CONTENTS

CHAPTER 1GENERAL ........................................................................................................................ 1-1

1.TRACTOR INDENTIFICATION ......................................................................................................................... 1-3
2.TRACTOR VIEW ................................................................................................................................................. 1-4
3.GENERTAL PRECATIONS ................................................................................................................................ 1-5
3.1 ASSEMBLY AND DISASSEMBLY ............................................................................................................ 1-5
3.2 ELECTRICAL SYSTEM ........................................................................................................................... 1-6
3.3 TUBE AND RUBBERS ............................................................................................................................ 1-7

3.4 LUBICANT ................................................................................................................................................ 1-7

4.HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING ..................................................... 1-8
5.SPECIFICATION ................................................................................................................................................. 1-9
6.LUBRICANTS,FUEL AND COOLANT ............................................................................................................. 1-10
7.TIGHTENING TORQUE .................................................................................................................................... 1-11

7.1 GENERAL USE SCREW,BOLTS AND NUTS ...................................................................................... 1-11

7.2 STUD BOLTS ............................................................................................................................................ 1-11
7.3 AMERICAN STANDARD SCREW,BOLTS AND NUTS WITH UNC OR UNF THREADS ................. 1-12
8.MAINTENANCE CHECK LIST ......................................................................................................................... 1-13
9.CHECK AND MAINTENANCE .......................................................................................................................... 1-15
9.1DAILY CHECK ............................................................................................................................................ 1-15
9.2EVERY 50 HOURS ................................................................................................................................... 1-19
9.3EVERY 100 HOURS ................................................................................................................................. 1-21
9.4EVERY 200 HOURS ................................................................................................................................. 1-26

CHAPTER 2.ENGINE .......................................................................................................................... 2-1

1.FEATURE ............................................................................................................................................................ 2-3
2.LUBRICATING SYSTEM .................................................................................................................................... 2-4
3.COOLING SYSTEM ............................................................................................................................................ 2-5
4.FUEL SYSTEM ................................................................................................................................................... 2-6
5.TROUBLESHOOTING ....................................................................................................................................... 2-7
6.SERVICING SPECIFICATION .......................................................................................................................... 2-10
6.1ENGINE BODY .......................................................................................................................................... 2-10
6.2LUBRICATING SYSTEM ........................................................................................................................... 2-13
6.3COOLING SYSTEM ................................................................................................................................... 2-14
6.4FUEL SYSTEM ........................................................................................................................................... 2-14
6.5TIGHTENING TORQUE ............................................................................................................................ 2-15
7.DISASSEMBLING AND MAINTENANCE ........................................................................................................ 2-16
7.1SEAPRATING THE ENGINE .................................................................................................................... 2-16
7.2ENGINE DISASSEMBLED VIEW ............................................................................................................ 2-17
7.3ENGINE BODY .......................................................................................................................................... 2-29
 7.4LUBRICATING SYSTEM ........................................................................................................................... 2-54
7.5COOLING SYSTEM ................................................................................................................................... 2-54
7.6FUEL SYSTEM ........................................................................................................................................... 2-56

CHAPTER 3.CLUTCH ......................................................................................................................... 3-1

1.FEATURES .......................................................................................................................................................... 3-3
2.TROBLESHOOTING .......................................................................................................................................... 3-4
3.SPECIFICATIONS,TIGHTENING TROQUES AND SPECIAL TOOLS ......................................................... 3-5
3.1SPECIFICATIONS ...................................................................................................................................... 3-5
3.2TIGHTENING TORQUES .......................................................................................................................... 3-5
3.3SPECIAL TOOLS ....................................................................................................................................... 3-5

CHAPTER 4.TRANSMISSION SYSTEM ...................................................................................................................... 4-1

1.STRUCTURE ...................................................................................................................................................... 4-3
1.1POWER TRAIN DIAGRAM ......................................................................................................................... 4-3
1.2POWER TRAIN ........................................................................................................................................... 4-4
1.3TRANSMISSION SHIFT LINKAGE STRUCTURE ................................................................................ 4- 10
2.TROUBLESHOOTING ..................................................................................................................................... 4-11
2.1TROUBLESHOOTING FOR SHUTTLE SHIFT ..................................................................................... 4- 15
2.2TROUBLESHOOTING FOR MAIN SHIFTS SECTION IN OPERATION ERROR ............................. 4- 15
2.3TROUBLESHOOTING FOR AUXILIARY AND CREEP SHIFTS IN OPERATION ERROR .............. 4- 16
2.4TROUBLESHOOTING FOR REAR DIFFERENTIAL GEAR IN OPERATION ERROR .................... 4- 16
2.5TROUBLESHOOTING FOR FRONT WHEEL DRIVE IN OPERATION ERROR .............................. 4- 17
2.6TROUBLESHOOTING FOR PTO CLUTCH IN OPERATION ERROR .............................................. 4- 17
2.7TROUBLESHOOTING FOR PTO IN OPERATION ERROR ................................................................ 4- 17
2.8TROUBLESHOOTING FOR PARKING BRAKE IN OPERATION ERROR ........................................ 4- 17
3.SPECIFICATIONS ............................................................................................................................................ 4- 18
3.1TIGHTENING TORQUES ........................................................................................................................ 4- 18
4.DISASSEMBLING AND MAINTENANCE ....................................................................................................... 4- 19
4.1DISASSEMBLING TRANSMISSION ....................................................................................................... 4- 19

CHAPTER 5.REAR AXLE ................................................................................................................... 5-1

1.STRUCTURE ...................................................................................................................................................... 5-2
2.TROUBLESHOOTING ....................................................................................................................................... 5-4
3.TIGHTENING TORQUE ..................................................................................................................................... 5-5
4.DISASSEMBLING AND MAINTENANCE ......................................................................................................... 5-6
4.1DISASSEMBLING REAR AXLE ................................................................................................................. 5-6
4.2MAINTENANCE ......................................................................................................................................... 5-10

CHAPTER 6.BRAKE ........................................................................................................................... 6-1

1.STRUCTURE ...................................................................................................................................................... 6-2
2.TROUBLESHOOTING ....................................................................................................................................... 6-5
3.TIGHTENING TORQUE ..................................................................................................................................... 6-5
 4.TIGHTENING TORQUE MAINTENANCE ........................................................................................................ 6-7
5.CHECK,DISASSEMBLING AND MAINTENANCE .......................................................................................... 6-7
5.1ADJUSTMENT OF THE BRAKE ............................................................................................................... 6-7
5.2DISASSEMBLING AND ASSEMBLY ......................................................................................................... 6-8
5.3SERVICING ................................................................................................................................................ 6-11

CHAPTER 7.FRONT AXLE ................................................................................................................. 7-1

1.STRUCTURE ...................................................................................................................................................... 7-3
2.TROUBLESHOOTING ....................................................................................................................................... 7-4
3.SPECIFICATIONS .............................................................................................................................................. 7-5
4.TIGHTENING TORQUE ..................................................................................................................................... 7-7
5. CHECK,DISASSEMBLING AND MAINTENANCE ......................................................................................... 7-8
5.1CHECK AND MAINTENANCE .................................................................................................................. 7-8
5.2SEPARATING FRONT AXLE .................................................................................................................... 7-10
5.3DISASSEMBLING THE FRONT AXLE .................................................................................................... 7-12
5.4SERVICING ................................................................................................................................................ 7-22

CHAPTER 8 STEERING SYSTEM .................................................................................................... 8-1

1.STRUCTURE ...................................................................................................................................................... 8-2
1.1CHARACTERISTICS ................................................................................................................................. 8-3
1.2HYDRAULIC CIRCUIT OF POWER STEERING SYSTEM ................................................................... 8-4
1.3GEAR PUMP ............................................................................................................................................... 8-5
1.4POWER STEERING UNIT ........................................................................................................................ 8-6
1.5STEERING CYLINDER ............................................................................................................................. 8-7
1.6OIL FLOW .................................................................................................................................................... 8-8
2.TROUBELSHOOTING ...................................................................................................................................... 8-10
3.SPECIFICATIONS ............................................................................................................................................. 8-11
4.DISASSEMBLING AND MAINTENANCE ........................................................................................................ 8-12
4.1DISASSEMBLING TRANSMISSION ........................................................................................................ 4-19
4.1SEPARATING THE HYDRAULIC PUMP ................................................................................................. 8-12
4.2SEPARATING THE STEERING UNIT ..................................................................................................... 8-14
4.3DISASSEMBLING OF THE STEERING CYLINDER ............................................................................. 4-22
4.4SERVICING ................................................................................................................................................ 4-24

CHAPTER 9 HYDRAULIC SYSTEM .............................................................................................................................. 9-1

1.STRUCTURE ...................................................................................................................................................... 9-2
1.1HYDRAULIC OIL FLOW SHEMATIC ........................................................................................................ 9-3
1.2HYDRAULIC CIRCUIT SHEMATIC .......................................................................................................... 9-4
1.3HYDRAULIC FILTER SHEMATIC ............................................................................................................. 9-5
1.4HYDRAULICPUMP SHEMATIC ................................................................................................................ 9-5
1.5POWER STEERING SYSTEM .................................................................................................................. 9-6
1.6PTO CLUTCH VALVE SYSTEM ................................................................................................................ 9-8
 1.74WD,Q/T AND Q/T(AB) SYSTEM ............................................................................................................... 9-9
1.8JOYSTICK VALVE ....................................................................................................................................... 9- 10
1.9HORIZONTAL CONTROL SYSTEM(ONLY JP) ...................................................................................... 9- 13
1.10HYDRAULIC POWER LIFT SYSTEM .................................................................................................... 9- 12
1.11AUXILIARY CONTROL VALVE(ONLY EQUIPPED) .............................................................................. 9- 13
2.TROUBLINGSHOOTING .................................................................................................................................. 9-14
2.1JOYSTICK VALVE ....................................................................................................................................... 9- 14
2.2HYDRAULIC LIFT SYSTEM ...................................................................................................................... 9- 15
3.CHECKING,DISASSEMBLING AND MAINTENANCE .................................................................................. 9- 16
3.1HYDRAULIC FILTER ................................................................................................................................. 9 -16
3.2HYDRAULIC PUMP ................................................................................................................................... 9- 16
3.3 POWER STEERING UNIT ....................................................................................................................... 9- 18
3.4PTO CLUTCH VALVE ................................................................................................................................. 9 -19
3.5 4WA,Q/T AND Q/T(AB) VALVE ................................................................................................................. 9- 23
3.6JOYSTICK VALV ......................................................................................................................................... 9- 27
3.7HORIZONTAL CONTROL VALVE ............................................................................................................. 9- 28
3.8HYDRAULIC LIFT SYSTEM ...................................................................................................................... 9- 30

CHAPTER 10 CABIN SYSTEM .................................................................................................................................. 10-1

1.STRUCTURE ..................................................................................................................................................... 10 -3
1.1HEATER ...................................................................................................................................................... 10 -3
1.2AIR-CONDITIONER ................................................................................................................................... 10 -4
2.TROUBLESHOOTING ...................................................................................................................................... 10 -6
3.INSPECTION AND ADJUSTMENTS ............................................................................................................... 10 -4

CHAPTER11 ELECTRIC SYSTEM .............................................................................................................................. 11-1

1.HOW TO WIRING DIAGRAM ............................................................................................................................ 11-3
1.1WIRE CODE ............................................................................................................................................... 11-3
1.2WIRE SIZE .................................................................................................................................................. 11-3
1.3INSTRUMENT PANEL BULBS ................................................................................................................. 11-4
1.4RELAY AND SWITCH ................................................................................................................................. 11-5
1.5MULTIPLE SWITCH ................................................................................................................................... 11-5
1.6RELAY BOX ................................................................................................................................................. 11-6
1.7FUSE CHECK ............................................................................................................................................ 11-7
1.8WIRING DIAGRAM ..................................................................................................................................... 11-9
2.INSTRMENT PANEL ........................................................................................................................................ 11-11
2.1SYMBOL DESCRIPTION ......................................................................................................................... 11-11
2.2CIRCUIT DIAGRAM OF INSTRUMENT(USA) ....................................................................................... 11 -14
3.STSRTING SYSTEM ........................................................................................................................................ 11 -15
3.1IGNITION CIRCUIT(WITHOUT THE INSTALLATION OF HORIZONTAL CONTROLLER ............... 11 -15
3.2IGNITION CIRCUIT(HORIZONTAL CONTROL INSTALLATION EXPECTATION ONLY JP ............. 11 -16
3.3MAJOR COMPONENTS ........................................................................................................................... 11 -17
4.CHARGING SYSTEM ....................................................................................................................................... 11 -22
4.1CIRCUIT DIAGRAM .................................................................................................................................. 11 -22
4.2AC (ALTERNATING CURRENT)ALTERNATOR .................................................................................... 11 -23
5.ENGINE GLOW PLUG SYSTEM .................................................................................................................... 11 -25
5.1CIRCUIT DIAGRAM .................................................................................................................................. 11 -25
5.2MAJOR COMPONENTS ........................................................................................................................... 11- 26
6.PTO SYSTEM(ONLY USA) .............................................................................................................................. 11 -28
6.1CIRCUIT DIAGRAM .................................................................................................................................. 11 -28
6.2CIRCUIT DESCRIPTION ........................................................................................................................ 11 -30
6.3TROUBLESHOOTING ............................................................................................................................. 11-3 0
7.ROTARY LEVEL CONTROL INSTALLATION(ONLY JP) ............................................................................. 11 -31
7.1SYSTEM COMPOSITION PARTS ........................................................................................................... 11 -31
7.2OUTLINE ................................................................................................................................................... 11 -32
7.3LEVEL CONTROL INSTALLATION FUCTION ...................................................................................... 11 -34
7.4TERMINAL ARRANGEMENT TABLE ...................................................................................................... 11 -37
8.QUECK TURN(ONLY JP) ................................................................................................................................ 11- 38
8.1ELECTRIC CIRCUIT ................................................................................................................................ 11- 38
8.2MAIN PARTS COMPOSITION .................................................................................................................. 11 -40
8.3REPAIRS FOR QUECK TURN1 MALFUCTION ................................................................................... 11 -42
9.AIR CONDITIONING SYTEM .......................................................................................................................... 11 -43
9.1CIRCUIT DIAGRAM .................................................................................................................................. 11 -43
9.2MAJPR COMPONENTS ........................................................................................................................... 11- 44
10.HEATER SYSTEM .......................................................................................................................................... 11 -46
 TO THE READER

TO THE READER

This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism,
service and maintenance of DAEDONG tractors DK45S(DK451). It is divided into two parts, “Mechanism” and
“Servicing”.

MECHANISM
Information on the construction and functions are included. The part should be completely understood before
proceeding with troubleshooting, disassembling or servicing.

SERVICING
In this section you will find general precautions, maintenance and special tools. The are other sections which
include troubleshooting, servicing, specifications lists, disassembling, assembling and servicing that explains in
detail procedures, precautions, factory specifications and acceptable limits.

This manual contains the latest production information on illustrations and specifications based on the most up to
date production information available at the time of publication.

We reserve the right to make changes throughout the entire manual at any time without notice.

DC45-WOO Nov. 2004 1

DK45S(DK451)

SAFETY FIRST

This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and the decals on the machine
itself to warn of the possibility of personal injury. It is essential that you read the instructions and safety regulations
before you attempt to repair or operate this unit. Read these instructions carefully.

SIGNS DESCRIPTION

This mark indicates hazardous situation which, if not observed, may

DANGER 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

WARNING
observed, may result in death or moderate injury.

This mark indicates potentially hazardous situation which, if not

CAUTION 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

IMPORTANT procedures or information on working procedures and technology for
convenient use.

NOTE Gives helpful information.

BEFORE SERVICING AND REPAIRING

1. Read all safety instructions in this manual and be
aware of the safety decals on your machine itself.
2. Thoroughly clean your work area and the machine.
3. Make sure the machine is on firm and level ground
and that the parking brake is set.
4. Lower the implement to the ground.
5. Stop the engine and remove the key.
6. Disconnect the negative battery cable.
7. Place a “DO NOT OPERATE” tag in operator station.

C45W001A

SAFETY STARTING
1. Always use the safety start switch to start the 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. N eve r s tart the en gin e u nle ss y ou are in the
operator’s seat.

C45W002A

2 DC45-WOO Nov. 2004

 TO THE READER

SAFETY WORKING
1. Do not operate or service the machine while under
the influen ce of alcoho l, med ication , or o ther
substances.
2. Never wear loose fitting clothing and always use
safety equipment appropriate to the job.
3. Never use improvised tools, parts or procedures.
Use only recommended tools appropriate to the
work.
4. Be careful to perform all work safely when servicing
is done by two or more people.
5. Always support the machine by safety stands. Never
work under the machine that is supported solely by C45W003A
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.

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

DC45-WOO Nov. 2004 3

DK45S(DK451)

VENTILATE WORK AREA

1. Exhaust contains poisonous carbon monoxide, so
you should never run the engine in a closed area. If
th e en gin e m ust be runn ing wh ile p erf ormi ng
maintenance, make sure the area is well ventilated.

C45W006A

PREVENT ACID BURNS

1. Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill elec-
trolyte on yourself, flush with water, and get medi-
cal attention immediately.

C45W007A

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

4 DC45-WOO Nov. 2004

 TO THE READER

PREPARE FOR EMERGENCIES

1. Be sure to keep a first aid kit and fire extinguisher
handy at all times.
2. Keep emergency numbers for the nearest fire
d e pa r t m en t , ho s p it a l , d o c to r a n d a m b u la n c e
service, near your telephone in case of emergency.

C45W009A

DC45-WOO Nov. 2004 5

DK45S(DK451)

SAFETY DECALS

The following safety decals are installed on the machine.

If a decal becomes damaged, illegible or is not on the machine, replace it. The decal part number is listed in the
parts list.

ROPS

C45W010A

6 DC45-WOO Nov. 2004

 TO THE READER

CABIN

C45W011A

(1) Parts No. : T4625-52191 (2) Parts No. : T4837-51181

DC45-WOO Nov. 2004 7

DK45S(DK451)

(3) Parts No. : T4685-52311 (4) Parts No. : T4818-52142

(5) Parts No. : T2325-50743 (6) Parts No. : T4625-52351

(7) Parts No. : T4625-52361 (8) Parts No. : T4625-53191

8 DC45-WOO Nov. 2004

 TO THE READER

(9) Parts No. : T2241-50702 (10) Parts No. : T2445-50724

(11) Parts No. : T4837-51093 (12) Parts No. : T2615-54112

(13) Parts No. : T4818-52132 (14) Parts No. : T2615-55112

DC45-WOO Nov. 2004 9

DK45S(DK451)

(15) Parts No. : T4817-52201 (16) Parts No. : T2615-53561

CARE OF DANGER, WARNING AND CAUTION LABELS

1. Keep danger, warning and caution labels clean and free from obstructing material.
2. Clean danger, warning and caution labels with soap and water, dry with a soft cloth.
3. Replace damaged or missing danger, warning and caution labels with new labels.
4. If a component with danger, warning or caution label(s) is replaced, make sure new label(s) is (are) attached
in the same locations(s) as the replaced component.
5. Mount new labels by applying on a clean dry surface and pressing any bubbles to outside edge.

10 DC45-WOO Nov. 2004

CHAPTER 1

GENERAL
 GENERAL

1. TRACTOR IDENTIFICATION

When contacting your local KIOTI distributor, always specify engine serial number, tractor serial number and hour
meter reading.

C45W101A C45W102A

(1) Statutory Plate (2) Identification Plate (3) Engine Serial Number

C45W103A

(4) Hour Meter

DC45-WOO Nov. 2004 1-3

CHAPTER 1 DK45S(DK451)

2. TRACTOR VIEW

C45W104A

1-4 DC45-WOO Nov. 2004


3. GENERAL PRECAUTIONS
3.1 ASSEMBLY AND DISASSEMBLY
(1) Grease
(2) Snap Ring for Shaft
(3) Snap Ring for Hole
1. Place the tractor on firm and level ground prior to any
service or adjustment.
2. Work with the engine stopped whenever possible.
Be careful when doing any testing that requires the
engine to be running.
3. Use only DAEDONG approved special tools. Servic-
in g d eal ers ma y m ach ine to ols to DE ADO NG
specifications, if the tool will not be used often.
4. Keep your work area and the tractor clean during all
p h as e s o f t he di s a ss e m b ly a n d r e a ss e m b ly
process.
5. After removal, keep parts clean and organized.
Tighten nuts to m ating bolts by hand to keep
matched sets together.
6. Be careful during disassembly, assembly, and stor-
age of hydraulic parts. Dust and metal chips can
contaminate the whole hydraulic system. Keep parts
covered whenever possible.
7. Use only approved manufactures cleaning agents
fo r p arts cl ean ing . H yd rau lic par ts sho uld be
cleaned with an approved cleaning oil. Diesel fuel
should never be used for cleaning.
8. Remove all oil and contaminates before performing
any measurement of parts.
9. Disconnect the battery negative (-) cable before re-
moving or installing any live electrical components.
10.Use only DAEDONG ( KIOTI) genuine parts to main-
tain the performance and safety of your KIOTI tractor.
DC45-WOO Nov. 2004
GENERAL
C45W105A
(4) Assemble Towards to be Forced
(5) Reciprocating
(6) Rotating
11. When assembling an outside snap ring, on a shaft,
or an inside snap ring, in a hole, assemble with the
head in the direction of force. Reference the above
figure.
12.When replacing a new part also replace the associ-
ated packing (gasket), bearing(s), and o-ring(s).
Apply grease properly for O-rings and oil seals be-
fore assembly.
13.Locate the split portion of any spring pin by refer-
encing the direction of force, like the above figure.
14.Replace any split pin with a new one.
IMPORTANT
• Use packing bond, gasket sealer, equivalent to
three bond 1208D.
• Remove all existing sealer before applying new
sealer to the part.
• Apply the bond, sealer, in a bead centered on the
sealing flange area. If a bolt hole is encountered,
continue bead to the center of the inner sealing
surface.
• Assemble the parts within 10 minutes of bond,
sealer, application. Wait 30 minutes before add-
ing oil to the sealed parts, if applicable.
1-5
CHAPTER 1 DK45S(DK451)

3.2 ELECTRICAL SYSTEM

1. Check all electrical connectors daily for any damage

or short circuit at their junctions. In addition, annu-
ally schedule a complete electrical system inspec-
tion with your local KIOTI dealer.
2. Do not modify or reorganize the wiring harness or
the electric field parts.
3. When disconnecting battery cables, disconnect the
negative cable first. Reinstall the positive cable first
when reinstalling.

NOTE:
• Be sure to turn the starting key OFF when connect-
ing or disconnecting the cable.
C45W106A
4. When disconnecting a connector, grasp the plastic
section, not the wiring.
5. When reconnecting the connector, Insert it until it
snaps.

C45W107A

6. When replacing a broken fuse with a new one, be

sure to use the fuse with the correct amperage
capacity. Use your owner’s manual to establish the
correct capacity.
7. Be sure not to drop sensors and relays. They are
fragile.

C45W108A

1-6 DC45-WOO Nov. 2004

 GENERAL

3.3 TUBES AND RUBBERS

Keep the tubes (hoses) and rubber parts free from oil
and other petroleum products. This may cause a
change in quality in these parts, and may shorten prod-
uct life.

C45W109A

3.4 LUBRICANT

During assembly and repair, apply designated lubri-

cant where specified in accordance with this repair
manual.

C45W110A

DC45-WOO Nov. 2004 1-7

CHAPTER 1 DK45S(DK451)

4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING

To ensure safety and prevent damage to the machine

and surrounding equipment, heed the following pre-
cautions in handling electrical parts and wiring.

IMPORTANT
• Check electrical wiring for damage and loosened
connection every year. To this end, educate the
customer to do his or her own check. At the same
time recommend that the dealer performs a peri-
odic check during regular maintenance.
• Do not attempt to modify or remodel any electri-
cal parts and/ or wiring.
• When removing the battery cables, disconnect the C45W111A
negative cable first. When installing the battery
cables, connect the positive cable first.

1-8 DC45-WOO Nov. 2004

 GENERAL

5. SPECIFICATIONS

Model DK45S DK451

Model 4A220B
Type Liquid-cooled, 4-cylinder diesel
Engine gross HP (kW) 45 (33.6)
Engine P.T.O HP (kW) 38 (28.3)
Displacement cc (cu.in) 2,197 (134.1)
Rated revolution r.p.m min-1 2,600
Fuel tank capacity (gal.) 58 (15.32)
Clutch Dry type single stage
Transm ission Synchro
Speeds 12F 12R

Drive train Differential lock Standard

Brake Wet disc type
P.T.O Trans
Rear (rpm) 1 speed (540 rpm at 3 speed (560/728/1040
2,600 engine rpm) rpm at 2,600 engine rpm)
Pump capacity (Max. flow rate) /min (gpm) Main pump 37.4 (9.88)
Power steering pump 16.4 (4.33)

Hydraulic 3-point hitch Cat.I

system Maximum lifting capacity kgf (lbs.) 1,204 (2,654)
Hydraulic lift control system Position, draft and Mixed control
Steering Hydrostatic

Standard Front 9.5 - 16, 6PR 9.5 - 16, 6PR

tire size Rear (AG, TURF, INDUSTRIAL) 14.9 - 24, 6PR 13.6 - 26, 6PR
Forward (At rated engine rpm) km/h (mph) 0.39 ~ 25.90 0.38 ~ 25.67
(0.24 ~ 16.09) (0.236 ~ 15.95)
Traveling
sp ee ds Reverse (At rated engine rpm) km/h (mph) 0.32 ~ 21.44 0.32 ~ 21.25
(0.20 ~ 13.32) (0.20 ~ 13.20)
Overall length (with 3p) mm (in.) 3,243 (126.8)
Overall width (minimum tread) mm (in.) 1,564 (61.6)
Overall height (Top of Cabin) mm (in.) 2,333 (91.9) 2,325 (91.5)
Wheel base mm (in.) 1,880 (74.0)
Dimen-
sio ns Min. ground clearance mm (in.) 370 (14.6)
Tread Front mm (in.) 1,265 (49.8)
Rear mm (in.) 1,208 ~ 1,490 (47.6 ~ 58.7)
Min. turning radius (with brake) m (Ft.) 2,865 (112.8)
Weight (with Cabin) kgf (lbs.) 2,030 (4,475)
NOTE: The specifications are subject to change for the purpose of improvement without any notice.

DC45-WOO Nov. 2004 1-9

CHAPTER 1 DK45S(DK451)

6. LUBRICANTS, FUEL AND COOLANT

No. Locations Capacities Lubricants

No.2-D diesel fuel

1 Fuel 58.0 (15.32 U.S.gal.) No.1-D diesel fuel if temperature is below
-10°C (14°F)
2 Coolant 8.6 (2.30 U.S.gal.) Fresh clean water with anti-freeze

Engine oil: API Service Classification CC or CD

Above 25°C (77°F) SAE30, SAE10W-30 or 10W-40
3 Engine crankcase 8.0 (2.1 U.S.gal.)
0 to 25°C (32 to 77°F) SAE20, SAE10W-30 or 10W-40
Below 0°C (32°F) SAE10W, SAE10W-30 or 10W-40

Multi-gradetransmission fluid the fluid listed below or

equivalent are recommended.
Mobilfluid 423 or 424
4 Transmission case 38.0 (10.04 U.S.gal) Exxonmobil
Exxon hydraul 560
Shell DONAX-TD/TD Plus
BP Tractran UTH

5 Front axle case 8.2 (2.17 U.S.gal.) SAE 90 gear oil

Applying grease Capacity Type of grease

Hydraulic control lever shaft section Small quantity SAE multi-purpose type
3 point link section Until grease exits grease
6 Brake pedal link section
Bracket section in front and rear of the
front axle
Clutch release hub Supply when removed

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 GENERAL

7. TIGHTENING TORQUES

7.1 GENERAL USE SCREWS, BOLTS AND NUTS

Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be tightened
according to the table below.

Indication on
top of bolt 4 No-grade or 4T 7 7T 9 9T

Material of SCr435,
bolt SS400, S20C S43C, S48C
SCM435
Material of
opponent part Ordinariness Aluminum Ordinariness Aluminum Ordinariness

Unit
N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
Diameter

M6 7.85 0.80 5.79 7.85 0.80 5.79 9.81 1.00 7.24 7.85 0.80 5.79 12.3 1.25 9.05
~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
(6 mm, 0.24 in.) 9.31 0.95 6.87 8.82 0.90 6.50 11.2 1.15 8.31 8.82 0.90 6.50 14.2 1.45 10.4

M8 17.7 1.8 13.1 16.7 1.7 12.3 23.6 2.4 17.4 17.7 1.8 13.1 29.5 3.0 21.7
~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
(8 mm, 0.31 in.) 20.5 2.1 15.1 19.6 2.0 14.4 27.4 2.8 20.2 20.5 2.1 15.1 34.3 3.5 25.3

M10 39.3 4.0 29.0 31.4 3.2 23.2 48.1 4.9 35.5 39.3 4.0 29.0 60.9 6.2 44.9
~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
(10 mm, 0.39 in.) 45.1 4.6 33.2 34.3 3.5 25.3 55.8 5.7 41.2 44.1 4.5 32.5 70.6 7.2 52.0

M12 62.8 6.4 46.3 77.5 7.9 57.2 62.8 6.4 46.3 103 10.5 76.0
~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
(12 mm, 0.47 in.) 72.5 7.4 53.5 90.2 9.2 66.5 72.5 7.4 53.5 117 12.0 86.7

M14 108 11.0 79.6 124 12.6 91.2 167 17.0 123
~ ~ ~ ~ ~ ~ ~ ~ ~
(14 mm, 0.55 in.) 125 12.8 92.5 147 15.0 108 196 20.0 144

M16 167 17.0 123 197 20.0 145 260 26.5 192
~ ~ ~ ~ ~ ~ ~ ~ ~
(16 mm, 0.63 in.) 191 19.5 141 225 23.0 166 304 31.0 224

M18 246 25.0 181 275 28.0 203 344 35.0 254
~ ~ ~ ~ ~ ~ ~ ~ ~
(18 mm, 0.71 in.) 284 29.0 209 318 32.5 235 402 41.0 296

M20 334 34.0 246 368 37.5 272 491 50.0 362
~ ~ ~ ~ ~ ~ ~ ~ ~
(20 mm, 0.79 in.) 392 40.0 289 431 44.0 318 568 58.0 419

7.2 STUD BOLTS

Material of opponent part Ordinariness Aluminum

Unit
N·m kgf·m lbf·ft N·m kgf·m lbf·ft
Diameter
M8 (8 mm, 0.31 in.) 11.8 ~ 15.6 1.2 ~ 1.6 8.68 ~ 11.5 8.82 ~ 11.8 0.90 ~ 1.2 6.51 ~ 8.67
M10 (10 mm, 0.39 in.) 24.6 ~ 31.3 2.5 ~ 3.2 18.1 ~ 23.1 19.7 ~ 25.4 2.0 ~ 2.6 14.5 ~ 18.8
M12 (12 mm, 0.47 in.) 29.5 ~ 49.0 3.0 ~ 5.0 21.7 ~ 36.1 31.4 3.2 23.1

DC45-WOO Nov. 2004 1-11

CHAPTER 1 DK45S(DK451)

7.3 AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF
THREADS

Grade SAE GR.5 SAE GR.8

Unit

Nominal
diameter N·m kgf·m lbf·ft N·m kgf·m lbf·ft

5/16 23.1 ~ 27.8 2.35 ~ 2.84 17.0 ~ 20.5 32.5 ~ 39.3 3.31 ~ 4.01 24.0 ~ 29.0
3/8 47.5 ~ 57.0 4.84 ~ 5.82 35.0 ~ 42.0 61.0 ~ 73.2 6.22 ~ 7.47 45.0 ~ 54.0
1/2 108.5 ~ 130.2 11.07 ~ 13.29 80.0 ~ 96.0 149.2 ~ 179.0 15.22 ~ 18.27 110.0 ~ 132.0
9/16 149.2 ~ 179.0 15.22 ~ 18.27 110.0 ~ 132.0 217.0 ~ 260.4 22.14 ~ 26.57 160.0 ~192.0
5/8 203.4 ~ 244.1 20.75 ~ 24.91 150.0 ~ 180.0 298.3 ~ 358.0 30.44 ~ 36.53 220.0 ~ 264.0

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 GENERAL

8. MAINTENANCE CHECK LIST

Period After
Indication On Hour Meter Purchase
No. Important
1 2
50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1500 3000
Item year years

1 Engine oil Change

2 Engine oil filter Replace
3 Transmission oil filter Replace
4 Transmission fluid Change
5 Front axle case oil Change
6 Front axle pivot Adjust
7 Engine start system Check
8 Greasing -
9 Wheel bolt torque Check
10 Battery condition Check
Clean
11 Air cleaner element
Replace
Check
12 Fuel filter element
Replace
13 Fan belt Adjust
14 Clutch Adjust
15 Brake Adjust

Radiator hose and Check

16
clamp Replace

Power steering oil Check

17
line Replace
Check
18 Fuel line
Replace
Check
19 Intake air line
Replace
20 Toe-in Adjust

Engine valve
21 Adjust
clearance

Fuel injection
22 nozzle injection Check
pressure

23 Injection pump Check

24 Cooling system Flush
25 Coolant Change
26 Fuel system Bleed Service
27 Fuse Replace as
required
28 Light bulb Replace

DC45-WOO Nov. 2004 1-13

CHAPTER 1 DK45S(DK451)

Period After
Indication On Hour Meter Purchase
No. Important
1 2
50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1500 3000
Item year years

Air conditioner
29 Clean Daily
condenser net
Air conditioner belt
30 Replace
tension
31 Air conditioner filter Clean
32 Condensor blocked Check
Air conditioner hose
33 Check
and pipe
34 Cabin rubber Check
35 Lubrication system Check
Service
36 Washer liquid Check as
required
37 Refrigerant capacity Check

IMPORTANT
• The jobs indicated by must be done after the first 50 hours of operation.
*1 Air cleaner should be cleaned more often in dusty conditions than in normal conditions.
*2 Every year or every 6 times of cleaning.
*3 Replace only if necessary.
*4 When the battery is used for less than 100 hours per year, check the fluid level annually.
• The items listed above (@ marked) are registered as emission related critical parts by DAEDONG in the
US.EPA non-road emission regulation. As the engine owner, you are responsible for the performance of the
required maintenance on the engine according to the above instruction.
Please see the Warranty Statement in detail.

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 GENERAL

9. CHECK AND MAINIENANCE

9.1 DAILY CHECK

For your own safety and maximum service life of the Walk Around Inspection
machine, make a thorough daily inspection before op- Look around and under the tractor for such items as
erating the machine to start the engine. loose bolts, trash build-up, oil or coolant leaks, broken
or worn parts.
CAUTION
To avoid personal injury:
• Be sure to check and service the tractor on a flat
place with the engine shut off and the parking
brake “ON”.

A. CHECKING AND REFUELING

58.0
Fuel tank capacity
(15.32 U.S.gal.)

CAUTION
To avoid personal injury:
• Do not smoke while refueling.
• Be sure to stop the engine before refueling.

1. Turn the key switch to “ON”, check the amount of

fuel showing on the fuel gauge.
2. Fill fuel tank when the fuel gauge shows 1/4 or less
fuel in the tank. C45W112A

3. Use grade No.2-Diesel fuel at all temperatures

above -10°C (14°F). (1) Fuel Tank Cap

IMPORTANT NOTE:
• Do not permit dirt or trash to get into the fuel • No.2-D is a distillate fuel of lower volatility for en-
system. gines in industrial and heavy mobile service. (SAE
• Be careful not to let the fuel tank become empty, J313 JUN 87)
otherwise air will enter the fuel system, requiring
• Grade of Diesel Fuel Oil According to ASTM D975
the fuel system to be bled before next engine start.
• Be careful not to spill during refueling. If a spill
should occur, wipe it off at once. Fuel on the trac-
tor may cause a fire.
• To prevent condensation( water) accumulation in
the fuel tank, fill the tank before parking the trac-
tor overnight.

Flash Point °C (°F) Water and Sediment, Carbon Residue On, Ash, Weight %
Volume % 10 Percent Residuum, %
Min Max Max Max
52 (125) 0.05 0.35 0.01

Distillation Copper
Temperatures, Viscosity Kinematic cSt Viscosity Saybolt, Sulfur, Strip Cetane
°C (°F) 90% Point or mm²/s at 40°C SUS at 100°F Weight % Corrosion Number

Min Max Min Max Min Max Max Max Min

282 (540) 338 (640) 1.9 4.1 32.6 40.1 0.50 No.3 40

DC45-WOO Nov. 2004 1-15

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