the best service repair manual

1. 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

2. 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

3. 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

4. 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

5. 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 ............................................................................................................................. 11-30
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

6. TO THE READER
1
DC45-WOO Nov. 2004
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.

7. DK45S(DK451)
2 DC45-WOO Nov. 2004
SAFETY STARTING
1. Always use the safety start switch to start the en-
gine 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. Never start the engine unless you are in the
operator’s seat.
C45W002A
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.
SAFETY FIRST
SIGNS
DANGER
WARNING
CAUTION
IMPORTANT
DESCRIPTION
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.
This mark indicates potentially hazardous situation which, if not
observed, may result in death or moderate injury.
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.
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

8. TO THE READER
3
DC45-WOO Nov. 2004
SAFETY WORKING
1. Do not operate or service the machine while under
the influence of alcohol, medication, or other
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.
6. Do not touch any rotating or hot parts while the en-
gine 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 pres-
sure 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.
C45W003A
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 acci-
dental 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

9. DK45S(DK451)
4 DC45-WOO Nov. 2004
DISPOSE OF FLUIDS PROPERLY
1. Observe relevant environmental protection regula-
tions when disposing of oil, fuel, coolant, electro-
lyte and other harmful waste. Never pour fluids into
the ground, down a drain, or into a stream, pond, or
lake.
C45W008A
VENTILATE WORK AREA
1. Exhaust contains poisonous carbon monoxide, so
you should never run the engine in a closed area. If
the engine must be running while performing
maintenance, make sure the area is well ventilated.
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 elec-
trolyte on yourself, flush with water, and get medi-
cal attention immediately.
C45W006A
C45W007A

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11. TO THE READER
5
DC45-WOO Nov. 2004
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
department, hospital, doctor and ambulance
service, near your telephone in case of emergency.
C45W009A

12. DK45S(DK451)
6 DC45-WOO Nov. 2004
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.
C45W010A
ROPS
SAFETY DECALS

13. TO THE READER
7
DC45-WOO Nov. 2004
(1) Parts No. : T4625-52191 (2) Parts No. : T4837-51181
C45W011A
CABIN