Daedong DK752C Instruction manual

DK752C/DK902C
TRACTORS
WORKSHOP MANUAL
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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
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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
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0-2 DS42-W00 Nov. 2007
DK752C/DK902C
SAFETY FIRSTGENERALENGINECLUTCHTRANSMISSIONREAR AXLEBRAKEFRONT AXLESTEERINGHYDRAULICELECTRICCABINA/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
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SAFETY FIRSTGENERALENGINECLUTCHTRANSMISSIONREAR AXLEBRAKEFRONT AXLESTEERINGHYDRAULICELECTRICCABINA/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
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0-4 DS42-W00 Nov. 2007
DK752C/DK902C
SAFETY FIRSTGENERALENGINECLUTCHTRANSMISSIONREAR AXLEBRAKEFRONT AXLESTEERINGHYDRAULICELECTRICCABINA/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
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SAFETY FIRSTGENERALENGINECLUTCHTRANSMISSIONREAR AXLEBRAKEFRONT AXLESTEERINGHYDRAULICELECTRICCABINA/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
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0-6 DS42-W00 Nov. 2007
DK752C/DK902C
SAFETY FIRSTGENERALENGINECLUTCHTRANSMISSIONREAR AXLEBRAKEFRONT AXLESTEERINGHYDRAULICELECTRICCABINA/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
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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
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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
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SAFETY FIRSTGENERALENGINECLUTCHTRANSMISSIONREAR AXLEBRAKEFRONT AXLESTEERINGHYDRAULICELECTRICCABINA/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
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