Muffler ......................................2-54
6.25 T010A air cleaner.................................2-55
6.26 T380A oil cooler...................................2-56
7. SERVICING ........................................... 2-57
7.1 engine assembly removal
and installation.....................................2-57
7.1.1 Transmission fluid .................... 2-57
7.1.2 Coolant.....................................2-57
7.1.3 Propeller shaft..........................2-58
7.1.4 Bonnet......................................2-59
7.1.5 Muffler......................................2-61
7.1.6 Shield plate ..............................2-62
7.1.7 components around engine .....2-63
7.1.8 Air cleaner and inlet duct .........2-67
7.1.9 Oil cooler assembly..................2-68
7.1.10 Air condenser assembly...........2-70
7.1.11 Radiator assembly ...................2-71
7.1.12 Front axle frame.......................2-73
7.1.13 Engine assembly......................2-74
7.1.14 parts around engine.................2-75
7.2 Disassembly, inspection and
assembly of engine..............................2-76
7.2.1 Cylinder head assembly...........2-76
7.2.2 Piston and connecting
rod assemblies.........................2-90
7.2.3 Crankshaft assembly ...............2-99
7.2.4 Timing case and
drive assembly........................2-111
7.2.5 Cylinder block assembly ........2-125
7.2.6 Engine timing .........................2-127
7.3 Aspiration system ..............................2-131
7.3.1 Turbochargers........................2-131
7.3.2 To remove turbocharger.........2-132
7.3.3 Turbocharger faults................2-134
7.3.4 Open engine breather............2-135
7.4 Lubrication system.............................2-136
7.4.1 General description................2-136
7.4.2 Lubrication system
flow diagram...........................2-137
7.4.3 Filter canister .........................2-138
7.4.4 Filter head..............................2-138
7.4.5 Oil pan....................................2-139
7.4.6 Dipstick tube ..........................2-141
7.4.7 Oil strainer and suction pipe ..2-141
7.4.8 Lubricating oil pump
assembly................................2-142
7.4.9 To remove and to fit the
relief valve of the balancer....... 2-143
7.5 Fuel system .......................................2-144
7.5.1 General description................2-144
7.5.2 Cold start advance unit
(KSB) .....................................2-146
7.5.3 Fuel filter ................................2-147
7.5.4 Atomisers...............................2-149
7.5.5 Fuel lift pump and
filter assembly........................2-151
7.5.6 Air in the fuel system..............2-152
7.5.7 Bosch VP30 fuel
injection pump........................2-152
7.5.8 Bosch EVPE fuel
injection pump........................2-156
7.5.9 Delphi DP210 fuel
injection pump........................2-158
7.6 Cooling system ..................................2-161
7.6.1 General description................2-161
7.6.2 Thermostat.............................2-162
7.6.3 Coolant pump.........................2-164
7.6.4 Fan.........................................2-167
7.6.5 Fan drive................................2-167
7.6.6 Lubricating oil cooler..............2-167
7.7 Flywheel and housing........................2-169
7.7.1 Flywheel.................................2-169
7.7.2 Ring gear ...............................2-170
7.7.3 Flywheel housing ...................2-170
7.8 Electrical equipment ..........................2-171
7.8.1 Alternators..............................2-171
7.8.2 Starter motor..........................2-174
7.8.3 Glow plug...............................2-176
8. LIST OF SPECIAL TOOLS ................. 2-177
TABLE OF CONTENTS
M39_AU.indb 2
M39_AU.indb 2 2007-10-29 오후 8:25:48
2007-10-29 오후 8:25:48

12. SAFETY
FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
REAR
AXLE
BRAKE
FRONT
AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C
SYSTEM
DS42-W00 Nov. 2007 2-3
DK752C/DK902C
This indicates that there is a possible danger to the
person.
WARNING
This indicates that there is a possible danger to the
engine.
CAUTION
Is used where the information is important, but
there is not a danger.
REMARK
1. GENERAL INFORMATION
1.1 INTRODUCTION
This Workshop Manual has been written to provide
assistance in the service and overhaul of DAEDONG
1100 series 4 cylinder engines. It should be used in
conjunction with normal workshop practise and infor-
mation contained in current service bulletins. Mention
of certain accepted practices therefore, has been pur-
posely omitted in order to avoid repetition. For overhaul
procedures, the aspantion is made that the engine is
removed from the application.
The engine conforms with USA (EPA/CARB) stage 2
and EEC stage 2 emission legislation.
Most of the general information which is included in the
relevant User's Manual has not been repeated in this
workshop manual and the two publications should be
used together.
Where the information applies only to certain engine
types, this is indicated in the text.
The details of some operations will be different accord-
ing to the type of fuel injection pump which is fitted.
The specific pump type used can be found by refer-
ence to the manufacturer's identification plate on the
pump body but, generally, the type of pump fitted is
shown below:
Delphi - DP210 Series
Bosch - VP 30
Bosch - EPVE
When reference is made to the "left" or "right" side of
the engine, this is as seen from the flywheel end of the
engine.
•
•
•
POWERPART recommended consumable products are
listed under "POWERPART recommended consumable
products". Reference to the relevant consumable prod-
ucts is also made at the beginning of each operation.
Data and dimensions are included in "2.2 Engine Spec-
ification and Data".
Read and remember "1.3 Safety precautions". They
are given for your protection and must be used at all
times.
Danger is indicated in the text by three methods:
ENGINE - GENERAL INFORMATION
M39_AU.indb 3
M39_AU.indb 3 2007-10-29 오후 8:25:51
2007-10-29 오후 8:25:51

13. 2-4 DS42-W00 Nov. 2007
SAFETY
FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
REAR
AXLE
BRAKE
FRONT
AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C
SYSTEM
DK752C/DK902C
(1) Fuel injection pump
(2) Inlet manifold
(3) Oil inlet
(4) Fuel filter
(5) Turbo charger
(6) Oil pan
(7) Exhaust manifold
(8) Cylinder head
(9) Cylinder block
(10) Cooling fan
(11) Water pump
(12) Oil filter
(13) Oil Dipstick gauge
(14) Alternator
COMPONENTS
5
2
5
7
8
9
6
3
4
12
10 11
3 3
6
7
9
10
14
5
6
6
1 13
14
4
5
10
1.2 ENGINE VIEWS AND ENGINE IDENTIFICATION
1.2.1 ENGINE VIEWS
T85W201A
ENGINE - GENERAL INFORMATION
M39_AU.indb 4
M39_AU.indb 4 2007-10-29 오후 8:25:55
2007-10-29 오후 8:25:55

14. SAFETY
FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
REAR
AXLE
BRAKE
FRONT
AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C
SYSTEM
DS42-W00 Nov. 2007 2-57
DK752C/DK902C
7. SERVICING
7.1 ENGINE ASSEMBLY REMOVAL AND INSTALLATION
7.1.1 TRANSMISSION FLUID
A. DRAINING
Underlay oil pan under transmission.
Remove the drain plug (1) and filling plug (2) to
drain the oil.
After draining reinstall the plugs.
1.
2.
3.
1
T85W229A
Remove the filling plug (2) and replenish fluid up to
the max. limit of the fuel gauge (3).
Run the engine for a few minutes and stop the en-
gine. Then, check the transmission fluid level and
replenish with fluid if necessary.
Fluid specification: DAEDONG genuine TF65
Fluid capacity: 19.54 U.S.gal. (74ℓ)
A: The fluid level should be between the max. and
min. limits.
1.
2.
•
•
•
3
2
T85W230A
Stop the engine and cool down coolant.
Open the bonnet and remove the cap (2) and
drain cork (1) of the radiator to drain the coolant.
After draining the coolant completely, install the
drain cork (1).
1.
2.
3.
1
A
B
2
3
T85W232A
T85W231A
B. REPLENISHMENT
Fill the radiator with coolant.
Fill the reservoir tank (3) with coolant until the level
is between Full (A) and Low (B).
Coolant capacity: 4.89 U.S.gal. (18.5ℓ)
1.
2.
•
7.1.2 COOLANT
A. DRAINING
B. REPLENISHMENT
Do not remove the radiator cap while coolant is hot.
Unscrew the cap a little to release the pressure
before removing the cap completely.
•
•
WARNING
ENGINE - SERVICING
M39_AU.indb 57
M39_AU.indb 57 2007-10-29 오후 8:29:30
2007-10-29 오후 8:29:30

15. 2-58 DS42-W00 Nov. 2007
SAFETY
FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
REAR
AXLE
BRAKE
FRONT
AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C
SYSTEM
DK752C/DK902C
A. REMOVAL
Park the machine on a flat surface and apply the
parking brake. Then, chock the wheels.
1.
2
1
3
4
T85W2Z8A
Remove the propeller shaft mounting bolt (2) on the
transmission side and push the propeller shaft cover
(1) in towards the engine.
Separate the spring pin (3) from the coupling (4)
installed to the propeller shaft on the transmission
side and then slide it into the propeller shaft cover.
2.
3.
Unscrew one propeller shaft mounting bolt (1) (10
mm) on the front axle shaft side and insert the pro-
peller shaft cover (2) towards the transmission.
Separate the spring pin (4) from the coupling (3) in-
stalled to the propeller shaft on the front axle shaft
side and then slide it into the propeller shaft cover.
Remove the propeller shaft.
4.
5.
6.
1
2
3
4
T85W2Z9A
B. INSTALLATION
5
2
2
5
3
8
9
9 3
4 8 4
6
10
4
6
5 10 5 1
4
7
1
T85W201B
(1) Propeller shaft cover 1
(2) Packing
(3) Bolt with captive washer
(4) Coupling
(5) Spring pin
(6) Front drive shaft 3
(7) O-ring
(8) Propeller shaft cover 2
(9) Bolt with captive washer
(10) O-ring
Replace the O-ring with new one.
Apply grease to the O-ring when installing it.
Apply grease to the front drive shaft and the
coupling.
Be careful of the direction of the spring pin when
assembling.
Since it rotates, the split portion of any spring
pin should be at a right angle to the shaft.
1.
2.
3.
4.
•
WHEN ASSEMBLING
2
1
3 3
T85W202B
Apply grease to the O-rings (3) of the front drive
shaft support bracket (1) and the clutch housing (2).
Install in the reverse order of removal.
1.
2.
7.1.3 PROPELLER SHAFT
ENGINE - SERVICING
M39_AU.indb 58
M39_AU.indb 58 2007-10-29 오후 8:29:41
2007-10-29 오후 8:29:41

16. SAFETY
FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
REAR
AXLE
BRAKE
FRONT
AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C
SYSTEM
DS42-W00 Nov. 2007 2-59
DK752C/DK902C
7.1.4 BONNET
A. REMOVAL
T85W242A
Open the bonnet (1) and disconnect the negative
battery cable.
Remove the side covers (RH/LH) (2).
- Pull the lower part and lift it up to remove it.
1.
2.
Remove six mounting nuts from the bonnet.
4.
T85W244A
3
T85W243A
Disconnect the bonnet wiring (3) connector.
3.
Remove the bonnet by separating it from its bracket
hook.
5.
T85W245A
Remove the fixing pins (1) on the upper and lower
parts of the air cylinder from the bonnet bracket and
remove the air cylinder.
6.
1
T85W246A
T85W247A
ENGINE - SERVICING
M39_AU.indb 59
M39_AU.indb 59 2007-10-29 오후 8:30:12
2007-10-29 오후 8:30:12

17. 2-60 DS42-W00 Nov. 2007
SAFETY
FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
REAR
AXLE
BRAKE
FRONT
AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C
SYSTEM
DK752C/DK902C
Unscrew mounting bolts/nuts and remove the bon-
net bracket (1).
7.
1
T85W248A
Install the bonnet bracket to the body.
Assemble the air cylinder.
Install the bonnet the bonnet bracket assembly.
Connect the bonnet wiring connector.
Install the side covers (RH/LH).
Connect the battery cable and apply grease to its
terminals.
1.
2.
3.
4.
5.
6.
B. INSTALLATION
When disconnecting battery cable, disconnect the
negative cable at first, but connect the positive
cable at first when assembling.
REMARK
ENGINE - SERVICING
M39_AU.indb 60
M39_AU.indb 60 2007-10-29 오후 8:30:27
2007-10-29 오후 8:30:27

18. SAFETY
FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
REAR
AXLE
BRAKE
FRONT
AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C
SYSTEM
DS42-W00 Nov. 2007 2-61
DK752C/DK902C
2
2
1
1
7.1.5 MUFFLER
A. REMOVAL
T85W249A
Unscrew mounting nuts (1) from the dustproof rub-
ber (2) of the muffler pipe bracket.
Dustproof rubber
adjusting nut (M10).........48.1 ~ 55.8 Nm
4.9 ~ 5.7 kgf-m
35.5 ~ 41.2 lb-ft
1.
Remove three mounting bolts (2) (10 mm) on the
muffler side of the muffler pipe (1) and remove the
muffler pipe assembly.
Muffler pipe mounting bolt on muffler side
(M10) ...............................48.1 ~ 55.8 Nm
4.9 ~ 5.7 kgf-m
35.5 ~ 41.2 lb-ft
2.
1
2
T85W250A
1
B
A
B
B
T85W251A
Remove three mounting bolts (12 mm) (B) on the
turbocharger side of the muffler (1) and one muffler
mounting bolt (12 mm) (A) and remove the muffler
gasket.
Muffler mounting nut (B) on turbocharger side
and muffler mounting bolt (A)
.........................................77.5 ~ 90.2 Nm
7.9 ~ 9.2 kgf-m
57.2 ~ 66.5 lb-ft
3.
T85W252A
Installation is carried out in reverse order of removal.
Assemble the muffler.
- Check if the gasket is damaged.
Assemble the muffler pipe assembly.
- Check if the gasket is damaged.
•
1.
2.
Muffler pipe Muffler
B. INSTALLATION
ENGINE - SERVICING
M39_AU.indb 61
M39_AU.indb 61 2007-10-29 오후 8:30:31
2007-10-29 오후 8:30:31

19. 2-62 DS42-W00 Nov. 2007
SAFETY
FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
REAR
AXLE
BRAKE
FRONT
AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C
SYSTEM
DK752C/DK902C
1
7.1.6 SHIELD PLATE
A. REMOVAL
T85W253A
Unscrew two mounting bolts (upper and lower) on
the left of the shield plate and remove the shield
plate (1).
Shield plate
mounting bolt..................48.0 ~ 55.9 Nm
4.9 ~ 5.7 kgf-m
35.4 ~ 41.2 lb-ft
1.
1
2
3
2
T85W254A
Undo the mounting clip (1) of the cable and the
hose attached to the shield plate (RH) and separate
the cable from the hose. Then, unscrew two shield
plate mounting bolts (2) and separate the shield
plate (3) (LH).
Shield plate
mounting bolt..................48.0 ~ 55.9 Nm
4.9 ~ 5.7 kgf-m
35.4 ~ 41.2 lb-ft
2.
With the shield plate (LH) separated, remove it by
removing the fuse box (1).
3.
1
T85W255A
B. INSTALLATION
Install the exterior fuse box to the shield plate (LH).
Install the shield plate (LH) to the bonnet support.
Install the shield plate (RH) to the bonnet support.
1.
2.
3.
ENGINE - SERVICING
M39_AU.indb 62
M39_AU.indb 62 2007-10-29 오후 8:30:50
2007-10-29 오후 8:30:50

20. SAFETY
FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
REAR
AXLE
BRAKE
FRONT
AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C
SYSTEM
DS42-W00 Nov. 2007 2-63
DK752C/DK902C
1
7.1.7 COMPONENTS AROUND ENGINE
A. ENGINE (LH)
T85W256A
Remove one upper mounting bolt (10 mm) and two
lower mounting bolts (17 mm) from the protective
cover (1) on the left side of the engine. Then, re-
move the protective cover.
1.
Disconnect the fuel filter port hose (1) and the heat-
er hose (2) and remove the union nut (19 mm) from
the oil cooler pipe (3).
2.
2
1
3
T85W257A
2
1
T85W259A
Disconnect the cold switch connector (1) from the
cylinder head and disconnect three alternator ca-
bles (2).
3.
Connect the cold switch and the alternator cable.
Install the front differential link.
1.
2.
Connect the fuel hose, heater hose and oil cooler pipe.
Oil cooler pipe
Tightening torque ...........9.8 Nm
1.0 kgf-m
7.2 lb-ft
3.
Install the protective cover.
Upper bolt (10 mm)......48.1 ~ 55.8 Nm
4.9 ~ 5.7 kgf-m
35.5 ~ 41.2 lb-ft
Lower bolt
(17 mm x 2EA)..............197 ~ 225 Nm
20 ~ 23 kgf-m
145 ~ 166 lb-ft
4.
•
•
REMOVAL
▶
Replace the split pin of the front differential lock
with a new one.
REMARK
Tightening of oil cooler pipe
The tightening value for the nut of the bite type
connecting pipe is for additional tightening after the
point of rapid increasing torque of nut regardless of
its size.
Minimum tightening: 1/6 rotation
Maximum tightening: 1/3 rotation
•
•
REMARK
INSTALLATION
▶
ENGINE - SERVICING
M39_AU.indb 63
M39_AU.indb 63 2007-10-29 오후 8:31:06
2007-10-29 오후 8:31:06

21. 2-64 DS42-W00 Nov. 2007
SAFETY
FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
REAR
AXLE
BRAKE
FRONT
AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C
SYSTEM
DK752C/DK902C
A
B
G
C
D
E
F
B. ENGINE (RH)
REMOVAL
▶
T85W261A
Remove the components install to the right side of
the engine.
1.
2 1
T85W265A
A. Disconnect the fuel hose (1) and the connector
(2) from the fuel filter.
B. Disconnect the accelerator cable (1) and the
engine stop switch connector (2) from the injec-
tion pump.
1
2
T85W262A
C. Disconnect the cable (1) from the drive motor
and unscrew three mounting bolts (2) (14 mm)
to remove the drive motor (3).
2
2
3
1
T85W263A
D. Disconnect the hose (1) and the connector (2)
from the air compressor.
Tightening torque of air conditioner hose
(17 mm x 1EA).......24.5 ~ 34.3 Nm
2.5 ~ 3.5 kgf-m
18.0 ~ 25.3 lb-ft
E. Disconnect the cooling hose, glow plug con-
nector (4) and cold sensor connector (3).
•
4
2
1
3
T85W264A
The refrigerant in the A/C system must be properly
removed before disconnecting the A/C hose from
the compressor.
CAUTION
ENGINE - SERVICING
M39_AU.indb 64
M39_AU.indb 64 2007-10-29 오후 8:31:14
2007-10-29 오후 8:31:14

22. SAFETY
FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
REAR
AXLE
BRAKE
FRONT
AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C
SYSTEM
DS42-W00 Nov. 2007 2-65
DK752C/DK902C
F. Disconnect the hydraulic pipe (1), steering hy-
draulic pipe (2) and hydraulic suction pipe (3)
from the gear pump.
Pipe tightening torque
...............................34.3 Nm
3.5 kgf-m
25.3 lb-ft
G. Separate the engine oil pressure switch (4)
from the engine oil filter.
•
2
3
4
1
T85W267A
Remove one mounting bolt (10 mm) and RH shield
plate (2) from the brake fluid reservoir tank (1).
2.
2
1
T85W268A
Disconnect the steering hose from the cabin.
Steering hose (LHD, yellow tag)
(1)..................................24.5 Nm
2.5 kgf-m
18.0 lb-ft
Steering hose (RHD, white tag)
(2)..................................24.5 Nm
2.5 kgf-m
18.0 lb-ft
3.
•
•
1
2
T85W269A
Remove the shield plate support.
Upper mounting bolt
(12 mm x 2EA) (1) ........62.8 ~ 72.5 Nm
6.4 ~ 7.4 kgf-m
46.3 ~ 53.5 lb-ft
Lower mounting bolts (LH/RH)
(14 mm x 2EA) (2) ........108 ~ 125 Nm
11.0 ~ 12.8 kgf-m
79.6 ~ 92.5 lb-ft
4.
•
•
1
1
2
T85W270A
ENGINE - SERVICING
M39_AU.indb 65
M39_AU.indb 65 2007-10-29 오후 8:31:26
2007-10-29 오후 8:31:26

23. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.

24. 2-66 DS42-W00 Nov. 2007
SAFETY
FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
REAR
AXLE
BRAKE
FRONT
AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C
SYSTEM
DK752C/DK902C
Install the shield plate support.
Upper mounting bolt
(12 mm x 2EA) (1) ........62.8 ~ 72.5 Nm
6.4 ~ 7.4 kgf-m
46.3 ~ 53.5 lb-ft
Lower mounting bolts (LH/RH)
(14 mm x 2EA) (2) ........108 ~ 125 Nm
11.0 ~ 12.8 kgf-m
79.6 ~ 92.5 lb-ft
Connect the steering hose to the cabin.
- Steering hose assembly (L): Yellow tag attached
- Steering hose assembly (R): White tag attached
Steering hose
Tightening torque........24.5 Nm
2.5 kgf-m
18.0 lb-ft
Install the LH shield plate and the brake fluid reser-
voir tank.
Shield plate mounting bolt 62.8 ~ 72.5 Nm
6.4 ~ 7.4 kgf-m
46.3 ~ 53.5 lb-ft
1.
•
•
2.
•
3.
•
5
6 7
2
5
6
1
4
3
1
T85W271A
Connect the suction pipe L2 (1) to the gear pump (2)
and install the suction hose (3) between the suction
pipe L2 (1) and the L3 (4).
4.
Make sure that the left and right clearance of the
suction is identical.
Pipe band .....................9.8 Nm
1 kgf-m
7.2 lb-ft
Mounting bolt on the
gear pump side............14.7 Nm
1.5 kgf-m
10.8 lb-ft
Connect the steering hydraulic pipe (5) to the gear
pump and to the steering hydraulic pulsating pipe.
Hydraulic pipe to the pulsating reducer
Mounting nut................34.3 Nm
3.5 kgf-m
25.3 lb-ft
•
•
5.
•
Connect the hydraulic pipe (4WD) (6).
Mounting bolt
(to gear pump) .............19.6 Nm
2.0 kgf-m
14.4 lb-ft
6.
•
Install other components to the left side of the en-
gine in order.
7.
INSTALLATION
▶
Tightening of the bite type connector pipe nut to the
connector (see JIS B 2351)
The tightening value for the nut of the bite type
connecting pipe is for additional tightening after the
point of rapid increasing torque of nut regardless of
its size.
- Minimum tightening: 1/6 rotation
- Maximum tightening: 1/3 rotation
REMARK
Tightening of the bite type connector pipe nut to the
connector (see JIS B 2351)
The tightening value for the nut of the bite type
connecting pipe is for additional tightening after the
point of rapid increasing torque of nut regardless of
its size.
- Minimum tightening: 1/6 rotation
- Maximum tightening: 1/3 rotation
REMARK
ENGINE - SERVICING
M39_AU.indb 66
M39_AU.indb 66 2007-10-29 오후 8:31:36
2007-10-29 오후 8:31:36

25. SAFETY
FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
REAR
AXLE
BRAKE
FRONT
AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C
SYSTEM
DS42-W00 Nov. 2007 2-67
DK752C/DK902C
7.1.8 AIR CLEANER AND INLET DUCT
A. REMOVAL
T85W272A
Remove the front duct (1) from the air cleaner and
disconnect the air filter sensor connector (2).
1.
Undo the duct band clamp (1) on the air cleaner as-
sembly (3) and remove the mounting bolt (2) to re-
move the air cleaner assembly (3).
2.
3
2
1
T85W273A
Undo the band clamp (1) on the middle duct and
remove the front plate moulding (2) and two middle
duct plate mounting bolts (12 mm) (3) to remove
the middle duct.
3.
2
3
1
2
T85W274A
Install the middle duct to the front plate groove and
engage the band clamp.
Install the plate moulding to the front plate.
Install the air cleaner assembly.
Install the front duct and connect the air filter sen-
sor connector.
1.
2.
3.
4.
B. INSTALLATION
ENGINE - SERVICING
M39_AU.indb 67
M39_AU.indb 67 2007-10-29 오후 8:31:42
2007-10-29 오후 8:31:42

26. 2-68 DS42-W00 Nov. 2007
SAFETY
FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
REAR
AXLE
BRAKE
FRONT
AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C
SYSTEM
DK752C/DK902C
1
2
7.1.9 OIL COOLER ASSEMBLY
A. REMOVAL
T85W275A
Remove the air cleaner assembly(1) and the plate
moulding(2).
1.
3
4
2
1
4
T85W276A
Remove the coolant reservoir tank (1) and discon-
nect the connector (3) and the high and low pres-
sure pipes (4) from the receiver drier (2) of the A/C.
Coolant reservoir tank
(12 mm x 2EA)..............14.7 ~ 24.5 Nm
1.5 ~ 2.5 kgf-m
10.8 ~ 18.1 lb-ft
2.
•
3
1
4
2
5
5
T85W277A
Disconnect the battery cable (1), horn connector (2),
power relay connector (3) and preheat relay con-
nector (4) and remove the bonnet open cable (5).
3.
T85W278A
Remove four air cleaner support mounting bolts (12
mm) and remove the air cleaner support from the
radiator housing.
Air cleaner support
mounting bolt (M12)....77.5 ~ 90.2 Nm
7.9 ~ 9.2 kgf-m
57.2 ~ 66.5 lb-ft
4.
•
ENGINE - SERVICING
M39_AU.indb 68
M39_AU.indb 68 2007-10-29 오후 8:32:08
2007-10-29 오후 8:32:08