Daedong Workshop Manual Production Release 1.0

DAEDONG
WORKSHOP MANUAL
INDUSTRIAL DIESEL ENGINES
Contents
1. 3C Series Workshop Manual
2. 3A Series Workshop Manual
3. 4A, 3B, 4B Series Workshop Manual

1. 3C Series Workshop Manual
CK20S/CK20S(H) ENGINE - ENGINE IDENTIFICATION
1. ENGINE IDENTIFICATION
GENERAL
1.1 GENERAL FEATURES
196W207B ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BARKE
FRONT AXLE
STEERING
The 3C100A is a vertical, water-cooled, 4-cycle diesel

engine. They are incorporated with DAEDONGs lead-
ing technologies. They feature greater power, lower
fuel consumption, and little vibration and quiet opera-
HYDRAULIC
tion due to the DAEDONGs circular combustion

chamber, well-known Bosch K type injection pump and
well-balanced designs.
ELECTRIC
INDEX
SS30-W00 May. 2007 2-3

ENGINE - ENGINE IDENTIFICATION CK20S/CK20S(H)
1.2 ENGINE EPA DECAL

GENERAL
This aluminum decal is riveted on the engine cylinder

head cover. This provides the information such as model
number, displacement, rated output, valve clearance, IMPORTANT ENGINE INFORMATION
Engine Family: 5DCLL02.2D87 Injection Timing: 18 DEG BTDC
injection timing, etc. Engine Type: Displacement: 2.197 L
Advertised Power: 33.6 kW a 2600 RPM Idle Min: 850 RPM
This decal represents that this engine is in compliance Valve Clearance(mm): Inlet 0.25 Exhaust 0.3 e11*97/68DA*2002/88*0182*03
ENGINE
Adjustments should be made when the engine is at normal operating

with the U.S.EPA and California (CARB) exhaust emis- temperature with transmission in neutral.
This engine conforms to 2005 U.S EPA andCalifornia regulations
sion regulation. for off-road compression-ignition engines.
This engine is certified to operate on commercially available diesel
fuel. Refer to owner's manual for maintemance specifications and
adjustmints. E6305-99506
1.3 BAR CODE FOR ENGINE NUMBER
CLUTCH
The bar code for the DAEDONG engine number is

located on the intake manifold. T46W202A
1.4 ENGINE NUMBER ASSIGNMENT

TRANSMISSION
STANDARD
The engine number is also stamped near the fuel injec-
tion pump on the cylinder block, in case the bar code
is not available due to damage.
HST
IMPORTANT
The engine number is necessary information that
is requested on the warranty registration form.
This number should be on the form as well as the
REAR AXLE
tractor serial number and the amount of time used.
For example, FD4000001 means that this engine is F D 4 0 0 0 0 0 1

the first manufactured unit, 3B183 LXM, in 2006.
Serial number
BARKE
Engine model
3B183LXM D40
3B183LXH D41
4A200LXM D22
FRONT AXLE
4A200LXH D23
4A220LXM D24
4A220LXH D25
4B243LXM D38
STEERING
4B243LXH D39
Year of manufacturing
... ...
8 1998
HYDRAULIC
9 1999
0 2000
1 2001
2 2002
ELECTRIC
3 2003
D 2004
E 2005
F 2006
G 2007
INDEX
... ...
2-4 SS30-W00 May. 2007

CK20S/CK20S(H) ENGINE - SPECIFICATIONS
2. SPECIFICATIONS
GENERAL
2.1 GENERAL SPECIFICATIONS
Item Factory Specification
ENGINE
Model 3C100A
Type Vertical, water-cooled 4 cycle diesel engine
Number of cylinders 3
Bore stroke 75 X 76 mm
CLUTCH
Total displacement 1007 cm 3, 61.45 cu.in.
Engine gross power 22 HP (16.2 kW) / 2,800 rpm.
Maximum idle speed 3,000 rpm
TRANSMISSION
Minimum idle speed 1,000 rpm
Maximum torque 63.7 Nm, 6.5 kgf-m, 47 lbs-ft/1,900 rpm
Combustion chamber Spherical type, swirl chamber
Fuel injection pump Bosch type K mini pump
Plunger bore 5 mm, 0.197 in.
Governor Centrifugal ball mechanical governor
HST
Injection type Indirect injection with pre combination chamber
Injection timing 18 before top dead center
Injection pressure 14.2 MPa, 145 kgf/cm2, 2,062 psi
REAR AXLE
Compression ratio 21.5 : 1
Lubricating system Forced lubrication by rotor-type pump
Lubricating oil filter Full flow paper filter (cartridge type)
Oil relief pressure 4.5 ~ 5.4 kgf/cm2(64 ~ 76 psi)
BARKE
Lubricating oil capacity 3.2 (0.84 U.S.gal.)
Engine oil specification SAE 15W-40, CD or high or of API grode
Cooling system Pressurized radiator, forced circulation (with pump)
Coolant capacity 4.6 (1.21 U.S.gal.)
FRONT AXLE
Antifreeze Ethylene glycol 50% with anti corrosive agent
Starting system Electric starting with start motor
Battery 12 V, 80AH, Equivalent (CCA, 630AH)
Starting support device By glow plug in combustion chamber STEERING
Dynamo for charging 12 V, 240 W
Fuel Diesel fuel No.2-D (ASTM D975)
Weight (Dry) 98 kg, 216 lbs.
Injection order 1-2-3
HYDRAULIC
Direction of rotation Counterclockwise (wiewed from flywheel side)
The engine gross output is measured with the cooling fan removed.
The cylinder number for ignition sequence is given from the cylinder on the engine cooling fan side.
ELECTRIC
If the coolant level drops due to its evaporation, add only water. If the coolant level drops due to the leakage, add
coolant mixed with anti-freeze.
The freezing point of the coolant mixture is -37C (-34F) in a normal condition.
When replacing the coolant with a different type of coolant, flush the cooling system thoroughly beforehand.
INDEX
SS30-W00 May. 2007 2-5

ENGINE - SPECIFICATIONS CK20S/CK20S(H)
2.2 PERFORMANCE CURVE

GENERAL
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BARKE
FRONT AXLE
196W203B
NOTE:
STEERING
Performance curve, obtained in accordance with SAE J 1995.

SFC (Specific Fuel Consumption)
According to the curve,
197g/Hp-hr at 2,800 rpm
HYDRAULIC
197g/Hp-hr X 22 HP = 4,334 kg/hr

4,334 kg/hr 0.81 kg/ = 5.35 /hr
1 of diesel fuel is 0.81 kg
ELECTRIC
INDEX
2-6 SS30-W00 May. 2007

2.3 DIMENSIONS
GENERAL
mm (in.)
494 (19.4)
502 (19.7)
ENGINE
CLUTCH
626.5 (24.7)
TRANSMISSION
HST
REAR AXLE
BARKE
FRONT AXLE
STEERING
HYDRAULIC
196W204B
ELECTRIC
INDEX
SS30-W00 May. 2007 2-7

2.4 SERVICE SPECIFICATIONS

GENERAL
2.4.1 CYLINDER HEAD
Item Reference Value Allowable Limit

Distortion of cylinder head surface length. 0.05 mm (0.0020 in.) /
ENGINE
100 mm (4 in.) of cylinder head -

surface length.
Thickness of gasket When tightened
-
1.15 ~ 1.25 mm (0.045 ~ 0.049 in.)
Top clearance 0.7 ~ 0.9 mm (0.0275 ~ 0.0354 in.) -
CLUTCH
Tightness of head bolts 58.8 ~ 63.7 Nm

6.0 ~ 6.5 kgf-m -
(43.4 ~ 47.0 lb-ft)
TRANSMISSION
2.4.2 VALVES

Valve seat width 2.1 mm -
0.083 in.
HST
Valve seat angle (intake, exhaust) 1.047, 0.785 rad. -

60, 45
O.D. of valve stems (intake, exhaust) 6.960 ~ 6.975 mm -
REAR AXLE
0.2740 ~ 0.2746 in.

I.D. of valve guides (intake, exhaust) 7.010 ~ 7.025 mm -
0.2759 ~ 0.2765 in.
Clearance between valve 0.035 ~ 0.065 mm 0.1 mm
stems and guides 0.0014 ~ 0.0026 in. 0.004 in.
BARKE
Valve recessing -0.05 ~ +0.15 mm 1.3 mm

-0.002 ~ +0.006 in. 0.051 in.
Valve clearance (intake, exhaust) cold 0.15 mm
-
0.006 in
FRONT AXLE
2.4.3 VALVE SPRINGS

STEERING
Free length 35.1 ~ 35.6 mm 34.8 mm

1.382 ~ 1.402 in. 1.37 in.
Fitted length 30.99 mm -
1.2201 in.
HYDRAULIC
Load to compress to fitted length 74 N / 31 mm 63 N / 31 mm

7.5 kgf / 31 mm, 6.4 kgf / 31 mm,
16.5 lbs / 1.22 in. 14.1 lbs / 1.22 in.
Squareness 1.3 mm
-
0.051 in.
ELECTRIC
INDEX
2-8 SS30-W00 May. 2007

GENERAL
2.4.4 VALVE ROCKER ARMS

O.D. of rocker arm shafts 12.955 ~ 12.980 mm -
ENGINE
0.5100 ~ 0.5110 in.
I.D. of rocker arm bushings 13.000 ~ 13.025 mm -
0.5118 ~ 0.5128 in.
Clearance between rocker arm shafts and 0.02 ~ 0.07 mm 0.12 mm
bushings 0.0008 ~ 0.0027 in. 0.0047 in.
CLUTCH
Adjustment of compression release 0.750 ~ 1.125 mm
-
0.0295 ~ 0.0443 in.
TRANSMISSION
2.4.5 CAMSHAFT

O.D. of camshaft bearing journal 32.934 ~ 32.950 mm
-
1.2966 ~ 1.2972 in.
HST
I.D. of camshaft bearing 33.000 ~ 33.025 mm
-
1.2992 ~ 1.3002 in.
Clearance between camshaft 0.050 ~ 0.091 mm 0.15 mm
REAR AXLE
bearing journals and bearings 0.0020 ~ 0.0036 in. 0.0020 in.
Alignment of camshaft 0.05 mm
- 0.0020 in.
Cam height Intake 26.75 mm 26.83 mm
1.0530 in. 1.0563 in.
BARKE
Exhaust 26.88 mm 26.88 mm
1.0583 in. 1.0583 in.
Gear backlash 0.042 ~ 0.115 mm 0.2 mm
0.0017 ~ 0.0045 in. 0.0079 in.
FRONT AXLE
2.4.6 PISTON RINGS

STEERING
Ring gap Top ring 0.15 ~ 0.30 mm 1.25 mm
0.0059 ~ 0.0118 in. 0.0492 in.
2nd ring 0.30 ~ 0.45 mm 1.25 mm
0.0118 ~ 0.0177 in. 0.0492 in.
HYDRAULIC
Oil ring 0.20 ~ 0.35 mm 1.25 mm

0.0079 ~ 0.0138 in. 0.0492 in.
Side clearance of ring Top ring
- -
in groove
2nd ring 0.04 ~ 0.08 mm
-
ELECTRIC
0.0016 ~ 0.0031 in.

Oil ring 0.02 ~ 0.06 mm
-
0.0008 ~ 0.0024 in.
INDEX
SS30-W00 May. 2007 2-9

2.4.7 PISTONS
GENERAL

I.D. of piston bosses 20.000 ~ 20.013 mm 20.03 mm
0.7874 ~ 0.7879 in. 0.7885 in.
O.D. of piston pin 20.002 ~ 20.011 mm
-
ENGINE
0.7875 ~ 0.7878 in.

I.D. of connecting rod small end bushings (fitted) 20.025 ~ 20.040 mm
-
0.7884 ~ 0.7890 in.
Clearance between piston pin 0.014 ~ 0.038 mm 0.15 mm
and small end bushings 0.0006 ~ 0.0015 in. 0.0059 in.
CLUTCH
Connecting rod alignment 0.02 mm 0.05 mm

0.0008 in. 0.0020 in.
TRANSMISSION
2.4.8 CRANKSHAFT

Crankshaft alignment 0.02 mm 0.08 mm
0.0008 in. 0.0031 in.
HST
O.D. of crankshaft journals 47.934 ~ 47.950 mm

-
1.8872 ~ 1.8878 in.
I.D. of crankshaft bearing 1 48.068 ~ 48.138 mm
-
1.8924 ~ 1.8952 in.
REAR AXLE
I.D. of crankshaft bearing 2 47.980 ~ 48.006 mm

-
1.8890 ~ 1.8900 in.
Clearance between crankshaft 0.118 ~ 0.204 mm 0.20 mm
journals and bearing 1 0.0046 ~ 0.0080 in. 0.0079 in.
Clearance between crankshaft 0.030 ~ 0.072 mm 0.20 mm
BARKE
journals and bearing 2 0.0012 ~ 0.0028 in. 0.0079 in.

O.D. of crankpins 39.959 ~ 39.975 mm
-
1.5732 ~ 1.5738 in.
I.D. of crankpin bearings 39.994 ~ 40.020 mm
-
FRONT AXLE
1.5746 ~ 1.5756 in.

Clearance between 0.035 ~ 0.061 mm 0.20 mm
crankpins and bearings 0.0014 ~ 0.0024 in. 0.0079 in.
End play of crankshaft 0.15 ~ 0.31 mm 0.5 mm
0.0059 ~ 0.0122 in. 0.0197 in.
STEERING
2.4.9 FUEL INJECTION NOZZLES

HYDRAULIC
Opening pressure 14.2 ~ 15.2 MPa

145 ~ 155 kgf/cm, -
2,062 ~ 2,204 psi.
Fuel tightness of nozzle valve seat Dry nozzle at 12.7 MPa
-
130 kgf/cm, 1,848.6 psi.
ELECTRIC
INDEX
2-10 SS30-W00 May. 2007

2.4.10 INJECTION PUMP
GENERAL
Tightness of plunger More than 60 seconds; initial pres- 30 seconds
sure from 34.32 ~ 39.23 MPa
350 ~ 400 kgf/cm2, 4,978 ~ 5,689 psi.
ENGINE
Tightness of delivery valve More than 10 seconds; initial 5 seconds
pressure from 20.59 ~ 21.57 MPa
210 ~ 220 kgf/cm2, 2,987 ~ 3,129 psi
Injection timing 22 Before Top Dead Center -
CLUTCH
2.4.11 OIL PUMP
TRANSMISSION
Oil At rated speed 245 ~ 441 kPa 245 kPa
pressure 2.5 ~ 4.5 kgf/cm2, 36 ~ 64 psi. 2.5 kgf/cm2, 36 psi
At idle speed More than 49 kPa
-
0.5 kgf/cm 2, 7.11 psi.
Rotor type Rotor lobe clearance 0.11 ~ 0.15 mm 0.20 mm
0.0043 ~ 0.0059 in. 0.0079 in.
HST
Radial clearance between 0.07 ~ 0.15 mm 0.25 mm
outer rotor and pump body 0.0028 ~ 0.0059 in. 0.0098 in.
End clearance between 0.08 ~ 0.13 mm 0.2 mm
REAR AXLE
rotor and cover 0.0031 ~ 0.0051 in. 0.0079 in.
2.4.12 RADIATOR
BARKE
Opening pressure of cap 88.3 kPa
-
0.9 kgf/cm 2, 12.8 psi.
Test pressure 88.3 kPa -
FRONT AXLE
0.9 kgf/cm 2, 12.8 psi.
2.4.13 THERMOSTAT
Item Reference Value Allowable Limit STEERING

Opening temperature cap Beginning 80.5C ~ 83.5C
-
176.9F ~ 182.3F
Full-open 95C
-
203F
HYDRAULIC
Distance of lift 8 mm
-
0.3150 in.
2.4.14 FANBELT
ELECTRIC

Belt sag under load of 78.5 N
8 mm (0.32 in.) -
(8 kgf, 17.6 lbs.)
INDEX
SS30-W00 May. 2007 2-11

2.4.15 TIGHTENING TORQUE

GENERAL
Indicate the bolts with mark and manually tighten first.
Item Nm kgf-m lb-ft

Head bolt, nut 58.8 ~ 63.7 6.0 ~ 6.5 43.4 ~ 47.0
Bearing case bolt 1 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3
ENGINE
Bearing case bolt 2 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3

Flywheel bolt 53.9 ~ 58.8 5.5 ~ 6.0 39.7 ~ 43.4
Connecting rod bolt 26.5 ~ 30.4 2.7 ~ 3.1 19.5 ~ 22.4
Rocker arm bracket sink bolt 23.5 ~ 27.5 2.4 ~ 2.8 17.4 ~ 20.3
CLUTCH
Idle gear shaft bolt 7.8 ~ 9.8 0.8 ~ 1.0 5.7 ~ 7.2
Glow plug (no lubrication) 19.6 ~ 24.5 2.0 ~ 2.5 14.4 ~ 18.1
Waste oil plug 32.4 ~ 37.3 3.3 ~ 3.8 23.9 ~ 27.5
TRANSMISSION
Nozzle holder 49.0 ~ 68.6 5.0 ~ 7.0 36.1 ~ 50.5

Overflow pipe nut 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3
Oil switch Bis 1.4 ~ 1.9 0.14 ~ 0.20 1.0 ~ 1.4
Taper screw 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Fuel supply limit cap nut 27.5 ~ 34.3 2.8 ~ 3.5 20.3 ~ 25.3
HST
Idle limit fixing nut 13.7 ~ 15.7 1.4 ~ 1.6 10.1 ~ 11.5
Injection pipe nut 24.5 ~ 34.3 2.5 ~ 3.5 18.0 ~ 25.3
Crankshaft nut 137.2 ~ 156.9 14 ~ 16 101.2 ~ 115.7
REAR AXLE
BARKE
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
2-12 SS30-W00 May. 2007

CK20S/CK20S(H) ENGINE - OPERATING PRINCIPLE
3. OPERATING PRINCIPLE
GENERAL
3.1 BODY AND POWER TRAIN
3.1.1 CYLINDER HEAD
ENGINE
The cylinder head has openings on both sides that
allow cross-flow type inlet/exhaust ports to the engine.
Because the inlet/exhaust ports overlap and are
smaller than other ports, the suction air can be pro-
tected from being heated and expanded by exhaust air.
The cool, high mass suction air has a high large effec-
CLUTCH
tiveness and raises the power of the engine. Deforma-
tion of the cylinder head by heat exhaust air is reduced
because inlet ports are arranged alternately. The com-
bustion chamber is of DAEDONGs select circular com-
TRANSMISSION
bustion chamber type. Suction air is combustion and
reduces fuel consumption. Throttle type injection
nozzles and rapid heating enclosed glow plugs are
installed in the combustion. 196W208A
This glow plug assures easier engine starts even at a

temperature of -15C (5F).
HST
REAR AXLE
BARKE
196W209B
(1) Combustion chamber (4) Nozzle assembly
FRONT AXLE
(2) Inlet port (5) Glow plug
(3) Exhaust port (6) Cylinder head
3.1.2 CYLINDER BLOCK

STEERING
The engine features a high resilience tunnel-type cyl-
inder block. Pressure-fitted cylinders allow effective
cooling, less distortion, higher wear-resistance quali-
ties and each cylinder having its own chamber helps to
minimize noise.
HYDRAULIC
ELECTRIC
196W210B
INDEX
SS30-W00 May. 2007 2-13

ENGINE - OPERATING PRINCIPLE CK20S/CK20S(H)
3.1.3 CRANKSHAFT
GENERAL
The crankshaft drives the pistons and connecting rods,

and transfers its reciprocating movement to a circular
camshaft. Six counterweights are integrated into one
unit to minimize bearing wear and lubricating oil tem-
perature rise.
ENGINE
Seal sliding sections are induction-hardened to raise

wear resistance quality.
Crankshaft journals are supported by the main bear-
ing cases in which bearings are used.
Crankshaft bearing 1 at the front end is a wind type
bushing.
CLUTCH
Thrust bearing 1, 2 of split type are mounted on both

sides of the main bearing case at the flywheel side. 196W211B
Crankshaft bearing and thrust bearings are plated with (1) Crankshaft (5) Crankshaft bearing 2
special raised alloy wear resistance.
TRANSMISSION
(2) Piston (6) Thrust bearing

(3) Connecting rod (7) Counterweight
(4) Crankshaft bearing 1 (8) Main bearing case
3.1.4 PISTON AND PISTON RINGS

HST
Piston circumference has special elliptic shape in con-

sideration of expansion due to heat. The piston head
is flat formed and ribbed to reduce distortion and to
help heat radiation.
REAR AXLE
Pistons are made of special aluminum alloy of low

thermal expansion and high temperature resistance.
The key stone type top ring is well fitted to the wall and
plated with hard chrome.
Second ring type is effective in preventing oil rising.
The oil ring is effective because it is closely fitted to the
BARKE
cylinder wall by a coil so oil can be scraped from the

upper and lower ends of its sliding cylinder walls.
A portion of the scraped oil is forced inside the piston 196W212A
through escape holes of the. rings and pistons. The oil

FRONT AXLE
ring is plated with hard chrome to raise the wear resis- (1) Rib (4) Hard chrome
tance quality. (2) Top ring (5) 2nd ring
(3) Surface (6) Coil expander ring
STEERING
3.1.5 CONNECTING RODS

The connecting rod is used to connect the piston with
the crankshaft. The big end of this rod has crankpin
bearings (split type) and the small end has a bushing
(solid type).
HYDRAULIC
ELECTRIC
196W213A
(1) Connecting rod (3) Bushing

INDEX
(2) Crankpin bearing
2-14 SS30-W00 May. 2007

3.1.6 CAMSHAFT AND FUEL CAMSHAFT
GENERAL
The camshaft is made of special cast iron; the journal
and cam sections are chromed to resist wear. The jour-
nal sections are force-lubricated. The fuel camshaft
controls the reciprocating movement of the injection
pump, and is also equipped with a ball to control the
governor. Fuel camshaft is made of carbon steel and
ENGINE
cam sections are covered and tempered to provide
greater wear resistance.
CLUTCH
196W214A
TRANSMISSION
HST
REAR AXLE
196W215A
(1) Tappet (7) Governor ball case

(2) Push rod (8) Cir-clip
BARKE
(3) Camshaft (9) Cir-clip
(4) Camshaft gear (10) Fuel camshaft
(5) Injection pump gear (11) Ball
(6) Governor sleeve (12) Ball bearing
FRONT AXLE
3.1.7 ROCKER ARM ASSEMBLY
The rocker arm assembly includes the rocker arms,
arm brackets and arm shafts and converts the move- STEERING
ment of the push rods to open/close of the inlet and
exhaust valves. Valve controlled timing must be ad-
justed with screws on the rocker arms. Lubrication oil
is pressurized through arm bearings and the entire
system is lubricated.
HYDRAULIC
ELECTRIC
196W216B
(1) Rocker arm (4) Valve

(2) Rocker arm shaft (5) Push rod
(3) Rocker arm bracket
INDEX
SS30-W00 May. 2007 2-15

3.1.8 INLET AND EXHAUST VALVES

GENERAL
The inlet and exhaust valves and their guides are dif-
ferent from each other. Other parts, such as valve
springs, spring retainers, valve spring collets, valve
stem seals, and valves all contact or sliding parts, which
are covered and tempered to resist, wear.
ENGINE
CLUTCH
196W217A
(1) Valve spring retainer (5) Valve guide

TRANSMISSION
(2) Valve spring collets (6) Intel valve

(3) Valve spring (7) Exhaust valve
(4) Valve stem seal
3.1.9 TIMING GEARS

HST
The crankshaft drives the oil pump and the idle gear
engages the fuel camshaft and camshaft. The timings
for opening and closing the valve are extremely impor-
tant to achieve effective air intake and sufficient gas
REAR AXLE
exhaust. The appropriate timing can be obtained when

assembling by aligning the mark on the crankshaft gear
either with (6) the one on the idle gear or (5), the idle
gear with camshaft gear (3), idle gear (5) or with injec-
tion pump gear (1).
BARKE
196W218A
FRONT AXLE
(1) Injection pump gear (5) Idle gear

(2) Fuel camshaft (6) Crankshaft gear
(3) Camshaft gear (7) Crankshaft
(4) Camshaft
STEERING
3.1.10 FLYWHEEL
The flywheel is installed on the rear end of the crank-
shaft and keeps the flywheel turning at a constant
speed. While the crankshaft tends to speed up during
HYDRAULIC
the power stroke it slows down during other strokes.

The flywheel has a ring gear (1), which meshes with
the drive pinion of the starter. The flywheel has marks
TC and FI on its outer rim. The mark TC shows the
pistons top dead center and the mark FI shows the
fuel injection timing, when they are aligned with the
ELECTRIC
mark of window on the clutch housing.
Injection sequence
Three cylinders: 1 2 3
196W219B
INDEX
(1) Ring gear (3) Crankshaft

(2) Flywheel
2-16 SS30-W00 May. 2007

3.2 LUBRICATION SYSTEM
GENERAL
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BARKE
FRONT AXLE
STEERING
HYDRAULIC
196W200B
A. Oil filter 1 C. Oil filter cartridge and relief D. Camshaft

B. Oil pump valve E. Rocker arm rocker arm shaft
ELECTRIC
1. Inlet hole 3. To rocker arm shaft and F. Piston

camshaft
2. Outlet hole G. Crankpin bearing
4. To crankshaft
H. Oil switch
5. Relief valve
I. Idle gear
6. From pump
INDEX
SS30-W00 May. 2007 2-17

3.2.1 ENGINE OIL FLOW

GENERAL
ENGINE
Rocker arm shaft

CLUTCH
Rocker arm Rocker arm Rocker arm Engine oil pressure sensor
Valve
TRANSMISSION
cam
shaft Valve cam shaft Valve cam shaft Valve cam shaft Valve cam shaft Valve cam shaft Valve cam shaft Valve cam shaft
journal journal journal journal
gear
Fuel
cam
Fuel cam shaft Tappet Tappet Tappet
HST
shaft
gear
REAR AXLE
Piston Piston Piston

Bore Connecting rod's small end Bore Connecting rod's small end Bore Connecting rod's small end
BARKE
No.1 Connecting rod's small end No.2 Connecting rod's small end No.3 Connecting rod's small end
FRONT AXLE
journal bearing No.1 main bearing No.2 main bearing No.3 main bearing
STEERING
Idle gear Main oil gallery

HYDRAULIC
Crank shaft gear Oil pump gear Oil pump gerotor Relief valve Oil fiter
ELECTRIC
Pressurized Oil pan Strainer

Splash, flow
INDEX
T46W223A
2-18 SS30-W00 May. 2007

3.2.2 RELIEF VALVE
GENERAL
The relief valve prevents damage to the lubrication sys-
tem due to high oil pressure. Control range of the relief
valve is 196 to 441 Kpa (2.0 to 4.5 kgh/cm, 28 to 64 psi).
ENGINE
3.2.3 BY-PASS VALVE
Oil filter cartridge has a by-pass valve inside, to pre-
vent the lack of lubrication oil in the engine, If the oil
filter element is clogged the by-pass valve opens and
lets the oil pass to each part of the engine without pass-
CLUTCH
ing through the filter.
196W222A
(1) Relief valve (4) From pump
TRANSMISSION
(2) By-pass valve (5) To crankshaft
(3) To rocker arm shaft and camshaft
3.2.4 OIL PRESSURE SWITCH

The oil pressure switch is installed on the cylinder
HST
block and leads to the oil passage of the lubricating
oil.
When the oil pressure falls below the specified value,
the contacts of the oil pressure switch closes to turn
REAR AXLE
on the warning lamp (1).
(A) At lower oil pressure

(49 kPa (0.5 kgf/cm2, 7 psi) or less)
(B) At proper oil pressure
BARKE
196W223B
(1) Warning lamp (5) Contact
FRONT AXLE
(2) Battery (6) Oil passage
(3) Rubber gasket (7) Cylinder block
(4) Contact rivet (8) Oil
STEERING
3.2.5 OIL PUMP
The oil pump is a gear pump, whose rotors have tro-
choid lobes. The inner rotor (3) has 4 lobes and the
outer rotor (4) has 5 lobes, and they are eccentrically
engaged with each other. The inner rotor, which is driven
HYDRAULIC
by the crankshaft through the gears, rotates the outer

rotor in the same direction, varying the space between
the lobes.
While the rotors rotate from (A) to (B), the space lead-
ing to the inlet port increases, which causes the oil to
flow through the inlet port.
ELECTRIC
When the rotors rotate to (C), the port to which the space
leads is changed from inlet to outlet.
At (D), the space decreases and sucked oil is dis- 196W224A
charged from the outlet port.
(1) Inlet (3) Inner rotor
INDEX
(2) Outlet (4) Out rotor
SS30-W00 May. 2007 2-19

3.3 COOLING SYSTEM

GENERAL
The cooling system consists of a radiator, centrifugal

water pump, suction fan and thermostat.
The water is cooled through the radiator core, and the
fan set behind the radiator pulls cooling air through the
core to improve cooling.
ENGINE
The pump sucks the cooled water, forces it into the

cylinder block and draw out the hot water. Then the
cooling is repeated. Furthermore, to control tempera-
ture of water, a thermostat is provided on the way. When
the thermostat opens, the water moves directly to
CLUTCH
radiator, but when it closes, the water moves toward

the water pump through the by-pass between thermo-
stat and water pump.
The opening temperature of thermostat is about 83C
TRANSMISSION
(180F).
196W225B
HST
(1) Radiator (4) Cylinder block

(2) Suction fan (5) Cylinder head
(3) Water pump (6) Thermostat
REAR AXLE
3.3.1 WATER PUMP

35 /min. (7.7 lmp.gals/min, 9.2 U.S gals/min) of water
is forced into the crankcase and cylinder head to cool
them. The impeller, of backward type, is bent as far as
BARKE
possible from the center, in the opposite direction to

rotation; the bearing unit prevents cooling water from
entering by a special mechanical seal.
FRONT AXLE
STEERING
196W226A
(1) Water pump impeller (3) Water pump body

(2) Mechanical seal (4) Bearing unit
HYDRAULIC
ELECTRIC
INDEX
2-20 SS30-W00 May. 2007

3.3.2 THERMOSTAT
GENERAL
The thermostat is wax pellet type, which controls the
flow of the cooling water to the radiator to keep the
proper temperature. The case has a seat (1) and the
pellet has a valve (2). The spindle attached to the case
is inserted into the synthetic rubber in the pellet. The
pellet is charged with wax.
ENGINE
(A) At low temperature (lower than 71C (160F))
The valve (2) is seated by the spring (7) and the
cooling water circulates in the engine through the
water return pipe but does not engine the radiator.
(B) At high temperature (higher then 71C (160F))
CLUTCH
As the water temperature rises, the wax in the pellet
(3) melts expands, repelling the spindle. The pellet 196W227A
lowers and the valve (2) opens to send the cooling

water to the radiator. (1) Seat (6) Wax (solid)
TRANSMISSION
(2) Valve (7) Spring
(3) Pellet (8) Leak hole
(4) Spindle (9) Wax (liquid)
(5) Synthetic rubber
HST
3.3.3 RADIATOR
The radiator core consists of water carrying tubes (2)
with fins (3) at a right angle to it.
REAR AXLE
The air flowing through between the tube wall and the
fin cools the water in the radiator.
BARKE
196W228A
FRONT AXLE
(1) Cooling air (3) Fin
(2) Tube
STEERING
3.3.4 RADIATOR CAP
The pressure type cap is installed on the radiator, which
prevents the pressure difference between the inside
and the outside of the radiator from deforming the
radiator.
HYDRAULIC
(A) At high pressure(higher than 88 kPa (0.9 kgf/cm, 13 psi))

When the water temperature rises and the pres-
sure in the radiator increase above the specified
pressure, the pressure valve (1) opens to reduce
the internal pressure.
ELECTRIC
(B) At low pressure

When the water temperature falls and a vacuum is
formed in the radiator, the vacuum valve (2) opens
to allow the air to enter the radiator. 196W229A
(1) Pressure valve (2) Vacuum valve

INDEX
SS30-W00 May. 2007 2-21

3.4 FUEL SYSTEM

GENERAL
3.4.1 FLOW OF FUEL

The fuel is feed from the fuel tank (1) through the fuel
filter (2) to the injection pump (4) by the fuel feed pump
(3). The injection pump force-feeds the fuel through
ENGINE
the injection nozzles (6), which inject the fuel into the
cylinders for combustion. Any excessive fuel from the 9
injection pump to the injection nozzles is collected in 8
the fuel overflow pipes (7) and returns to the fuel tank.
CLUTCH
TRANSMISSION
196W230B
(1) Fuel tank (6) Injection nozzle

(2) Fuel filter (7) Fuel overflow pipe
(3) Fuel feed pump (8) Air bleed bolt
(4) Injection pump (9) Nozzle holder nut
(5) Injection pipe
HST
3.4.2 FUEL FILTER

REAR AXLE
A fuel filter is used to prevent dirty fuel from reaching

the injection pump and injection nozzles. The filter ele-
ment will require occasional replacement to maintain
an adequate flow. This flow will vary according to the
cleanliness of available fuel and the care used in
storage.
BARKE
The fuel filter between the tank and pump to eliminate

foreign matter and protect injection pump and nozzles
filters fuel pumped by the fuel pump from the fuel tank.
When fuel enters the filter, it passes through the filter
elements circumference toward the center for filtering.
FRONT AXLE
The maximum filtrated granular size of this element is

48 m (0.048 mm, 0.0019 in.) and general size is form
196W231A
10 to 20 m (0.01 to 0.02 mm, 0.0004 to 0.0008 in.).
(1) Cock body (3) Element
(2) Retainer ring (4) Filter cup
STEERING
3.4.3 AIR BLEED BOLT

1. Check the fuel level in the fuel tank and fill the tank
HYDRAULIC
with fuel if necessary.

2. Check the fuel level in the fuel filter is 2/3 or higher.
If not, loosen the air bleed bolt (8) and crank the
engine to bleed the system.
3. When air stops bleeding, tighten the air bleed bolt
and crank the engine.
ELECTRIC
4. If the engine still fails to start, loosen the nozzle

holder nut (9) or injection nozzle nut (6) and crank
the engine to bleed the system.
5. Tighten the loosened nut and start the engine.
INDEX
2-22 SS30-W00 May. 2007

3.4.4 FUEL FEED PUMP (A) (B)
GENERAL
From fuel tank To fuel filter
The diaphragm (6) is linked to the tappet (3) with the
push rod (2). The tappet is reciprocated by the eccen-
tric cam on the fuel camshaft (7).
1 4
2 5
ENGINE
A. INTAKE STROKE 6
When the diaphragm is pulled down by the spring, it
builds a vacuum in the chamber (5) causing the ex- 3
haust valve (4) to close and the atmospheric pressure
in the fuel tank to force the fuel into the chamber, open-
7
ing the intake valve (1).
CLUTCH
T46W235B
B. SCAVENGING STROKE
(1) Intake valve (5) Chamber
When the diaphragm is pushed up by the cam, the pres-
TRANSMISSION
sure in the chamber causes the intake valve to close (2) Push rod (6) Diaphragm
and forces out the fuel, opening the exhaust valve. (3) Tappet (7) Fuel camshaft
(4) Exhaust valve
3.4.5 FUEL INJECTION PUMP
HST
This fuel injection pump is Bosch K type fuel injection
pump. It features a compact and light weight design. a
REAR AXLE
1
b
2
3
4
BARKE
6 5
FRONT AXLE
8
T46W236A STEERING
(a) To injection nozzle (b) From fuel filter
(1) Delivery valve holder (5) Plunger

HYDRAULIC
(2) Delivery valve spring (6) Control rack

(3) Delivery valve (7) Plunger spring
(4) Cylinder (8) Tappet
ELECTRIC
INDEX
SS30-W00 May. 2007 2-23

A. PUMP ELEMENT
GENERAL
The pump element (1) consists of a plunger (3) and

cylinder (2) which their sliding surfaces are finely ma-
chined to maintain the fuel tightness. The plunger (3)
is installed in the control sleeve (5) and the sleeve is 4
engaged with the control rack that rotates the plunger
in the cylinder to control the amount of fuel delivered.
ENGINE
1 5
CLUTCH
6
3
7
TRANSMISSION
T46W237A
(1) Pump element (5) Control sleeve

HST
(2) Cylinder (6) Control groove

(3) Plunger (7) Sliding surface
(4) Feed hole
REAR AXLE
B. OPERATION OF PUMP ELEMENT

a . Before delivery
As the plunger (2) lowers, fuel is drawn into the delivery
BARKE
chamber (1) through the feed hole (4) from the fuel cham- 3
ber (5). 1 4
5
FRONT AXLE
b. Beginning of delivery 6
When the plunger is pushed up by the cam and the 2
head of the plunger closes the feed hole (4), the pres-
sure in the delivery chamber (1) rises to push the deliv-
ery valve (3) open.
STEERING
c. Delivery
While the plunger (2) is rising, delivery of fuel continues.
HYDRAULIC
d. End of delivery
When the plunger rises further and the control groove T46W238A
(6) on its periphery meets the feed hole, the injection
stops because the pressure in the delivery chamber (1) Delivery chamber (4) Feed hole
(1) is reduced to the opening pressure. (2) Plunger (5) Fuel chamber
ELECTRIC
(3) Delivery valve (6) Control

INDEX
2-24 SS30-W00 May. 2007

C. AMOUNT OF FUEL DELIVERY
GENERAL
4
a . No fuel delivery 1
When the control rack (3) is at the engine stop position, 2 5
the lengthwise slot (1) on the plunger (2) aligns with 6
3
the feed hole (5). The pressure in the delivery chamber
does not build up and no fuel is forced to the injection
ENGINE
nozzle since the delivery chamber (4) is opened to the
feed hole during the entire stroke of the plunger.
CLUTCH
TRANSMISSION
T46W239A
(1) Slot (4) Delivery chamber

(2) Plunger (5) Feed hole
(3) Control rack (6) Control groove
HST
b. Fuel delivery
The plunger is rotated by the control rack and the feed
Location of fuel d e f
hole is not aligned with the lengthwise slot. When the
REAR AXLE
supply hole
plunger is pushed up, the feed hole is closed by the
plunger. The pressure in the delivery chamber builds
up and forces the fuel to the injection nozzle until the
control groove (6) meets the feed hole. The amount of D D
the fuel to be forced into the nozzle corresponds to
BARKE
distance A. In the above figure, the amount of injected
fuel in (c) is larger than the amount of injected fuel in
(b).
Stop Low speed High speed
FRONT AXLE
T46W240A
D. DELIVERY VALVE
1
The delivery valve (2) prevents the fuel in the injection STEERING
pipe from flowing back into the delivery chamber and
2 3
the fuel in the injection nozzle from dribbling after
injection.
4
The relief plunger (6) sucks the fuel back from the in-
jection pipe to prevent the leakage dribbling and un-
HYDRAULIC
necessary subsequent injection after the major

injection.
The stroke of A corresponds to the amount of fuel sucked
back (35 mm3). 6
5
ELECTRIC
T46W241A
INDEX
(1) Valve spring (4) Fuel chamber

(2) Delivery valve (5) Valve face
(3) Valve seal (6) Relief plunger
SS30-W00 May. 2007 2-25
E. INJECTION NOZZLE
GENERAL
Supplied
fuel
ENGINE
CLUTCH
1
TRANSMISSION
Excessive fuel

3
HST
4
REAR AXLE
6
7
9
BARKE
T46W242A
FRONT AXLE
(1) Nozzle holder assembly (4) Push rod (7) Needle valve
(2) Adjusting washer (5) Lock nut (8) Heat seal
(3) Nozzle spring (6) Nozzle body (9) Packing
STEERING
This injection nozzle is throttle type nozzle. It features

the low fuel consumption and works well with
DAEDONG combustion chamber. The nozzle valve
HYDRAULIC
opening pressure is about 14.7 MPa (150 kgf/cm, 2134

psi). When the pressure overcomes the counterforce
of nozzle valve spring (3), the pressure pushes up the
needle valve (7) constantly and then the proper amount
of fuel is injected into the swirling air inside the com-
bustion chamber for combustion.
ELECTRIC
The opening pressure can be adjusted by adding or

reducing the washer (2). A washer of 0.1 mm corre-
sponds to 980 kPa (10 kgf/cm, 142 psi) change in
opening pressure. The heat seal (8) is adopted to im-
prove the durability and reliability of the nozzle.
INDEX
2-26 SS30-W00 May. 2007

3.5 GOVERNOR SYSTEM
GENERAL
3.5.1 DISASSEMBLED VIEW
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BARKE
FRONT AXLE
196W239B
(1) Start spring (6) Fork lever shaft (11) Steel ball
(2) Governor spring 1 (7) Fork lever holder (12) Governor sleeve
STEERING
(3) Governor spring 2 (8) Governor lever (13) Steel ball
(4) Fork lever 1 (9) Fuel injection camshaft (14) Fork lever pin
(5) Fork lever 2 (10) Governor ball case
HYDRAULIC
The governor keeps the engine speed constant by au-

tomatically adjusting the amount of fuel supplied to the
engine according to changes in the load. The engine
employs an all-speed governor, which controls cen-
trifugal force of the steel ball (13) weight, produced by
ELECTRIC
rotation of the fuel camshaft (9), and tension of the gov-

ernor spring 1 (2) and 2 (3) are balanced.
INDEX
SS30-W00 May. 2007 2-27

3.5.2 BASIC PRINCIPLE OF GOVERNOR SYSTEM

GENERAL
4 5 1 2
ENGINE
7 15 14 3
8 10
CLUTCH
TRANSMISSION
13
HST
12
REAR AXLE
#
Torque Spring
11
Wls
Torque control screw

BARKE
FRONT AXLE
T46W246B
(1) Governor spring 1, 2 (6) Steel ball (11) Governor sleeve

(2) Solenoid guide (7) Governor lever (12) Fork lever 2
(3) Stop solenoid (8) Idle spring (13) Fork lever 1
STEERING
(4) Pump rack (9) Start spring (14) Fuel limit bolt
(5) Rack pin (10) Idle shaft (15) Torque spring
HYDRAULIC
As shown in the above figure, the steel ball (6) in the

fuel camshaft gear is supported by the governor sleeve
(11) to prevent from coming out. The sleeve pushes
the fork lever 1 (13) to transfer the power to the fuel
injection pump pin (5).
ELECTRIC
INDEX
2-28 SS30-W00 May. 2007

3.5.3 OPERATION OF GOVERNOR
GENERAL
A. WHEN STOPPED E. LOAD INCREASE AT HIGH SPEED
The fuel is blocked since the solenoid (3) pushes
the speed control rack (4) to the left.
ENGINE
e
B. WHEN TURNING THE KEY SWITCH ON
When the electromagnet in the stop solenoid oper-
d
ates and the pin is retracted, the speed rack (4) of
the fuel injection pump is pushed to the right by the
CLUTCH
start spring (9) and the start shaft (10) to supply the
sufficient amount of fuel to start the engine.
TRANSMISSION
C. WHEN STARTING THE ENGINE AND RUN- Torque Curve
NING THE ENGINE AT LOW IDLE SPEED T46W247B
When the engine is started, the steel ball (6) pushes

the sleeve (11) to the left as the centrifugal force of When a load is applied to the engine running at a high
the steel ball increases. Therefore, the governor fork speed, the centrifugal force of steel ball (6) decreases
as the engine speed drops. Also, the fork lever 2 (12) is
lever 1 (13) pushes the speed rack (4) of the pump
HST
pulled to the right by the governor spring until it con-
to the left to reduce the amount of fuel supplied. tacts the fuel limit bolt (14). Until then, the amount of
As the speed rack is stopped by the idle spring (8), injected fuel per one stroke of the injector plunger and
it keeps the balance with the centrifugal force of the the torque increase.
steel ball so that at least minimum amount of fuel is This range (a) is between the max. speed point with no
REAR AXLE
delivered for stable engine running at idle speed. load and the max. power point of the torque curve.
When the fork lever 2 is blocked by the fuel limit bolt
(14) and does not move any more and the load is
D. ACCELERATION AND DECELERATION increased, the centrifugal force of steel ball drops fur-
ther and the torque spring (15) compressed between
When depressing the accelerator pedal, the gover-
the fork lever 1 and 2 is loosened. Then, the fork lever 2
BARKE
nor spring (1) pulls the fork lever 2 (12) to the right moves to the right until the torque spring is free, and
and then pushes the fork lever 1 (13) to the right. the amount of fuel supplied and the torque increase
The fork lever (13) is stopped by the sleeve (11). simultaneously.
When the centrifugal force of the steel ball (6) that This range (b) is between the max. power and the max.
FRONT AXLE
is proportional to the engine speed is balanced with torque point in the torque curve.
the tension of the governor spring (1) that is deter-
mined by the driver, the stable speed is maintained. IMPORTANT
The fuel limit bolt (14), idle spring (9) and max.
rpm setting bolt are set at factory. Unauthorized
adjustment of such components can negatively STEERING
effect the performance of the engine. Therefore,
never adjust them without permission from
DAEDONG. Such action violates the EPA regula-
tion and also can void the warranty.
HYDRAULIC
F. WHEN STOPPED
When the key switch is moved to the OFF position,
the stop solenoid power is cut off to release the
electromagnet. Therefore, the stop pin comes off by
the return force of the spring and pushes the solenoid
ELECTRIC
guide (2) and fuel injection pump rack to the stop posi-
tion to stop the engine.
INDEX
SS30-W00 May. 2007 2-29

3.6 INTAKE AND EXHAUST SYSTEM

GENERAL
3.6.1 FLOW OF INTAKE AIR AND EXHAUST

GAS
ENGINE
CLUTCH
196W244B
TRANSMISSION
(A) Inlet air (3) Cylinder head

(B) Exhaust gas (4) Muffler
(1) Inlet manifold (5) Exhaust manifold
(2) Air cleaner
HST
3.6.2 AIR CLEANER

The air cleaner is dry-cyclone type and easy to maintain.
The air from the inlet port (2) circulated along the fin (3)
and around the air cleaner element (4) and the heavier
REAR AXLE
dust is carried to the evacuator (6), where the dusts

exhaust port. The fine dust in the air is filtered with the
air cleaner element (4), and the filtered air flows to the
outlet port (1).
BARKE
196W245B
FRONT AXLE
(A) Inlet air (1) Outlet port

(B) To inlet manifold (2) Inlet port
(C) Heavier dust (3) Air cleaner element
(4) Body
STEERING
(5) Evacuator
3.6.3 MUFFLER
HYDRAULIC
The exhaust noises are absorbed and dumped, while

the gas pass through a series of holes on the inner
tube and fiberglass wool of muffler.
ELECTRIC
INDEX
196W246A
2-30 SS30-W00 May. 2007

3.6.4 PCV VALVE
GENERAL
A. PCV (POSITIVE CRANKCASES
VENTILATION) 5
1
2
The PCV system is a system that prevents air pollution
by returning the blow-by gas to the intake manifold
through the bleeding pipe of the cylinder head cover for 4
ENGINE
recirculation of the gas. (However, the turbo charged
engine has the open crankcase type that discharges
the blow-by gas to the air.) 3
CLUTCH
T46W248A
6 12
TRANSMISSION
10
7 11
HST
8
9 T46W249A
REAR AXLE
(1) Head cover bolt (7) Bleeding pipe
(2) Oil filler flange (8) Intake valve
(3) Oil baffle plate (9) Cylinder head
(4) Head cover gasket (10) Cylinder head cover
(5) Cylinder head cover (11) Oil baffle plate
BARKE
(6) Intake manifold (12) Bleeding pipe
connection
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
SS30-W00 May. 2007 2-31

ENGINE - TROUBLESHOOTING CK20S/CK20S(H)
4. TROUBLESHOOTING
GENERAL
ENGINE DOES NOT START.
Crankshaft Frictional resis- Crankshaft and camshaft have seized up.

does not turn tance of moving
ENGINE
Piston and cylinder liner have seized up.

parts is too much
Bearings are oil-stuck.
Lubrication system not working property.
Starter faulty.
CLUTCH
Battery capacity is low or terminal loose.

TRANSMISSION
Fuel supply to Fuel pipe broken.

injection pump is Air enters fuel pipe through connection.
insufficient.
Fuel filter clogged.
Fuel pump faulty.
No or small Injection pump Plunger has worn or seized up.

HST
fuel injection does not send on Delivery valve spring broken.

sounds. fuel.
Delivery valve not completely oil-tight.
Fuel does not Needle valve stuck.

REAR AXLE
inject through
Needle spring broken.
injection nozzle.
Injection pressure misadjusted.
Crankshaft Injection pipe mounting nut loose.
turns
BARKE
Injection mistimed. Injection timing misadjusted.
Contact between intake/exhaust valve and

seat not tight.
FRONT AXLE
Intake/exhaust valve spring broken.

Intake/exhaust valve stuck.
Gasket faulty.
Regular fuel
injection Compressed air Tightness torque of cylinder head not
leaks. enough.
STEERING
sounds.
Piston ring stuck.
Piston ring worn.
Cylinder liner worn.
HYDRAULIC
Tightness torque of injection nozzle and

glow plug not enough.
Valve action timing Valve clearance excessive.

out of adjustment.
ELECTRIC
INDEX
2-32 SS30-W00 May. 2007

CK20S/CK20S(H) ENGINE - TROUBLESHOOTING
GENERAL
Engine does not turn normally.

Fuel pipes broken or loose.
ENGINE
Revolution is Injection Air in pump.
not smooth at pump wrong. Pump capacity not constant.
high speeds.
Tappet roller and pin worn.
CLUTCH
Injection Fuel leaks from nozzle tip.

nozzle faulty. Fuel not spraying properly.
TRANSMISSION
Irregular Governor spring deformed.
Revolution Valve clearance incorrect.
Injection pump or nozzle not functioning

normally.
HST
Compression pressure is different
among cylinders.
Governor not Governor sleeve not sliding property.
REAR AXLE
Idling not
functioning Fork lever not functioning normally.
smooth.
normally.
Start spring deformed.
Control rack not sliding property.
Idling Idling regulator misadjusted.
BARKE
misadjusted. Accelerator rod misadjusted.
Engine output insufficient.
FRONT AXLE
Main moving parts have almost seized up.
Engine overheated.
Injection mistimed.
Governor not functioning normally. STEERING
Filter clogged.
Slow engine Fuel supply Fuel pipe broken or loose.
revolutions. insufficient. Injection pumps capacity not enough.
HYDRAULIC
Nozzle needle valve worn.
Compression Air leaking.

pressure not Air cleaner clogged.
enough.
ELECTRIC
INDEX
SS30-W00 May. 2007 2-33

ENGINE - TROUBLESHOOTING CK20S/CK20S(H)
GENERAL
Color of exhaust fumes not normal.
Piston ring stuck.

Piston ring worn.
ENGINE
Lubricant Excessive gap between cylinder liner and

White or blue rises through piston.
smoke. piston gap. Too much oil.
CLUTCH
Injection delayed.
Compression pressure insufficient.
Injection Injection too early.

TRANSMISSION
mistimed. Injection delayed.
Fuel pumps Plunger does not return completely

Black or dark injecting because spring is stuck or broken.
gray smoke. capacity varies. Plunger worn.
HST
Needle valve stuck.

Nozzle does Nozzle spring broken.
not inject fuel
properly. Too much carbon sticks to nozzle tip.
REAR AXLE
Injection pressure too low.
Compressed air leaks.

Not enough air.
BARKE
Excessive lubricant consumption.
Excessive gap between piston and liner.

Piston ring stuck.
FRONT AXLE
Piston ring worn.

Excessive gap between intake/exhaust
valve and valve stem.
Valve stem seal broken.
STEERING
Oil leaks from defective seals.
Lubricant increasing.
HYDRAULIC
Fuel mixed Injection pump plunger leaking.

with oil. Fuel pump leaking.
Water mixed Head gasket seal faulty.

ELECTRIC
with oil. Crankcase cracked.
Gear oil mixed Hydraulic pumps oil seal broken.

with oil.
INDEX
2-34 SS30-W00 May. 2007

CK20S/CK20S(H) ENGINE - MEASUREMENT AND ADJUSTMENT
5. MEASUREMENT AND ADJUSTMENT
GENERAL
5.1 FAN BELT
1. Measure the deflection, depressing the belt half-
way between the fan drive pulley and the alternator
pulley at 78.5 N (8 kgf, 17.6 lbs) of force.
ENGINE
2. If the deflection is not between the factory
specifications, loosen the bolts and nuts, and relo-
cate the alternator to adjust.
3. Replace the belt if damaged or worn
CLUTCH
Item Factory spec.
Belt tension (deflection) 8 mm(0.32 in.) at 78.5 N
(8 kgf, 17.6 lbs) of force
TRANSMISSION
196W248A
5.2 COMPRESSION PRESSURE

1. Run the engine until warm.
2. Stop the engine and remove the air cleaner, the
HST
muffler and all nozzle holders.
3. Set a compression tester to the adaptor installed in
the nozzle holder hole and fixed with the locating
screw.
REAR AXLE
4. Pull the stop lever to cut the fuel and run the engine
with the starter at 200 to 300 rpm for 5 to 10 seconds.
Measure the maximum pressure while running, sev-
eral times
For the test, use a fully charged battery and the
specified valve clearance.
BARKE
196W252B
If the pressure does not reach the allowable limit,
apply a small amount of oil to the cylinder wall
through the nozzle holder hole and measure the
pressure again.
FRONT AXLE
f JUDGMENT
If the pressure raises after applying oil, check the
cylinder wall and piston rings.
If the pressure still low, check the top clearance,
valve clearance and cylinder head. STEERING
If the compression differs more than 10% among
the cylinders, trace the cause of pressure variation
and take corrective measures.
Item Factory spec. Allowable limit

HYDRAULIC
Compression 2.8 ~ 3.2 Mpa 2.32 Mpa

pressure 29 ~ 33 kgf/cm2 23.7 kgf/cm 2
412 ~ 269 psi. 337 psi.
Difference
between two - 10 %
ELECTRIC
cylinders
NOTE:
Check the compression pressure with the specified
valve clearance for proper air intake.
INDEX
SS30-W00 May. 2007 2-35

ENGINE - MEASUREMENT AND ADJUSTMENT CK20S/CK20S(H)
5.3 VALVE CLEARANCE

GENERAL
1. Remove the cylinder head cover and the timing win-

dow cover on the flywheel housing and all glow
plugs.
2. Turn the flywheel and align the 1TC to mark with the
timing mark of window on the flywheel housing to
ENGINE
position the 1st cylinder valves at the top dead cen-

ter during compression.
3. Measure the clearance at the valves marked with c
in the table below with a feeler gauge.
4. If the clearance is not within the factory
CLUTCH
specifications, turn the adjusting screw to adjust.

5. Turn the flywheel just one turn to position the 1st 196W253B
cylinder valves at the top dead center during overlap.
6. Measure the clearance at the valves marked with z (A) Gear case
TRANSMISSION

7. If the clearance is not within the factory
specifications, adjust.
Item Factory spec.

Valve clearance 0.15 mm
HST
0.006 in.
Cylinder No. 1 2 3
Valve IN. EX. IN. EX. IN. EX.
REAR AXLE
Checking cc zc cz
196W254B
BARKE
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
2-36 SS30-W00 May. 2007

5.4 INJECTION TIMING MEASURE-
GENERAL
MENT AND ADJUSTMENT
NOTE:
Perform the work with the engine installed in the
tractor.
ENGINE
1. Remove the engine stop solenoid.
CLUTCH
TRANSMISSION
T46W256B
2. Remove the timing check window cover of the clutch

housing.
3. Turn the flywheel to find 1, 4 FI mark for 4-cylinder
engine or 1 FI mark for 3-cylinder engine on the
flywheel.
HST
4. When the mark is found, turn the crankshaft coun-
terclockwise approx. 30 (when looking at the front
of the engine).
- 1, 4 FI means the injection timing of the No. 1 or
REAR AXLE
4 cylinders.
T46W257A
BARKE
- When turning the crankshaft, use a socket for turn-
ing the crankshaft.
FRONT AXLE
NOTE:
How to use the crankshaft turning socket
STEERING
T46W258A
HYDRAULIC
T46W259A
You can use DAEDONG special tool kit

(part No.: G0611-B0010) for spline socket.
ELECTRIC
INDEX
SS30-W00 May. 2007 2-37

ENGINE - MEASUREMENT AND ADJUSTMENT CK20S/CK20S(H)
4. Remove the No. 1 high pressure pipe.
GENERAL
5. Unscrew the nozzle holder (1) slightly and tighten it

when it is filled with fuel.
ENGINE
CLUTCH
T46W260C
TRANSMISSION
6. Remove the fuel in the nozzle holder with clean cloth

and leave only small amount of fuel. fuel

7. Observe the fuel of the nozzle holder while turning
the crankshaft clockwise (when looking at the front
of the engine) slowly.
8. When the amount of the fuel in the nozzle holder
HST
increases abruptly, that moment is the injection

timing.
- If the fuel increases too much, it means that the
injection timing is passed already. Repeat the
above process to identify the moment when the
REAR AXLE
amount of fuel starts to increase.

- If the fuel does not increase, it means that it is
the exhaust cycle. Therefore, turn the crankshaft T46W261A
360 to find the compression cycle and repeat
the above procedures.
9. Mark the measured injection timing on the flywheel
BARKE
through the timing window and measure the dis-

tance between the 1, 4 FI or 1 FI and the mark
you made.
FRONT AXLE
10.To advance the injection timing, reduce the amount

of shims. To delay the injection timing, increase the
amount of shims(2).
Diameter Flywheel Amount of

STEERING
Injection 2
Model of circumfer- shims to
timing
flywheel ence for 1 adjust 1
CK20 BTDC 270 mm 2.35 mm 0.1 mm
22 (10.6 in.) (0.093 in.) (0.004 in.)
CK20S/ BTDC 270 mm 2.35 mm 0.1 mm
HYDRAULIC
22 18 (10.6 in.) (0.093 in.) (0.004 in.)
- BTDC: Before top dead center
T46W2I1B
ELECTRIC
INDEX
2-38 SS30-W00 May. 2007

5.5 ENGINE OIL PRESSURE
GENERAL
1. Remove the oil pressure switch and install adap-
tors and pressure tester.
2. Start the engine and run it until it is warmed up, and
measure the oil pressure both at idling and rated
speed.
ENGINE
3. If the oil pressure is less than the allowable limit,
check the amount of oil, oil filter, oil pump relief
valve, oil passages and oil clearances.
(When reassembling)
Supply the specified amount of recommended oil.
CLUTCH
The oil filter must not be clogged or broken.
196W2F4B
Engine At idle More than 49 kPa
TRANSMISSION
oil speed
0.5 kgf/cm2 -
pressure
7.11 psi.
At 245 ~ 441 kPa 245 kPa
rated 2
2.5 kgf/cm2
2.5 ~ 4.5 kgf/cm
speed
36 ~ 64 psi. 36 psi.
HST
(Reference)
Item Tightening torque
REAR AXLE
Oil pressure switch 14.7 ~ 19.6 Nm
1.5 ~ 2.0 kgf-m
10.8 ~ 14.5 lb-ft
BARKE
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
SS30-W00 May. 2007 2-39

CK20S/CK20S(H) ENGINE - EXPLODED VIEW (CK20S/CK22)
6. EXPLODED VIEW (CK20S/CK22)
GENERAL
ENGINE
48
CLUTCH
TRANSMISSION
47
HST
REAR AXLE
46
39
BARKE
FRONT AXLE
9
49
STEERING
HYDRAULIC
196W247B
(1) Cylinder Block (7) Cylinder Head (12) Bearing Case Bolt 1 (18) Push Rod (24) Connecting Rod (30) Glow Plug (36) Engine Stop Solenoid (41) Alternator (46) Idle Limit System
(2) Oil Pressure Switch (8) Head Bolt (13) Mainbearing Case (19) Tappet (25) Crankshaft (31) Nozzle (37) Manual Stop Lever (42) Fan Drive Pulley (47) Speed Control
ELECTRIC
(3) Oil Pump (9) Gearcase (14) Bearing Case Bolt 2 (20) Camshaft (26) Flywheel (32) Fuel Injection Pump (38) Fork Lever (43) Cooling Fan (48) PCV V/v
(4) Oil Pan (10) Oil Filter (15) Rocker Arm (21) Camshaft Gear (27) Rear End Plate (33) Fuel Feed Pump (Governor) (44) Inlet Manifold (49) Fuel Control Limit
(5) Oil Strainer (11) Mainbearing Case (16) Inlet, Exhaust Valve (22) Idle Gear (28) Starter (34) Fuel Camshaft (39) Water Pump (45) Exhaust Manifold
(6) Dipstick Cover (17) Cylinder Hear Cover (23) Piston (29) Injection Pipe (35) Fuel Camshaft Gear (40) Thermostat
INDEX
SS30-W00 May. 2007 2-41
CK20S/CK20S(H) ENGINE - SERVICING
7. SERVICING
GENERAL
7.1 REMOVAL AND REASSEMBLE
7.1.1 ENGINE ASSEMBLY
Drain the oil and the water, if disassemble the engine
ENGINE
body.
1. Remove the muffler and exhaust manifold (7).
2. Remove the oil pressure switch (8).
3. Pull out the dipstick (6).
CLUTCH
4. Remove the alternator (5) and the belt (2).
5. Loosen the oil filter cartridge (3) with the filter wrench
and remove it and the flange (4).
TRANSMISSION
(When reassembling)
Apply liquid gasket (Three bond 1215 or equivalent)
on the thread of the oil pressure switch. 196W249B
Apply liquid gasket to the both sides of the hour

(1) Cooling fan (5) Alternator
meter gasket.
Apply oil to the O-ring and tighten the oil filter car- (2) Fan belt (6) Dipstick
tridge not with wrench but by hands (3) Oil filter cartridge (7) Exhaust manifold
HST
Adjust the fan belt tension. (See Fan Belt) (4) Filter flange (8) Oil pressure switch

REAR AXLE
1.5 ~ 2.0 kgf-m
10.8 ~ 14.4 lb-ft
7.1.2 ENGINE STOP SOLENOID
BARKE
1. Disconnect the wire connector of solenoid (1).
2. Remove the nut (2).
3. Remove the stop solenoid (1).
FRONT AXLE
STEERING
196W250B
(1) Engine stop solenoid

HYDRAULIC
(2) Nut
ELECTRIC
INDEX
SS30-W00 May. 2007 2-43

ENGINE - SERVICING CK20S/CK20S(H)
7.1.3 INTAKE MANIFOLD AND FUEL HOSES

GENERAL
1. Disconnect the fuel hose (3).

2. Loosen the injection pipe fittings with two wrenches
and remove the injection pipes (2).
3. Remove the inlet manifold (1) and the fuel feed
pump (4).
ENGINE
IMPORTANT
Tighten or loosen injection pipe fittings using the
one-hand two-wrench squeeze method.
Cap the nozzle inlet to prevent entrance of foreign
CLUTCH
materials.
196W251B

(1) Intake manifold (3) Fuel hose
Injection pipe nut 19 mm 14.7 ~ 24.5 Nm
TRANSMISSION
(0.75 in.) across flats (2) Injection pipe (4) Fuel feed pump
1.5 ~ 2.5 kgf-m
10.8 ~ 18.1 lb-ft
7.1.4 INJECTION NOZZLE

HST
ATTENTION
When reassembling, replace all the O-rings and
gaskets by new ones.
REAR AXLE
A. REMOVING HEAD COVER

1. Remove the head cover bolts.
2. Remove the head cover.
(Note for reassembling)

Check to see if the cover gasket is not defective.
BARKE
To prevent valve stem seizure, apply enough en-

gine oil to the valve guide and valve stem.

FRONT AXLE
Nut x 2, Bolt x 5 48.1 ~ 55.8 Nm

(10 mm) 4.9 ~ 5.7 kgf-m
196W255B
35.5 ~ 41.2 lb-ft
(1) Head cover
STEERING
B. REMOVING INJECTION PIPES 1, 2 AND 3

1. Loosen the screws on the pipe clamps.
2. Detach the injection pipes in the order of 1, 2 and 3.
HYDRAULIC

Send compressed air, into the pipes to blow out
dust. Then reassemble the pipes in the reverse
order.
ELECTRIC

Injecion pipe nuts 24.5 ~ 34.3 Nm
2.5 ~ 3.5 kgf-m
18.1 ~ 25.3 lb-ft 196W256B
INDEX
Pipe clamp (1) Injection pipe 1 (3) Injection pipe 3

Feed pipe (17 mm) (2) Injection pipe 2
Injection pipe
2-44 SS30-W00 May. 2007

C. REMOVING NOZZLE HOLDER ASSEMBLIES
GENERAL
1. Remove the pipe clips holding the fuel overflow
pipes, and detach the pipes.
2. Detach the nozzle holders using a 27 mm (1.0630 in.)
nozzle holder socket wrench, after loosening the
lock nuts.
ENGINE
3. Detach the copper gaskets on the seats on which
the nozzles are to be installed.

Return the nozzle holders after confirming that there
are no metallic particles or foreign matter on the
CLUTCH
surface on which the nozzles are to be installed.
196W257B
(1) Nozzle holder socket wrench
Nozzle holder assy 49.0 ~ 68.6 Nm
TRANSMISSION
(2) Lock nut
5.0 ~ 7.0 kgf-m
36.1 ~ 50.6 lb-ft
D. HEAT SEAL ROMOVAL PROCEDURE

1. Drive screw driver lightly into the heat seal hole.
HST
2. Turn screw driver three or four times each way.
3. While turning the screw driver, slowly pull the heat
seal put together with the injection nozzle gasket. If
the heat seal drops, repeat the above procedure.
REAR AXLE
4. Heat seal and injection nozzle gasket must be
changed when the injection nozzle is removed for
cleaning or for service.
NOTE:
Use a plus screw driver that has a diameter which is
BARKE
bigger than the geat seal hole 1/4 in (approx. 6 mm)
196W258B
(1) Plus screw driver

(2) Nozzle
FRONT AXLE
(3) Injection nozzle gasket
(4) Heat seal
E. NOZZLE HOLDER
STEERING
f DISASSEMBLING NOZZLE HOLDER
1. Secure the retaining nut with a vise.
2. Remove the nut, the over flow pipe Assy and the
plain washer.
3. Remove the nozzle holder body and take out parts inside.
HYDRAULIC

When disassembling and reassembling the nozzle
piece dip it in clean fuel.
Install the push rod, noting its direction(upside down).
ELECTRIC
Do not tighten it too much, or the needle valve will

not slide easily and the injection performance will 196W268A
be decreased.
(1) Retaining nut (6) Adjusting washer
Item Tightening torque (2) Nozzle holder body (7) Nozzle spring
Retaining nut 29.4 ~ 49.0 Nm (3) Nut (8) Push rod
INDEX
3 ~ 5 kgf-m (4) Over flow pipe assy (9) Distance piece

21.7 ~ 36.1 lb-ft (5) Gasket (10) Nozzle piece
SS30-W00 May. 2007 2-45

7.1.5 ROCKER ARM AND PUSH-RODS

GENERAL
A. ROCKER ARM ASSEMBLY

1. Loosen the nuts in several steps and the specified
sequence shown in the figure and remove them.
To loosen (3) to (1).
ENGINE
To tighten (1) to (3).

2. Remove the rocker arm and shaft assembly.
(When reassembling)
Rest the end of push rod at the indent of tappet and
CLUTCH
install the rocker arm assembly.

Tighten the bolts in several steps and the specified
sequence shown in the figure to the specified torque.
Adjust the valve clearance after assembling the 196W260B
rocker arm assembly.
TRANSMISSION
IMPORTANT
When assembling the rocker arm assembly, lo-
cate groove of rocker arm shaft on stud bolt.

HST
Rocker arm shaft on 16.7 ~ 20.6 Nm

stud bolt 1.7 ~ 2.1 kgf-m
12.3 ~ 15.2 lb-ft
REAR AXLE
196W261B
(1) Rocker arm shaft (3) Rocker arm bracket

BARKE
(2) Rocker arm (4) Bolt
B. REMOVING PUSH-RODS
FRONT AXLE
1. Remove the six push-rods.

Before inserting the push rods into the tappets,
check to see if their ends are properly engaged with
the grooves. If a push rod is roughly inserted, it may
STEERING
hit the shoulder of the tappet and be damaged.

HYDRAULIC
196W262B
(1) Push-rod (2) Glow plug cable

ELECTRIC
INDEX
2-46 SS30-W00 May. 2007

7.1.6 CYLINDER HEADS AND VALVES
GENERAL
A. REMOVING CYLINDER HEADS AND
GASKET.
1. Remove the fourteen cylinder head set bolts and
two nuts.
ENGINE
To loosen (14) to (1)
To tighten (1) to (14)
2. Lift up the cylinder head to detach.
3. Remove the cylinder head gasket.
CLUTCH
Tighten the bolts and nuts after applying sufficient
oil.
Tighten the bolts and nuts in diagonal sequence 196W263B
TRANSMISSION
starting from the center. Tighten them uniformly, or
the head may deform in the long run.
Before installing the gasket, check to see there is
no foreign matter on the cylinder head and the
cylinder.
IMPORTANT
HST
When overhauling the engine, replace the gasket
with a new one without confusing its front and
back. Retighten the cylinder head after running
the engine for 30 minutes.
REAR AXLE
Tighten the cylinder head bolts and nuts to:

196W264A
Cylinder head bolts 58.8 ~ 63.7 Nm
6.0 ~ 6.5 kgf-m (A) Gear case side (B) Flywheel side
BARKE
43.4 ~ 47.0 lb-ft
FRONT AXLE
STEERING
HYDRAULIC
196W265B
(1) Cylinder head gasket

ELECTRIC
INDEX
SS30-W00 May. 2007 2-47

B. REMOVING TAPPETS
GENERAL
1. Remove the six tappets from the crankcase.

Visually check the contact between tappets and
cams for proper rotation. If a defect is found, re-
place tappets.
ENGINE
Before installing the tappets, apply a thin coat of oil

around them.
CLUTCH
196W266B
(1) Tappets
TRANSMISSION
C. VALVES
1. Compress the valve spring with a valve spring re-
placer and remove the collet (2).
2. Remove the valve spring retainer (3), valve spring
(4), valve stem seal (5) and the valve (1).
HST
IMPORTANT
Do not interchange valves and valve parts. Mark
the cylinder number on the valve and the parts to
REAR AXLE
prevent interchanging.
(When reassembling)
Apply oil to the stem of valve and install in the cylin- 196W267B
der head.
Lubricate the valve and the parts after reassembling. (1) Valve (4) Valve spring
BARKE
(2) Collet (5) Valve stem seal

(3) Retainer
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
2-48 SS30-W00 May. 2007

7.1.7 FUEL FEED PUMP AND INJECTION
GENERAL
PUMP
A. FUEL FEED PUMP 2
f REMOVING FUEL FEED PUMP
1. Remove the two fuel feed pump mounting nuts.
ENGINE
2. Detach the fuel feed pump.
3. Remove the injection pump cover(2).
(Note for assembling)

Be careful the install the fuel feed pump in the right
CLUTCH
direction.
Install the fuel feed pump gasket after applying non-
drying adhesive to it.
196W269B
TRANSMISSION
(1) Fuel feed pump assembly (2) Cover
B. INJECTION PUMP
1. Remove the injection pipes (1) and the intake mani- 1
fold (2).
HST
2. Remove the overflow pipe (3).
REAR AXLE
3
2
BARKE
T46W298B
(1) Injection pipes

(2) Intake manifold
FRONT AXLE
(3) Overflow pipe
3. Remove the stop solenoid (1) with guide (2).
STEERING
2
HYDRAULIC
T46W299A
ELECTRIC
(1) Stop solenoid

(2) Stop solenoid guide
INDEX
SS30-W00 May. 2007 2-49

4. Remove the idle limit system (3).
GENERAL
5. Remove the injection pump mounting bolts and nuts

(A).
6. Align the control rack pin (4) with the slot (5) on the
cylinder and remove the injection pump.
7. The injection pump should not be disassembled.
ENGINE

Install the injection pump by aligning the control rack
with the indicated position. A
Addition or reduction of one shim (0.1 mm) delays
or advances the injection timing by 0.017 rad. (1).
CLUTCH
4
TRANSMISSION
196W272B
HST
IMPORTANT
Make sure that the lever of the pump control rack
is on the outer side from the fork lever 1 when Lqmhfwlrq#Sxps
Frqwuro#Odfn#Ohyhu
#
installing the pump. Otherwise, the engine can be
REAR AXLE
damaged by over speed or cannot be started.

Irun#Ohyhu#4
BARKE
T46W294A
FRONT AXLE
C. INJECTION PUMP
IMPORTANT
If replacing the pump element, the amount of fuel
STEERING
injection should be adjusted on specified bench.

HYDRAULIC
ELECTRIC
196W2H2A
(1) Pump body (5) Delivery valve

(2) Control rack (6) Tappet roller
(3) Delivery valve holder (7) Cylinder
(4) Delivery valve spring (8) Plunger
INDEX
2-50 SS30-W00 May. 2007

7.1.8 CRANK CASE
GENERAL
A. DETACH THE GOVERNOR SPRING
4
1. Detach the governor spring 1, 2 and speed control
plate from governor lever.
2. Remove the manual stop lever plate (4).
ENGINE
Be careful not to drop the governor spring 1, 2 in the
gear case.
Fix the governor spring 1, 2 to the fork lever and pull
the spring, hook on the governor lever.
CLUTCH
196W274B
TRANSMISSION
4
HST
REAR AXLE
196W277B
(1) Speed control plate (3) Governor lever

(2) Governor spring 1, 2 (4) Manual stop lever
BARKE
3. Detach governor spring on the side of fork lever if
needed. 5
FRONT AXLE
STEERING
HYDRAULIC
196W275B
(5) Governor springs

ELECTRIC
INDEX
SS30-W00 May. 2007 2-51

B. REMOVING FAN DRIVE PULLEY

GENERAL
1. Flatten the crankshaft washer.

2. Loosen and remove the crankshaft nut.
3. Draw out the pulley with a puller.

ENGINE
Bend the crankshaft washer against one side of the

nut.

Crankshaft nut 137.3 ~ 156.9 Nm
CLUTCH
14 ~ 16 kgf-m
101.3 ~ 115.7 lb-ft 196W278B
C. REMOVING GEAR CASE

TRANSMISSION
1. Remove the gear case cover.

2. Remove the O-ring.

Apply a thin coat of engine oil to the oil seal, and
install it, noting the lip come off.
HST
Before installing the gear case gasket, apply a non

drying adhesive.
Tighten the oil filter cartridge by hand.
Stick the O-ring to the gear case with thin grease to
REAR AXLE
prevent from coming off during reassembling.

196W279B
(1) O-ring
BARKE
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
2-52 SS30-W00 May. 2007

7.1.9 TIMING GEARS, CAM SHAFTS AND
GENERAL
OIL PUMP
A. REMOVING CRANKSHAFT OIL SLINGER
1. Remove the crankshaft collar.
2. Remove the O-ring.
ENGINE
3. Detach the crankshaft oil slinger.
CLUTCH
196W280A
TRANSMISSION
(1) Crankshaft oil slinger (2) O-ring
(3) Crankshaft collar
B. REMOVING IDLE GEAR

1. Remove the external circle clip.
HST
2. Detach the idle gear collar 2.
3. Detach the idle gear.
4. Detach the idle gear collar 1.
REAR AXLE
Check to see each gear is aligned with its aligning
mark:
1) Idle gear and crank gear
2) Idle gear and camshaft gear
3) Idle gear and injection pump gear
BARKE
196W281A
Idle gear shaft mounting 7.8 ~ 9.8 Nm
bole torque
FRONT AXLE
0.8 ~ 1.0 kgf-m
5.7 ~ 7.2 lb-ft
STEERING
HYDRAULIC
196W282A
(1) External circle clip (2) Gear collar 2

(3) Idle gear
ELECTRIC
INDEX
SS30-W00 May. 2007 2-53

C. REMOVING CAMSHAFT STOPPER

GENERAL
1. Align the round hole on the cam gear with the cam-
shaft stopper mounting bolt position.
2. Remove the camshaft stopper mounting bolt.
3. Detach the camshaft stopper.
ENGINE
CLUTCH
196W283A
(1) Camshaft stopper

TRANSMISSION
D. REMOVING GEAR AND CAMSHAFT

Draw the camshaft and the cam gear.

Apply a thin coat of engine oil to the camshaft be-
fore installation.
HST
REAR AXLE
196W284A
(1) Camshaft assembly

BARKE
E. REMOVING FORK LEVER ASSEMBLY AND

FUEL INJECTION CAMSHAFT
1. Remove the fuel injection camshaft stopper.
FRONT AXLE
2. Remove the two fork lever holder mounting bolts.

3. Detach the fork lever assembly and fuel camshaft.
STEERING
HYDRAULIC
196W285B
(1) Fork lever assembly

(2) Fuel camshaft assembly
ELECTRIC
INDEX
2-54 SS30-W00 May. 2007

F. REMOVING OIL PUMP DRIVE GEAR
GENERAL
1. Remove the nut from oil pump.
2. Draw out the oil pump drive gear with gear puller.

Ensure there is a feather key.
ENGINE
CLUTCH
196W287A
(1) Crank gear (2) Oil pump drive gear
TRANSMISSION
G. REMOVING OIL PUMP
Remove the four oil pump mounting bolts. Detach the
oil pump.

Remove the gear with crank gear removal tool or
HST
pulley removal tool.

Bolts of oil pump 9.8 ~ 11.8 Nm
REAR AXLE
1.0 ~ 1.2 kgf-m
7.2 ~ 8.7 lb-ft
196W288A
(1) Oil pump assembly
BARKE
H. REMOVING CRANK GEAR
Remove the gear with crank gear removal tool or pulley
removal tool.
FRONT AXLE
Check to see that the key is on the crankshaft.
Heat the crank gear to about 80C (176F), and fit
on the crankshaft. If there is fear of the shaft being
damaged, heat the gear more and fit. STEERING
HYDRAULIC
196W289A
(1) 13T gear (crank gear)

ELECTRIC
INDEX
SS30-W00 May. 2007 2-55

7.1.10 PISTON
GENERAL
A. REMOVING OIL PAN

1. Lay the engine on the engine cradle on its side.
2. Remove the eighteen oil pan mounting bolts.
3. Detach the oil pan by lightly tapping the groove of
ENGINE
the pan with a wooden hammer.

Wipe off oil on the oil pan mounting surface, apply a
non-drying adhesive, and install the oil pan.
To avoid uneven tightening, tighten mounting bolts
CLUTCH
in diagonal order from the center.

Ensure that the drain plug is tight. 196W290B
(1) Oil pan

TRANSMISSION
B. REMOVING OIL STRAINER

1. Remove the mounting bolt of oil strainer.
2. Detach oil strainer, being careful of the O-ring.
HST

After cleaning the oil strainer, check to see that the
strainer mesh is clean, and install it.
Visually check the O-ring, apply engine oil, and in-
REAR AXLE
stall it.
After checking to see that the O-ring is securely
installed, attach the oil strainer.
196W291A
BARKE
(1) Oil strainer
C. REMOVING CONNECTING ROD CAP

FRONT AXLE
1. Remove the connecting rod bolts from connecting

rod cap.
2. Detach the connecting rod caps.
STEERING
IMPORTANT
Apply engine oil to the connecting rod bolt.
Align the marks with each other.
Face the marks toward the injection pump.
HYDRAULIC

Connecting Rod 26 ~ 30 Nm 196W292A
2.7 ~ 3.1 kgf-m

(1) Connecting rod cap
20 ~ 22 lb-ft
(a) Align the marks with each other
ELECTRIC
(b) Face the marks toward the injection pump

INDEX
2-56 SS30-W00 May. 2007

D. REMOVING PISTONS
GENERAL
1. Turn the crankshaft and bring the piston to top dead
center.
2. Draw out the piston upward by lightly tapping it from
the bottom of the crankcase with the grip of a
hammer.
ENGINE
3. Draw out the other two pistons in the same method
as above.

Before inserting the pistons into the cylinders, ap-
ply enough engine oil to the pistons.
CLUTCH
196W294A
IMPORTANT
Install the piston rings with their end gaps mak- (1) Piston
TRANSMISSION
ing an angle of 120 (2.09 rad) or 180 (3.14 rad) to
each other. (Place the top ring with their gaps on
the opposite side of the combustion chamber.)
Attach a ring to the pistons securely with a piston
ring compressor, and set them to the cylinder,
being careful about the cylinder number and the
position of the connecting rod (Connecting rods
HST
must be installed with their ends bearing the num-
ber toward the fuel injection pump).
Carefully insert the pistons. Otherwise, their
chrome plated section may be scratched, caus-
REAR AXLE
ing trouble inside the liner.
Set the gap of top ring toward the opposite direc-
tion of combustion chamber.
BARKE
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
SS30-W00 May. 2007 2-57

E. PISTON RING AND PISTON PIN

GENERAL
1. Remove the piston rings with a piston ring replac-

ing tool.
2. Remove the piston pin.
(When reassembling)
ENGINE
Clean all the parts before assembling.

Heat the piston in approx. 80C (176F) of oil for 10
~ 15 minutes, when inserting the piston pin into the
piston.
Install the piston and connecting rod with the mark
CLUTCH
FW on the piston to the flywheel and the mark on

the connecting rod to the injection pump.
196W295B
Install the piston rings with their manufacturers
mark to the top of piston.
Install the top ring with its gap at 90 (1.57 rad) from
TRANSMISSION
piston pin to the exhaust port.

Install the second ring and oil ring with their gap at
every 120 (2.09 rad) or 180 (3.14 rad).
Install the expander in the oil ring with its gap oppo-
site to the gap of oil ring.
HST
REAR AXLE
196W296A
BARKE
FRONT AXLE
STEERING
196W297A
(1) Piston pin (9) Mark

(2) Piston (10) Casting mark
HYDRAULIC
(3) Piston pin snap ring (11) Expander joint

(4) Top ring (12) Oil ring gap
(5) Second ring (13) Manufacturers mark
(6) Oil ring (14) Top ring
ELECTRIC
(7) Connecting rod (15) Second ring

(8) Connecting rod cap (16) Oil ring gap
INDEX
2-58 SS30-W00 May. 2007

7.1.11 FLYWHEEL AND MAIN BEARING
GENERAL
CASE COVER
A. FLYWHEEL AND REAR PLATE
1. Loosen the flywheel bolt and remove the flywheel.
2. Loosen the bolt and remove the rear plate.
ENGINE
(When reassembling)
Check the end of crankshaft any uneven wear, lack
or crack of teeth.
Clean the end of crankshaft and the mating surface
of the flywheel.
CLUTCH
Apply oil to flywheel screws.
196W298A
To ease alignment of the crankshaft and the flywheel,
bring the crank of one of the cylinders to TC (top (1) Rear plate
dead center). Make sure of the flywheel TC, align it
TRANSMISSION
with the punch mark of the rear and plate, and set
the flywheel.
Tighten the flywheel bolts to in diagonal order.
NOTE:
Screw longer screws to the flywheel to carry it, if
HST
needed.

Flywheel screw 54 ~ 59 Nm
REAR AXLE
5.5 ~ 6.0 kgf-m
40 ~ 43 lb-ft
196W299A
(1) Bearing case cover
BARKE
B. BEARING CASE COVER
Loosen the screws first inside and next outside, and
FRONT AXLE
lift the cover (1) by screwing two screws gradually and
evenly, referring to the photo.
(When reassembling)
Apply grease to the oil seal lip and take care that it
is not rolled when installing. STEERING

Bearing case cover screw 12.7 ~ 15.7 Nm
1.3 ~ 1.6 kgf-m
HYDRAULIC
9.8 ~ 11.2 lb-ft
NOTE:
When installing the main bearing case cover, the
UP mark on it should be at the highest position so up
ELECTRIC
that its holes are aligned with the holes of the cylin-
der block.
T46W2D3B
INDEX
SS30-W00 May. 2007 2-59

7.1.12 CRANKSHAFT AND JOURNAL

GENERAL
BEARING
A. REMOVING BEARING CASE BOLT 2
Detach the bearing case bolts.

ENGINE
When tightening the main bearing case bolts, align

the direction of the holes so that the crankshaft can
be easily installed.
Apply oil to the bearing case screw.
CLUTCH

196W2A1A
Main bearing case 30 ~ 34 Nm
screw 2 3.0 ~ 3.5 kgf-m (1) Bearing case bolt 2
TRANSMISSION
22 ~ 25 lb-ft
B. REMOVING CRANKSHAFT
Pull the crankshaft from the back of the cylinder block
by lightly tapping it with a brass hammer.

HST
Before installing the crankshaft, clean the oil holes

in the crankshaft with compressed air.
REAR AXLE
196W2A2A
BARKE
C. REMOVING MAIN BEARING CASE

1. Remove the two mounting bolts for main bearing
case assembly 1.
FRONT AXLE
2. Detach the main bearing case, being careful with

the side and crankshaft bearing.
3. Detach the other bearing cases 2 and 3 in the same
method. Be careful not to mix them up.

STEERING
Clean the oil holes in the main bearing case.

Install the main bearing case with their side marks
toward the flywheel. Z
Be sure to install main bearing 1 with its oil groove
196W2A3B
facing outward.
HYDRAULIC
Tighten the bearing case bolts 1 to 20 ~ 24 Nm (2.0 ~ (1) Main bearing case assembly 1
2.4 kfg-m, 15 ~ 17 lb-ft).
(2) Main bearing case assembly 2
Item Tightening torque (3) Main bearing case assembly 3
Bearing case bolts 30 ~ 34 Nm (4) Bearing case bolt 1
ELECTRIC
3.0 ~ 3.5 kgf-m (5) Thrust bearing

22 ~ 25 lb-ft (6) Alignment mark
INDEX
2-60 SS30-W00 May. 2007

7.2 INSPECTION FOR OVERHAUL
GENERAL
7.2.1 CYLINDER HEAD
A. CYLINDER HEAD SURFACE FLATNESS
1. Thoroughly clean the cylinder head surface.
ENGINE
2. Place a straightedge on the cylinder head and mea-
sure the clearance with a feeler gage as shown in
the figure.
3. If the measurement exceeds the allowable limit, re-
place the cylinder head.
CLUTCH
IMPORTANT
Do not place the straight edge on the combustion
chamber.
TRANSMISSION
196W2A9A
Item Allowable limit

Flatness 0.05 mm
0.0019 in.
HST
REAR AXLE
196W2B0A
BARKE
B. CYLINDER HEAD SURFACE FLAW
1. Clean the cylinder head surface with the detergent
(B).
2. Spray the cylinder head surface with the red perme-
FRONT AXLE
ative liquid (A).
3. Wash away the red permeative liquid on the cylin-
der head surface with the detergent (B) after ten
minutes.
4 Spray the cylinder head surface with the white de-
veloper (C). STEERING
5. If any flaw is found such as a red mark, replace the

cylinder head.
196W2B1A
HYDRAULIC
ELECTRIC
INDEX
SS30-W00 May. 2007 2-61

C. VALVE STEM CLEARANCE

GENERAL
1. Remove the carbon from the valve guide.

2. Measure the valve stem O.D. with an outside
micrometer.
3. Measure the valve guide I.D. of cylinder head, and
calculate the clearance.
ENGINE
4. If the measurement exceeds the allowable limit,

replace the valve guide or the valve.
IMPORTANT
When changing the valve guide, be sure to ream
CLUTCH
as the figure indicates after inserting the valve

guide. 196W2B2B
0.035 ~ 0.065 mm
Reference value
TRANSMISSION
0.0014 ~ 0.0026 in.

0.1 mm
Allowable limit
0.004 in.
HST
REAR AXLE
196W2B3B
(A) Finishing size of inlet valve guide

(B) Finishing size of exhaust valve guide
BARKE
(1) 7.010 ~ 7.025 mm 0.2760 ~ 0.2766 in.

(2) 7.010 ~ 7.025 mm 0.2760 ~ 0.2766 in.
D. VALVE RECESSING
FRONT AXLE
1. Clean the cylinder head, the valve face and the seat.
2. Insert the valve in the guide.
3. Measure the valve recessing with a depth gauge.
4. If the recessing exceeds the allowable limit, replace
the valve and check the valve seating.
STEERING

Valve 0.9 ~ 1.1 mm 1.3 mm
recessing 0.035 ~ 0.043 in. 0.051 in.
HYDRAULIC
196W2B4A
ELECTRIC
INDEX
2-62 SS30-W00 May. 2007

7.2.2 VALVE SPRING
GENERAL
A. CHECKING VALVE SPRING FREE LENGTH
1. Measure the spring with a set of vernier calipers.
replace.
ENGINE
35.1 ~ 35.6 mm
Reference value
1.382 ~ 1.402 in.
34.8 mm
Allowable limit
1.37 in.
CLUTCH
196W2B9A
B. CHECK VALVE SPRING SQUARENESS
TRANSMISSION
1. Put the spring on a surface plate, place a square on
the side of the spring, and check to see if the entire
side is in contact with the square.
2. Rotate the spring and measure the maximum A.
3 If the measurement exceeds the allowable limit,
replace.
HST
The flat surface at the end of the spring coil must
exceed the full circumference by two-thirds.
Check the entire surface of the spring for scratches.
REAR AXLE
1.3 mm
Allowable limit
0.051 in.
196W2C0A
C. CHECKING VALVE SPRING TENSION

1. Place the spring on a tester and compress it to the
BARKE
same degree that it is actually compressed in the
engine. (31 mm, 12 in.)
2. Read the compression load on the gauge.
FRONT AXLE
74 N / 31 mm
Reference value 7.5 kgf / 31 mm
16.5 lbs / 1.22 in.
63 N / 31 mm
Allowable limit 6.4 kgf / 31 mm STEERING
14.1 lbs / 1.22 in.
196W2C2A
HYDRAULIC
ELECTRIC
INDEX
SS30-W00 May. 2007 2-63

7.2.3 CHECKING OIL CLEARANCE BE-

GENERAL
TWEEN ROCKER ARM SHAFT AND

BUSHING
1. Measure the rocker arm I.D.
2. Measure the rocker arm O.D.
3. If the clearance exceeds the allowable limit, replace.
ENGINE
0.02 ~ 0.08 mm
Reference value 9
0.0008 ~ 0.0031 in. 10
11
0.12 mm
CLUTCH
Allowable limit
0.0047 in.
196W2C3A
12.955 ~ 12.980 mm
Rocker arm shaft O.D.
0.5100 ~ 0.5110 in.
TRANSMISSION
13.000 ~ 13.035 mm
Rocker arm bushing I.D.
0.5118 ~ 0.5132 in.
7.2.4 CHECKING TOP CLEARANCE

HST
1. Remove the nozzle holder.

2. Lover the piston in the cylinder to be measured.
3. Insert a high-quality fuse from the nozzle holder
hole. Be careful not to let the fuse touch the valve
REAR AXLE
surface.
4. Rotate the engine with your hand.
5. Take the fuse out carefully.
6. Measure the place where the fuse was crushed with
vernier calipers.
BARKE
0.7 ~ 0.9 mm
Reference value
0.0275 ~ 0.0354 in. 196W2C4B
1.14 ~ 1.26 mm
FRONT AXLE
Thickness of gasket
when tightened 0.045 ~ 0.050 in.
STEERING
HYDRAULIC
ELECTRIC
INDEX
2-64 SS30-W00 May. 2007

7.2.5 TIMING GEARS AND CAMSHAFTS
GENERAL
A. TIMING GEAR BACKLASH
1. Set a dial indicator (lever type) with its tip on the
gear tooth.
2. Clamp one gear, rotate the other and measure the
backlash.
ENGINE
3. If the backlash exceeds the allowable limit, replace.

Reference value 0.042 ~ 0.115 mm
CLUTCH
0.0017 ~ 0.0045 in.
Allowable limit 0.2 mm 196W2C9A
0.0079 in.
TRANSMISSION
B. IDLE GEAR SIDE CLEARANCE
1. Pull the idle gear collar 2 (1) and push the idle gear
(2) to each end.
2. Measure the clearance A between the idle gear and
the idle gear collar 2 with a feeler gauge.
3. If the clearance exceeds the allowable limit, replace
HST
the idle gear collar 1 (3).

Side 0.20 ~ 0.51mm 0.9 mm
REAR AXLE
clearance (A) 0.0079 ~ 0.0201 in. 0.035 in.
196W2D0A
(1) Idle gear collar 2 (3) Idle gear collar 1
BARKE
(2) Idle gear snap ring (4) Idle gear
C. CAM GEAR SIDE CLEARANCE

1. Pull the cam gear (2) with the camshaft (1) to its
FRONT AXLE
end.
2. Measure the clearance A between the cam gear (2)
and the camshaft stopper (3).
3. It the clearance exceeds the allowable limit, replace
the camshaft stopper (3).
STEERING
Side 0.07 ~ 0.22 mm 0.3 mm
clearance (A) 0.028 ~ 0.078 in. 0.0118 in.
HYDRAULIC
196W2D1A
(1) Camshaft (3) Stopper

(2) Cam gear
ELECTRIC
INDEX
SS30-W00 May. 2007 2-65

D. INJECTION PUMP GEAR SIDE CLEARANCE

GENERAL
1. Pull the fuel camshaft and pull the injection pump

gear (1) to each end.
2. Measure the clearance A between the injection pump
gear (1) and the snap ring (2) on the fuel camshaft.
3. If the clearance exceeds the allowable limit, check
ENGINE
the gear, the bearing and the key.

Side 0.15 ~ 0.57 mm 0.9 mm
clearance (A) 0.0059 ~ 0.0224 in. 0.035 in.
CLUTCH
196W2D2A
(1) Injection pump gear

TRANSMISSION
(2) Snap ring
E. IDLE GEAR OIL CLEARANCE

1. Measure the idle gear shaft O.D. with an outside
micrometer.
HST
2. Measure the idle gear bushings I.D. with an inside

micrometer.
the bushing
REAR AXLE

Oil 0.025 ~ 0.066 mm 0.1 mm
clearance 0.00098 ~ 0.00259 in. 0.004 in.
Shaft O.D 23.967 ~ 23.98 mm
-
BARKE
0.9436 ~ 09441 in. 196W2D3A
Bushing I .D 24.000~ 24.021 mm

-
0.9449 ~ 0.9457 in.
FRONT AXLE
F. REPLACING IDLE GEAR BUSHINGS

1. Press out the bushings using an idle gear bushing
replacing tool.
STEERING
2. Clean the bushings and the bore, and apply oil to

them.
3. Press in the bushing using the replacing tool.
HYDRAULIC
196W2D4A
ELECTRIC
INDEX
2-66 SS30-W00 May. 2007

G. CAMSHAFT OIL CLEARANCE
GENERAL
1. Measure the I.D. of the camshaft bore on the crank-
case with an inside micrometer.
2. Measure the O.D. of the camshaft journal with an
outside micrometer.
ENGINE
the shaft.

Oil 0.050 ~ 0.090 mm 0.15 mm
clearance 0.0020 ~ 0.0036 in. 0.0059 in.
CLUTCH
Journal O.D. 32.934 ~ 32.950 mm
- 196W2D5A
1.2966 ~ 1.2972 in.
Bore I .D 33.000 ~ 33.025 mm
-
TRANSMISSION
1.2992 ~ 1.3002 in.
H. CAMSHAFT ALIGNMENT
1. Support the camshaft with V blocks on the surface
plate at both end journals and set a dial indicator
HST
with its tip on the intermediate journal.
2. Rotate the camshaft in the V block and get the ec-
centricity (half of the measurement).
3. If the eccentricity exceeds the allowable limit, re-
REAR AXLE
place the camshaft.

Eccentricity 0.08 mm
0.0031 in.
BARKE
196W2D6A
I. CAM HEIGHT
FRONT AXLE
1. Measure the height of the camshaft lobes at their
largest O.D. with an outside micrometer.
2. If the measurement is less than the allowable limit,
replace the camshaft.
Item Allowable limit STEERING
Reference value 26.75 mm

1.0531 in.
Allowable limit 26.83 mm
HYDRAULIC
1.0563 in.
196W2D7A
ELECTRIC
INDEX
SS30-W00 May. 2007 2-67

7.2.6 CONNECTING ROD AND PISTON

GENERAL
A. PISTON PIN BORE

1. Measure the I.D. of piston pin bore in piston
(lengthwise and widthwise of the piston) with a cyl-
inder gauge.
ENGINE
replace the piston.

Piston pin 20.000 ~ 20.013 mm 20.03 mm
bore I.D.
CLUTCH
0.7874 ~ 0.7879 in. 0.7886 in.
196W2D9A
TRANSMISSION
B. PISTON PIN AND BUSHING CLEARANCE

1. Measure the piston pin O.D. with an outside
micrometer.
2. Measure the piston pin busing I.D. with an inside
micrometer.
3. Of the clearance exceeds the allowable limit, re-
HST
place the bushing.

4. If the clearance still exceeds the allowable limit with
new bushing, replace the piston pin.
REAR AXLE

Piston pin 0.014 ~ 0.038 mm 0.15 mm
and bushing
0.00055 ~ 0.00150 in. 0.0059 in. 196W2E0A
clearance
Piston pin 20.002 ~ 20.011 mm
O.D. -
BARKE
0.7875 ~ 0.7878 in.

Bushing I.D. 20.025 ~ 20.040 mm
-
0.7884 ~ 0.7890 in.
FRONT AXLE
C. REPLACING PISTON PIN BUSHING

1. Press out the bushing, using a piston pin bushing
replacing tool.
2. Clean the new bushing and the bore and apply oil
STEERING
to them.
3. Press in the bushing, using the replacing tool.
IMPORTANT
HYDRAULIC
Align the oil holes of the connecting rod and the

bushing.
196W2E1A
ELECTRIC
INDEX
2-68 SS30-W00 May. 2007

D. PISTON RING GAP
GENERAL
1. Push down the ring into the cylinder to the lower
limit of ring travel in the assembled engine with a
piston.
2. Measure the ring gap with a feeler gauge.
3. If the gap exceeds the allowable limit, replace the
ENGINE
piston ring.

Piston Top ring 0.15 ~ 0.30 mm 1.25 mm
ring
0.0059 ~ 0.0118 in. 0.0492 in.
CLUTCH
gap
2nd ring 0.30 ~ 0.45 mm 1.25 mm
196W2E2A
0.0118 ~ 0.0177 in. 0.0492 in.
Oil ring 0.25 ~ 0.35 mm 1.25 mm
TRANSMISSION
0.0098 ~ 0.0138 in. 0.0492 in.
IMPORTANT
Measure The piston ring gap at the point of the
minimum inside diameter of the cylinder liner.
HST
E. PISTON RING CLEARANCE
1. Clean the rings and the ring grooves, and install
each ring in its groove.
REAR AXLE
2. Measure the clearance between the ring and the
groove with a feeler gauge.
the piston ring.
BARKE
new ring, replace the piston.
NOTE:
As the top ring is a keystone type, it cannot be mea-
FRONT AXLE
sured by this method.
196W2E3A
Item Reference value

Second ring 0.085 ~ 0.112 mm
0.0033 ~ 0.0044 in.
STEERING
Oil ring 0.020 ~ 0.055 mm
0.0008 ~ 0.0022 in.
HYDRAULIC
ELECTRIC
INDEX
SS30-W00 May. 2007 2-69

F. CONNECTING ROD ALIGNMENT

GENERAL
1. Remove the connecting rod bearing and install the

bearing cap.
2. Install the piston pin in the connecting rod.
3. Install the connecting rod on the connecting rod
alignment tool.
ENGINE
4. Put a gauge over the piston pin and move it against

the face plate.
5. If the gauge does not fit squarely against the
faceplate, measure the space between the pin of
the gauge and the faceplate.
CLUTCH

replace the connecting rod.
196W2E4A
0.02 mm
Reference value
TRANSMISSION
0.0008 in.
0.05 mm
Allowable limit
0.0020 in.
IMPORTANT
Because the I.D. of the connecting rod small end
HST
bushing is used as the basis for this check, check

it is not worn beforehand.
REAR AXLE
BARKE
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
2-70 SS30-W00 May. 2007

7.2.7 CRANKSHAFT
GENERAL
A. FLYWHEEL DEFLECTION AND CRANK-
SHAFT END PLAY
1. Set a dial indicator with its tip on the rear friction
face of the flywheel near the edge.
ENGINE
2. Turn the flywheel and measure the deflection or the
uneven wear.
remove the flywheel and check the mating faces of
the crankshaft and flywheel.
4. If scored or worn excessively, regrind or replace the
CLUTCH
flywheel.
196W2E5B
5. Move the crankshaft with flywheel back and forth to
each end and measure the end play.
6. If the play exceeds the allowable limit, replace the
TRANSMISSION
side bearing.

Deflection 0.05 mm
-
0.0020 in.
End play 0.15 ~ 0.31 mm 0.5 mm
HST
0.0059 ~ 0.0122 in. 0.020 in.
B. CRANKSHAFT ALIGNMENT
REAR AXLE
1. Support the crankshaft with V blocks on the surface
plate at its front and rear journals and set a dial
indicator with its tip on the intermediate journal.
2. Rotate the crankshaft in the V blocks and get the
misalignment (half of the measurement)
BARKE
3. If the misalignment exceeds the allowable limit, re-
place the crankshaft.
FRONT AXLE
Misalignment 0.02 mm 0.08 mm
0.0008 in. 0.0031 in.
196W2E6A
C. CRANKSHAFT JOURNAL AND BEARING 1 STEERING
OIL CLEARANCE
1. Measure the I.D. of the crankshaft bearing 1 with an
inside micrometer.
2. Measure the O.D. of the crankshaft journal with an
HYDRAULIC
outside micrometer.
the bearing replacing to Replacing Crankshaft Bear-
ing 1.

ELECTRIC
Oil clearance 0.034 ~ 0.092 mm 0.20 mm

0.0013 ~ 0.0036 in. 0.0079 in. 196W2E7A
Journal O.D. 43.934 ~ 43.950 mm

-
1.7297 ~ 1.7303 in.
INDEX
Bearing 1 I.D. 43.984 ~ 44.040 mm

-
1.7317 ~ 1.7339 in.
SS30-W00 May. 2007 2-71

D. REPLACING CRANKSHAFT BEARING 1

GENERAL
1. Press out the bearing 1 with crankshaft replacing

tool.
2. Clean a new bearing 1 and bore, and apply engine
oil to them.
3. Press fit a new bearing 1 using a inserting tool,
ENGINE
taking due care to see that the seam of bearing 1

faces the exhaust manifold side.
Item Factory spec.

Depressed depth of 4.2 ~ 4.5 mm
CLUTCH
bush at block 0.165 ~ 0.177 in.

196W2E8A
(1) Seam
TRANSMISSION
E. CRANKSHAFT JOURNAL AND BEARING 2

OIL CLEARANCE
1. Paste a press gauge with grease on the crankshaft
bearing
HST
2. Install the bearing cap and tighten the screws to the

specified torque once, and remove the cap again.
3. Detach the bearing case slowly, and measure the
depression of the press gauge with a sheet of
REAR AXLE
gauge (paper).
the bearing.

196W2E9A
Bearing cap 20 ~ 24 Nm
BARKE
2.0 ~ 2.4 kgf-m

15 ~ 17 lb-ft
0.034 ~ 0.092 mm
Reference value
0.0013 ~ 0.0036 in.
FRONT AXLE
0.20 mm
Allowable limit
0.0079 in.
43.934 ~ 43.950 mm
Crankshaft journal O.D.
1.7297 ~ 1.7303 in.
43.984 ~ 44.026 mm
STEERING
Crankshaft bearing 2 I.D.

1.7317 ~ 1.7333 in.
HYDRAULIC
ELECTRIC
INDEX
2-72 SS30-W00 May. 2007

F. CRANKPIN AND CONNECTING ROD BEAR-
GENERAL
ING OIL CLEARANCE
1. Paste a press gauge onto the crank pin bearing
with grease.
2. Install the connecting rod cap and tighten the screws
to the specified torque once, and remove the cap
ENGINE
again.
3. Remove the connecting rod gently, and measure
the depression of the press gauge with a sheet of
gauge (paper).
CLUTCH
the bearing.
Item Tightening torque 196W2F0A
Connecting rod cap 26.5 ~ 30.4 Nm

2.7 ~ 3.1 kgf-m
TRANSMISSION
19.52 ~ 22.42 lb-ft
0.029 ~ 0.091 mm
Reference value
0.0011 ~ 0.0036 in.
0.20 mm
Allowable limit
0.0079 in.
HST
(Note for measuring)
Fasten the crankshaft so that it does not turn.
Do not insert the press gauge into the crank pin
hole.
REAR AXLE
Crankpin bearing measuring points are shown
below.
196W2F1A
BARKE
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
SS30-W00 May. 2007 2-73

7.2.8 LUBRICATING SYSTEM

GENERAL
A.ENGINE OIL PRESSURE

1. Remove the oil pressure switch and install adap-
tors and pressure tester.
2. Start the engine and run it until it is warmed up, and
measure the oil pressure both at idling and rated
ENGINE
speed.
check the amount of oil, oil filter, oil pump relief
valve, oil passages and oil clearances.
CLUTCH
(When reassembling)
Supply the specified amount of recommended oil. 196W2F4B
The oil filter must not be clogged or broken.
TRANSMISSION

Engine At idle More than 49 kPa
oil speed
0.5 kgf/cm2 -
pressure
7.11 psi.
At 245 ~ 441 kPa 245 kPa
rated 2
2.5 kgf/cm2
2.5 ~ 4.5 kgf/cm
HST
speed
36 ~ 64 psi. 36 psi.
(Reference)
REAR AXLE

1.5 ~ 2.0 kgf-m
10.8 ~ 14.5 lb-ft
BARKE
B. RELIEF VALVE
1. Remove the relief valve.
FRONT AXLE
2. Check the relief valve for dirt, and the seat (2) and
ball (1) for damage.
3. If damaged, replace.
4. Check the free length of spring (3).
5. If less than the allowable limit, replace.
STEERING

Spring free 35 mm 30 mm
length 1.38 in. 1.18 in.
HYDRAULIC
NOTE:
Install the relief valve cover with the mark Sup.

ELECTRIC
196W2F5A
Relief cover screw 32.4 ~ 36.3 Nm
3.3 ~ 3.7 kgf-m (1) Relief valve ball
23.9 ~ 36.8 lb-ft (2) Relief valve seat
(3) Relief valve spring
INDEX
2-74 SS30-W00 May. 2007

C. ROTOR AND LOBE CLEARANCE OF OIL
GENERAL
PUMP
1. Measure the clearance between the outer and in-
ner rotor with a feeler gauge.
2. Measure the clearance between the outer and the
housing with a feeler gauge.
ENGINE
the pump.

Outer and 0.11 ~ 0.15 mm 0.20 mm
CLUTCH
inner rotor
0.0043 ~ 0.0059 in. 0.0079 in.
clearance
196W2F6A
Outer rotor 0.07 ~ 0.15 mm 0.25 mm
and hous-
0.0028 ~ 0.0059 in. 0.0098 in.
TRANSMISSION
ing clear-
ance
HST
REAR AXLE
196W2F7A
D. ROTOR END CLEARANCE OF OIL PUMP
BARKE
1. Put a strip of Plastic gauge on the rotor and as-
semble the pump.
2. Disassemble the pump and measure the amount
of the flattening with the scale to get the clearance.
FRONT AXLE
the pump.

End 0.08 ~ 0.13 mm 0.20 mm
STEERING
clearance 0.00315 ~ 0.00512 in. 0.0079 in.
196W2F8A
HYDRAULIC
ELECTRIC
INDEX
SS30-W00 May. 2007 2-75

7.2.9 COOLING SYSTEM

GENERAL
A. CHECKING AND ADJUSTING

f Fan Belt
1. Measure the deflection, depressing the belt half-
way between the fan drive pulley and the alternator
pulley at 78.5 N (8 kgf, 17.6 lbs.) of force.
ENGINE
2. If the deflection is not between the factory

specifications, loosen the bolts and nuts, and relo-
cate the alternator to adjust.
3. If the belt is damaged or worn (See figure), replace
the belt.
CLUTCH
Item Factory spec. 196W2F9A
Belt tension (deflection) 8 mm(0.32 in.) at 78.5 N

(8 kgf, 17.6 lbs.) of force
TRANSMISSION
f Radiator Water Tightness

1. Fill the radiator with water to the specified amount
and warm up the engine.
2. Set a radiator tester and raise the water pressure to
the specified pressure.
HST
3. Check the radiator for water leaks.

4. For water leak from the pin holes, repair with the
radiator cement, and for other leaks, replace the
radiator.
REAR AXLE
Item Factory spec.

Radiator water tightness No leaks at 137 kPa
(1.4 kgf/cm, 20 psi) 196W2G0A
BARKE
f Radiator Cap Tightness

1. Set a radiator tester on the radiator cap.
2. Apply 88 kPa (0.9 kgf/cm, 13 psi) of pressure and
measure the pressure for 10 seconds.
FRONT AXLE
3. If the pressure falls below 59 kPa (0.6 kgf/cm, psi),

replace the radiator cap.
Item Factory spec.

Radiator cap tightness More than 10 seconds
STEERING
for pressure fall from

88 ~ 59 kPa
(0.9 ~ 0.6 kgf/cm2, 13 ~ 9 psi).
196W2G1A
HYDRAULIC
ELECTRIC
INDEX
2-76 SS30-W00 May. 2007

B. DISASSEMBLING AND ASSEMBLING
GENERAL
f THERMOSTAT
1. Remove the thermostat cover (2).
2. Take out the thermostat (1).
(When reassembling)
ENGINE
Apply liquid gasket (Three Bond 1,215 or equivalent)
to the gasket.
CLUTCH
196W2G2A
(1) Thermostat (2) Thermostat Cover
TRANSMISSION
f WATER PUMP
1. Remove the fan and fan pulley(1).
2. Remove the water pump body from gear case cover.
3. Remove the water pump flange (2).
4. Remove the impeller and water pump shaft (3).
HST
5. Remove the impeller from the water pump shaft.
6. Remove the mechanical seal (5).
(When reassembling)
REAR AXLE
Replace the mechanical seal (5) with new one.
If changing the water pump, change the whole one.
If disassembling the water pump, check to see the
clearance between the water pump impeller and 196W2G3B
body.
(1) Fan pullry (4) Water pump body
BARKE
(2) Flange (5) Mechanical seal
(3) Pump shaft (6) Impeller
FRONT AXLE
C. THERMOSTAT
1. Suspend the thermostat in the water by a string with
its end inserted between the valve and seat.
2. Heating the water gradually, read the temperatures
when the valve open and leave the string and when STEERING
the valve opens approx. 8 mm (0.315 in.)
3. If the measurements are not within the factory
specification, replace the thermostat.
Item Factory spec.

HYDRAULIC
Opening temperature 82 1.5C

(180 3F)
at beginning
196W2G4A
lower than 95C (203F)
at 8 mm (0.315 in.)
ELECTRIC
of opening.
INDEX
SS30-W00 May. 2007 2-77

7.2.10 FUEL SYSTEM

GENERAL
A. DELIVERY VALVES FUEL TIGHTNESS

1. Remove the injection pipes, glow plugs and the in-
let manifold, and install the pressure tester.
2. With the speed control lever at the fuel injection
position, turn the crankshaft counterclockwise
ENGINE
(facing the flywheel) until the pressure build up to

the fuel injection pressure.
3. Release the pressure in the delivery chamber by
moving down the plunger to bottom dead center
(turn the crankshaft clockwise approx. 1.57 rad (90)
CLUTCH
from the F1 timing).

4. If the pressure drop for 5 seconds exceeds the al- 196W2G7B
lowable limit, replace the delivery valve or pump
assembly.
TRANSMISSION
5. If the pressure does not built up, replace the pump

element with new one and test again.

Fuel 21.57 MPa 20.59 MPa
injection 220 kgf/cm 2
210 kgf/cm2
pressure
HST
3,129 psi 2,987 psi.

Standards 10 sec 5 sec
REAR AXLE
CAUTION
Never contact with spraying diesel fuel under
pressure, which can have sufficient force to pen-
etrate the skin, causing serious personal injury.
Be sure nobody is in the direction of the spray.
196W2G8A
BARKE
(1) Pump element (3) Plunger

(2) Cylinder
FRONT AXLE
B. FUEL LECTION PRESSURE

1. Set the injection nozzle to the nozzle tester.
2. Measure the injection pressure.
3. If the measurement is not within the factory
specification, adjust with the adjustment washer (1)
STEERING
inside the nozzle holder.
(Reference)
Pressure variation with 0.1 mm (0.004 in.) difference of
adjusting washer thickness is approx. 10 kgf/cm.
HYDRAULIC
Fuel injection pressure
Item Factory spec.

196W2G9A
Fuel injection pressure 13.73 ~ 14.71 MPa
140~ 150 kgf/cm
ELECTRIC
1,991 ~ 2,133 psi.

INDEX
2-78 SS30-W00 May. 2007

C. FUEL TIGHTNESS OF NEEDLE VALVE SEAT
GENERAL
TIGHTNESS
2. Apply a pressure 130 kgf/cm (12.75 MPa, 1,849 psi).
After keeping the nozzle under this pressure for 10
seconds. Check to see if fuel leaks from the nozzle.
ENGINE
3. If the should leak, replace the nozzle.
CLUTCH
196W2H1A
D. INJECTION NOZZLE
TRANSMISSION
Nozzle holder
1. Secure the nozzle retaining nut (7) with a vise.
2. Remove the nozzle holder (1) , and take out parts
inside.
(When reassembling)
HST
Assemble the nozzle in clean fuel oil.
Install the push rod (4), noting its direction.
REAR AXLE
196W2H3A
BARKE
(1) Nozzle holder (3) Nozzle spring
(2) Adjusting washer (4) Push rod
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
SS30-W00 May. 2007 2-79

MEMO
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2. 3A Series Workshop Manual
ENGINE - SPECIFICATIONS CK25/27/30/35
1. SPECIFICATIONS
GENERAL
1.1 TD1300 SPECIFICATIONS (CK25)
1.1.1 ENGINE BODY
ENGINE
A. CYLINDER HEAD
Item Factory Specification Allowable Limit

Cylinder head surface flatness 0.05 mm / 100 mm
-
0.002 in. / 3.94 in.
CLUTCH
Top clearance 0.7 ~ 0.9 mm
-
0.0276 ~ 0.0354 in.
Thickness of gasketfree When tightened
TRANSMISSION
1.18 ~ 1.28 mm -
0.0465 ~ 0.0504 in.
Compression pressure 3.24 ~ 3.73 MPa 2.55 MPa
(when cranking with starting motor)
33 ~ 38 kgf/cm 2
26 kgf/cm 2
469 ~ 540 psi 370 psi
HST
* Variance of compression pressure among cylinders should be 10% or less.
B. VALVES
REAR AXLE
Valve clearance (cold) IN. 0.1 mm 0.0039 in.
-
EX. 0.1 mm 0.0039 in.
Valve seat angle IN. 0.785 rad. 45
-
BARKE
EX. 0.785 rad. 45
Valve face angle IN. 1.047 rad. 60
-
EX. 1.047 rad. 60
Valve recessing 1.1 ~ 1.3 mm 1.6 mm
FRONT AXLE
0.0433 ~ 0.0512 in. 0.0630 in.
Clearance between valve stem and valve guide 0.025 ~ 0.055 mm 0.10 mm
0.0010 ~ 0.0022 in. 0.004 in.
Valve stem O.D 7.960 ~ 7.975 mm
- STEERING
0.31339 ~ 0.31398 in.
Valve stem I.D 8.0 ~ 8.015 mm
-
0.31496 ~ 0.31555 in.
HYDRAULIC
C. VALVE TIMING

Inlet valve Open 0.349rad 20 before T.D.C
-
Close 0.785rad 45 after B.D.C
ELECTRIC
Exhaust valve Open 0.873rad 50 before B.D.C

-
Close 0.262rad 15 after T.D.C
INDEX
D704-W01 Jun. 2008 2-3

CK25/27/30/35 ENGINE - SPECIFICATIONS
D. CYLINDER BORE
GENERAL

Cylinder bore inner diameter 82.000 ~ 82.022 mm 0.15 mm
3.2283 ~ 3.2292 in. 0.0059 in.
ENGINE
E. VALVE SPRING

CLUTCH
1.6417 ~ 1.6614 in. 1.6220 in.

Assembling load / Assembling length 12.0 kgf / 35.15 mm 10.2 kgf / 35.15 mm
26.5 lbs / 1.3839 in. 22.5 lbs / 1.3839 in.
TRANSMISSION
Squareness 1.0 mm
-
0.039 in.
F. ROCKER ARM

HST
Rocker arm shaft O.D 13.973 ~ 13.984 mm

-
0.55012 ~ 0.55055 in.
Rocker arm bushing I.D 13.998 ~ 14.023 mm
-
REAR AXLE
0.55110 ~ 0.55209 in.
G. TAPPET

BARKE
Clearance between tappet and guide 0.020 ~ 0.062 mm 0.07 mm

0.00079 ~ 0.00244 in. 0.0028 in.
Tappet O.D 23.959 ~ 23.980 mm
-
FRONT AXLE
0.94327 ~ 0.94410 in.

Tappet guide I.D 24.000 ~ 24.021 mm
-
0.94488 ~ 0.94571 in.
H. CAMSHAFT
STEERING

Camshaft alignment 0.01 mm 0.05 mm
0.0004 in. 0.0020 in.
HYDRAULIC
Cam height IN. 33.5 ~ 33.6 mm 33.45 mm

1.319 ~ 1.323 in. 1.3169 in.
EX. 33.5 ~ 33.6 mm 33.45 mm
1.319 ~ 1.323 in. 1.3169 in.
ELECTRIC

0.00197 ~ 0.00358 in. 0.0059 in.
Camshaft journal O.D 39.934 ~ 39.950 mm 39.88 mm
1.57221 ~ 1.57284 in. 1.5701 in.
Camshaft counter bore I.D 40.000 ~ 40.025 mm
-
INDEX
1.57480 ~ 1.57579 in.
2-4 D704-W01 Jun. 2008

I. TIMING GEAR
GENERAL
Timing gear backlash 0.04 ~ 0.11 mm 0.15 mm
0.0016 ~ 0.0043 in. 0.0059 in.
Idle gear side clearance 0.20 ~ 0.51 mm 0.9 mm
ENGINE
0.0079 ~ 0.0201 in. 0.035 in.
Clearance between Idle gear shaft and idle 0.020 ~ 0.054 mm 0.1 mm
gear bushing 0.00079 ~ 0.00213 in. 0.0039 in.
CLUTCH
Idle gear shaft O.D 27.967 ~ 27.980 mm
-
1.10106 ~ 1.10157 in.
Idle gear bushing I.D 28.000 ~ 28.021 mm
-
1.10236 ~ 1.10319 in.
TRANSMISSION
J. PISTON RING

Piston pin-bore I.D 23.00 ~ 23.013 mm 23.053 mm
0.90551 ~ 0.90602 in. 0.9076 in.
HST
Clearance between Oil ring and ring groove 0.020 ~ 0.060 mm 0.15 mm
0.00079 ~ 0.00236 in. 0.0059 in.
Oil ring groove width 5.01 ~ 5.03 mm
REAR AXLE
-
0.19724 ~ 0.19803 in.
Oil ring width 4.97 ~ 4.99 mm
-
0.19567 ~ 0.19646 in.
Clearance between 2nd ring and ring groove 0.065 ~ 0.100 mm 0.15 mm
BARKE
0.00256 ~ 0.00394 in. 0.0059 in.
2nd ring groove width 2.055 ~ 2.070 mm
-
0.08091 ~ 0.08150 in.
2nd ring width 1.97 ~ 1.99 mm
FRONT AXLE
-
0.07756 ~ 0.07834 in.
Top ring, oil ring end gap 0.25 ~ 0.40 mm 1.25 mm
0.0098 ~ 0.01570 in. 0.0492 in.
2nd ring end gap 0.25 ~ 0.40 mm 1.25 mm
STEERING
0.0098 ~ 0.01570 in. 0.0492 in.
K. CONNECTING ROD
HYDRAULIC

Connecting rod alignment 0.05 mm
-
0.0020 in.
Clearance between Piston and small end 0.014 ~ 0.038 mm 0.15 mm
bushing 0.00055 ~ 0.00150 in. 0.0059 in.
ELECTRIC
Piston pin O.D 23.002 ~ 23.011 mm

-
0.90560 ~ 0.90594 in.
Small end bushing I.D 23.025 ~ 23.040 mm
-
0.90650 ~ 0.90708 in.
INDEX
D704-W01 Jun. 2008 2-5

L. CRANKSHAFT
GENERAL

Crankshaft alignment 0.08 mm
-
0.0031 in.
Clearance between Crankshaft and crankshaft 0.20 mm
ENGINE
0.040 ~ 0.118 mm
bearing 1 0.00157 ~ 0.00465 in. 0.0079 in.
Crankshaft O.D 51.921 ~ 51.940 mm
-
2.04414 ~ 2.04488 in.
Crankshaft bearing 1 I.D
CLUTCH
51.980 ~ 52.039 mm
-
2.04646 ~ 2.04878 in.
Clearance between Crankshaft and crankshaft 0.040 ~ 0.104 mm 0.20 mm
bearing 2 0.00157 ~ 0.00409 in. 0.0079 in.
TRANSMISSION

-
2.04414 ~ 2.04488 in.
Crankshaft bearing 2 I.D 51.980 ~ 52.025 mm
-
2.04646 ~ 2.04823 in.
Clearance between Crank pin and crank pin 0.035 ~ 0.093 mm 0.20 mm
HST
bearing 0.0014 ~ 0.0037 in. 0.0079 in.

Crank pin O.D 43.959 ~ 43.975 mm
-
1.73067 ~ 1.73130 in.
REAR AXLE
Crank pin bearing I.D 44.010 ~ 44.052 mm

-
1.73268 ~ 1.73433 in.
Crankshaft side clearance 0.15 ~ 0.31 mm 0.5 mm
0.0059 ~ 0.0122 in. 0.020 in.
BARKE

A. OIL PUMP
FRONT AXLE

Engine oil pressure At idle speed more than 68.6 kPa
(oil temp. 85 ~ 95 C, 0.7 kgf/cm2 -
185 ~ 203 F) 9.95 psi
STEERING
At rated speed 294.2 ~ 441 kPa 294.2 kPa

2
3.0 ~ 4.5 kgf/cm 3.0 kgf/cm2
42.7 ~ 64.0 psi 42.7 psi
Clearance between inner rotor and outer rotor 0.10 ~ 0.16 mm 0.2 mm
HYDRAULIC
0.0039 ~ 0.0063 in. 0.0079 in.

Radial clearance between outer rotor and pump 0.11 ~ 0.19 mm 0.25 mm
0.0043 ~ 0.0078 in. 0.0098 in.
End clearance between inner rotor and cover 0.105 ~ 0.150 mm 0.2 mm
ELECTRIC
0.00413 ~ 0.00591 in. 0.00787 in.

INDEX
2-6 D704-W01 Jun. 2008

GENERAL
A. THERMOSTAT
Valve opening temperature at beginning 69.5 ~ 72.5 C (157.1 ~ 162.5 F)

Opened completely (height 8 mm 0.315 in.) 85 C (185 F)
ENGINE
B. RADIATOR
Radiator tightness No leak at 137 kPa, 1.4 kgf/cm2, 20 psi

10 seconds or more for pressure
CLUTCH
falling from 88 ~ 59 kPa
Radiator cap tightness from 0.9 ~ 0.6 kgf/cm2
from 13 ~ 9 psi
TRANSMISSION
Fan belt tension 7 ~ 9 mm
[deflection at 78 N (8 kgf, 18 lbs) of force] 0.28 ~ 0.35 in.
1.1.4 FUEL SYSTEM
HST
A. INJECT PUMP
Injection timing (BTDC) 20
REAR AXLE
B. INJECTION NOZZLE
Fuel injection pressure 14.709 MPa

150 kgf/cm2
2,134 psi
BARKE
Fuel tightness of nozzle valve seat No fuel leak for 5 sec.
at pressure
12.75 MPa
FRONT AXLE
130 kgf/cm2
1,849 psi
NOTE:
Injection Sequence
Three Cylinders: 1 2 3 STEERING
(The cylinder number is given in order from the gear
case end.)
HYDRAULIC
ELECTRIC
INDEX
D704-W01 Jun. 2008 2-7

1.1.5 TIGHTENING TORQUES

GENERAL
Item Size x Pitch Nm kgf-m lb-ft

Cylinder head screws M11 x 1.25 103.0 ~ 107.9 10.5 ~ 11.0 75.9 ~ 79.6
Head cover bolts M6 x 1.0 8.8 ~ 11.8 0.9 ~ 1.2 6.5 ~ 8.7
* Bearing case screw 1 M9 x 1.25 46.1 ~ 51.0 4.7 ~ 5.2 34.0 ~ 37.6
ENGINE
* Flywheel screw M12 x 1.25 98.1 ~ 107.9 10.0 ~ 11.0 72.3 ~ 79.6
* Connecting rod screws M8 x 1.0 46.1 ~ 51.0 4.5 ~ 5.0 34.0 ~ 37.6
CLUTCH
Rocker arm support bolts M10 x 1.25 68.0 ~ 70.6 6.2 ~ 7.2 44.8 ~ 52.1
Drain plug M12 x 1.25 32.4 ~ 37.3 3.3 ~ 3.8 23.9 ~ 37.3
Glow plugs M10 x 1.25 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Oil switch PT1/8 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
TRANSMISSION
Nozzle locating screws M20 x 1.5 49.1 ~ 68.7 5.0 ~ 7.0 36.2 ~ 50.6
Injection pipe nuts M12 x 1.5 24.5 ~ 34.3 2.5 ~ 3.5 18.1 ~ 25.3
NOTE:
For *marked screw, bolts and nuts on the table,
apply engine oil to their threads and seats before
HST
tightening.
The letter M in Size x Pitch means that the screw,
bolt or nut dimension stands for metric. The size is
the nominal outside diameter in mm of the threads.
REAR AXLE
The pitch is the nominal distance in mm between two

threads.
BARKE
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
2-8 D704-W01 Jun. 2008

1.2 3A139(CK27) / 3A150 (CK30) / 3A165 (CK35)
GENERAL
1.2.1 ENGINE BODY
A. CYLINDER HEAD
ENGINE
-
0.002 in. / 3.94 in.
Top clearance 0.750 ~ 0.9 mm
-
0.0294 ~ 0.0354 in.
CLUTCH
Thickness of gasketfree When tightened
(MSL Gasket) 1.21 mm -
0.0476 in.
3.24 ~ 3.73 MPa 2.55 MPa
TRANSMISSION
Compression pressure 33 ~ 38 kgf/cm 2
26 kgf/cm 2
(when cranking with starting motor)
469 ~ 540 psi 370 psi
* Variance of compression pressure among cylinders should be 10% or less.
B. VALVES
HST
Valve clearance (cold) IN. 0.25 mm 0.0098 in. 0.05mm
REAR AXLE
EX. 0.30 mm 0.0118 in.
Valve seat angle IN. 1.047 rad. 60
-
EX. 0.785 rad. 45
Valve face angle IN. 1.047 rad. 60
-
EX. 0.785 rad. 45
BARKE
Valve recessing 0.2 ~ 0.5 mm 0.8 mm
0.0079 ~ 0.0197 in. 0.0315 in.
Clearance between valve stem and valve guide 0.040 ~ 0.070 mm 0.10 mm
FRONT AXLE
0.0016 ~ 0.0028 in. 0.0039 in.
Valve stem O.D 7.960 ~ 7.975 mm
-
0.31339 ~ 0.31398 in.
Valve stem I.D 8.015 ~ 8.030 mm
-
0.3156 ~ 0.3161 in. STEERING
C. VALVE TIMING

HYDRAULIC
Inlet valve Open 0.14rad 8 before T.D.C

-
Close 0.611rad 35 after B.D.C
Exhaust valve Open 0.785rad 45 before B.D.C
-
Close 0.140rad 8 after T.D.C
ELECTRIC
INDEX
D704-W01 Jun. 2008 2-9

D. CYLINDER BORE
GENERAL

Cylinder bore inner 3A139 80.000 ~ 80.022 mm 0.15 mm
diameter 3.1496 ~ 3.1505 in. 0.0059 in.
3A165 87.000 ~ 87.022 mm
ENGINE
3.4252 ~ 3.4261 in.

3A150 83.000 ~ 83.022 mm
3.2677 ~ 3.2690 in.
CLUTCH
E. VALVE SPRING

TRANSMISSION
1.6417 ~ 1.6614 in. 1.6220 in.

Assembling load / Assembling length 12.0 kgf / 35.15 mm 10.2 kgf / 35.15 mm
26.5 lbs / 1.3839 in. 22.5 lbs / 1.3839 in.
Squareness - 1.0 mm
0.039 in.
HST
F. ROCKER ARM

REAR AXLE
Rocker arm shaft O.D 18.955 ~ 18.980 mm

-
0.7463 ~ 0.7472 in.
Rocker arm bushing I.D 19.000 ~ 19.025 mm
-
0.7480 ~ 0.7490 in.
BARKE
G. TAPPET

FRONT AXLE
0.00079 ~ 0.00244 in. 0.0028 in.

Tappet O.D 23.959 ~ 23.980 mm
-
0.94327 ~ 0.94410 in.
Tappet guide I.D 24.000 ~ 24.021 mm
-
0.94488 ~ 0.94571 in.
STEERING
H. CAMSHAFT

HYDRAULIC

0.0004 in. 0.0020 in.
Cam height IN. 33.59 mm 33.54 mm
1.3224 in. 1.3205 in.
EX. 33.69 mm 33.64 mm
ELECTRIC
1.326 in. 1.3244 in.

0.00197 ~ 0.00358 in. 0.0059 in.
Camshaft journal O.D 39.934 ~ 39.950 mm 39.88 mm
1.57220 ~ 1.57283 in. 1.5701 in.
INDEX
Camshaft counter bore I.D 40.000 ~ 40.025 mm

-
1.57480 ~ 1.57579 in.
2-10 D704-W01 Jun. 2008

I. TIMING GEAR
GENERAL
0.0016 ~ 0.0043 in. 0.0059 in.
ENGINE
0.0079 ~ 0.0201 in. 0.035 in.
Clearance between Idle gear shaft and idle 0.025 ~ 0.066 mm 0.1 mm
gear bushing 0.00098 ~ 0.00250 in. 0.0039 in.
CLUTCH
Idle gear shaft O.D 37.9590 ~ 37.9750 mm
-
1.49445 ~ 1.49508 in.
Idle gear bushing I.D 38.000 ~ 38.025 mm
-
1.49608 ~ 1.49705 in.
TRANSMISSION
J. PISTON RING
Piston pin-bore I.D 25.00 ~ 25.006 mm 25.03 mm
0.98425 ~ 0.98448 in. 0.9854 in.
HST
Clearance between Oil ring and ring groove 0.020 ~ 0.060 mm 0.15 mm
0.00079 ~ 0.00236 in. 0.0059 in.
-
REAR AXLE
0.1185 ~ 0.1193 in.
-
0.1169 ~ 0.1177 in.
Clearance between 2nd ring and ring groove 0.04 ~ 0.08 mm 0.15 mm
0.0016 ~ 0.0031 in. 0.0059 in.
BARKE
-
0.0799 ~ 0.0807 in.
FRONT AXLE
-
0.07756 ~ 0.07834 in.
Top ring, oil ring 3A150 Model 0.20 ~ 0.40 mm 1.25 mm
end gap Oil ring end gap 0.0079 ~ 0.0157 in. 0.0492 in.
3A150 Model 0.25 ~ 0.40 mm 1.25 mm
Top ring and gap
0.0098 ~ 0.0157 in. 0.0492 in. STEERING
3A165/3A139 Model
2nd ring end gap 0.55 ~ 0.70 mm

0.0217 ~ 0.0276 in.
HYDRAULIC
K. CONNECTING ROD
-
0.0020 in.
ELECTRIC
Clearance between Piston and small end 0.014 ~ 0.038 mm 0.15 mm

bushing 0.00055 ~ 0.00150 in. 0.0059 in.
Piston pin O.D 25.002 ~ 25.011 mm
-
0.98433 ~ 0.98469 in.
INDEX
Small end bushing I.D 25.025 ~ 25.040 mm

-
0.98524 ~ 0.98583 in.
D704-W01 Jun. 2008 2-11

L. CRANKSHAFT
GENERAL

Crankshaft alignment 0.08 mm
-
0.0031 in.
Clearance between Crankshaft and crank- 0.20 mm
ENGINE
0.040 ~ 0.118 mm
shaft bearing 1 0.00157 ~ 0.00465 in. 0.0079 in.
-
2.04414 ~ 2.04488 in.
CLUTCH

-
2.04646 ~ 2.04878 in.
Clearance between Crankshaft and crank- 0.040 ~ 0.104 mm 0.20 mm
shaft bearing 2 0.00157 ~ 0.00409 in. 0.0079 in.
TRANSMISSION

-
2.04414 ~ 2.04488 in.
-
2.04646 ~ 2.04823 in.
Clearance between Crank pin and crank pin 0.025 ~ 0.087 mm 0.20 mm
HST
bearing 2 0.0010 ~ 0.0034 in. 0.0079 in.

Crank pin O.D 46.959 ~ 46.975 mm
-
1.84877 ~ 1.84940 in.
REAR AXLE
Crank pin bearing 47.000 ~ 47.046 mm

-
I.D 1.85039 ~ 1.85220 in.
0.0059 ~ 0.0122 in. 0.020 in.
BARKE

A. OIL PUMP
FRONT AXLE

Engine oil pressure At idle speed more than 68.6 kPa
(oil temp. 85 ~ 95 C, 0.7 kgf/cm2 -
185 ~ 203 F) 9.95 psi
STEERING
At rated speed 245.1 ~ 441.2 kPa 245.0 kPa

2
2.5 ~ 4.5 kgf/cm 2.5 kgf/cm 2
35.5 ~ 64.0 psi 35.6 psi
Clearance between inner rotor and outer rotor 0.10 ~ 0.16 mm 0.2 mm
HYDRAULIC
0.0039 ~ 0.0063 in. 0.0079 in.

Radial clearance between outer rotor and pump 0.11 ~ 0.19 mm 0.25 mm
0.0043 ~ 0.0078 in. 0.0098 in.
End clearance between inner rotor and cover 0.105 ~ 0.150 mm 0.2 mm
ELECTRIC
0.00413 ~ 0.00591 in. 0.00787 in.

INDEX
2-12 D704-W01 Jun. 2008

GENERAL
A. THERMOSTAT
Valve opening temperature at beginning 69.5 ~ 72.5 C (157.1 ~ 162.5 F)

Opened completely (height 8 mm 0.315 in.) 85 C (185 F)
ENGINE
B. RADIATOR
Radiator tightness No leak at 137 kPa, 1.4 kgf/cm2, 20 psi

10 seconds or more for pressure
CLUTCH
falling from 88 59 kPa
Radiator cap tightness from 0.9 0.6 kgf/cm2
from 13 9 psi
TRANSMISSION
Fan belt tension 7 ~ 9 mm
[deflection at 78 N (8 kgf, 18 lbs) of force] 0.28 ~ 0.35 in.
1.2.4 FUEL SYSTEM
HST
A. INJECT PUMP
Injection timing (BTDC) 18
REAR AXLE
B. INJECTION NOZZLE
Fuel injection pressure 14.709 MPa

150~160 kgf/cm2
2,134~2,276 psi
BARKE
Fuel tightness of nozzle valve seat No fuel leak for 5 sec.
at pressure
12.75 MPa
FRONT AXLE
130 kgf/cm2
1,849 psi
NOTE:
Injection Sequence
Three Cylinders: 1 2 3 STEERING
(The cylinder number is given in order from the
gear case end.)
HYDRAULIC
ELECTRIC
INDEX
D704-W01 Jun. 2008 2-13

1.2.5 TIGHTENING TORQUES

GENERAL
Item Size x Pitch Nm kgf-m lb-ft

Head cover bolts M6 x 1.0 8.8 ~ 11.8 0.9 ~ 1.2 6.5 ~ 8.7
ENGINE
* Flywheel screw M12 x 1.25 98.1 ~ 107.9 10.0 ~ 11.0 72.3 ~ 79.6
CLUTCH
Rocker arm support bolts M10 x 1.25 60.8 ~ 70.6 6.2 ~ 7.2 44.8 ~ 52.1
Drain plug M12 x 1.25 32.4 ~ 37.3 3.3 ~ 3.8 23.9 ~ 37.3
Glow plugs M10 x 1.25 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Oil switch PT1/8 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
TRANSMISSION
Nozzle locating screws M20 x 1.5 49.1 ~ 68.7 5.0 ~ 7.0 36.2 ~ 50.6
Injection pipe nuts M12 x 1.5 24.5 ~ 34.3 2.5 ~ 3.5 18.1 ~ 25.3
NOTE:
For *marked screw, bolts and nuts on the table,
apply engine oil to their threads and seats before
HST
tightening.
The letter M in Size x Pitch means that the screw,
bolt or nut dimension stands for metric. The size is
the nominal outside diameter in mm of the threads.
REAR AXLE
The pitch is the nominal distance in mm between two

threads.
BARKE
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
2-14 D704-W01 Jun. 2008

ENGINE - OPERATING PRINCIPLE CK25/27/30/35
2. OPERATING PRINCIPLE
GENERAL
2.1 LUBRICATING SYSTEM
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BARKE
FRONT AXLE
STEERING
704W217A
(1) Piston (5) Strainer (9) Rocker Arm Shaft (13) Oil Pressure Switch
HYDRAULIC
(2) Idle Gear (6) Oil Filter Element (10) Rocker Arm (14) Camshaft
(3) Oil Pump (7) Bypass Valve (11) Push Rod (15) Crankshaft
(4) Relief Valve (8) Oil Pan (12) Tappet
ELECTRIC
The lubricating oil is forced to each journal through the

oil passages of the cylinder block, cylinder head and
shafts. The oil, splashed by the crankshaft or thrown off
from the bearings, lubricates other engine parts such as
the push rods (11), tappets (12), camshaft (14), and
crankshaft (15).
INDEX
D704-W01 Jun. 2008 2-15

CK25/27/30/35 ENGINE - OPERATING PRINCIPLE
2.2 COOLING SYSTEM

GENERAL
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BARKE
FRONT AXLE
704W221B
STEERING
(1) Water Return Pipe (5) Radiator

(2) Thermostat (6) Cooling Fan
(3) Cylinder Head Water Jacket (7) Water Pump
HYDRAULIC
(4) Cylinder Block Water Jacket
The cooling system consists of a radiator (5), a centrifu- water temperature is high, the thermostat opens to al-
gal water pump (7), a cooling fan (6) and a thermostat low the water to flow from the cylinder block to the radia-
(2). The water is cooled as it flows through the radiator tor. When the water temperature is low, the thermostat
core, and the fan behind the radiator pulls the cooling closes and the flow stays within the block. The opening
ELECTRIC
air through the radiator core. The water pump receives temperature of the thermostat is approx.
water from the radiator or from the cylinder head and 71C (160F).
forces it into cylinder block. The thermostat open or
closes according to the water temperature. When the
INDEX
2-16 D704-W01 Jun. 2008

2.3 FUEL SYSTEM
GENERAL
2.3.1 FUEL FLOW ROUTE
ENGINE
CLUTCH
6 5
TRANSMISSION
4
8
9
3
HST
1
REAR AXLE
2
BARKE
FRONT AXLE
T46W233B
(1) Fuel Tank (4) Injection Pipe (7) Fuel Feed Pump
(2) Fuel Filter (5) Injection Nozzle (8) Bleeding Bolt STEERING
(3) Fuel Injection Pump (6) Fuel Overflow Pipe (Hose) (9) Bleeding Hose
The fuel in the fuel tank (1) is drawn to the fuel feed
HYDRAULIC
pump (7) and then is supplied to the fuel injection pump

(3) passed through the fuel filter (2). Then, the fuel in-
jection pump feeds the fuel to the injection nozzles (5)
which then inject the fuel into the cylinders for
combustion. The excessive fuel from the fuel injection
pump to the injection nozzles is collected in the fuel over-
ELECTRIC
flow pipes (6) and returns to the fuel tank.
NOTE:
For air bleeding, see the next page.
INDEX
D704-W01 Jun. 2008 2-17

2.3.2 FUEL FILTER

GENERAL
The fuel from fuel feed pump enters into the filter port
a
through the (b) port and passes through the filter paper.
Then, it is drained through the (c) port and supplied to 2
the fuel injection pump. The filter paper collects the par-
ticles bigger than 90 microns (0.0034 in.) at 20 kPa (0.2 1
b
ENGINE
kgf/cm, 3 psi).
3
c
4
5
CLUTCH
T46W234A
(a) To fuel tank (c) To fuel injection pump

TRANSMISSION
(b) From fuel feed pump
(1) Cock (4) Retainer ring

(2) Air vent (5) Port
(3) Filter body (6) Filter element
HST
2.3.3 BLEEDING THE FUEL SYSTEM

1. Make sure that the amount of fuel in the fuel tank is
REAR AXLE
sufficient.
4
2. If there is air in the fuel filter, turn the filter cock (5),
shown in the figure, to the air side and crank the
engine. Then, the air in the filter port is discharged 3
through the bleeding hose (1) shown in the figure. 2
1
BARKE
CAUTION
Do not crank for over 5 seconds. Crank the en-
gine for several times while keeping the crank-
ing time below 5 seconds.
FRONT AXLE
3. When the amount of fuel in the fuel filter port goes

over 3/4 level, stop cranking the engine and turn the
cock (5) of the figure to the ON position.
5
NOTES:
STEERING
The bleeding process could be skipped if installing

the fuel port after filling the bowl with fuel.
4. Loosen the bleeding bolt (2) in the figure and crank

the engine to bleed air. Then tighten the bolt again.
HYDRAULIC
5. If the engine still cannot be started, loosen 1 or 2

nozzle holders (3) and crank the engine to bleed air. 704W2C6B
6. When the air bubble is not seen anymore in the bleed-

ing fuel, tighten the loose parts and start the engine.
ELECTRIC
INDEX
2-18 D704-W01 Jun. 2008

2.3.4 FUEL FEED PUMP
GENERAL
(A) From fuel tank (B)
To fuel filter
push rod (2). The tappet is reciprocated by the eccen-
tric cam on the fuel camshaft (7).
1 4
2 5
ENGINE
A. INTAKE STROKE 6
When the diaphragm is pulled down by the spring,
vacuum in the chamber (5) causes the exhaust valve 3
(4) to close and the atmospheric pressure in the fuel
tank to force the fuel into the chamber, opening the in- 7
CLUTCH
take valve (1).
T46W235B
B. SCAVENGING STROKE (1) Intake valve (5) Chamber
TRANSMISSION
When the diaphragm is pushed up by the cam, the pres- (2) Push rod (6) Diaphragm
sure in the chamber causes the intake valve to close
and forces out the fuel, opening the exhaust valve. (3) Tappet (7) Fuel camshaft
(4) Exhaust Valve
2.3.5 FUEL INJECTION PUMP
HST
pump. It features a compact and light weight design. a
REAR AXLE
1
b
2
3
4
BARKE
6 5
FRONT AXLE
8
T46W236A STEERING

HYDRAULIC

(3) Delivery valve (7) Plunger spring
(4) Cylinder (8) Tappet
ELECTRIC
INDEX
D704-W01 Jun. 2008 2-19

A. PUMP ELEMENT
GENERAL
The pump element (1) consists of a plunger (3) and cyl-

inder (2) which their sliding surfaces are finely machined
to maintain the fuel tightness. The plunger (3) is installed
in the control sleeve (5) and the sleeve is engaged with 4
the control rack that rotates the plunger in the cylinder
ENGINE
to control the amount of fuel delivered. 2
1 5
CLUTCH
7
TRANSMISSION
T46W237A

HST

(4) Feed hole
REAR AXLE
B. OPERATION OF PUMP ELEMENT

a. Before delivery
As the plunger (2) lowers, fuel is drawn into the delivery
BARKE
chamber (1) through the feed hole (4) from the fuel cham- 3
ber (5). 1 4
5
FRONT AXLE
b. Beginning of delivery 6
When the plunger is pushed up by the cam and the head 2
of the plunger closes the feed hole (4), the pressure in
the delivery chamber (1) rises to push the delivery valve
(3) open.
STEERING
c. Delivery
While the plunger (2) is rising, delivery of fuel continues.
HYDRAULIC
d. End of delivery
When the plunger rises further and the control groove T46W238A
stops because the pressure in the delivery chamber (1) (1) Delivery chamber (4) Feed hole
is reduced to the opening pressure. (2) Plunger (5) Fuel chamber
ELECTRIC
(3) Delivery valve (6) Control

INDEX
2-20 D704-W01 Jun. 2008

C. AMOUNT OF FUEL DELIVERY
GENERAL
4
a. No fuel delivery 1
When the control rack (3) is at the engine stop position, 2 5
the lengthwise slot (1) on the plunger (2) aligns with the 6
3
feed hole (5). The pressure in the delivery chamber does
not build up and no fuel is forced to the injection nozzle
ENGINE
since the delivery chamber (4) is opened to the feed
hole during the entire stroke of the plunger.
CLUTCH
TRANSMISSION
T46W239A
(1) Slot (4) Delivery chamber

(2) Plunger (5) Feed hole
(3) Control rack (6) Control groove
HST
b. Fuel delivery
Location of fuel d e f
REAR AXLE
hole is not aligned with the lengthwise slot. When the supply hole
plunger. The pressure in the delivery chamber builds up
and forces the fuel to the injection nozzle until the con-
trol groove (6) meets the feed hole. The amount of the D D
fuel to be forced into the nozzle corresponds to distance
BARKE
A. In the above figure, the amount of injected fuel in (c)
is larger than the amount of injected fuel in (b).
Stop Low speed High speed
FRONT AXLE
T46W240A
D. DELIVERY VALVE
The delivery valve (2) prevents the fuel in the injection 1
pipe from flowing back into the delivery chamber and STEERING
the fuel in the injection nozzle from dribbling after
injection. 2 3
The relief plunger (6) sucks the fuel back from the injec- 4
tion pipe to prevent the leakage dribbling and unneces-
HYDRAULIC
sary subsequent injection after the major injection.

The stroke of A corresponds to the amount of fuel sucked
back (35 mm3).
6
5
ELECTRIC
T46W241A
INDEX
(1) Valve spring (4) Fuel chamber

(2) Delivery valve (5) Valve face
(3) Valve seal (6) Relief plunger
D704-W01 Jun. 2008 2-21
E. INJECTION NOZZLE
GENERAL
Supplied
fuel
ENGINE
CLUTCH
Excessive fuel
TRANSMISSION
3
HST
4
REAR AXLE
6
7
9
BARKE
8
FRONT AXLE
T46W242A
STEERING
This injection nozzle is throttle type nozzle. It features

the low fuel consumption and works well with DAEDONG
combustion chamber. The nozzle valve opening pres-
HYDRAULIC
sure is about 14.7 MPa (150 kgf/cm, 2134 psi). When

the pressure overcomes the counterforce of nozzle valve
spring (3), the pressure pushes up the needle valve (7)
constantly and then the proper amount of fuel is injected
into the swirling air in the combustion chamber for
combustion.
ELECTRIC
The opening pressure can be adjusted by adding or re-

ducing the washer (2). A washer of 0.1 mm corresponds
to 980 kPa (10 kgf/cm, 142 psi) change in opening
pressure. The heat seal (8) is adopted to improve the
durability and reliability of the nozzle.
INDEX
2-22 D704-W01 Jun. 2008

2.4 GOVERNOR SYSTEM
GENERAL
2.4.1 BASIC PRINCIPLE OF GOVERNOR SYSTEM
ENGINE
4 5 1 2
7 15 14 3
CLUTCH
8 10
TRANSMISSION
9
13
HST
6
REAR AXLE
12
Torque
# spring
11
Tip
Wls
BARKE
##
FRONT AXLE
T46W246A
(1) Governor Spring 1, 2 (6) Steel Ball (11) Governor Sleeve

(2) Solenoid Guide (7) Governor Lever (12) Fork Lever 2
STEERING
(3) Stop Solenoid (8) Idle Spring (13) Fork Lever 1
(4) Pump Rack (9) Start Spring (14) Fuel Limit Bolt
(5) Rack Pin (10) Idle Shaft (15) Torque Spring
HYDRAULIC

(11) to prevent from coming out. The sleeve pushes the
fork lever 1 (13) to transfer the power to the fuel injec-
ELECTRIC
tion pump pin (5).

INDEX
D704-W01 Jun. 2008 2-23

2.4.2 OPERATION OF GOVERNOR

GENERAL
A. WHEN STOPPED E. LOAD INCREASE AT HIGH SPEED

The fuel is blocked since the solenoid (3) pushes the
speed control rack (4) to the left.
ENGINE
B. WHEN TURNING THE KEY SWITCH ON

e
When the electromagnet in the stop solenoid operates
and the pin is retracted, the speed rack (4) of the fuel
injection pump is pushed to the right by the start spring d
(9) and the start shaft (10) to supply the sufficient amount
CLUTCH
of fuel to start the engine.
C. WHEN STARTING THE ENGINE AND RUN-

NING THE ENGINE AT LOW IDLE SPEED
TRANSMISSION
When the engine is started, the steel ball (6) pushes the Torque curve
#
sleeve (11) to the left as the centrifugal force of the steel T46W247A
ball increases. Therefore, the governor fork lever 1 (13)
pushes the speed rack (4) of the pump to the left to re- When a load is applied to the engine running at a high
duce the amount of fuel supplied. speed, the centrifugal force of steel ball (6) decreases
as the engine speed drops. Also, the fork lever 2 (12)
As the speed rack is stopped by the idle spring (8), it
is pulled to the right by the governor spring until it con-
keeps the balance with the centrifugal force of the steel
HST
tacts the fuel limit bolt (14). Until then, the amount of
ball so that at least minimum amount of fuel is delivered
injected fuel per one stroke of the injector plunger and
for stable engine running at idle speed.
the torque increase.
This range (a) is between the max. speed point with no
D. ACCELERATION AND DECELERATION
REAR AXLE
load and the max. power point of the torque curve.

When depressing the accelerator pedal, the governor
spring (1) pulls the fork lever 2 (12) to the right and then
(14) and does not move any more and the load is
pushes the fork lever 1 (13) to the right. The fork lever
increased, the centrifugal force of steel ball drops fur-
(13) is stopped by the sleeve (11).
ther and the torque spring (15) compressed between
When the centrifugal force of the steel ball (6) that is the fork lever 1 and 2 is loosened. Then, the fork lever
BARKE
proportional to the engine speed is balanced with the 2 moves to the right until the torque spring is free, and
tension of the governor spring (1) that is determined by the amount of fuel supplied and the torque increase
the driver, the stable speed is maintained. simultaneously.
This range (b) is between the max. power and the max.
FRONT AXLE
torque point in the torque curve.
IMPORTANT
adjustment of such components can negatively
STEERING

DAEDONG. Such action violates the EPA regu-
lation and also can void the warranty.
HYDRAULIC
F. WHEN STOPPED
When the key switch is moved to the OFF position,
the stop solenoid power is cut off to release the
electromagnet. Therefore, the stop pin comes off by
the return force of the spring and pushes the solenoid
ELECTRIC
guide (2) and fuel injection pump rack to the stop posi-
tion to stop the engine.
INDEX
2-24 D704-W01 Jun. 2008

2.5 PCV VALVE
GENERAL
2.5.1 PCV (POSITIVE CRANKCASES
VENTILATION)
2
The PCV system is a system that prevents air pollution
by returning the blow-by gas to the intake manifold 5
ENGINE
1
through the bleeding pipe of the cylinder head cover for
engine has the open crankcase type that discharges the 4
blow-by gas to the air.)
CLUTCH
3
T46W248B
TRANSMISSION
6 12
10
7 11
HST
REAR AXLE
8
9
T46W249A
(1) Head Cover Bolt
BARKE
(2) Oil Filler Cap
(3) Oil Baffle Plate
(4) Head Cover Gasket
FRONT AXLE
(5) Cylinder Head Cover
(6) Intake Manifold
(7) Bleeding Pipe
(8) Intake Valve
(9) Cylinder Head
STEERING
(10) Cylinder Head Cover
(11) Oil Baffle Plate
(12) Bleeding Pipe Connection
HYDRAULIC
ELECTRIC
INDEX
D704-W01 Jun. 2008 2-25

CK25/27/30/35 ENGINE - TROUBLESHOOTING
3. TROUBLESHOOTING
GENERAL
ENGINE DOES NOT START.
Crankshaft Frictional resis- Crankshaft and camshaft have seized up.

ENGINE
does not turn tance of moving Piston and cylinder liner have seized up.
parts is too much
Bearings are oil-stuck.
Lubrication system not working property.
Starter faulty.
CLUTCH
Battery capacity is low or terminal loose.

TRANSMISSION
Fuel supply to Fuel pipe broken.

injection pump is Air enters fuel pipe through connection.
insufficient.
Fuel pump faulty.
No or small Injection pump Plunger has worn or seized up.

HST
fuel injection does not send on Delivery valve spring broken.

sounds. fuel.
REAR AXLE
Fuel does not Needle valve stuck.

inject through
Needle spring broken.
injection nozzle.
Injection pressure maladjusted.
Crankshaft Injection pipe mounting nut loose.
turns
BARKE
Injection mistimed. Injection timing maladjusted.
Contact between intake/exhaust valve and

seat not tight.
FRONT AXLE
Intake/exhaust valve spring broken.

Intake/exhaust valve stuck.
Gasket faulty.
Regular fuel
Compressed air Tightness torque of cylinder head not
injection
STEERING
leaks. enough.
sounds.
Piston ring stuck.
Piston ring worn.
Cylinder liner worn.
HYDRAULIC
Tightness torque of injection nozzle and

glow plug not enough.
Valve action Valve clearance excessive.

timing improper.
ELECTRIC
INDEX
2-26 D704-W01 Jun. 2008

ENGINE - TROUBLESHOOTING CK25/27/30/35
Engine does not turn normally.
GENERAL
Fuel pipes broken or loose.
Revolution is Injection Air in pump.
ENGINE
not smooth at pump wrong. Pump capacity not constant.
high speeds.
Tappet roller and pin worn.
CLUTCH
Injection Fuel leaks from nozzle tip.
nozzle faulty. Fuel not spraying properly.
Irregular Governor spring deformed.
TRANSMISSION
Revolution Valve clearance incorrect.
Injection pump or nozzle not functioning

normally.
Compression pressure is different among
cylinders.
HST
Governor not Governor sleeve not sliding property.
Idling not
functioning Fork lever not functioning normally.
smooth.
normally.
REAR AXLE
Start spring deformed.
Control rack not sliding property.
Idling Idling regulator maladjusted.

maladjusted. Accelerator rod maladjusted.
BARKE
Engine output insufficient.
Main moving parts have almost seized up.
FRONT AXLE
Engine overheated.
Injection mistimed.
Governor not functioning normally.
Filter clogged.
STEERING
Slow engine Fuel supply Fuel pipe broken or loose.
revolutions. insufficient. Injection pumps capacity not enough.
Nozzle needle valve worn.
HYDRAULIC
Compression Air leaking.

pressure not Air cleaner clogged.
enough.
ELECTRIC
INDEX
D704-W01 Jun. 2008 2-27

CK25/27/30/35 ENGINE - TROUBLESHOOTING
Color of exhaust fumes not normal.

GENERAL
Piston ring stuck.

Piston ring worn.
White or blue Lubricant rises Excessive gap between cylinder liner and
piston.
ENGINE
exhaust through piston

fumes. gap. Too much oil.
Injection delayed.
Compression pressure insufficient.
CLUTCH
Injection Injection too early.

mistimed. Injection delayed.
TRANSMISSION
Black or dark Fuel pumps Plunger does not return completely

gray exhaust injecting because spring is stuck or broken.
fumes. capacity varies. Plunger worn.
Needle valve stuck.

Nozzle does Nozzle spring broken.
HST
not inject fuel

properly. Too much carbon sticks to nozzle tip.
Injection pressure too low.
REAR AXLE
Compressed air leaks.

Not enough air.
Excessive lubricant consumption.

BARKE
Excessive gap between piston and liner.

Piston ring stuck.
Piston ring worn.
FRONT AXLE
Excessive gap between intake/exhaust

valve and valve stem.
Valve stem seal broken.
Oil leaks from defective packings.
STEERING
Lubricant increasing.
Fuel mixed Injection pump plunger leaks much fuel.

with oil.
HYDRAULIC
Fuel pump leaks much fuel.
Water mixed Head gasket packing faulty.

with oil. Crankcase cracked.
ELECTRIC
Gear oil mixed Hydraulic pumps oil seal broken.

with oil.
INDEX
2-28 D704-W01 Jun. 2008

ENGINE - MEASUREMENT AND ADJUSTMENT CK25/27/30/35
4. MEASUREMENT AND ADJUSTMENT
GENERAL
4.1 FAN BELT
1. Measure the deflection, depressing the belt halfway
between the fan drive pulley and the alternator pul-
ENGINE
ley at 78 N (8 kgf, 18 lbs) of force.
2. If the deflection is not between the factory specifica-
tions, loosen the bolts and nuts, and relocate the al-
ternator to adjust.
CLUTCH
the belt.
Belt Factory 7 ~ 9 mm
tension spec 0.28 ~ 0.35 in.
(direction)
TRANSMISSION
at 78 N (8 kgf, 18 lbs) 704W2B5A
of force
4.2 ENGINE BODY
HST
4.2.1 CHECKING AND ADJUSTING
A. COMPRESSION PRESSURE
REAR AXLE
1. Run the engine until warmed up.
2. Stop the engine and remove the air cleaner, the
muffler and all nozzle holders.
3. Connect a compression tester to the nozzle holder
hole.
4. Pull the stop lever to cut the fuel and run the engine
BARKE
with the starter at 250 ~ 350 rpm for 5 ~ 10 seconds.
5. Measure the maximum pressure while running, sev-
eral times.
6. If the pressure does not reach the allowable limit,
FRONT AXLE
704W248B
apply a small amount of oil to the cylinder wall through
the nozzle holder hole and check the pressure again.
7. If the pressure raises after oil is apply, check the cyl-
inder wall and piston ring.
8. If the pressure is still low, check the top clearance,
valve clearance and cylinder head. STEERING
Compression Factory spec. 3.24 ~ 3.73 MPa

pressure
33 ~ 38 kgf/cm2
HYDRAULIC
470 ~ 541 psi

Allowable limit 2.55 MPa
26 kgf/cm 2
370 psi
ELECTRIC
Difference Allowable limit 10 %

between two
cylinders
NOTE:
Check the compression pressure with the specified
INDEX
valve clearance for proper air in taking.
D704-W01 Jun. 2008 2-29

CK25/27/30/35 ENGINE - MEASUREMENT AND ADJUSTMENT
4.3 VALVE CLEARANCE

GENERAL
1. Remove the cylinder head cover and the timing win-

dow cover on the flywheel housing and all glow plugs.
2. Turn the flywheel and align the 1 TC mark mark with
the timing mark of window on the flywheel housing.
This will position the 1st cylinder valves at the top
ENGINE
dead center during compression stroke.

3. Measure the clearance at the valves marked with
4. If the clearance is not within the factory specifications,
turn the adjusting screw to adjust.
CLUTCH
5. Turn the flywheel just one turn to position the 1st

cylinder valves at the top head center during overlap. 704W249A
6. Measure the clearance at the valves marked with

TRANSMISSION
7. If the clearance is not within spec. ; adjust. See

above.
Factory spec. 3A139/ In. : 0.25 mm 0.0098 in.

3A150 Ex. : 0.30 mm 0.0118 in.
HST
3A165 In. : 0.1 mm 0.0039 in.

TD1300 Ex. : 0.1 mm 0.0039 in.
REAR AXLE
Cylinder NO. 1 2 3
Valve IN. EX. IN. EX. IN. EX.
704W250A
Checking
(A) Gear Case
BARKE
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
2-30 D704-W01 Jun. 2008

4.4 INJECTION TIMING MEASURE-
GENERAL
MENT AND ADJUSTMENT
NOTE:
Perform the work with the engine installed in the
tractor.
ENGINE
CLUTCH
704W2D4B
TRANSMISSION
2. Remove the timing check window cover of the fly-
wheel housing.
3. Turn the flywheel to find 1 FI mark for 3-cylinder en-
gine on the flywheel.
4. When the mark was found, turn the crankshaft coun-
HST
of the engine).
REAR AXLE
704W2D3B
BARKE
- When turning the crankshaft, use a special ser-
vice tool (socket) for turning the crankshaft by en-
gaging it with the socket wrench.
FRONT AXLE
NOTE:
How to make the crankshaft turning socket
STEERING
T46W258A
HYDRAULIC
T46W259A
a. Cut the coupler (DAEDONG part No.: 37805-4452-1)

in half.
ELECTRIC
b. Weld the 1/2 socket to the coupler.

c. You can use DAEDONG speical tool kit
(part No.: G0611-B0010).
INDEX
D704-W01 Jun. 2008 2-31

CK25/27/30/35 ENGINE - MEASUREMENT AND ADJUSTMENT

GENERAL

ENGINE
CLUTCH
T46W260B
7. Remove the fuel in the nozzle holder with clean cloth

TRANSMISSION
and leave only small amount of fuel. Fuel

of the engine) slowly.
9. When the amount of the fuel in the nozzle holder
increases abruptly, that moment is the injection
HST
timing.
REAR AXLE

the exhaust cycle. Therefore, turn the crankshaft T46W261A
360 to find the compression cycle and repeat the

above procedures.
BARKE
through the timing window and measure the dis-

tance between the 1 FI and the mark you made.
11. To advance the injection timing, reduce the amount

FRONT AXLE

amount of shims(2).
Diameter Flywheel Amount of

Injection 2
Model of circumfer- shims to
timing
flywheel ence for 1 adjust 1
STEERING
CK25
CK27 BTDC 282 mm 2.46 mm 0.1 mm
CK30 18 (11.1 in.) (0.097 in.) (0.004 in.)
CK35
HYDRAULIC
* BTDC: Before top dead center
Example) T46W2I1B
For 3A150 / 3A165, if the measured injection timing is

on the 2.74 mm above the FI mark, it means that the
injection timing is 1 advanced. Therefore, the measured
ELECTRIC
injection timing is BTDC 19. In this case, the injection

is adjusted to 18 if adding 0.1 mm of shim under the
fuel injection pump.
INDEX
2-32 D704-W01 Jun. 2008

4.5 ENGINE OIL PRESSURE
GENERAL
1. Remove the oil pressure switch. Install the adapter
and pressure tester in its place.
2. Start the engine and run it until it is warmed up. Mea-
sure the oil pressure at both idling and rated speed.
ENGINE
check the oil level, oil filter, oil pump relief valve, oil
passages and oil clearance.
Engine At idle Factory spec. more than 49.0 kPa
CLUTCH
speed
oil 0.5 kgf/cm
pres-
7.11 psi T46W262A
sure
At rated 3A139 Factory 245 ~ 441 kPa
speed 3A150 spec. 2.5 ~ 4.5 kgf/cm
TRANSMISSION
3A165
35.6 ~ 64.0 psi
Allowable 245 kPa
limit 2.5 kgf/cm
35.6 psi
TD1300 Factory 245 ~ 441 kPa
HST
spec.
2.5 ~ 4.5 kgf/cm
35.6 ~ 64.0 psi
Allowable 245 kPa
REAR AXLE
limit 2.5 kgf/cm
35.6 psi
(Reference)
BARKE
Tightening Oil 14.7 ~ 19.6 Nm
torque pressure
1.5 ~ 2.0 kgf-m
switch
10.8 ~ 14.5 lb-ft
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
D704-W01 Jun. 2008 2-33

ENGINE - EXPLODED VIEW (CK25/27/30/35) CK25/27/30/35
5. EXPLODED VIEW (CK25/27/30/35)
GENERAL
ENGINE
50
47
17
45 29
44
26
30
CLUTCH
31
15
46
27
TRANSMISSION
7
8
23
49 40
24
25
33 48
HST
11
28
37 52 6 16
34
12
REARAXLE
32 51
13
1
36
54
2
14
BARKE
35
39
22 3
18 5
19
43 53
FRONTAXLE
20
4
10
21 32
STEERING
41
9
42
HYDRAULIC
704W243C
(1) Cylinder Block (8) Head Bolt (14) Bearing Case Bolt 2 (21) Camshaft Gear (27) Flywheel Housing (33) Fuel Feed Pump (38) Fork Lever (43) Cooling Fan (49) Air Cleaner
(2) Oil Pressure Switch (9) Gearcase (15) Rocker Arm (22) Idle Gear (28) Starter (34) Fuel Camshaft (Governor) (44) Radiator (50) PCV V/v
ELECTRIC
(3) Oil Pump (10) Oil Filter (16) Inlet, Exhaust Valve (23) Piston (29) Injection Pipe (35) Fuel Camshaft Gear (39) Water pump (45) Reserve Tank Assy (51) Idle Limit System
(4) Oil Pan (11) Mainbearing Case (17) Cylinder Hear Cover (24) Connecting Rod (30) Glow Plug (36) Engine Stop Sole- (40) Thermostat (46) Inlet Manifold (52) Oil Filter
(5) Oil Strainer Cover (18) Push Rod (25) Crankshaft (31) Nozzle noid (41) Alternator (47) Muffler (53) Speed Control
(6) Oil Gauge (12) Bearing Case Bolt 1 (19) Tappet (26) Flywheel (32) Fuel Injection Pump (37) Manual Stop Lever (42) Fan Drive Pulley (48) Exhaust Manifold (54) Fuel Control Limit
INDEX
(7) Cylinder Head (13) Mainbearing Case (20) Camshaft
D704-W01 Jun. 2008 2-35

ENGINE - SERVICING CK25/27/30/35
6. SERVICING
GENERAL
6.1 REMOVAL AND REASSEMBLY
6.1.1 DRAINING THE COOLANT
ENGINE
CAUTION
Never open radiator cap when the coolants
temprature reaches boiling point.
Do not remove the radiator cap when the engine
CLUTCH
is hot. Then loosen cap slightly to the stop. Re-
lieve any excess pressure before removing cap
completely.
1. Stop the engine and let it cool down.
TRANSMISSION
2. After open the bonnet
3. To drain the coolant, open the radiator drain plug and
remove radiator cap. The radiator cap must be re- 704W143B
moved to completely drain the coolant.

(1) Drain Plug
4. After all coolant is drained, close the drain plug.
(Filling)
HST
Fill water up the point between Full and Low mark
on the recovery water tank.
7.4
REAR AXLE
CK25/27/35
Coolant (2.0 U.S.gal.)
capacity 7.8
CK30
(2.1 U.S.gal.)
BARKE
704W144A
FRONT AXLE
(1) Radiator Cap (A) FULL
(2) Recovery Tank (B) LOW
STEERING
HYDRAULIC
ELECTRIC
INDEX
D704-W01 Jun. 2008 2-37

CK25/27/30/35 ENGINE - SERVICING
6.1.2 DRAINING THE ENGINE OIL

GENERAL
CAUTION
To avoid personal injury:
Be sure to stop the engine before changing the
oil.
ENGINE
Allow engine to cool down sufficiently, oil can

be hot and can burn.
1. To drain the used oil, remove the drain plug at the
bottom of the engine and drain the oil completely into A
the oil pan.
CLUTCH
All the used oil can be drained out easily when the
engine is still warm. 704W2C5A
2. After draining reinstall the drain plug.

(1) Oil Inlet
3. Fill with the new oil up to the upper notch on the
TRANSMISSION
dipstick. (2) Dipstick

(A) Oil Level is Acceptable Within this Range
5.8
Oil capacity with filter
(1.53 U.S.gal.)
HST
REAR AXLE
BARKE
704W307A
(1) Drain Plug

FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
2-38 D704-W01 Jun. 2008

6.1.3 BONNET
GENERAL
1. Open the bonnet (1) and disconnect the electronic
connector (2).
2. Remove the air-cylinder (3).
3. Remove the snap-pin, joint-pin and bonnet(1).
ENGINE
4. Remove the side cover (LH/RH) (4).
5. Disconnect the battery terminal (-) (5).
NOTE:
When disconnecting the battery cords, disconnect the
CLUTCH
(-) cord first. Connecting, (+) cable first.
704W308A
(For assembly)
After connecting the battery terminal (-), apply a little (1) Bonnet (4) Side Cover
TRANSMISSION
grease to it. (2) Connector (5) Battery Terminal (-)
(3) Air-cylinder
6.1.4 HYDRAULIC PIPE AND ELECTRIC

WIRING
1. Remove the steering hoses(R, P, T).(2, 3, 4).
HST
2. Remove the accelerator wires (hand, pedal).(5, 6)
3. Disconnect the bonnet wire harness 2 Assy. 3
4. Remove the rubber pipe 1 (7) out of suction pipe 3 4
REAR AXLE
5
(8).
5. Remove the hydraulic pipe (B1).(9) 2
6. Remove the cooling pipe 3 (HST type)
1
7. Remove the steering hose (L).(10)
6 8
8. Remove the cooling pipe 4 (HST type)
BARKE
704W309B
9. Disconnect the bonnet wire harness 1 Assy.(11)
(When reassembling)
FRONT AXLE
A hose classification
- Steering hose P : A red tag attachment
- Steering hose R : A white tag attachment
- Steering hose L : A yellow tag attachment
- Steering hose T : No tag
STEERING

10
Steering hose P, R, L 9.8 Nm
1.0 kgf-m 9
HYDRAULIC
7.2 lb-ft
704W310B
Pipe bed 9.8 Nm
(1) Steering Hose (R)
1.0 kgf-m
(2) Steering Hose (P)
7.2 lb-ft
(3) Steering Hose (T)
ELECTRIC
(4) Accelerator Wire (Hand)

(5) Accelerator Wire (Pedal)
(6) Rubber Pipe
(7) Suction Pipe 3
INDEX
(8) Hydraulic Pipe (B1)

(9) Steering Hose (L)
(10) Bonnet Wire Harness 1 Assy
D704-W01 Jun. 2008 2-39
6.1.5 PROPELLER SHAFT

GENERAL
1. Remove the bolts and slide the propeller shaft cover .

2. Tap out the spring pin (8), and then slide the cou-
pling (2) to the rear.
3. Romove the propeller shaft and cover.
ENGINE
(When reassembling)
Apply grease to the splines of the propeller shaft.
CLUTCH
704W311A
(1) Propeller Shaft (6) O-ring

TRANSMISSION
(2) Coupling (7) O-ring

(3) Cir-Clip (8) Spring Pin
(4) Propeller Shaft Cover 1 (9) O-ring
(5) Propeller Shaft Cover 2 (10) Bolt
HST
6.1.6 SEPARATING ENGINE & CLUTCH

HOUSING
1. Place the jacket to the bottom of the clutch housing
REAR AXLE
and engine.
2. Remove the mounting bolts for the fuel tank support.
3. Separate engine and clutch housing.
(When reassembling)
BARKE
Apply grease to the spline of main shaft.

Apply liquid gasket (Three Bond 1,211 or equivalent)
to the joint face of the flywheel housing and clutch
housing.
FRONT AXLE
704W312A

Bolts, nuts 48.1 ~ 55.9 Nm
4.9 ~ 5.7 kgf-m
1.004 ~ 1.167 lb-ft
STEERING
Stud bolts 24.5 ~ 31.4 Nm

2.5 ~ 3.2 kgf-m
0.512 ~ 0.655 lb-ft
HYDRAULIC
ELECTRIC
INDEX
2-40 D704-W01 Jun. 2008

6.1.7 REMOVING CLUTCH
GENERAL
1. Put alignment marks on the clutch cover and fly
wheel. (CK25/27/30/35)
2. Insert the clutch center tool.
3. Remove the clutch assembly.
ENGINE
CLUTCH
704W313A
TRANSMISSION
6.1.8 SEPARATING THE FUEL TANK
1. Remove the bonnet wire-harness1 (1).
2. Remove the air cleaner (2).
3. Remove the reovery tank (3).
4. Loosen bolts and remove the fuel tank (4).
HST
5. Remove the muftler (5).
6. Remove the bonnet wire harness2 (6).
7. Remove the water pipe (7, 8)
REAR AXLE
BARKE
FRONT AXLE
STEERING
704W314A
(1) Bonnet Wire Harness 1

(2) Air Cleaner
HYDRAULIC
(3) Recovery Tank

(4) Fuel Tank
(5) Muftler
(6) Bonnet Wire Harness2
ELECTRIC
(7) Water Pipe (Upper)

(8) Water Pipe (Lower)
INDEX
D704-W01 Jun. 2008 2-41

6.1.9 DISASSEMBLING FRONT AXLE

GENERAL
FRAME
1. Lift engine with chain hook and support it.
2. Loosen bolts and remove the engine from the front
axle frame.
ENGINE

M10 Bolt 60.9 ~ 70.6 Nm
(Only CK30) 6.2 ~ 7.2 kgf-m
44.9 ~ 52.0 lb-ft
CLUTCH
M12 Bolts 103 ~ 117 Nm

10.5 ~ 12.0 kgf-m 704W313A
76.0 ~ 86.7 lb-ft

TRANSMISSION
6.1.10 DISASSEMBLING OTHER ENGINE

PARTS.
1. Remove the gear pump assy (1) and pump holder.
HST
2. Remove the fan belt (2), cooling fan (3) and fan
pulley.
3. Remove the dynamo assy (4).
4. Remove the start motor (5).
REAR AXLE
BARKE
FRONT AXLE
STEERING
704W312C
HYDRAULIC
(1) Gear Pump (4) Dynamo Assy

(2) Fan Belt (5) Starter Motor
(3) Cooling Fan
ELECTRIC
INDEX
2-42 D704-W01 Jun. 2008

6.1.11 CYLINDER HEAD COVER, GLOW
GENERAL
PLUGS AND FUEL OVERFLOW
PIPES
1. Remove the injection pipes and over flow pipe.
2. Remove the glow plugs.
ENGINE
3. Remove the injection nozzles, gaskets, and heat seals.
4. Remove the cylinder head cover.
(When reassembling)
Check that the cylinder head cover gasket is not
CLUTCH
defective.
Tighten the cylinder head cover cap nuts in several 704W251A
steps.
(1) Injection Nozzle (3) Heat Seal
TRANSMISSION
(2) Gasket
6.1.12 HEAT SEAL REMOVAL PROCEDURE
HST
1. Drive screw driver lightly into the heat seal hole.
2. Turn screw driver three or four times each way.
3. While turning the screw driver, slowly pull the heat
seal and the injection nozzle gasket. If the heat seal
REAR AXLE
drops, repeat the above procedure.
4. The heat seal and injection nozzle gasket must be
changed when the injection nozzle is removed for
cleaning or for service.
BARKE
NOTE:
Use a philips screw driver that has a diameter
704W252A
which is bigger than the heat seal hole 1/4 in.
(approx. 6 mm). (1) Philips Screw Driver
FRONT AXLE
(2) Nozzle
(3) Injection Nozzle Gasket
(4) Heat Seal
STEERING
HYDRAULIC
ELECTRIC
INDEX
D704-W01 Jun. 2008 2-43

6.1.13 ROCKER ARM ASSEMBLY

GENERAL
1. Loosen the bolts in several steps and the specified

sequence shown in the figure and remove them.
To loosen (3) to (1)
2 1 3
To tighten (1) to (3)
ENGINE
2. Remove the rocker arm assembly and the push rod.
(When reassembling)
Rest the end of push rod at the indent of tappet and
install the rocker arm assembly.
CLUTCH
Tighten the bolts in several steps and in the speci-

fied sequence to the specified torque. Refer to the
704W253A
figure.
Adjust the valve clearance after assembling the (A) Gear Case
rocker arm assembly.
TRANSMISSION
Tightening 3A139 60.8 ~ 70.6 Nm

torque
3A150 6.2 ~ 7.2 kgf-m
3A165 44.8 ~ 52.1 lb-ft
TD1300 29.4 ~ 34.3 Nm
HST
3.0 ~ 3.5 kgf-m

21.7 ~ 25.3 lb-ft
REAR AXLE
704W254A
BARKE
(1) Rocker Arm Shaft (3) Rocker Arm Bracket

(2) Rocker Arm (4) Bolt
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
2-44 D704-W01 Jun. 2008

6.1.14 CYLINDER HEAD
GENERAL
1. Remove the screw in the specified sequence shown
in the figure and remove the cylinder head (1) and
head gasket. 2
To loosen (14) to (1) 1
To tighter (1) to (14)
ENGINE
2. Remove the water flange (2).
3. Take out the tappets from the cylinder block.
NOTE:
CLUTCH
Mark the cylinder number to the tappets to prevent
interchanging.
704W255A
(When reassembling) (1) Cylinder Head (2) Water Flange
TRANSMISSION
Apply liquid gasket (Three bond 1215 or equivalent)
on the both sides of the water flange gasket.
Replace the head gasket with a new one and place on
the cylinder block, be careful of its direction and side.
When using the head gasket shim, install the shim
on the cylinder head prior to the gasket.
HST
Before installing the tappets apply engine oil around
them.
IMPORTANT
REAR AXLE
Apply oil to the thread of screws and tighten in
several steps and the specified sequence shown
in the figure to the specified torque.
Check the torque after 30 minutes operation of the 704W256B
assembled engine, and adjust valve clearance.
(A) Gear Caser
BARKE
Tightening 3A139 103.0 ~ 107.9 Nm
torque 3A150 10.5 ~ 11.0 kgf-m
3A165 75.9 ~ 79.6 lb-ft
TD1300 78.5 ~ 83.4 Nm
FRONT AXLE
8.0 ~ 8.5 kgf-m
57.9 ~ 61.5 lb-ft
6.1.15 VALVE
1. Compress the valve spring and remove the collect STEERING
(2).
2. Remove the retainer (3), valve spring (4), valve stem
seal (5) and the valve (1).
HYDRAULIC
IMPORTANT
Do not interchange valves and valve parts.
Mark the cylinder number on the valve and the
parts to prevent interchanging.
ELECTRIC
(When reassembling)
704W257A
Apply oil to the stem of valve and install in the cylin-
der head.
(1) Valve (4) Valve Spring
Lubricate the valve and the parts after reassem-bling.
(2) Collect (5) Valve Stem Seal
(3) Retainer
INDEX
D704-W01 Jun. 2008 2-45

6.1.16 INJECTION PUMP

GENERAL
A. INJECTION PUMP REMOVAL

1. Remove the injection pipes (1) and the intake mani- 1
fold (2).
2. Remove the overflow pipe (3).
ENGINE
3. Remove the oil filler flange (4).
3
CLUTCH
4
704W2C5C
TRANSMISSION
(1) Injection Pipes (3) Overflow Pipe

(2) Intake Manifold (4) Oil Filler Flange
4. Remove the idle adjusting bolt (1) and oil filler flange
(3).
HST
5. Remove the manual stop lever cover (4).

REAR AXLE
1
BARKE
T46W298B
(1) Idle Adjusting Bolt

FRONT AXLE
(2) Fuel Injection Pump

(3) Oil Filler Flange
(4) Manual Stop Lever Cover
6. Remove the stop solenoid (1). Be careful not to drop

STEERING
the stop solenoid guide (2).

HYDRAULIC
2
ELECTRIC
T46W299A
(1) Stop Solenoid

(2) Stop Solenoid Guide
INDEX
2-46 D704-W01 Jun. 2008

GENERAL
7. Remove the fuel injection pump (1).
8. Keep the shims just like they were. 1
ENGINE
CLUTCH
704W2C6C
TRANSMISSION
B. INJECTION PUMP INSTALLATION
1. Apply the liquid gasket (Three bond 1215, 1104 or
equivalent) on the pump installation surface of the Injection pump

cylinder block.
HST
control rack lever
#
2. Install the shims as they were.
3. Make sure that the lever of the pump control rack is Fork lever 1
4#
on the outer side from the fork lever 1 when install-
REAR AXLE
ing the pump.
BARKE
704W2C8B
4. Tighten the nuts to the specified torque in several

steps in the correct sequence as shown in the figure. Tightening sequence of bolt or nut:
1 2 3 4
FRONT AXLE
Tightening M8 23.5 ~ 27.4 Nm
torque 4
2.4 ~ 2.8 kgf-m 1
17.3 ~ 20.2 lb-ft
5. Tighten the idle limit spring mounting bolt. STEERING
3 2
HYDRAULIC
704W2C9B
ELECTRIC
INDEX
D704-W01 Jun. 2008 2-47

C. INJECTION PUMP DISASSEMBLY

GENERAL
IMPORTANT
3
When disassembling the pump components, the
amount of fuel injection should be adjusted on a
4
designated bench.
ENGINE
Only authorized service personnel should disas-

semble or reassemble the fuel injection pump. 5
1
7
CLUTCH
2
8
TRANSMISSION
704W2D0B
(1) Pump Body (5) Delivery Valve

HST
(2) Control Rack (6) Tappet Roller

(3) Delivery Valve Holder (7) Plunger
(4) Delivery Valve Spring (8) Cylinder
REAR AXLE
D. NOZZLE HOLDER DISASSEMBLY

BARKE
2. Remove the nozzle holder (1) and take out the inter-
nal components.
a. Installation
FRONT AXLE
Before installing the nozzle, soak it in clean fuel.

When installing the push rod (4), be careful of its
direction.
STEERING
HYDRAULIC
T46W297A
ELECTRIC
(1) Nozzle Holder (5) Distance Piece

(2) Adjusting Washer (6) Nozzle
(3) Nozzle Spring (7) Nozzle Nut
(4) Push Rod
INDEX
2-48 D704-W01 Jun. 2008

E. GOVERNOR SPRING AND STOP SOLE-
GENERAL
NOID
a. Removal
1. Remove the idle adjusting bolt (1), stop solenoid fuel
injection pump (2) and oil filler flange (3).
3
ENGINE
3. Open the governor lever cover. 1
CLUTCH
T46W298B
(1) Idle Adjusting Bolt
TRANSMISSION
(2) Fuel Injection Pump
(3) Oil Filler Flange
(4) Manual Stop Lever Cover
4. Remove the governor spring using a hook after re-
HST
moving the throttle cover (1).
Be careful not to pop out the governor spring.
- The governor spring can also be removed by dis-
REAR AXLE
engaging it from the fork lever and then removing
it engaged with the throttle lever.
BARKE
T46W2A0A
FRONT AXLE
(1) Throttle Cover
STEERING
HYDRAULIC
ELECTRIC
INDEX
D704-W01 Jun. 2008 2-49

b. Installation
GENERAL
1. When installing the governor spring, make sure that

the governor spring 2 is installed on the inside of
governor spring 1.
CAUTION
ENGINE
Be careful of the direction of the governor spring

1. The longer side should face the governor fork.
If the governor spring is dropped during the
installation, the crankcase should be disas-
sembled again. Therefore, use a hook not to drop
CLUTCH
the governor spring.
2. The governor spring can also be installed by install-

ing one end to the throttle lever first and then the
other end to the long hole of the governor fork.
TRANSMISSION
HST
T46W2A5A
(1) Governor Spring 1 (3) Fork Lever 2

(2) Governor Spring 2
REAR AXLE
BARKE
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
2-50 D704-W01 Jun. 2008

6.1.17 CRANKCASE
GENERAL
A. REMOVAL
1. Straighten the locking washer (1) and remove the
crankshaft nut (2).
2. Remove the fan drive pulley (3).
ENGINE
Tightening Crankshaft 137.3 ~ 156.9 Nm
torque nut
14.0 ~ 16.0 kgf-m
101.3 ~ 115.7 lb-ft
CLUTCH
T46W2A2A
(1) Locking Washer (3) Fan Drive Pulley
TRANSMISSION
(2) Crankshaft Nut
3. Unscrew the crankcase mounting bolts to remove the

gear case.
HST
REAR AXLE
T46W2A3A
BARKE
B. INSTALLATION
1. Apply the liquid gasket (Three bond 1215 or
FRONT AXLE
equivalent) to the both sides of the gearcase gasket.
2. Apply the grease to the crankshaft oil seal (1) lip on
the gearcase and take care not to damage it when
installing.
3. Apply the grease on the O-ring (2) and attach it to
the gearcase to prevent it from coming off during STEERING
1
reassembling.
4. Make sure that the gearcase mounting bolts are in-
stalled at correct locations.
HYDRAULIC
2 T46W2A4A
IMPORTANT
In general, the bolt should be screwed as 1.5 (1) Crankshaft Oil Seal (2) O-ring
times as the diameter of the bolt in length.
ELECTRIC
5. Install all bolts and increase the tightening torque

gradually (in 2 to 3 steps).
Tightening M8 23.5 ~ 27.4 Nm

torque
2.4 ~ 2.8 kgf-m
17.3 ~ 20.2 lb-ft
INDEX
D704-W01 Jun. 2008 2-51

6.1.18 IDLE GEAR AND CRANK GEAR

GENERAL
A. REMOVAL
1. Remove the crankshaft collar (6), O-ring (5), oil
slinger (4) and oil pump drive gear 1 (3) in order.
2. Remove the idle gear (1).
ENGINE
3. Remove the crankshaft gear (2) with a puller set.
NOTE:
The oil pump drive gear (3) is only for the B series
engine. It is not installed to the A series engine.
CLUTCH
Instead, the crankshaft gear (2) of the A series en-

gine is longer than that of the B series as much as T46W2A6B
the thickness of the oil pump drive gear (3).
(1) Idle Gear (4) O-ring
TRANSMISSION
(2) Crankshaft Gear (5) Crankshaft Collar

(3) Oil Slinger
B. INSTALLATION
1. If necessary, heat the crankshaft (2) gear up to
HST
approx. 80C (176F) and insert it to the crankshaft.

2. Apply the oil to the O-ring (5) on the left figure.
3. The tapered face of the crankshaft collar should be
REAR AXLE
first to contact with the O-ring.

4. Install the idle gear while aligning the marks on the
all gears as shown in the figure.
IMPORTANT
Even the one misalignment of these marks on the
BARKE
gears can lead to fatal failure of the engine.

T46W2A7A
(1) Idle Gear

FRONT AXLE
(2) Crankshaft Gear

(3) Oil Pump Gear
(4) Fuel Camshaft Gear
(5) Valve Camshaft Gear
STEERING
HYDRAULIC
ELECTRIC
INDEX
2-52 D704-W01 Jun. 2008

6.1.19 VALVE CAMSHAFT
GENERAL
A. REMOVAL
1. Align the holes on the cam gear (2) with the bolt holes
and unscrew the bolts through the service hole with
a T handle wrench.
ENGINE
2. Remove the camshaft (1). Service
hole
3. Remove the cam gear (2).
B. INSTALLATION
CLUTCH
1. If necessary, heat the cam gear up to approx. 80C
(176F) and insert it to the camshaft (1).
T46W2A8A
(1) Camshaft (2) Cam Gear
TRANSMISSION
6.1.20 FUEL CAMSHAFT
A. REMOVAL
1. Remove the fuel camshaft stopper (1).
HST
REAR AXLE
T46W2F5A
BARKE
(1) Fuel Camshaft Stopper
2. Unscrew the fork lever holder screws and remove

the fuel camshaft (4), fork lever holder (5), fork lever
FRONT AXLE
1 (1) and fork lever 2 (2) at the same time.
3. Remove the fuel camshaft gear (3) from the fuel cam-
shaft if necessary.
B. INSTALLATION
STEERING
If necessary, heat the fuel camshaft gear up to
approx. 80C (176F) and insert it to the camshaft.
HYDRAULIC
T46W2A9A
(1) Fork Lever 1 (4) Camshaft

(2) Fork Lever 2 (5) Fork Lever Holder
(3) Fuel Injection Pump Gear
ELECTRIC
INDEX
D704-W01 Jun. 2008 2-53


GENERAL
A. OIL PAN AND OIL FILTER

1. Remove the oil pan.
2. Remove the oil strainer (1).
ENGINE
(When reassembling)
Be sure to install the O-ring (2) between the oil
strainer and the cylinder block.
CLUTCH
704W269A
(1) Oil Strainer (2) O-ring

TRANSMISSION
B. PISTON AND CONNECTING ROD

1. Remove the screws and the connecting rod cap.
2. Push out the rod and piston assembly.
(When reassembling)
HST
Apply oil to the crankpin bearing, cylinder wall and

connecting rod cap screw.
Insert the connecting rod and piston assembly with
REAR AXLE
the mark on the rod facing the injection pump, using

a piston ring compressor.
IMPORTANT
Mark the cylinder number on the piston and con- 704W270A
necting rod to prevent interchanging.

BARKE
Carefully insert the piston and ring assembly in

the cylinder. Be careful when compressing the
rings not to damage the chrome-plate on the pis-
ton rings.
FRONT AXLE
If the connecting rod cap screws can not be

screwed to the end by hand, replace the screw.
STEERING
HYDRAULIC
ELECTRIC
INDEX
2-54 D704-W01 Jun. 2008

C. PISTON RING AND PISTON PIN
GENERAL
1. Remove the piston rings with a piston ring replacing
tool.
2. Remove the piston pin.
ENGINE
CLUTCH
704W271A
(1) Piston Pin (5) Second Ring
TRANSMISSION
(2) Piston (6) Oil Ring
(3) Piston Pin Snap (7) Connecting Rod
Ring
(4) Top Ring
(When reassembling)
HST
Clean all the parts before assembling.
Heat the piston in approx. 80C (176F) of oil for 10
~ 15 minutes, when inserting the piston pin into the
REAR AXLE
piston.
Install the piston and connecting rod with the mark
FW on the piston towards the flywheel and the mark
on connecting rod towards the injection pump.
Install the piston rings with their manufactures mark
to the top of piston.
BARKE
Install the expander in the oil ring with its gap oppo-
site to the gap of oil ring.
Install the top ring with its gap at 1.57 rad (90) from 704W272A
the piston pin to the exhaust port.
FRONT AXLE
Install the second ring and the oil ring with their gap
at every 2.09 rad (120).
STEERING
HYDRAULIC
704W273A
(7) Connecting Rod (11) Expander Joint

ELECTRIC
(8) Connecting Rod Cap (12) Oil Ring Gap

(9) Casting Mark (13) Manufacturers Mark
(10) Marks
INDEX
D704-W01 Jun. 2008 2-55

6.1.22 CRANKSHAFT
GENERAL
A. FLYWHEEL
1. Install the stopper to the flywheel and loosen the screw.
2. Remove the flywheel stopper and the flywheel.
ENGINE
(When reassembling)
Clean the end of the crankshaft and the mating sur-
face of the flywheel.
Apply oil to flywheel screws.
Fit the flywheel hole to crankshaft hole and tighten
CLUTCH
the flywheel bolts to specified torque.

704W274A
NOTE:
Screw longer screws to the flywheel to carry it if
TRANSMISSION
needed.
Tightening Flywheel 98.1 ~ 107.9 Nm

torque screw
10.0 ~ 11.0 kgf-m
72.3 ~ 79.6 lb-ft
HST
B. BEARING CASE COVER

Loosen the screw first inside and next outside, and lift
REAR AXLE
the cover (1) by screwing the two screws gradually and

evenly, referring to the photo.
(When reassembling)
Apply grease to the oil seal lip. Take care that the lip
seal is is not rolled while installing.
BARKE
Tightening Bearing 23.5 ~ 27.5 Nm

torque case
2.4 ~ 2.8 kgf-m
cover screw
17.4 ~ 20.3 lb-ft
FRONT AXLE
up
STEERING
T46W2D3B
HYDRAULIC
ELECTRIC
INDEX
2-56 D704-W01 Jun. 2008

C. CRANKSHAFT
GENERAL
1. Remove the bearing case screw 2.
2. Pull out the crankshaft, taking care not to damage
the crankshaft bearing 1.
(When reassembling)
ENGINE
Apply oil to the bearing case screw 2.
Clean the oil passage of the crankshaft with com-
pressed air.
Bearing 3A139 68.7 ~ 73.6 Nm
CLUTCH
case 3A150
7.0 ~ 7.5 kgf-m
screw 2 3A165
50.6 ~ 54.2 lb-ft 704W276A
TD1300 63.8 ~ 68.7 Nm

(1) Bearing Case Scraw 2
6.5 ~ 7.0 kgf-m
TRANSMISSION
47.0 ~ 50.6 lb-ft
D. MAIN BEARING CASE

1. Remove the bearing case screws 1 (4) and remove
HST
the main bearing case 1, 2, 3 (1, 2, 3).
2. Remove the thrust bearing from the flywheel end
bearing case.
REAR AXLE
BARKE
704W277A
(1,2,3) Main Bearing Case Assembly 1, 2, 3

(4) Bearing Case Screw 1
FRONT AXLE
(5) Thrust Bearings
IMPORTANT
Mark the location line to the bearing case, to pre-
vent interchanging. STEERING
(When reassembling)
Clean the parts and the oil passage of the bearing
case.
HYDRAULIC
Apply oil to the journal, bearing inserts and the bear-

ing case screws.
Place the thrust bearings on the bearing case with
their oil groove outside.
Install the main bearing case with the mark FLY
ELECTRIC
WHEEL toward the flywheel. 704W278A
Bearing 3A139 46.1 ~ 51.0 Nm (6) Bearing Case

case 3A150
4.7 ~ 5.2 kgf-m
screw 1 3A165
34.0 ~ 37.6 lb-ft
INDEX
TD1300 29.4 ~ 34.3 Nm

3.0 ~ 3.5 kgf-m
21.7 ~ 25.3 lb-ft
D704-W01 Jun. 2008 2-57
6.2 INSPECTION FOR OVERHAUL

GENERAL
6.2.1 CYLINDER HEAD AND VALVE

A. CYLINDER HEAD SURFACE FLATNESS
ENGINE
2. Place a straight edge on the cylinder head and mea-

sure the clearance with a feeler gage as shown in
the figure.
place the cylinder head.
CLUTCH
IMPORTANT
704W279A
Do not place the straight edge on the combus-
tion chamber.
TRANSMISSION
Flatness Allowable 0.05 mm

limit
0.002 in.
NOTE:
When installing the main bearing case cover, the UP
mark on it should be at the highest position so that
HST
its holes are aligned with the holes of the cylinder

block.
REAR AXLE
196W2B0A
B. CYLINDER HEAD SURFACE FLAW

BARKE
1. Prepare an air spray red check.

2. Clean the cylinder head surface with the detergent
(B).
FRONT AXLE
3. Spray the cylinder head surface with the red perme-

ative liquid (A).
4. Wash away the red permeative liquid on the cylinder
head surface with the detergent (B) after ten minutes.
5. Spray the cylinder head surface with the white de-
STEERING
veloper (C).
6. If any flaw is found such as a red mark, replace the
cylinder head.
704W280A
(A) Red Permeative Liquid

HYDRAULIC
(B) Detergent
(C) White Developer
ELECTRIC
INDEX
2-58 D704-W01 Jun. 2008

C. VALVE STEM CLEARANCE
GENERAL
1. Remove the carbon from the valve guide.
2. Measure the valve stem O.D. with an outside
micrometer.
3. Measure the valve guide I.D. of cylinder head, and
calculate the clearance.
ENGINE
place the valve guide of the valve.
Valve stem Factory 3A139 0.040 ~ 0.070 mm

clearance spec. 3A150
CLUTCH
3A165 0.00157 ~ 0.00276 in.
TD1300 0.025 ~ 0.055 mm
704W281A
0.00098 ~ 0.00216 in.
TRANSMISSION
0.004 in.
Valve guide Factory 3A139 8.015 ~ 8.030 mm
bore I.D. spec. 3A150
3A165 0.31555 ~ 0.31614 in.
TD1300 8.0 ~ 8.015 mm
0.31496 ~ 0.31555 in.
HST
Valve stem Factory 7.960 ~ 7.975 mm
O.D. spec.
0.31339 ~ 0.31398 in.
REAR AXLE
D. VALVE RECESSING
12
1. Clean the cylinder head, the valve face and the seat.
11
10
2. Insert the valve in the guide.

9
3. Measure the valve recessing with a depth gauge.

8
7
BARKE
4. If the recessing exceeds the allowable limit, replace
6
the valve and check the valve seating.

5
4
3A139
3
Valve Factory 0.2 ~ 0.5 mm

3A150
2
recessing spec.
FRONT AXLE
3A165 0.0079~ 0.0197 in.
1
0
TD1300 1.1 ~ 1.3 mm

0.0433 ~ 0.0512 in.
Allowable 3A139 0.8 mm 704W282A
limit 3A150
0.0315 in.
3A165 STEERING
TD1300 1.6 mm
0.0630 in.
HYDRAULIC
ELECTRIC
INDEX
D704-W01 Jun. 2008 2-59

E. VALVE SEAT
GENERAL
1. Coat the valve face lightly with red lead and put the
valve on its seat to check the contact.
2. If the valve does not seat all the way around the valve
seat or the valve contact is less than 70%, correct
the valve seating as follows.
ENGINE
3. Apply compound on the valve face evenly.

4. Put the valve on its seat hold it with the valve flapper.
5. Turn and lap the valve back and forth on the valve
seat to lap.
CLUTCH
6. Remove the compound and clean the valve and the

seat.
704W283A
7. Apply oil on the valve face and finish to complete
fitting.
TRANSMISSION
8. Repeat lapping until the valve seats correctly.

HST
REAR AXLE
BARKE
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
2-60 D704-W01 Jun. 2008

6.2.2 VALVE SPRING
GENERAL
A. VALVE SPRING
1. Measure the free length of the spring with venire
calipers.
2. Place the spring on a spring compression tester and
ENGINE
compress to the specified length, and get the tension.
replace the valve spring.
CLUTCH
Tension Factory 17.7 N / 35.15 mm
spec.
12.0 kgf / 35.15 mm
26.5 lbs / 1.3839 in.
704W284A
Allowable 100 N / 35.15 mm
TRANSMISSION
limit 10.2 kgf / 35.15 mm
22.5 lbs / 1.3839 in.
Free Factory 41.7 ~ 42.2 mm
length spec.
1.6417 ~ 1.6614 in.
Allowable 41.2 mm
HST
limit
1.622 in.
REAR AXLE
B. VALVE SPRING SQUARENESS (TILT)
1. Place the spring on the surface plate and a square
at its side.
2. Measure the maximum distance A (See figure), ro-
tating spring.
BARKE
3. If the measurement exceeds the allowable limit
replace.
Valve spring Allowable 1.0 mm

square ness limit
FRONT AXLE
0.039 in.
704W285A
STEERING
HYDRAULIC
ELECTRIC
INDEX
D704-W01 Jun. 2008 2-61

6.2.3 CHECKING OIL CLEARANCE BE-

GENERAL
TWEEN ROCKER ARM SHAFT AND

BUSHING
A. ROCKER ARM BUSHING AND SHAFT
CLEARANCE
ENGINE
1. Measure the rocker arm I.D. with an inside micrometer.

2. Measure the rocker arm shaft O.D. with an outside
micrometer.
the rocker arm.
CLUTCH
4. If the clearance still exceeds the allowable limit after

replacing the rocker arm replace the rocker arm shaft. 9
10
11
Clearance Factory 3A139 0.020 ~ 0.070 mm

TRANSMISSION
spec. 3A150
3A165 0.00079 ~ 0.00276 in.
704W286A
TD1300 0.014 ~ 0.050 mm
0.00055 ~ 0.00197 in.
0.0059 in.
HST
Rocker arm Factory 3A139 18.955 ~ 18.980 mm

shaft O.D. spec. 3A150
3A165 0.74626 ~ 0.74724 in.
TD1300 13.973 ~ 13.984 mm
REAR AXLE
0.5501 ~ 0.5506 in.

Rocker Factory 3A139 19.000 ~ 19.025 mm
arm I.D. spec. 3A150
3A165 0.74803 ~ 0.74902 in.
TD1300 13.998 ~ 14.023 mm
0.5513 ~ 0.5529 in.
BARKE
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
2-62 D704-W01 Jun. 2008

6.2.4 TIMING GEARS AND CAMSHAFTS
GENERAL
A. TIMING GEAR BACKLASH
1. Set a dial indicator (lever type) with its tip on the gear
tooth.
2. Move the gear to measure the backlash, holding its
ENGINE
mating gear.
3. If the backlash exceeds the allowable limit, check
the oil clearance of the shafts and the gear.
4. If the oil clearance is improper, replace the gear.
CLUTCH
Clearance Factory 0.04 ~ 0.11 mm
spec. 0.0016 ~ 0.0043 in. 704W287A
Allowable 0.15 mm
limit 0.0059 in.
TRANSMISSION
B. IDLE GEAR SIDE CLEARANCE
1. Pull the idle gear collar 2 (1) and push the idle gear
(2) to each end.
HST
2. Measure the clearance A between the idle gear and
the idle gear collar 2 with a feeler gauge.
the idle gear collar 1 (3).
REAR AXLE
Side Factory 0.20 ~ 0.51 mm
clearance spec.
0.0079 ~ 0.0201 in.
Allowable 0.9 mm
limit
0.035 in.
BARKE
704W288B
FRONT AXLE
(1) Idle Gear Collar 2 (2) Idle Gear
C. CAM GEAR SIDE CLEARANCE STEERING

1. Pull the cam gear (2) with the camshaft (1) to its end.
2. Measure the clearance A between the cam gear (2)
and the camshaft stopper (3).
HYDRAULIC


clearance spec.
0.0028 ~ 0.0087 in.
ELECTRIC
Allowable 0.3 mm
limit 0.0118 in.
704W289A
(1) Camshaft (3) Camshaft Stopper

(2) Cam Gear
INDEX
D704-W01 Jun. 2008 2-63

D. INJECTION PUMP GEAR SIDE CLEAR-

GENERAL
ANCE
1. Pull the fuel camshaft and pull the injection pump A
gear (1) to each end.
2. Measure the clearance A between the injection pump
gear (1) and the snap ring (2) on the fuel camshaft.
ENGINE
3. If the clearance exceeds the allowable limit, check

the gear, the bearing and the key.
clearance spec.
0.0059 ~ 0.0224 in.
CLUTCH
Allowable 0.9 mm
limit
0.035 in. 704W290A
(1) Injection Pump Gear (2) Snap Ring

TRANSMISSION
E. IDLE GEAR OIL CLEARANCE

1. Measure the idle gear shaft O.D. with an outside
micrometer.
2. Measure the idle gear bushings I.D. with an inside
HST
micrometer.
the bushing.
REAR AXLE
Oil Factory 3A139 0.025 ~ 0.066 mm

3A165 0.00098 ~ 0.00260 in.
TD1300 0.02 ~ 0.054 mm
0.00078 ~ 0.00212 in.
704W291A
BARKE
0.0039 in.
Shaft Factory 3A139 37.959 ~ 37.975 mm
O.D. spec. 3A150
3A165 1.49445 ~ 1.49508 in.
FRONT AXLE
TD1300 27.967 ~ 27.980 mm

1.10106 ~ 1.10157 in.
Bushing Factory 3A139 38.000 ~ 38.025 mm
I.D. spec. 3A150
3A165 1.49606 ~ 1.49705 in.
TD1300 28.0 ~ 28.021 mm
STEERING
1.10236 ~ 1.10319 in.
F. REPLACING IDLE GEAR BUSHINGS

HYDRAULIC
1. Press out the bushings using an idle gear bushing

replacing tool.
2. Clean the bushings and the bore, and apply oil to
them.
ELECTRIC

INDEX
704W292A
2-64 D704-W01 Jun. 2008

G. CAMSHAFT OIL CLEARANCE
GENERAL
1. Measure the I.D. of the camshaft bore on the crank-
case with an inside micrometer.
2. Measure the O.D. of the camshaft journal with an
outside micrometer.
ENGINE
the shaft.
Oil Factory 0.050 ~ 0.091mm

clearance spec.
0.00197 ~ 0.00358 in.
CLUTCH
Allowable 0.15 mm
limit
0.0059 in.
704W293A
Journal Factory 39.934 ~ 39.950 mm
O.D. spec.
1.57221 ~ 1.57284 in.
TRANSMISSION
Bore Factory 40.000 ~ 40.025 mm
I.D. spec.
1.57480 ~ 1.57579 in.
H. CAMSHAFT ALIGNMENT
HST
1. Support the camshaft with V blocks on the surface
plate at both end journals and set a dial indicator
with its tip on the intermediate journal.
2. Rotate the camshaft in the V block and get the ec-
REAR AXLE
centricity (half of the measurement).
3. If the eccentricity exceeds the allowable limit, replace
the camshaft.
Eccentricity Allowable 0.05 mm

limit
0.002 in.
BARKE
704W294A
FRONT AXLE
I. CAM HEIGHT
1. Measure the height of the camshaft lobes at their
largest. O.D. with an outside micrometer.
replace the camshaft. STEERING
Cam 3A139 (IN.) Specification 33.59 mm

height 3A150 1.3224 in.
3A165 33.54 mm
Allowable
limit
HYDRAULIC
1.3205 in.
(EX.) Specification 33.69 mm
1.3264 in.
Allowable 33.64 mm
limit 1.3244 in. 704W295A
TD1300 (IN.) Specification 33.5 ~ 33.6 mm

ELECTRIC
1.31889 ~ 1.32283 in.

Allowable 33.45 mm
limit 1.3169 in.
(EX.) Specification 33.5 ~ 33.6 mm
1.31889 ~ 1.32283 in.
Allowable 33.45 mm
INDEX
limit 1.3169 in.
D704-W01 Jun. 2008 2-65


GENERAL
A. PISTON PIN BORE

1. Measure the I.D. of piston pin bore in piston (length-
wise and widthwise of the piston) with a cylinder
gauge.
ENGINE

place the piston.
Piston pin 3A139 Factory 25.000 ~ 25.006 mm

bore I.D. 3A150 spec. 0.9843 ~ 0.9845 in.
3A165
CLUTCH
Allowable 25.03 mm
limit 0.9854 in. 704W296A
TD1300 Factory 23.0 ~ 23.013 mm

spec. 0.9055 ~ 0.9060 in.
TRANSMISSION
Allowable 23.053 mm
limit 0.9076 in.
B. PISTON PIN AND BRUSHING CLEARANCE

HST
1. Measure the piston pin O.D. with an outside microme-

ter.
REAR AXLE
micrometer.
3. If the clearance exceeds the allowable limit with new
bushing, replace the piston pin.
9
10
Piston pin Factory spec. 0.014 ~ 0.038 mm

11
and
0.00055 ~ 0.00150 in.
BARKE
bushing
clearance Allowable limit 0.15 mm
0.0059 in.
704W297A
Piston pin Factory 3A139 25.002 ~ 25.011 mm
O.D. spec. 3A150
FRONT AXLE
3A165 0.98433 ~ 0.98469 in.

TD1300 23.002 ~ 23.011 mm
0.90559 ~ 0.90594 in.
Bushing Factory 3A139 25.025 ~ 25.040 mm
I.D. spec. 3A150
3A165 0.98524 ~ 0.98583 in.
STEERING
TD1300 23.025 ~ 23.040 mm

0.90650 ~ 0.90709 in.
HYDRAULIC
C. REPLACING PISTON PIN BUSHING

1. Press out the bushing, using a piston pin bushing
replacing tool.
2. Clean the new bushing and the bore and apply oil to
them.
ELECTRIC
3. Press in the bushing, using the replacing tool.
IMPORTANT
Align the oil holes of the connecting rod and the
bushing.
INDEX
704W298A
2-66 D704-W01 Jun. 2008

D. PISTON RING END GAP
GENERAL
1. Push down the ring into the cylinder to the lower limit
of ring travel in the assembled engine with a piston.
2. Measure the ring gap with a feeler gauge.
3. If the gap exceed the allowable limit, replace the pis-
ton ring.
ENGINE
Piston 2nd Factory 3A139 0.55 ~ 0.70 mm
ring ring spec. 3A150
3A165 0.0217 ~ 0.0276 in.
end
gap TD1300 0.25 ~ 0.40 mm
CLUTCH
0.0098 ~ 0.05575 in.
Allowable limit 1.25 mm 704W299A
0.0492 in.
Top Factory spec. 0.25 ~ 0.40 mm
TRANSMISSION
ring
0.0098 ~ 0.0157 in.
Oil Factory 3A139 0.25 ~ 0.40 mm
ring spec. 3A165
0.0098 ~ 0.0157 in.
3A150 0.20 ~ 0.40 mm
0.0078 ~ 0.0157 in.
HST
Top Allowable limit 1.25 mm
ring,
oil ring 0.0492 in.
REAR AXLE
E. PISTON RING CLEARANCE
1. Clean the ring and the ring grooves, and install each
ring in its groove.
2. Measure the clearance between the ring and the
BARKE
groove with a feeler gauge.
the piston ring.
FRONT AXLE
the new ring, replace the piston.
Piston 2nd Factory 3A139 0.04 ~ 0.08 mm

ring ring spec. 3A150
clear- 3A165 0.00157 ~ 0.00315 in.
ance TD1300 0.065 ~ 0.10 mm 704W2A0A
STEERING
0.00256 ~ 0.00394 in.
0.0059 in.
Oil Factory 3A139 0.02 ~ 0.06 mm
HYDRAULIC
ring spec. 3A150

3A165 0.00079 ~ 0.00236 in.
TD1300 0.02 ~ 0.06 mm
0.0008 ~ 0.00236 in.
ELECTRIC
0.0059 in.
INDEX
D704-W01 Jun. 2008 2-67

F. CONNECTING ROD ALIGNMENT

GENERAL
1. Remove the connecting rod bearing and install the

bearing cap.
2. Install the piston pin in the connecting rod.
3. Install the connecting rod on the connecting rod align-
ment tool.
ENGINE
4. Put a gauge over the piston pin and move it against

the face plate.
5. If the gauge does not fit squarely against the face
plate, measure the space between the pin of the
CLUTCH
gauge and the face plate.

place the connecting rod. 704W2A1A
Space between Allowable 0.05 mm (0.0020 in.)

TRANSMISSION
gauge pin and limit

at 100 mm (3.94 in.)
face plate
of gauge pin span
HST
REAR AXLE
BARKE
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
2-68 D704-W01 Jun. 2008

6.2.6 CRANKSHAFT
GENERAL
A. FLYWHEEL DEFLECTION AND CRANK-
SHAFT END PLAY
1. Set a dial indicator with its tip on the rear friction face
of the flywheel near the edge.
ENGINE
2. Turn the flywheel and measure the deflection or the
uneven wear.
move the flywheel and check the mating faces of the
crankshaft and flywheel.
CLUTCH
4. If scored of worn excessively, regrind or replace the
flywheel.
704W2A2A
5. Move the crankshaft with flywheel back and forth to
each end and measure the end play.
TRANSMISSION
6. If the play exceeds the allowable limit, replace the
side bearing.
Deflection Allowable 0.05 mm

limit
0.0020 in.
End play Factory 0.15 ~ 0.31 mm
HST
spec. 0.0059 ~ 0.0122 in.
Allowable 0.5 mm
limit 0.020 in.
REAR AXLE
B. CRANKSHAFT ALIGNMENT
1. Support the crankshaft with V blocks on the surface
plate at its front and rear journals and set a dial indi-
BARKE
cator with its tip on the intermediate journal.
2. Rotate the crankshaft in the V blocks and get the
misalignment (half of the measurement).
3. If the misalignment exceeds the allowable limit, re-
FRONT AXLE
Misalignment Allowable 0.08 mm

limit
0.0031 in.
704W2A3A STEERING
HYDRAULIC
ELECTRIC
INDEX
D704-W01 Jun. 2008 2-69

C. CRANKSHAFT JOURNAL AND BEARING 1

GENERAL
OIL CLEARANCE
1. Measure the I.D. of the crankshaft bearing 1 with an
inside micrometer.
2. Measure the O.D. of the crankshaft journal with an
outside micrometer.
ENGINE
3. If the clearance exceeds the allowable limit, replace 9

10
11
the bearing referring to Replacing Crankshaft Bear-

ing 1.
Oil Factory 0.040 ~ 0.118 mm

CLUTCH
clearance spec.
0.00157 ~ 0.00465 in.
Allowable 0.20 mm 704W2A4A
limit
0.0079 in.
TRANSMISSION
Journal Allowable 51.921 ~ 51.940 mm

O.D. limit 2.04414 ~ 2.04488 in.
Bearing 1 Allowable 51.980 ~ 52.039 mm
I.D. limit 2.04646 ~ 20.4878 in.
HST
D. REPLACING CRANKSHAFT BEARING 1

1. Press out the crankshaft bearing 1 using replacing
tool.
REAR AXLE
2. Clean a new crankshaft bearing 1 and bore, and ap-

ply engine oil to them.
3. Press fit a new bearing 1 using a inserting tool, tak-
ing due care to see that the seam of bearing 1 faces
the exhaust manifold side.
BARKE
Allowable limit 4.5 mm (0.177 in.)

FRONT AXLE
704W2A5A
(1) Seam
STEERING
HYDRAULIC
ELECTRIC
INDEX
2-70 D704-W01 Jun. 2008

E. CRANKSHAFT JOURNAL AND BEARING 2
GENERAL
OIL CLEARANCE
1. Put plasticgauge lengthwise in the center of the
journal.
2. Install the bearing cap and tighten the screw to the
specified torque once, and remove the cap again.
ENGINE
3. Measure the amount of the flattening with the scale
and get the oil clearance.
replace the bearing.
CLUTCH
Oil Factory 0.040 ~ 0.104 mm
clearance spec. 704W2A6A
0.00157 ~ 0.00409 in.
Allowable 0.20 mm
limit
TRANSMISSION
0.0079 in.
Journal Allowable 51.921 ~ 51.940 mm
O.D. limit 2.04414 ~ 2.04488 in.
Bearing 2 Factory 51.980 ~ 52.025 mm
I.D. spec 2.04646 ~ 2.04823 in.
HST
F. CRANK PIN AND CONNECTING ROD
BEARING 2 OIL CLEARANCE
REAR AXLE
1. Put a strip of Plastigage lengthwise in the center of
the crank pin.
2. Install the connecting rod and tighten the screws to
the specified torque once, and remove the cap again.
3. Measure the amount of the flattening with the scale
BARKE
the bearing.
FRONT AXLE
Oil Factory 3A139 0.025 ~ 0.087 mm
3A165 0.00098 ~ 0.00343 in.
704W2A7A
TD1300 0.035 ~ 0.093 mm

0.0014 ~ 0.0037 in.
Allowable limit 0.20 mm STEERING
0.0079 in.
Journal Factory 3A139 46.959 ~ 46.975 mm
O.D. spec. 3A150
3A165 1.84876~ 1.84947 in.
TD1300 43.959 ~ 43.975 mm
HYDRAULIC
1.73067 ~ 1.73130 in.

Bushing 1 Factory 3A139 47.000 ~ 47.046 mm
I.D. spec. 3A150
3A165 1.85040 ~ 1.85221 in.
TD1300 44.010 ~ 44.052 mm
ELECTRIC
1.73268 ~ 1.73433 in.

INDEX
D704-W01 Jun. 2008 2-71

6.2.7 CYLINDER BORE

GENERAL
A. CYLINDER BORE DIAMETER

1. Measure the cylinder liner I.D. at sit positions shown
in the figure to find the maximum wear.
TD1300 82.000 ~ 82.022 mm

ENGINE
3.2283 ~ 3.2292 in.

3A139 80.000 ~ 80.022 mm
3.1496 ~ 3.1505 in.
CLUTCH
3A150 83.000 ~ 83.022 mm

3.2677 ~ 3.2690 in.
704W2A8A
3A165 87.000 ~ 87.022 mm
3.4252 ~ 3.4261 in.
TRANSMISSION
HST
REAR AXLE
704W2A8A
(A) Axial Direction

(B) Transverse Direction
BARKE
1,2,3 Measuring Points

FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
2-72 D704-W01 Jun. 2008

GENERAL
A. ENGINE OIL PRESSURE
1. Remove the oil pressure switch. Install the adapter
and pressure tester in its place.
2. Start the engine and run it until it is warmed up. Mea-
ENGINE
sure the oil pressure at both idling and rated speed.
check the oil level, oil filter, oil pump relief valve, oil
passages and oil clearance.
CLUTCH
Engine At idle Factory spec. more than 68.6 kPa
speed
oil 0.7 kgf/cm
pres-
7.11 psi T46W262A
TRANSMISSION
sure
At rated 3A139 Factory 245 ~ 441 kPa
speed 3A150 spec.
2.5 ~ 4.5 kgf/cm
3A165
35.6 ~ 64.0 psi
Allowable 245 kPa
limit 2.5 kgf/cm
HST
35.6 psi
TD1300 Factory 245 ~ 441 kPa
spec.
2.5 ~ 4.5 kgf/cm
REAR AXLE
35.5 ~ 64.0 psi
Allowable 245 kPa
limit 2.5 kgf/cm
35.6 psi
BARKE
(Reference)
Tightening Oil 14.7 ~ 19.6 Nm

torque pressure
1.5 ~ 2.0 kgf-m
FRONT AXLE
switch
10.8 ~ 14.5 lb-ft
B. OIL FILTER
1. Drain the engine oil and remove the oil filter to check it.
2. Check the relief valve for dirt, and the seat (2) and STEERING
ball (1) for damage.
3. If damaged, replace the filter.
4. Check the free length of spring (3).
HYDRAULIC
5. If it is less than the allowable limit, replace it.
Spring free Factory 35 mm

length spec
1.38 in.
Allowable 30 mm
ELECTRIC
limit 1.18 in.

INDEX
704W2B1A
(1) Relief Valve Ball (3) Relief Valve Spring

(2) Relief Valve Seat
D704-W01 Jun. 2008 2-73
C. ROTOR AND LOBE CLEARANCE OF OIL

GENERAL
PUMP
1. Measure the clearance between the outer and inner
rotor with a feeler gauge.
2. Measure the clearance between the outer and the
housing with a feeler gauge.
ENGINE

the pump.
Outer and Factory 0.10 ~ 0.16 mm

inner rotor spec.
0.0039 ~ 0.0063 in.
CLUTCH
clearance
Allowable 0.20 mm
limit 704W2B2A
0.0079 in.
Outer and Factory 0.11 ~ 0.19 mm
TRANSMISSION
inner spec. 0.0043 ~ 0.0075 in.

housing
clearance Allowable 0.25 mm
limit 0.0098 in.
HST
REAR AXLE
704W2B3A
D. ROTOR END CLEARANCE OF OIL PUMP

BARKE
1. Put a strip of plastigage on the rotor and assemble

the pump.
2. Disassemble the pump and measure the amount of
FRONT AXLE
the flattening with the scale to get the clearance.

the pump.
End Factory 0.105 ~ 0.150 mm

clearance spec.
0.00413 ~ 0.00591 in.
STEERING
Allowable 0.20 mm
limit
0.00781 in.
704W2B4A
HYDRAULIC
ELECTRIC
INDEX
2-74 D704-W01 Jun. 2008

GENERAL
A. CHECKING ADJUSTING
FAN BELT
1. Measure the deflection, depressing the belt halfway
ENGINE
between the fan drive pulley and the alternator pul-
ley at 78 N (8 kgf, 18 lbs) of force.
2. If the deflection is not between the factory specifica-
tions, loosen the bolts and nuts, and relocate the al-
ternator to adjust.
CLUTCH
the belt.
Belt Factory 7 ~ 9 mm
tension spec 0.28 ~ 0.35 in. 704W2B5A
TRANSMISSION
(direction)
at 78 N (8 kgf, 18 lbs)
of force
RADIATOR WATER TIGHTNESS

1. Fill radiator with water to the specified amount and
HST
warm up the engine.
2. Set a radiator tester and raise the water pressure to
the specified pressure.
3. Check the radiator for water leaks.
REAR AXLE
4. Pinhole water leaks may be repaired with radiator
cement. Larger leaks require radiator replacement.
Radiator Factory No leaks at 137 kPa

water spec
tightness (1.4 kgf/cm, 20 psi)
BARKE
704W2B6A
643W2D1A
RADIATOR CAP TIGHTNESS
FRONT AXLE
1. Attach a radiator tester on the radiator cap.
2. Apply 88 kPa (0.9 kgf/cm, 13 psi) of pressure and
measure the pressure for 10 seconds.
3. If the pressure falls below 59 kPa (0.6 kgf/cm, 9 psi),
replace the radiator cap.
STEERING
Radiator Factory More than 10 seconds
cap spec
for pressure fall
tightness
from 88 ~ 59 kPa
HYDRAULIC
(0.9 ~ 0.6 kgf/cm, 13 ~ 9 psi)
704W2B7A
ELECTRIC
INDEX
D704-W01 Jun. 2008 2-75

B. DISASSEMBLING AND ASSEMBLING

GENERAL
THERMOSTAT
2. Take out the thermostat (1).
ENGINE
(When reassembling)
Apply liquid gasket (Three Bond 1215 or equivalent)
to the gasket.
CLUTCH
704W2B8A
(1) Thermostat (2) Thermostat Cover

TRANSMISSION
WATER PUMP
NOTE:
If the coolant is leaked from the hole indicated by
the arrow in the figure, it means that the mechanical
seal is damaged.
HST
a. Removal
1. Remove the fan and fan pulley.
REAR AXLE
2. Remove the water pump body from the gear case

cover.
4. Remove the impeller and water pump body (3). S76W2P9B
5. Remove the impeller from the water pump shaft.

BARKE
6. Remove the mechanical seal (4).
b. Installation
FRONT AXLE
CAUTION
The components of the water pump is firmly as-
sembled together and they cannot be easily dis-
assembled or assembled without a special
STEERING
equipement. Therefore, it is recommended to re-

place the whole water pump assembly.
T46W2F4A
(1) Water Pump Flange (4) Mechanical Seal

HYDRAULIC
(2) Water Pump Bearing (5) Impeller

(3) Water Pump Body
ELECTRIC
INDEX
2-76 D704-W01 Jun. 2008

C. SERVICING
GENERAL
THERMOSTAT VALVE OPENING TEMPERA-
TURE
1. Suspend the thermostat in the water by a string with
its end inserted between the valve and seat.
2. Heating the water gradually, read the temperature
ENGINE
when the valve opens and then when the valve opens
to approx. 8 mm (0.315 in.).
3. If the measurements are not within the factory speci-
fications, replace the thermostat.
CLUTCH
Opening Factory 71 1.5 C
temperature spec. (160 3 F) 704W2C0A
at beginning
TRANSMISSION
Lower than 85 C (185 F)
At 8 mm (0.315 in.)
Of opening
HST
REAR AXLE
BARKE
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
INDEX
D704-W01 Jun. 2008 2-77

6.2.10 FUEL SYSTEM

GENERAL
A. INJECTION NOZZLE
CAUTION
Never contact with spraying diesel fuel under
ENGINE
pressure, pressure, which can have sufficient

force to penetrate the skin, causing serious per-
sonal injury.
Be sure nobody is in direction of the spray.
CLUTCH
FUEL INJECTION PRESSURE

TRANSMISSION
3. If the measurement is not within the factory specifica-

tions, adjust with the adjustment washer (1) inside
the nozzle holder.
(Reference)
Each adjustment washer of 0.1 mm (0.004 in.) will ad-
just the fuel injection pressure by approx. 10 kgf/cm.
HST
Fuel Factory 14.71 MPa

injection spec.
150~160 kgf/cm 704W2C3A
pressure
REAR AXLE
2,134~2,276 psi
(1) Adjustment Washer
FUEL TIGHTNESS OF NEEDLE VALVE SEAT

1. Connect the injection nozzle to the nozzle tester.
BARKE
2. Apply a pressure 130 kgf/cm (12.75 MPa, 1849 psi).

Keep the nozzle under this pressure for 10 seconds.
Check to see if fuel leaks from the nozzle.
3. If the fuel should leak, replace the nozzle.
FRONT AXLE
STEERING
704W2C4A
HYDRAULIC
ELECTRIC
INDEX
2-78 D704-W01 Jun. 2008

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3. 4A,3B,4B Series Workshop Manual
DK35/40(C)/45(C)SE ENGINE - ENGINE IDENTIFICATION
1. Engine identification
SAFETY FIRST
1.2 Engine number (B)
The engine number is stamped near the fuel injection
pump on the cylinder block, in case the bar code is not
GENERAL
available due to damage.
Important
The engine number is necessary information that
ENGINE
is requested on the warranty registration form.
This number should be on the form as well as the
tractor number and the amount of time used.
CLUTCH
T46W201B
Engine number assignment standard
H D 8 1 0 0 0 0 1
TRANSMISSION
1.1 Engine EPA decal (A)
Serial number
HST
Engine model
D78 3B183LWM
REAR AXLE
D82 3B183LWH
D79 4A200LWM
D83 4A200LWH
D80 4A220LWM
BRAKE
D84 4A220LWH
T46W202C
D81 4B243LWM
FRONT AXLE
This aluminum decal is riveted on the engine cylinder D85 4B243LWH
head cover. This provides the information such as
model number, displacement, rated output, valve clear-
ance, injection timing, etc. Year of manufacturing
STEERING
This decal represents that this engine is in compliance

with the U.S.EPA and California (CARB) exhaust emis-
sion regulation. 9 1999
0 2000
HYDRAULIC
1 2001
2 2002
3 2003
ELECTRIC
D 2004
E 2005
F 2006
G 2007
CABIN
H 2008

A/C & HEATER
For example, HD8100001 means that this engine is the

first manufactured unit, 4B243 LWM, in 2008.
DH14-W00 Jul. 2008 2-

ENGINE - ENGINE IDENTIFICATION DK35/40(C)/45(C)SE
SAFETY FIRST
1.3 Assignment standard for engine model code

4 B 2 4 3 LW M
GENERAL
Mechanical or HST
D, B, A, M Mechanical
E, H HST
ENGINE
Tier3 type
CLUTCH
TRANSMISSION
Displacement
139 Approx. 1,390 cc

HST

REAR AXLE

BRAKE
Stroke
FRONT AXLE
A 92.4 mm (3.638 in.)

B 102.4 mm (4.031 in.)
STEERING
Number of cylinders
3 3 cylinders
4 4 cylinders
HYDRAULIC
ELECTRIC
CABIN
A/C & HEATER
2- DH14-W00 Jul. 2008

DK35/40(C)/45(C)SE ENGINE - SPECIFICATIONS
2. Specifications
SAFETY FIRST
2.1 General specifications
Tractor model DK35SE DK40(C)SE DK45(C)SE DK50(C)SE
GENERAL
Engine Mechanical 3B183LWM 4A200LWM 4A220LWM 4B243LWM
model HST 3B183LWH 4A200LWH 4A220LWH 4B243LWH
Bore I.D. X Stroke (mm) 87 102.4 83 92.4 87 92.4 87 102.4
ENGINE
Honing Plateau honing
Number of cylinders 3 4
Ignition sequence 1-2-3 1-3-4-2
CLUTCH
Displacement () 1.826 1.999 2.197 2.435
Max./Min. speed (rpm) 2,800 / 1,000
TRANSMISSION
Max. gross output kw(HP)/rpm. 28.3(38) / 2,600 30.6(41) / 2,600 33.6(45) / 2,600 36.5(49) / 2,600
Max. torque (kgm/rpm) 119.6(12.2) / 1,700 129.4(13.2) / 1,700 140.1(14.3) / 1,700 159.7(16.3) / 1,700
Compression ratio 22:1 21.7:1 22:1
Indirect injection
HST
Combustion chamber type type (Swirl chamber
type)
Injection timing (BTDC) 18 22
REAR AXLE
BOSCH K MINI
Fuel injection pump type BOSCH K MINI
(CTD)
Injection pressure 14,700~15,680

kPa(kgf/cm2) (150 ~ 160)
BRAKE
Engine oil capacity () 5.5 8 8 7.7
Engine oil specification SAE 15W 40, CD or higher of API grade
Coolant capacity () 8.0 8.9 8.7 8.9
FRONT AXLE
Anti-freeze Ethylene glycol 50% with anti-corrosive agent
The engines for mechanical and HST tractors are the same except for the flywheel. They are compatible with
STEERING
each other once the flywheel is replaced.
The engine gross output is measured with the cooling fan removed.
The cylinder number for ignition sequence is given from the cylinder on the engine cooling fan side.
HYDRAULIC
If the coolant level drops due to its evaporation, add only water. If the coolant lever drops due to the leakage, add
coolant mixed with anti-freeze.
The freezing point of the 50% coolant mixture is -37C (-34F) in a normal condition.
When replacing the coolant with a different type of coolant, flush the cooling system thoroughly beforehand.
ELECTRIC
CABIN
A/C & HEATER
DH14-W00 Jul. 2008 2-

ENGINE - SPECIFICATIONS DK35/40(C)/45(C)SE
2.2 Engine performance curve

SAFETY FIRST
3B183LWM(H): DK35SE(H)
GENERAL
Gross power

13
ENGINE
12
(kgff--m)
m)
CLUTCH
Torque (kg

11
TRANSMISSION
40 10
HST
REAR AXLE
35
BRAKE
(HP)
(HP)
30
Power
FRONT AXLE
25
STEERING
HYDRAULIC
20 210
(g/HP - hr)
(g/HP-hr)
200
ELECTRIC
consumption

190
Fuel
CABIN
180
1400 1600 1800 2000 2200 2400 2600
Engine speed(rpm)
(rpm)
A/C & HEATER
T46W203A
2- DH14-W00 Jul. 2008

SAFETY FIRST
4A200LWM(H): DK40(C)SE(H)
Gross power
GENERAL

13
ENGINE
12
(kgf f--m)
Torque (kg
m)
CLUTCH
11
TRANSMISSION
40 10
HST
35
REAR AXLE
(HP)
(HP)
30
BRAKE
Power
FRONT AXLE
25
STEERING
20 210
(g/HP - hr)
HYDRAULIC
(g/HP-hr)
200
consumption

ELECTRIC
190
Fuel
180
1400 1600 1800 2000 2200 2400 2600

CABIN
Engine speed(rpm)
(rpm)
T46W204A
A/C & HEATER
DH14-W00 Jul. 2008 2-

A/C & HEATER CABIN ELECTRIC HYDRAULIC STEERING FRONT AXLE BRAKE REAR AXLE HST TRANSMISSION CLUTCH ENGINE GENERAL SAFETY FIRST
2-
Power (HP)
4A220LWM(H): DK45(C)SE(H)
Engine speed (rpm)

ENGINE - SPECIFICATIONS
Gross power
Fuel consumption (g/HP - hr) Torque (kgf - m)
T46W205A
DH14-W00 Jul. 2008

DK35/40(C)/45(C)SE
Power (HP)
DH14-W00 Jul. 2008

DK35/40(C)/45(C)SE
4B243LWM(H): DK50(C)SE(H)
Engine speed (rpm)

ENGINE - SPECIFICATIONS
Gross power
Fuel consumption (g/HP - hr) Torque (kgf - m)
T46W206A
2-
2.3 Engine performance curve analysis

SAFETY FIRST
A. Torque b. Brake horse power (HP)

When applying the rotating resistance to the fly- The power is proportional to the rotating force
wheel, the engine speed drops and the rotating (torque) and the rotating speed (rpm). Its formula
GENERAL
force of flywheel increases. is as follows:

Torque curve shows this force as a graph.
Torque (Kgf - m) rpm
Power (HP) =
726.3
ENGINE
Torque
1kw = 1.341 HP
(kgf -f-m)
(kg m)
If substituting the torque and rpm in the left figure for

CLUTCH
Max.
torque
point the above formula and getting the power value, the
below curve is provided. As shown in the below figure,
when the power reaches the maximum point at 2,600
rpm, the power starts to drop. This is because the rpm
TRANSMISSION
drops sharply even the torque increases gradually.

HST
1400 1800 2200 2600 3000 rpm Power

(HP)
(HP) Max.
power
point
T46W207A
REAR AXLE
When running the engine at full speed without load, the

engine rotates at approx. 2,800 rpm as shown in the
figure. When the resistance is applied to the flywheel
by braking with some kind of dynomometer, the rotating
force of the dynomometer increases (arrow direction)
BRAKE
as shown in the figure. In this case, the engine speed

gradually decreases. When the engine speed reaches
approx. 1,700 rpm, the torque starts to decrease. In
1400 1800 2200 2600 3000 rpm
FRONT AXLE
other words, this point (1,700 rpm) is the maximum

torque point. T46W208A
STEERING
c. S.F.C (Specific Fuel Consumption)

The unit used here is "g/HP-hr".
For example, 192g/HP-hr means that 192g of fuel
is consumed by 1 horse power when running the
HYDRAULIC
engine for 1 hour.

This can be converted as follows:
Since the fuel consumption at full power in the
power curve (4B243) is 192g/HP-hr, the fuel con-
ELECTRIC
sumption for 44 horse power is 192g x 44/hr = 8.448

kg/hr.
When converting this value to volume value,
8.448 0.835 /hr = 10.12 /hr
CABIN
Because: Diesel fuel 1 = 0.835 kg

A/C & HEATER
2-10 DH14-W00 Jul. 2008

2.4 Servicing specifications
SAFETY FIRST
2.4.1 A series engine (4A200, 4A220)
Engine body
GENERAL
(4A200, 4A220)
Item Specification Allowable limit

-
ENGINE
(0.002 in. / 3.94 in.)
T.D.C clearance 0.750 ~ 0.9 mm
-
(0.0294 ~ 0.0354 in.)
CLUTCH
Gasket Thickness Tightened
A. Cylinder Head -
1.21(0.0476 in.)
Compression Pressure (When cranking 3.24 ~ 3.73 MPa 2.55 MPa
with starter motor)
TRANSMISSION
33 ~ 38 kgf/cm2 26 kgf/cm2
469 ~ 540 psi 370 psi
Variance of compression pressure
among cylinders should be 10% or less.
Valve Clearance IN. 0.25 mm (0.010 in.) 0.05 mm (0.002 in.)
HST
(Cold)
EX. 0.30 mm (0.012 in.) 0.05 mm (0.002 in.)
Valve Seat Angle IN. 60 (1.047 rad.) -
REAR AXLE
EX. 45 (0.785 rad.) -
Valve Face Angle IN. 60 (1.047 rad.) -
EX. 45 (0.785 rad.) -
B. Valves Valve recess 0.2 ~ 0.5 mm 0.8 mm
BRAKE
(0.0079 ~ 0.0197 in.) (0.0315 in.)
Clearance Between Valve Stem and 0.040 ~ 0.070 mm 0.10 mm
Valve Guide
FRONT AXLE
(0.0016 ~ 0.0028 in.) (0.039 in.)
Valve Stem O.D. 7.960 ~ 7.975 mm
-
(0.31339 ~ 0.31398 in.)
Valve Stem I.D. 8.015 ~ 8.030 mm
STEERING
-
(0.3156 ~ 0.3161 in.)
Intake Valve Open 0.14 rad (8) before T.D.C
-
Close 0.611 rad (35) after B.D.C
HYDRAULIC
C. Valve Timing Exhaust Valve Open 0.785 rad (45) before

B.D.C -
Close 0.140 rad (8) after T.D.C
ELECTRIC
4A200 83.000 ~ 83.022 mm 0.15 mm

D. Cylinder Bore (3.2677 ~ 3.2690 in.) (0.0059 in.)
I.D. 4A220 87.000 ~ 87.022 mm 0.15 mm
(3.425 ~ 3.426 in.) (0.0059 in.)
CABIN
A/C & HEATER
DH14-W00 Jul. 2008 2-11

SAFETY FIRST
(4A200, 4A220)

(1.6417 ~ 1.6614 in.) (1.6220 in.)
GENERAL
Load after assembled / Length after 12.0 kgf / 35.15 mm 10.2 kgf / 35.15 mm
E. Valve spring assembled (26.5 lbs / 1.3839 in.) (22.5 lbs / 1.3839 in.)
Squareness 1.0 mm
ENGINE
-
(0.039 in.)
Rocker arm shaft O.D. 18.955 ~ 18.980 mm
-
(0.7463 ~ 0.7472 in.)
CLUTCH
F. Rocker Arm
Rocker arm bushing I.D. 19.000 ~ 19.025 mm
-
(0.7480 ~ 0.7490 in.)
TRANSMISSION
(0.00079 ~ 0.00244 in.) (0.0028 in.)

Tappet O.D. 23.959 ~ 23.980 mm
G. Tappet -
(0.94327 ~ 0.94410 in.)
Tappet guide I.D. 24.000 ~ 24.021 mm
HST
-
(0.94488 ~ 0.94571 in.)
REAR AXLE
(0.0004 in.) (0.0020 in.)

(1.3346 in.) (1.3205 in.)
EX. 33.69 mm 33.64 mm
BRAKE
(1.3268 in.) (1.3244 in.)

H. Camshaft
(0.00197 ~ 0.00358 in.) (0.0059 in.)
FRONT AXLE
Camshaft journal O.D. 39.934 ~ 39.950 mm 39.88 mm

(1.57220 ~ 1.57283 in.) (1.5701 in.)
Camshaft counter bore I.D. 40.000 ~ 40.025 mm

-
STEERING
(1.57480 ~ 1.57579 in.)

Clearance between camshaft gear 0.07 ~ 0.22 mm
(axial direction) -
(0.003 ~ 0.009 in.)
HYDRAULIC

(0.0016 ~ 0.0043 in.) (0.0059 in.)
(0.0079 ~ 0.0201 in.) (0.035 in.)
ELECTRIC
Clearance between Idle gear shaft and 0.025 ~ 0.066 mm 0.1 mm

I. Timing Gear idle gear bushing (0.00098 ~ 0.00250 in.) (0.0039 in.)
Idle gear shaft O.D. 37.9590 ~ 37.9750 mm
-
CABIN
(1.49445 ~ 1.49508 in.)

Idle gear bushing I.D. 38.000 ~ 38.025 mm
-
(1.49608 ~ 1.49705 in.)
A/C & HEATER
2-12 DH14-W00 Jul. 2008

(4A200, 4A220)
SAFETY FIRST
Piston pin bore I.D. 25.00 ~ 25.006 mm 25.03 mm
(0.98425 ~ 0.98448 in.) (0.9854 in.)
GENERAL
Clearance between Oil ring and 0.020 ~ 0.060 mm 0.15 mm
ring groove (0.00079 ~ 0.00236 in.) (0.0059 in.)
Oil ring groove width 3.01 ~ 3.03 mm -
(0.11850 ~ 0.11929 in.)
ENGINE
Oil ring width 2.97 ~ 2.99 mm -
(0.11693 ~ 0.11772 in.)
Clearance between 2nd ring and 0.04 ~ 0.08 mm 0.15 mm
ring groove (0.00157 ~ 0.00315 in.) (0.0059 in.)
CLUTCH
J. Piston Ring
-
(0.07992 ~ 0.08150 in.)
TRANSMISSION
-
(0.07756 ~ 0.07834 in.)
Top ring, oil ring end gap 0.20 ~ 0.40 mm
4A200 (0.0079 ~ 0.0157 in.) 1.25 mm
0.25 ~ 0.40 mm (0.0492 in.)
4A220
(0.0098 ~ 0.01570 in.)
HST
(0.0217 ~ 0.0276 in.) (0.0492 in.)
REAR AXLE
-
(0.0020 in.)
Clearance Piston and small 0.014 ~ 0.038 mm 0.15 mm
K. Connecting between end bushing (0.00055 ~ 0.00150 in.) (0.0059 in.)
Rod 25.002 ~ 25.011 mm
Piston pin O.D.
BRAKE
-
(0.98433 ~ 0.98469 in.)
Piston pin bushing 25.025 ~ 25.040 mm
-
I.D. (0.98524 ~ 0.98583 in.)
FRONT AXLE
Crankshaft alignment (Deflection) 0.08 mm
-
(0.0031 in.)
Clearance between Crankshaft 0.040 ~ 0.118 mm 0.20 mm
and crankshaft bearing 1 (0.00157 ~ 0.00465 in.) (0.0079 in.)
STEERING
Crankshaft O.D. 51.921 ~ 51.940 mm
-
(2.04414 ~ 2.04488 in.)
Crankshaft bearing 1 I.D. 51.980 ~ 52.039 mm
-
HYDRAULIC
(2.04646 ~ 2.04878 in.)

Clearance between Crankshaft 0.040 ~ 0.104 mm 0.20 mm
and crankshaft bearing 2 (0.00157 ~ 0.00409 in.) (0.0079 in.)
L. Crankshaft
ELECTRIC
-
(2.04414 ~ 2.04488 in.)
-
(2.04646 ~ 2.04823 in.)
Clearance between crankshaft pin 0.025 ~ 0.087 mm 0.20 mm
CABIN
and crank pin bearing (0.00098 ~ 0.00343 in.) (0.0079 in.)

Crankshaft pin O.D. 46.959 ~ 46.975 mm
-
(1.84878 ~ 1.84941 in.)
A/C & HEATER
Crankshaft pin bearing I.D. 47 ~ 47.046 mm

-
(1.85039 ~ 1.85220 in.)
(0.0059 ~ 0.0122 in.) (0.020 in.)
DH14-W00 Jul. 2008 2-13

SAFETY FIRST
Lubricating system
(4A200, 4A220)

Engine oil pressure At idle over 68.6 kPa
GENERAL
(oil temp. 85 ~ 95 C) speed 0.7 kgf/cm2 -

9.95 psi
At rated 245.1 ~ 441.2 kPa 245.0 kPa
ENGINE
speed 2.5 ~ 4.5 kgf/cm2 2.5 kgf/cm2

35.5 ~ 64.0 psi 35.6 psi
A. Oil Pump
Clearance between inner rotor and 0.10 ~ 0.16 mm 0.2 mm
CLUTCH
outer rotor (0.0039 ~ 0.0063 in.) (0.0079 in.)

Clearance between outer rotor and 0.11 ~ 0.19 mm 0.25 mm
pump (0.0043 ~ 0.0078 in.) (0.0098 in.)
TRANSMISSION
Clearance between inner rotor and 0.105 ~ 0.150 mm 0.2 mm

cover (0.00413 ~ 0.00591 in.) (0.00787 in.)
HST
Cooling system
(4A200, 4A220)
REAR AXLE

Valve opening temperature at beginning 69.5 ~ 72.5
-
A. Thermostat (157.1 ~ 162.5F)
BRAKE
Opened completely (height: 8 mm) 85C (185F) -

Radiator tightness No leak at 1.4 kgf/cm2
-
(137 kpa, 20 psi)
FRONT AXLE
Radiator cap tightness 10 seconds or more for pressure

B. Radiator drop from 0.9 0.6 kgf/cm2 -
(88 59 kpa, 13 9 psi)
Fan belt tension [deflection at 98 N 7 ~ 9 mm (0.28 ~ 0.35 in.)
STEERING
-
(10 kgf, 22 lbs) of force]
HYDRAULIC
Fuel system
(4A200, 4A220)

ELECTRIC
A. Fuel injec- Injection timing (BTDC) 18

-
tion pump
Fuel injection pressure 150~160 kgf/cm2
-
(14.7~15.7 MPa, 2,133~2,275 psi)
CABIN
B. Injection
Nozzle
Tightness of nozzle valve seat No fuel leak at 130 kgf/cm2
-
(12.75 MPa, 1,849 psi)
A/C & HEATER
2-14 DH14-W00 Jul. 2008

Tightening torques for engine
SAFETY FIRST
(4A200, 4A220)
Tightening torque
Item Size x Pitch
Nm kgf-m lb-ft
GENERAL
Head cover bolt M8 x 1.0 8.8 ~ 11.8 0.9 ~ 1.2 6.5 ~ 8.7
* Bearing case bolt 1
M9 x 1.25 46.1 ~ 51.0 4.7 ~ 5.2 34.0 ~ 37.6
ENGINE
(Case cover bolt)
M10 x 1.25 68.6 ~ 73.6 7.0 ~ 7.5 50.6 ~ 54.2
(Case mounting bolt)
* Flywheel bolt M12 x 1.25 98.1 ~ 107.9 10.0 ~ 11.0 72.3 ~ 79.6
CLUTCH
Rocker arm bracket bolt M10 x 1.25 60.8 ~ 70.6 6.2 ~ 7.2 44.8 ~ 52.1
TRANSMISSION
Drain plug M12 x 1.25 32.4 ~ 37.3 3.3 ~ 3.8 23.9 ~ 37.3
Glow plug M10 x 1.25 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Oil switch PT1/8 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Nozzle holder assembly M20 x 1.5 49.1 ~ 68.7 5.0 ~ 7.0 36.2 ~ 50.6
HST
Injection pipe nut M12 x 1.5 24.5 ~ 34.3 2.5 ~ 3.5 18.1 ~ 25.3
Temperature meter switch PT1/8 13.7 ~ 15.7 1.4 ~ 1.6 10.1 ~ 11.6
REAR AXLE
D.C alternator pulley nut M15 x 1.5 39.2 ~ 53.9 4.0 ~ 5.5 28.9 ~ 39.8
CAUTION
BRAKE
For * marked screw, bolts and nuts on the table, apply engine oil to their
threads and seats before tightening.
The letter M in Size Pitch means that the screw, bolt or nut dimension
FRONT AXLE
stands for metric. The size is the nominal outside diameter in mm of the
threads. The pitch is the nominal distance in mm between two threads.
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C & HEATER
DH14-W00 Jul. 2008 2-15

2.4.2 B series engine (3B183, 4B243)

SAFETY FIRST
Engine body
(3B183, 4B243)
GENERAL

-
(0.002 in. / 3.94 in.)
ENGINE
T.D.C clearance 0.750 ~ 0.9 mm

-
(0.0294 ~ 0.0354 in.)
Gasket Thickness Tightened
A. Cylinder 1.21 mm -
CLUTCH
Head
(0.0476 in.)
Compression Pressure (When cranking 3.24 ~ 3.73 MPa 2.55 MPa
with starter motor) 33 ~ 38 kgf/cm 2
26 kgf/cm2
TRANSMISSION
469 ~ 540 psi 370 psi

Variance of compression pressure
among cylinders should be 10% or less.
Valve Clearance IN. 0.25 mm (0.010 in.) 0.05 mm (0.002 in.)
HST
(Cold)
EX. 0.3 mm (0.012 in.) 0.05 mm (0.002 in.)
Valve Seat Angle IN. 60 (1.047 rad.) -
REAR AXLE
EX. 45 (0.785 rad.) -

Valve Face Angle IN. 60 (1.047 rad.) -
EX. 45 (0.785 rad.) -
B. Valves Valve recess 0.2 ~ 0.5 mm 0.8 mm

BRAKE
(0.0079 ~ 0.0197 in.) (0.0315 in.)

Clearance Between Valve Stem and Valve 0.040 ~ 0.070 mm 0.10 mm
Guide (0.0016 ~ 0.0028 in.) (0.039 in.)
FRONT AXLE
Valve Stem O.D. 7.960 ~ 7.975 mm

-
(0.31339 ~ 0.31398 in.)
Valve Stem I.D. 8.015 ~ 8.030 mm
STEERING
-
(0.3156 ~ 0.3161 in.)
Intake Valve Open 0.14 rad (8) before T.D.C
-
Close 0.611 rad (35) after B.D.C
HYDRAULIC
C. Valve Timing Exhaust Valve Open 0.785 rad (45) before

B.D.C -
Close 0.140 rad (8) after T.D.C
ELECTRIC
3B183 87.000 ~ 87.022 mm 0.15 mm

D. Cylinder (3.425 ~ 3.426 in.) (0.0059 in.)
Bore I.D. 4B243 87.000 ~ 87.022 mm 0.15 mm
(3.425 ~ 3.426 in.) (0.0059 in.)
CABIN
A/C & HEATER
2-16 DH14-W00 Jul. 2008

(3B183, 4B243)
SAFETY FIRST
(1.6417 ~ 1.6614 in.) (1.6220 in.)
GENERAL
Load after assembled / Length after 12.0 kgf / 35.15 mm 10.2 kgf / 35.15 mm
E. Valve spring assembled (26.5 lbs / 1.3839 in.) (22.5 lbs / 1.3839 in.)
Squareness 1.0 mm
-
ENGINE
(0.039 in.)
Rocker arm shaft O.D. 18.955 ~ 18.980 mm
-
(0.7463 ~ 0.7472 in.)
F. Rocker Arm
CLUTCH
Rocker arm bushing I.D. 19.000 ~ 19.025 mm
-
(0.7480 ~ 0.7490 in.)
TRANSMISSION
(0.00079 ~ 0.00244 in.) (0.0028 in.)
Tappet O.D. 23.959 ~ 23.980 mm
G. Tappet -
(0.94327 ~ 0.94410 in.)
Tappet guide I.D. 24.000 ~ 24.021 mm
-
HST
(0.94488 ~ 0.94571 in.)
Camshaft deflection 0.01 mm 0.05 mm
(0.0004 in.) (0.0020 in.)
REAR AXLE
(1.335 in.) (1.3205 in.)
EX. 33.9 mm 33.64 mm
(1.335 in.) (1.3244 in.)
BRAKE
Journal oil clearance 0.050 ~ 0.091 mm 0.15 mm
H. Camshaft
(0.00197 ~ 0.00358 in.) (0.0059 in.)
FRONT AXLE
Camshaft journal O.D. 39.934 ~ 39.950 mm 39.88 mm
(1.57220 ~ 1.57283 in.) (1.5701 in.)
Camshaft counter bore I.D. 40.000 ~ 40.025 mm
-
(1.57480 ~ 1.57579 in.)
Clearance between camshaft gear 0.07 ~ 0.22 mm
- STEERING
(axial direction) (0.003 ~ 0.009 in.)
HYDRAULIC
(0.0016 ~ 0.0043 in.) (0.0059 in.)

Idle gear axial clearance 0.20 ~ 0.51 mm 0.9 mm
(0.0079 ~ 0.0201 in.) (0.035 in.)
ELECTRIC
Clearance between Idle gear shaft and 0.025 ~ 0.066 mm 0.1 mm

I. Timing Gear idle gear bushing (0.00098 ~ 0.00250 in.) (0.0039 in.)
Idle gear shaft O.D. 37.9590 ~ 37.9750 mm
-
(1.49445 ~ 1.49508 in.)
CABIN
Idle gear bushing I.D. 38.000 ~ 38.025 mm

-
(1.49608 ~ 1.49705 in.)
A/C & HEATER
DH14-W00 Jul. 2008 2-17

(3B183, 4B243)
SAFETY FIRST

Piston pin bore I.D. 25.00 ~ 25.006 mm 25.03 mm
(0.98425 ~ 0.98448 in.) (0.9854 in.)
GENERAL
Clearance between Oil ring and ring 0.020 ~ 0.060 mm 0.15 mm

groove (0.00079 ~ 0.00236 in.) (0.0059 in.)
-
(0.11850 ~ 0.11929 in.)
ENGINE

-
(0.11693 ~ 0.11772 in.)
Clearance between 2nd ring and ring 0.04 ~ 0.08 mm 0.15 mm
J. Piston Ring groove (0.00157 ~ 0.00315 in.) (0.0059 in.)
CLUTCH

-
(0.07992 ~ 0.08150 in.)
TRANSMISSION
-
(0.07756 ~ 0.07834 in.)
Top ring, oil ring end gap 0.25 ~ 0.40 mm 1.25 mm
(0.0098 ~ 0.01570 in.) (0.0492 in.)
HST
(0.0217 ~ 0.0276 in.) (0.0492 in.)

Connecting rod deflection limit 0.05 mm
-
(0.0020 in.)
REAR AXLE
Clearance between piston and small 0.014 ~ 0.038 mm 0.15 mm

K. Connecting end bushing (0.00055 ~ 0.00150 in.) (0.0059 in.)
Rod Piston pin O.D. 25.002 ~ 25.011 mm
-
(0.98433 ~ 0.98469 in.)
BRAKE
Piston pin bushing I.D. 25.025 ~ 25.040 mm

-
(0.98524 ~ 0.98583 in.)
Crankshaft deflection limit 0.08 mm
-
(0.0031 in.)
FRONT AXLE
Clearance between Crankshaft and 0.060 ~ 0.132 mm 0.20 mm

crankshaft bearing 1 (0.00236 ~ 0.00520 in.) (0.0079 in.)
-
STEERING
(2.35870 ~ 2.35945 in.)

-
(2.36181 ~ 2.36390 in.)
Clearance between Crankshaft and 0.05 ~ 0.114 mm 0.20 mm
HYDRAULIC
crankshaft bearing 2 (0.00197 ~ 0.00449 in.) (0.0079 in.)

L. Crankshaft -
(2.35870 ~ 2.35945 in.)
ELECTRIC
-
(2.36142 ~ 2.36319 in.)
Clearance between crankshaft pin and 0.025 ~ 0.087 mm 0.20 mm
crank pin bearing (0.00098 ~ 0.00343 in.) (0.0079 in.)
Crankshaft pin O.D. 46.959 ~ 46.975 mm
CABIN
-
(1.84878 ~ 1.84941 in.)
Crankshaft pin bearing I.D. 47 ~ 47.046 mm
-
(1.85040 ~ 1.85220 in.)
A/C & HEATER
Crankshaft axial clearance 0.15 ~ 0.31 mm 0.5 mm

(0.0059 ~ 0.0122 in.) (0.020 in.)
2-18 DH14-W00 Jul. 2008

SAFETY FIRST
Lubricating system
(3B183, 4B243)

Engine oil pressure At idle speed over 68.6 kPa
GENERAL
(oil temp. 85 ~ 95 C) 0.7 kgf/cm2 -
9.95 psi
At rated speed 245.1 ~ 441.2 kPa 245 kPa
ENGINE
2.5 ~ 4.5 kgf/cm2 2.5 kgf/cm2
35.5 ~ 64.0 psi 31.3 psi
A. Oil Pump
Clearance between inner rotor and outer 0.10 ~ 0.16 mm 0.2 mm
CLUTCH
rotor (0.0039 ~ 0.0063 in.) (0.0079 in.)
Clearance between outer rotor and pump 0.11 ~ 0.19 mm 0.25 mm
(0.0043 ~ 0.0078 in.) (0.0098 in.)
TRANSMISSION
Clearance between inner rotor and cover 0.105 ~ 0.150 mm 0.2 mm
(0.00413 ~ 0.00591 in.) (0.00787 in.)
HST
Cooling system
(3B183, 4B243)
REAR AXLE
Valve opening temperature at beginning 69.5 ~ 72.5
-
A. Thermostat (157.1 ~ 162.5F)
BRAKE
Opened completely (height: 8 mm) 85C (185F) -
Radiator tightness No leak at 1.4 kgf/cm2 (137 kpa,
-
20 psi)
FRONT AXLE
Radiator cap tightness 10 seconds or more for pressure
B. Radiator drop from 0.9 0.6 kgf/cm2 -
(88 59 kpa, 13 9 psi)
Fan belt tension [deflection at 98 N 7 ~ 9 mm (0.28 ~ 0.35 in.)
STEERING
-
(10 kgf, 22 lbs) of force]
HYDRAULIC
Fuel system
(3B183, 4B243)

ELECTRIC
A. Fuel injec- Injection timing 3B183 18 -

tion pump (BTDC)
4B243 22
Fuel injection pressure 150~160 kgf/cm2
-
CABIN
B. Injection (14.7~15.7 MPa, 2,133~2,275 psi)

Nozzle
Tightness of nozzle valve seat No fuel leak at 130 kgf/cm2
-
(12.75 MPa, 1,849 psi)
A/C & HEATER
DH14-W00 Jul. 2008 2-19

Tightening torques for engine

SAFETY FIRST
(3B183, 4B243)
Tightening torque
Item Size x Pitch
Nm kgf-m lb-ft
GENERAL
Head cover bolt M8 x 1.0 8.8 ~ 11.8 0.9 ~ 1.2 6.5 ~ 8.7
M9 x 1.25 46.1 ~ 51.0 4.7 ~ 5.2 34.0 ~ 37.6
ENGINE
(Case cover bolt)

M10 x 1.25 68.6 ~ 73.6 7.0 ~ 7.5 50.6 ~ 54.2
(Case mounting bolt)
* Flywheel bolt M12 x 1.25 98.1 ~ 107.9 10.0 ~ 11.0 72.3 ~ 79.6
CLUTCH
* Connecting rod bolt M8 x 1.0 46.1 ~ 51.0 4.5 ~ 5.0 34.0 ~ 37.6
Rocker arm bracket bolt M10 x 1.25 60.8 ~ 70.6 6.2 ~ 7.2 44.8 ~ 52.1
TRANSMISSION
Drain plug M12 x 1.25 32.4 ~ 37.3 3.3 ~ 3.8 23.9 ~ 37.3
Glow plug M10 x 1.25 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Oil switch PT1/8 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Nozzle holder assembly M20 x 1.5 49.1 ~ 68.7 5.0 ~ 7.0 36.2 ~ 50.6
HST
Injection pipe nut M12 x 1.5 24.5 ~ 34.3 2.5 ~ 3.5 18.1 ~ 25.3
Temperature meter switch PT1/8 13.7 ~ 15.7 1.4 ~ 1.6 10.1 ~ 11.6
REAR AXLE
D.C alternator pulley nut M15 x 1.5 39.2 ~ 53.9 4.0 ~ 5.5 28.9 ~ 39.8
CAUTION
BRAKE
For * marked screw, bolts and nuts on the table, apply engine oil to their
threads and seats before tightening.
The letter M in Size Pitch means that the screw, bolt or nut dimension
FRONT AXLE
stands for metric. The size is the nominal outside diameter in mm of the
threads. The pitch is the nominal distance in mm between two threads.
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C & HEATER
2-20 DH14-W00 Jul. 2008

DK35/40(C)/45(C)SE ENGINE - OPERATING PRINCIPLE
3. Operating principle
SAFETY FIRST
3.1 Body and power train system
A. Cylinder head B. Cylinder Block
GENERAL
ENGINE
1 1 1 1
CLUTCH
2 2 2 2
TRANSMISSION
T46W209A T46W211A
(1) Intake port (2) Exhaust port The engine has a high durability tunnel-type cylinder
block. Furthermore, liner less type, allows effective
The cylinder head is made of special alloy cast iron
HST
cooling, less distortion, and greater wear-resistance
which can resist high temperature and pressure caused
using special material. The noise is reduced to a mini-
by combustion. The intake and exhaust ports are ar-
mum level because each cylinder has its own chamber.
ranged cross-flow type to get high combustion efficien-
REAR AXLE
cy by protecting the suction air from being heated and
expanded by heated exhaust air.
C. Cylinder honing
BRAKE
3 # #
Standard honing {8333
Plateau honing
4
{83
FRONT AXLE
2
STEERING
HYDRAULIC
ELECTRIC
T46W210A T46W212A
(1) Combustion chamber (3) Glow plug The DAEDONG engine has adopted the plateau hon-
(2) Injection nozzle (4) Cylinder head ing in manufacturing to enhance the oil tightness of the
cylinder bore and the durability of the cylinder for the
CABIN
The Daedong swirl type combustion chamber is de-

longer engine life time.
signed for high combustion efficiency and reducing fuel
consumption. The glow plug helps to start the engine
even at -15C (5F).
A/C & HEATER
DH14-W00 Jul. 2008 2-21

ENGINE - OPERATING PRINCIPLE DK35/40(C)/45(C)SE
D. Crankshaft F. Connecting Rod

SAFETY FIRST
1
GENERAL
1 2
5
ENGINE
3 3
4
CLUTCH
T46W213A T46W215A
(1) Crankshaft (4) Crankshaft bearing 2 (1) Small end bushing (3) Crank pin bearing
(2) Crankshaft bearing 1 (5) Thrust bearing (2) Connecting rod
TRANSMISSION
(3) Main bearing case (side metal)
The crankshaft is made of forged steel and the journals, The connecting rod (2), which converts the reciprocat-
the crankpins and the bearing surface for the oil seal are ing motion of the pistons caused by the fuel combus-
induction-hardened to increase wear resistance. Each tion into the rotating motion of the crankshaft, is made
HST
crankshaft journal is supported by the main bearing case of hard forged steel. The connecting rod has bearings
(3) having a bearing (4) inside. The front crankshaft at both ends. The small end has a cylinder type bear-
bearing (2) is a cylinder type bushing and rear and in- ing (small end bushing (2)) and the big end has a split
termediate bearings are a split type (4). The crankshaft, type bearing (crank pin bearing (3)).
REAR AXLE
crankshaft bearings have oil holes for lubricant.
E. Piston and piston ring G. Camshaft

BRAKE
1
3
FRONT AXLE
2
1
2
STEERING
3
HYDRAULIC
T46W214A T46W216A
(1) Top ring (2) 2nd ring (3) Oil ring (1) Cam gear (3) Camshaft
(2) Camshaft stopper
The piston is made of an aluminum alloy that is tem- The camshaft (3) is made of forged steel and its journal
ELECTRIC
perature and pressure resistant. Three rings are in- and cams are hardened to increase wear resistance.
stalled in the grooves of the piston. The top ring (1) is The cams on the camshaft open and close the intake
a keystone type, which can withstand heavy loads, and and exhaust valves with the push rods and rocker
the barrel face on the ring fits well to the cylinder wall. arms. The journals and their bearings are force-lubri-
CABIN
The second ring (2) is an undercut type, which pre- cated.

vents the oil from being carried up. The oil ring (3) has
chamfered faces and an expander ring, which increase
the pressure of the oil ring against the cylinder wall to
A/C & HEATER
scrape the oil. The top ring is plated with hard chrome
to increase wear resistance.
2-22 DH14-W00 Jul. 2008

H. Fuel camshaft J. Intake and exhaust valves
SAFETY FIRST
1
1 2
3
GENERAL
4
ENGINE
6 5
CLUTCH
T46W217A T46W219A
(1) Fuel camshaft (2) Fuel camshaft gear (1) Valve spring collet (4) Valve stem seal
(2) Valve spring retainer (5) Exhaust valve
TRANSMISSION
(3) Valve spring (6) Intake valve
This fuel camshaft is made of forged steel and its cams The valve and its guide of the intake are different from
are hardened and tempered to increase wear resis- those for the exhaust. Other parts, such as the spring,
tance. The cams on the fuel camshaft (1) drive the fuel spring retainers, valve spring collets, valve stem seals
HST
injection pump and the fuel feed pump. The governor are the same for both the intake and the exhaust.
balls are installed on the fuel camshaft gear (2) to con-
The diameter of the intake valve is always larger than
trol the engine speed.
the that of the exhaust valve. The intake valve is locat-
REAR AXLE
ed prior to exhaust valve when seeing them from the
cooling fan side.
I. Rocker arm assembly K. Timing Gear
BRAKE
4 2
1 1 4
3
FRONT AXLE
3
5
2
STEERING
5
7
HYDRAULIC
6
T46W218A T46W220A
(1) Rocker arm (4) Rocker arm bracket (1) Fuel camshaft gear (5) Idle gear
(2) Lock nut (5) Rocker arm shaft (2) Fuel camshaft (6) Crankshaft gear
ELECTRIC
(3) Adjusting screw (3) Valve camshaft gear (7) Crankshaft

(4) Valve camshaft
The rocker arm assembly includes the rocker arms (1) The crankshaft drives the camshaft and the idle gear
and an adjusting screw (3), which is at the end of rock- engaged with fuel camshaft. The timings for open-
CABIN
er arm and rests on the push rod, rocker arm brackets ing and closing the valves is extremely important to
(4) and rocker arm shaft (5). The rocker arms are acti- achieve the effective air intake and sufficient gas ex-
vated by the reciprocating movement of the push rods haust. When assembling, the appropriate timing can be
and open or close the intake and exhaust valves. The obtained by aligning the mark on the crankshaft gear (6)
A/C & HEATER
rocker arm and other parts are lubricated through the with idle gear (5), idle gear with camshaft gear, and idle
drilled holes of the brackets and the rocker arm shaft. gear with fuel injection pump gear.
DH14-W00 Jul. 2008 2-23

L. Flywheel
SAFETY FIRST
2
GENERAL
3
ENGINE
1
CLUTCH
T46W221A
(1) Ring gear (3) Crankshaft

TRANSMISSION
(2) Flywheel
The ring gear (1) for connecting the start motor is

compressed in the flywheel. Therefore, it cannot be re-
placed separately.
HST
m. MLS cylinder head gasket

REAR AXLE
BRAKE
FRONT AXLE
STEERING
S76W2t4A
The MLS (Multi Layer Steel) cylinder head gasket has

a triple-layered steel structure complemented with non-
HYDRAULIC
asbestos gasket features.

The top clearance variation is minimized and the ther-
mal load is reduced while increasing durability.
ELECTRIC
CAUTION
When disassembling the cylinder head, its gasket
should be replaced with a new one.
CABIN
Be sure that there is no scratch or foreign

material between the cylinder head and the
surface of the block.
A/C & HEATER
2-24 DH14-W00 Jul. 2008

3.2 Lubricating system
SAFETY FIRST
Engine oil flow
GENERAL
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BRAKE
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
T46W222C
Components
CABIN
(1) Piston (6) Oil filter (11) Push rod

(2) Idle gear (7) Bypass valve (12) Tappet
(3) Oil pump (8) Oil pan (13) Oil pressure gauge
(4) Relief valve (9) Rocker arm shaft (14) Camshaft
A/C & HEATER
(5) Oil strainer (10) Rocker arm (15) Crankshaft
DH14-W00 Jul. 2008 2-25

SAFETY FIRST
Engine oil flow chart

GENERAL
Rocker arm shaft

ENGINE
Rocker arm Rocker arm Rocker arm Engine oil pressure

sensor
CLUTCH
Valve
cam Valve cam shaft Valve cam shaft Valve cam shaft Valve cam shaft
shaft Valve cam shaft Valve cam shaft Valve cam shaft
journal journal journal journal
gear
TRANSMISSION
Fuel
cam Fuel cam shaft Tappet Tappet Tappet
shaft
gear
HST
REAR AXLE
Piston Piston Piston

Bore Connecting rod's small end Bore Connecting rod's small end Bore Connecting rod's small end
BRAKE
No.1
1connecting
rod's
big end No.2
2connecting
rod's
big end No.33
connecting
rod's big
end
FRONT AXLE
Journal
bearing No.1 main bearing No.2 main bearing No.3 main bearing
STEERING
Idle gear Main oil gallery

HYDRAULIC
Crank shaft gear Oil pump gear Oil pump gerotor Relief valve Oil fiter
ELECTRIC
CABIN
Pressurized
Strainer
Oil pan
Splash,
, flow
A/C & HEATER
T46W223A
2-26 DH14-W00 Jul. 2008

DH14-W00 Jul. 2008
DK35/40(C)/45(C)SE
Function of lubricating system

ENGINE - OPERATING PRINCIPLE
T46W224C
2-27
A. Oil strainer (refer to figure (a) on page 2-27) B series engine

SAFETY FIRST
B. Oil pump (refer to figure (b) on page 2-27)

1. A series engine (4A200, 4A220 - refer to page 2-27)
Type: Gerotor type
GENERAL
Oil: SAE15W40
Standard oil temperature: 80C
Discharge pressure: 4.5 kg/cm2
ENGINE
Displacement: Over 10/min (1,000rpm)

Over 24.3/min (2,000rpm)
Drive gear speed ratio (crankshaft gear/pump gear)
= 34/45 = 0.755
CLUTCH
s76W224B
2. B series engine (3B183, 4B243) (1) Bypass valve (3) Relief valve
(2) Filter element (4) Oil cooler
Type: Gerotor type
TRANSMISSION
(A) Oil filter outlet (to crankshaft metal 1, idle gear,

Oil: SAE15W40
camshaft and lock arm shaft)
Standard oil temperature: 80C
(B) Oil filter outlet (to crankshaft journal and pin) Oil
Discharge pressure: 4.5 kg/cm2
(C) Oil filter inlet
Displacement: Over 8.81/min (1,000 rpm) (D) Coolant (Inlet - Outlet)
HST
Over 21.41/min (2,000 rpm)

Drive gear speed ratio (crankshaft gear/pump gear) - Relief valve opening pressure: 4.5 ~ 5.4 kgf/cm2
= 40/39 = 1.026 (64 ~ 76 PSI)
REAR AXLE
- Oil filter
C. Oil filter and relIEF valve Filter paper fineness: Max.: 99 5 microns,
Average: 75 5 microns
A series engine Filtered area: 1680 cm2
Bypass valve opening pressure (pressure difference
BRAKE
between inner and outer side of filter paper):

1 0.2 kgf/cm2
2
D. Valve camshaft (refer to figure (D) page 2-27)
FRONT AXLE
The oil enters the first journal bearing of the valve cam-
3
shaft and is sent to each journal through the oil holes
in the center of the camshaft. Then, it is sent to the oil
5
pressure sensor through the last journal.
STEERING
1
E. Rocker arm shaft (refer to figure (E)
page 2-27)
4
HYDRAULIC
T46W225B
The oil from the valve camshaft comes through the hole
(1) Relief valve in the support bracket of rocker arm, supplied to each
(2) Bypass valve rocker arm through the hole in the center of rocker arm
(3) Oil filter outlet (To metal, idle gear, camshaft, lock arm shaft) shaft. The oil drained from the hole on top of the rocker
ELECTRIC
(4) Oil filter inlet arm is used in lubrication on the contact surface of the
(5) Oil filter outlet (To crankshaft main bearing) valve and the rocker arm. Then, it flows along the push
rod to lubricate the contact surface between the push
rod and the tappet and between the tappet and the
valve cam.
CABIN
A/C & HEATER
2-28 DH14-W00 Jul. 2008

SAFETY FIRST
f. oil flow (refer to figure (F) page 2-27)
The oil in the oil gallery flows to the main bearing (or
metal bearing) and then to the connecting rod big end
journal bearing. The oil flowed out of the gap of the
GENERAL
connecting rod big end journal bearing is sprayed to
the connecting rod small end (piston pin), piston inte-
rior and cylinder bore as the crankshaft rotates.
ENGINE
G. Oil pressure switch (refer to figure (G)
page 2-27)
CLUTCH
TRANSMISSION
1 1
HST
REAR AXLE
T46W226A
The oil pressure switch is installed on the cylinder block

at the end of the valve camshaft and leads to the oil
passage which is passing through the valve camshaft.
BRAKE
When the oil pressure falls below the specified value,
the circuit is connected by the diaphragm in the switch
to turn on the warning lamp (1) on the instrument panel.
FRONT AXLE
When the key switch is turned to the "ON" position with
the engine stopped, the warning lamp comes on. When
the oil pressure rises, this lamp goes off.
Min. operating pressure of oil switch:
STEERING
0.5 0.1 kgf/cm2
0.0007 0.0001PSI
0.0049 0.0009Kpa
HYDRAULIC
ELECTRIC
CABIN
A/C & HEATER
DH14-W00 Jul. 2008 2-29

3.3 Cooling system

SAFETY FIRST
A. Coolant flow route

GENERAL
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BRAKE
T46W227B
FRONT AXLE
When the centrifugal water pump (1) connected to the The drain hose (5) is to completely drain the coolant in
cooling fan shaft rotates, the coolant in the cylinder cylinder block when opening the radiator lower cock (6).
block flows from the No. 1 cylinder to the No. 3 via the
No. 2 cylinder (subsequently to the No. 4 cylinder for The tractor equipped with the cabin heater draws hot
STEERING
4-cylinder model) and also flows to the cylinder head water from the return hose (3) to heat the heater and
(from lower to upper side). In the cylinder head, the then sends it back to the drain hose (5).
coolant flows from the No. 3 or 4 cylinder to the No. 1 Also, For the engine equipped with the engine oil cool-
cylinder through the No. 2 cylinder (from rear to front er, such as the turbo engine or 4B243, cools down the
HYDRAULIC
side). engine oil by connecting the cylinder block drain line to

The coolant collected in the thermostat flange (2) flows the engine oil cooler.
to the inlet of the water pump impeller through the re-
turn hose (3), and then returns to the cylinder block
ELECTRIC
through the outlet of the impeller.
When the coolant temperature rises over 71C (160F),

the thermostat (4) opens and most coolant flows to the
CABIN
radiator through the thermostat. The coolant flowed to

the top of the radiator through the radiator upper hose
(7) is cooled down by the cooling air and sinks. Then, it
flows to the inlet of the water pump impeller through the
A/C & HEATER
radiator lower hose (8) to return to the cylinder block.
2-30 DH14-W00 Jul. 2008

B. Water pump C. Thermostat (A series engine: 4A200,
SAFETY FIRST
4A220)
4
3
GENERAL
2
1 4
5
ENGINE
2 7
1
3 9
6
CLUTCH
T46W229A
(1) Seat (6) Wax (Solid)

Location of (2) Valve (7) Spring
TRANSMISSION
hole (A)
(3) Pellet (8) Leak hole
(4) Spindle (9) Wax (Liquid)
(5) Synthetic rubber
The thermostat is wax pellet type, which controls the
HST
flow of the cooling water to the radiator to keep the
proper temperature. The case has a seat (1) and the
T46W228A pellet has a valve (2). The spindle attached to the case
REAR AXLE
is inserted into the synthetic rubber in the pellet. The
(a) From thermostat (c) From radiator
pellet is charged with wax.
(b) To cylinder block
(A) At low temperature: below 71C (160F)
(1) Bearing (3) Mechanical seal
(2) Pump body (4) Pump impeller The valve (2) is seated by the spring (7) and the cool-
ing water circulates in the engine through the water
BRAKE
The water pump sucks the cooled water, forces it into return pipe but does not enter the radiator.
the cylinder block and draws out the hot water to the (B) At high temperature: over 71C (160F)
radiator repeatedly. The mechanical seal (3) prevents
As the water temperature rises, the wax in the pellet (3)
FRONT AXLE
the water from entering into the bearing (1).
becomes liquid and it pushes out the spindle.
Notes The pellet lowers and the valve (2) opens to send the
cooling water to the radiator.
If the coolant is leaked from hole (A), it means that
STEERING
the mechanical seal is damaged. Therefore, the
water pump assembly should be replaced. HYDRAULIC
ELECTRIC
By-pass valve
T46W230
CABIN
For the engine for cabin model, the thermostat is

equipped with the bypass valve. Therefore, the cooling
efficiency is enhanced as all coolant passes through
A/C & HEATER
the radiator since the internal circulation circuit is

blocked as soon as the thermostat opens.
DH14-W00 Jul. 2008 2-31

D. Radiator E. Radiator cap

SAFETY FIRST
2
GENERAL
1
1
ENGINE
CLUTCH
3
T46W231A
2
(1) Cooling air (3) Pin
TRANSMISSION
T46W232A
(2) Tube
(1) Pressure valve (2) Vacuum valve
The radiator core consists of water tubes (2) with fin (3)
at a right angle to it. The water in the radiator is cooled The radiator cap is equipped with the pressure valve (1)
down by the air flowing between the tube wall and the and vacuum valve (2).
HST
fin.
(A) At High Pressure - Over 88 kPa (0.9 kgf/cm,
13 psi)
REAR AXLE
When the water temperature rises and the pressure in

the radiator increases above the specified value, the
pressure valve (1) opens to drain the coolant to the
reservoir tank to reduce the internal pressure.
BRAKE
(B) At Low Pressure

When the water temperature drops down and a vacu-
um is generated in the radiator, the vacuum valve (2)
FRONT AXLE
opens to allow the coolant in the reservoir tank to enter

into the radiator.
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C & HEATER
2-32 DH14-W00 Jul. 2008

3.4 Fuel system
SAFETY FIRST
3.4.1 Fuel flow route
GENERAL
ENGINE
CLUTCH
6 5
TRANSMISSION
4
8
9
3
HST
1
REAR AXLE
2
BRAKE
7
FRONT AXLE
T46W233A
STEERING
Components
(1) Fuel tank (4) Injection pipe (7) Fuel feed pump
(2) Fuel filter (5) Injection nozzle (8) Bleeding bolt
HYDRAULIC
(3) Fuel injection pump (6) Fuel overflow pipe (hose) (9) Bleeding hose
The fuel in the fuel tank (1) is drawn to the fuel feed
pump (7) and then is supplied to the fuel injection pump
ELECTRIC
(3) passed through the fuel filter (2). Then, the fuel in-
jection pump feeds the fuel to the injection nozzles (5)
which then inject the fuel into the cylinders for combus-
tion. The excessive fuel from the fuel injection pump
CABIN
to the injection nozzles is collected in the fuel overflow

pipes (6) and returns to the fuel tank.
Notes
A/C & HEATER
For air bleeding, see the next page.
DH14-W00 Jul. 2008 2-33

3.4.2 Fuel filter 3.4.4 Fuel feed pump

SAFETY FIRST
a (A)
From
(B)
fuel tank
To fuel
filter
2
GENERAL
1 4
1
b 2 5
3 6
c
ENGINE
4
3
5
6
7
CLUTCH
T46W234A T46W235A
(a) To fuel tank (c) To fuel injection pump (1) Intake valve (5) Chamber
(b) From fuel feed pump (2) Push rod (6) Diaphragm
TRANSMISSION
(3) Tappet (7) Fuel camshaft

(1) Cock (4) Retainer ring
(4) Exhaust Valve
(2) Air vent (5) Port
(3) Filter body (6) Filter element
The fuel from fuel feed pump enters into the filter port push rod (2). The tappet is reciprocated by the eccen-
HST
through the (b) port and passes through the filter paper. tric cam on the fuel camshaft (7).
Then, it is drained through the (c) port and supplied
to the fuel injection pump. The filter paper collects the (A) Intake stroke
REAR AXLE
particles bigger than 90 microns (0.0034 in.) at 20 kPa

(0.2 kgf/cm, 3 psi). When the diaphragm is pulled down by the spring,
vacuum in the chamber (5) causes the exhaust valve (4)
3.4.3 Bleeding the fuel system to close and the atmospheric pressure in the fuel tank
to force the fuel into the chamber, opening the intake
1. Make sure that the amount of fuel in the fuel tank is
valve (1).
BRAKE
sufficient.
2. If there is air in the fuel filter, turn the filter cock (1),
shown in the figure (3.4.2), to the air side and crank (B) Scavenging stroke
the engine. Then, the air in the filter port is discharged
FRONT AXLE
When the diaphragm is pushed up by the cam, the

through the bleeding hose (9) shown in the figure (3.4.1).
pressure in the chamber causes the intake valve to
CAUTION close and forces out the fuel, opening the exhaust
valve.
Do not crank for over 5 seconds. Crank the
STEERING
engine for several times while keeping the

cranking time below 5 seconds.
3. When the amount of fuel in the fuel filter port goes

HYDRAULIC
over 3/4 level, stop cranking the engine and turn the
cock (1) of the figure (3.4.2) to the "ON" position.
Notes
ELECTRIC
The bleeding process could be skipped if installing

the fuel port after filling the bowl with fuel.
4. Loosen the bleeding bolt (8) in the figure (3.4.1)

and crank the engine to bleed air. Then tighten the
CABIN
bolt again.
5. If the engine still cannot be started, loosen 1 or 2
nozzle holders (No. 10 of figure 3.4.1) and crank
A/C & HEATER
the engine to bleed air.

6. When the air bubble is not seen anymore in the bleed-
ing fuel, tighten the loose parts and start the engine.
2-34 DH14-W00 Jul. 2008

3.4.5 Fuel injection pump Operation of Pump Element
SAFETY FIRST
a
GENERAL
1
3
b
1 4
2
5
3
6
ENGINE
4
2
6 5
CLUTCH
7
TRANSMISSION
T46W236A

T46W238A
HST
(3) Delivery valve (7) Plunger spring (1) Delivery chamber (4) Feed hole
(4) Cylinder (8) Tappet (2) Plunger (5) Fuel chamber
(3) Delivery valve (6) Control groove
REAR AXLE
pump. It features a compact and light weight design. (A) Before Delivery
As the plunger (2) lowers, fuel is drawn into the deliv-
Pump element
ery chamber (1) through the feed hole (4) from the fuel
chamber (5).
BRAKE
4 (B) Beginning of Delivery
When the plunger is pushed up by the cam and the
FRONT AXLE
2 head of the plunger closes the feed hole (4), the pres-
sure in the delivery chamber (1) rises to push the deliv-
ery valve (3) open.
1 5 (C) Delivery
STEERING
While the plunger (2) is rising, delivery of fuel contin-
6 ues.
3
(D) End of Delivery
HYDRAULIC
7
When the plunger rises further and the control groove
T46W237A
stops because the pressure in the delivery chamber (1)
is reduced to the opening pressure.
ELECTRIC

(4) Feed hole
CABIN
The pump element (1) consists of a plunger (3) and

cylinder (2) which their sliding surfaces are finely ma-
chined to maintain the fuel tightness. The plunger (3)
is installed in the control sleeve (5) and the sleeve is
A/C & HEATER
engaged with the control rack that rotates the plunger

in the cylinder to control the amount of fuel delivered.
DH14-W00 Jul. 2008 2-35

Amount of Fuel Delivery Delivery Valve

SAFETY FIRST
1
4
1
GENERAL
2 5
6
3 2 3
4
ENGINE
CLUTCH
6
5
TRANSMISSION
T46W239A T46W241A
HST
(1) Slot (4) Delivery chamber (1) Valve spring (4) Fuel chamber
(2) Plunger (5) Feed hole (2) Delivery valve (5) Valve face
(3) Control rack (6) Control groove (3) Valve seal (6) Relief plunger
REAR AXLE
(A) No Fuel Delivery The delivery valve (2) prevents the fuel in the injection
When the control rack (3) is at the engine stop position, pipe from flowing back into the delivery chamber and
the lengthwise slot (1) on the plunger (2) aligns with the fuel in the injection nozzle from dribbling after injec-
the feed hole (5). The pressure in the delivery chamber tion.
does not build up and no fuel is forced to the injection The relief plunger (6) sucks the fuel back from the
BRAKE
nozzle since the delivery chamber (4) is opened to the injection pipe to prevent the leakage dribbling and un-
feed hole during the entire stroke of the plunger. necessary subsequent injection after the major injec-
tion.
FRONT AXLE
a b c The stroke of A corresponds to the amount of fuel

Location of fuel
sucked back (35 mm3).
supply
hole
STEERING
A A
HYDRAULIC
Stop
Low
speed High
speed
T46W240A
ELECTRIC
(B) Fuel Delivery

hole is not aligned with the lengthwise slot. When the
CABIN
plunger. The pressure in the delivery chamber builds

up and forces the fuel to the injection nozzle until the
control groove (6) meets the feed hole. The amount of
the fuel to be forced into the nozzle corresponds to dis-
A/C & HEATER
tance A. In the above figure, the amount of injected fuel

in (c) is larger than the amount of injected fuel in (b).
2-36 DH14-W00 Jul. 2008

3.4.6 Injection Nozzle
SAFETY FIRST
GENERAL
Supplied
fuel
ENGINE
CLUTCH
1
Excessive
fuel
TRANSMISSION
2
HST
REAR AXLE
4
6
7
BRAKE
9
FRONT AXLE
STEERING
T46W242A
HYDRAULIC
This injection nozzle is throttle type nozzle. It features The opening pressure can be adjusted by adding or
ELECTRIC
the low fuel consumption and works well with DAE- reducing the washer (2). A washer of 0.1 mm cor-
DONG combustion chamber. The nozzle valve opening responds to 980 kPa (10 kgf/cm, 142 psi) change in
pressure is about 14.7~15.7 MPa (150~160 kgf/cm, opening pressure. The heat seal (8) is adopted to im-
2,134~2,276 psi). When the pressure overcomes the prove the durability and reliability of the nozzle.
counterforce of nozzle valve spring (3), the pressure
CABIN
pushes up the needle valve (7) constantly and then the

proper amount of fuel is injected into the swirling air in
the combustion chamber for combustion.
A/C & HEATER
DH14-W00 Jul. 2008 2-37

3.4.7 CTD pump (for 4B243 or any other turbo charged)

SAFETY FIRST
GENERAL
Upper
lid
Sub port

ENGINE
CTDstroke
CTD
Main port

CLUTCH
CTD
CTD cut
Main lid

TRANSMISSION
T46W243A
HST
The CTD (Compact Timing Control Device) pump controls the injection timing depending on the engine condition to
reduce the exhaust gas and noise of the engine. The basic structure is the same as for the standard pump. However,
the plunger for CTD pump has the CTD cut and the sub port with its diameter of 0.4 mm (0.016in.).
REAR AXLE
CTD
CTDcut

BRAKE
Sub port
blocked
Main port
blocked

Sub
port
Main
port

FRONT AXLE
Delayed

Upper
lid

Main
lid
STEERING
HYDRAULIC
T46W244A T46W245A
For the standard pump, the fuel is injected by the pres- The injection is hardly delayed by the reciprocation of
sure applied on the top of the plunger as the plunger the plunger at high speed since the diameter of the sub
ELECTRIC
rises and the side of the plunger blocks the main port. port is as small as 0.5 mm. Therefore, the CTD pump
For the CTD pump, the sub port is still open due to the delays the injection timing at low speed and high torque
CTD cut even after the main port is blocked. Therefore, to reduce the exhaust gas and noise.
the fuel is not injected until the sub port is blocked. In
CABIN
other words, the injection is delayed as much as the

height of the CTD cut.
A/C & HEATER
2-38 DH14-W00 Jul. 2008

3.5 Governor and stop system
SAFETY FIRST
3.5.1 Basic principle of governor system
GENERAL
4 5 1 2
7 15 14 3
ENGINE
8 10
CLUTCH
TRANSMISSION
9
13
HST
6
REAR AXLE
12
Torque
# spring
11
BRAKE
Wls

##
FRONT AXLE
T46W246A
STEERING
Components
(1) Governor spring 1, 2 (6) Steel ball (11) Governor sleeve

(2) Solenoid guide (7) Governor lever (12) Fork lever 2
HYDRAULIC
(3) Stop solenoid (8) Idle spring (13) Fork lever 1

(4) Pump rack (9) Start spring (14) Fuel limit bolt
(5) Rack pin (10) Idle control shaft (15) Torque spring
ELECTRIC

(11) to prevent from coming out. The sleeve pushes the
fork lever 1 (13) to transfer the power to the fuel injec-
CABIN
tion pump pin (5).

A/C & HEATER
DH14-W00 Jul. 2008 2-39

3.5.2 Operation of Governor

SAFETY FIRST
1. When stopped 5. Load increase at high speed

The fuel is blocked since the solenoid (3) pushes the
injection pump control rack (4) of the injection pump to
the left.
GENERAL
b
2. When turning the key switch ON
When the electromagnet in the stop solenoid operates
a
and the pin is retracted, the injection pump control rack
ENGINE
(4) is pushed to the right by the start spring (9) and the
idle control shaft (10) to supply the sufficient amount of
fuel in order to start the engine.
CLUTCH
3. When starting the engine and running

Torque
curve
the engine at low idle speed
T46W247A
When the engine is started, the steel ball (6) pushes
TRANSMISSION
the governor sleeve (11) to the left as the centrifugal When a load is applied to the engine running at a high
force of the steel ball increases. Therefore, the gover- speed, the centrifugal force of steel ball (6) decreases
nor fork lever 1 (13) pushes the pump rack (4) to the as the engine speed drops. Also, the fork lever 2 (12)
left to reduce the amount of fuel supplied. is pulled to the right by the governor spring until it con-
As the control rack is stopped by the idle spring (8), it tacts the fuel limit bolt (14). Until then, the amount of
HST
keeps the balance with the centrifugal force of the steel injected fuel per one stroke of the injector plunger and
ball so that at least minimum amount of fuel is deliv- the torque increase.
ered for stable engine running at idle speed. This range (a) is between the max. speed point with no
REAR AXLE
4. Acceleration and deceleration load and the max. power point of the torque curve.
When depressing the accelerator pedal, the governor
(14) and does not move any more and the load is in-
spring (1) pulls the fork lever 2 (12) to the right and
creased, the centrifugal force of steel ball drops further
then pushes the fork lever 1 (13) to the right. The fork
BRAKE
and the torque spring (15) compressed between the

lever (13) is stopped by the governor sleeve(11).
fork lever 1 and 2 is loosened. Then, the fork lever 2
When the centrifugal force of the steel ball (6) that is moves to the right until the torque spring is free, and
proportional to the engine speed is balanced with the the amount of fuel supplied and the torque increase si-
FRONT AXLE
tension of the governor spring (1) that is determined by multaneously.

the driver, the stable speed is maintained.
This range (b) is between the max. power and the max.
torque point in the torque curve.
STEERING
Important
HYDRAULIC
adjustment of such components can negatively

D A E D O N G . S u c h a c t i o n v i o l a t e s t h e E PA
regulation and also can void the warranty.
ELECTRIC
6. When stopped
When the key switch is moved to the "OFF" position,
CABIN
the stop solenoid power is cut off to release the electro-

magnet. Therefore, the stop pin comes off by the return
force of the spring and pushes the solenoid guide (2)
and fuel injection pump rack to the stop position to stop
A/C & HEATER
the engine.
2-40 DH14-W00 Jul. 2008

3.6 PCV valve
SAFETY FIRST
GENERAL
ENGINE
CLUTCH
T46W248B
12
TRANSMISSION
6
10
7 11
HST
REAR AXLE
8
9
T46W249A
BRAKE
(1) Head cover bolt (7) Bleeding pipe
(2) Oil filler flange (8) Intake valve
(3) Oil baffle plate (9) Cylinder head
(4) Head cover gasket (10) Cylinder head cover
FRONT AXLE
(5) Cylinder head cover (11) Oil baffle plate
(6) Intake manifold (12) Bleeding pipe connection
A. PCV (Positive Crankcases Ventilation)
STEERING
The PCV system is a system that prevents air pollu-
tion by returning the blow-by gas to the intake manifold
through the bleeding pipe of the cylinder head cover for
HYDRAULIC
engine has the open crankcase type that discharges

the blow-by gas to the air.)
ELECTRIC
CABIN
A/C & HEATER
DH14-W00 Jul. 2008 2-41

ENGINE - TROUBLE SHOOTING DK35/40(C)/45(C)SE
4. TROUBLESHOOTING
SAFETY FIRST
Symptom Causes Remedy

Engine Does Not No fuel Add fuel
Start Air in fuel system Bleed air
GENERAL
Water in fuel system Change fuel and repair or flush fuel system
Clogged fuel pipe Clean
Clogged fuel filter Clean or replace
Excessively high viscosity of fuel or engine oil at Use the specified fuel or engine oil
ENGINE
low temperature
Fuel with low cetane number Use the specified fuel
Fuel leak due to loose injection pipe mounting nut Tighten nut
Incorrect injection timing Adjust
CLUTCH
Worn fuel camshaft Replace

Clogged injection nozzle Clean or replace
Defective fuel injection pump Repair or replace
TRANSMISSION
Defective fuel transfer pump Repair or replace

Seizure of transfer pump, defective piston, cylin- Repair or replace
der bore or bearing
Compression leak from cylinder Replace head gasket, tighten cylinder
head screws, glow plug and nozzle holder
Improper valve seating, damaged valve spring, Repair or replace
HST
valve seized
Improper valve timing Correct or replace timing gear
Worn piston ring and bore Repair or replace
REAR AXLE
Excessive valve clearance Adjust

Start motor Does Discharged battery Charge
Not Run Defective start motor Repair or replace
Defective key switch Repair or replace
Disconnected wiring Connect
BRAKE
Engine Running is Clogged or dirty fuel filter Clean or replace

Not Smooth Clogged Air cleaner Clean or replace
Fuel leak due to loose injection pipe mounting nut Tighten nut
FRONT AXLE
Defective fuel injection pump Repair or replace

Incorrect nozzle opening pressure Adjust or replace
Seized or clogged nozzle Repair or replace
Clogged fuel overflow pipe Clean or replace
STEERING
Defective governor Repair or replace

Either White or Excessive engine oil Reduce to the specified level
Blue Exhaust Worn piston ring and bore or seized piston ring Repair or replace
Smoke is Pro-
HYDRAULIC

duced Insufficient compression pressure Adjust valve clearance
Either Black or Overheat or overload Reduce load
Dark Gray Exhaust Low grade fuel used Use the specified fuel
ELECTRIC
Smoke is Pro- Clogged fuel filter Clean or replace

duced Clogged Air cleaner Clean or replace
Insufficient Output Incorrect injection timing Adjust
Seized engine components Repair or replace
CABIN
Uneven fuel injection Repair or replace the fuel injection pump

Insufficient nozzle injection Repair or replace the nozzle
Compression pressure leak Replace cylinder head gasket, check
tightness of cylinder head screws and
A/C & HEATER
nuts, glow plug and nozzle holder
2-42 DH14-W00 Jul. 2008

DK35/40(C)/45(C)SE ENGINE - TROUBLE SHOOTING
SAFETY FIRST
Symptom Causes Remedy
Excessive Engine Oil Aligned gaps of piston rings Change the ring gap direction
Consumption Worn or seized oil ring Replace
GENERAL
Worn piston ring groove Replace piston
Worn valve stem and guide Replace
Worn crankshaft bearings and crank pin bearings Replace
Fuel in Engine Oil Worn fuel injection pump plunger Replace pump element or pump
ENGINE
(Increased oil amount) Damaged fuel transfer pump Replace
Hydraulic Oil in Engine Damaged hydraulic pump seal Replace or repair

Oil (Increased oil
CLUTCH
amount)
Water in Engine Oil Defective cylinder head gasket Replace
Cracked cylinder block or cylinder head Replace
TRANSMISSION
Low Oil Pressure Insufficient engine oil Add
Clogged oil strainer Clean
Clogged oil filter cartridge Replace
Relief valve stuck with dirt Clean
Weak or broken relief valve spring Replace
HST
Excessive oil clearance of crankshaft bearings Replace
Excessive oil clearance of crank pin bearings Replace
Excessive oil clearance of rocker arm bushings Replace
REAR AXLE
Clogged oil passage Clean
Improper type of oil Use the specified type of oil
Defective oil pump Repair or replace
High Oil Pressure Improper type of oil Use the specified type of oil
Defective relief valve Replace
BRAKE
Engine Overheating Insufficient engine oil Add
Damaged fan belt or improper tension Replace or adjust
Insufficient coolant Add
FRONT AXLE
Radiator screen and radiator fin clogged with dirt Clean
Corroded radiator Clean or replace
Corroded coolant flow line Clean or replace
Defective radiator cap Replace
STEERING
Damaged coolant pipe Replace
Defective thermostat Replace
Defective coolant pipe Replace
Overload running Reduce load
HYDRAULIC
Defective cylinder head gasket Replace

Improper fuel used Use the specified fuel
Coolant leakage Damaged mechanical seal on water pump Replace water pump
ELECTRIC
Frequently Discharged Insufficient battery electrolyte Add distilled water and charge
Battery Fan belt slip Adjust fan belt tension or replace it
Disconnected wiring Connect
Defective regulator or alternator Replace
CABIN
Defective battery Replace

A/C & HEATER
DH14-W00 Jul. 2008 2-43

ENGINE - MEASUREMENT AND ADJUSTMENT DK35/40(C)/45(C)SE
5. Measurement and adjustment

SAFETY FIRST
5.1 Fan belt 5.2 piston compression pressure

measurement
GENERAL
ENGINE
CLUTCH
TRANSMISSION
T46W250A T46W251A
Measure the deflection by depressing the center of the 1. Run the engine until it is warmed up.
belt between the fan drive pulley and the alternator pul- 2. Stop the engine and remove the air cleaner, the
ley at 98 N (10 kgf, 22 lbs) of force. muffler and all nozzle holders.
HST
If the deflection is out of the specified value, loosen the 3. Connect a compression tester to the nozzle holder hole.
bolts and nuts and adjust the location of the alternator.
4. Pull the stop lever or close the fuel filter with the
REAR AXLE
If the belt is damaged or worn (see figure), replace the cock to cut the fuel and crank the engine with the
belt. starter motor for 5 to 10 seconds.
Fan belt deflection...........7 ~ 9 mm 5. Measure the maximum pressure several times
(0.28 ~ 0.35 in.) while engine running.
6. If the pressure does not reach the allowable limit,
BRAKE
apply few drops of oil to the cylinder wall through the

nozzle holder hole and check the pressure again.
7. If the pressure rises after applying the oil, check the
FRONT AXLE
cylinder wall and piston ring for wear.

8. If the pressure is still low, check the top clearance,
valve clearance and cylinder head.
STEERING
Compression pressure Specified 3.24 ~ 3.73 MPa

value 33 ~ 38 kgf/cm
469 ~ 540 psi
Allowable 2.55 MPa
HYDRAULIC
lower limit 26 kgf/cm

370 psi
Pressure difference Allowable 10 %
between two cylinders limit
ELECTRIC
CAUTION
Check the compression pressure and adjust the
CABIN
valve clearance to the specified value.

A/C & HEATER
2-44 DH14-W00 Jul. 2008

DK35/40(C)/45(C)SE ENGINE - MEASUREMENT AND ADJUSTMENT
5.3 Valve clearance
SAFETY FIRST
A. 4 cylinders
1. The valve clearance should be measured only 5. Measure the clearance of the closed valves in the
when the engine temperature is same to the ambi- below table, which are the intake and exhaust valves
GENERAL
ent temperature. of the No. 1 cylinder, the intake valve of the No. 2
2. Disconnect the battery cables. cylinder and the exhaust valve of the No. 3 cylinder.
Adjust the clearance if necessary.
ENGINE
4. Turn the crankshaft slowly and then stop it when When the No. 4 cylinder is overlapped
the No. 4 cylinder (flywheel side) is at the overlap
1 2 3 4
period.
IN EX IN EX IN EX IN EX
CLUTCH
Notes
Special socket for rotating crankshaft
: closed, : open, : Overlap
TRANSMISSION
Overlap
HST
REAR AXLE
T46W254A
T46W252A
6. Turn the crankshaft just one turn (360) to position
the No. 1 cylinder valves to the overlap period.
BRAKE
Notes
Overlap:
When the exhaust stroke is completed and the
FRONT AXLE
intake stroke is about to start, the exhaust valve
is about to close, which is still open, and the
intake valve starts to open. This period is called
T46W253A
"overlap" and the center of the overlap period is
STEERING
when the height of the locker arms which push
- When turning the crankshaft, use only special two valves is same. At this time, the clearance
service tool (socket) with socket wrench. cannot be measured since the locker arms push
- How to make the crankshaft turning socket the intake and exhaust valves.
HYDRAULIC
a. C u t t h e c o u p l e r ( D A E D O N G p a r t N o . :
37805-4452-1) in half.
- You may also use DAEDONG special tool kit
ELECTRIC
(part No.: G0611-B0010).

CABIN
A/C & HEATER
DH14-W00 Jul. 2008 2-45

SAFETY FIRST
B. 3 cylinders
7. Measure the clearance of the closed valves in the 1. The valve clearance should be measured only
below table, which are the exhaust valve of No. 2 when the engine temperature is same to the ambi-
GENERAL
cylinder, the intake valve of the No. 3 cylinder and ent temperature.
the intake and exhaust valves of the No. 4 cylinder.
2. Disconnect the negative battery cable.
Adjust the clearance if necessary.
ENGINE
When the No. 1 cylinder is overlapped 4. Turn the crankshaft using the crankshaft turning
socket until the intake valve of the No. 2 cylinder
1 2 3 4
and the exhaust valve of the No. 3 cylinder move
IN EX IN EX IN EX IN EX simultaneously and the rocker arm height of these
CLUTCH
two valves is same.
: closed, : open, : Overlap

When the No. 1 cylinder is at T.D.C.
TRANSMISSION
1 2 3
IN EX IN EX IN EX
Overlap
HST
: closed, : open
5. Measure the clearance of the intake and exhaust

REAR AXLE
valves of the No. 1 cylinder, the exhaust valve of

T46W255A the No. 2 cylinder and the intake valve of the No. 3
cylinder. Adjust the clearance if necessary.
Important 6. Turn the crankshaft 360 and measure the clear-

ance of the intake valve of the No. 2 cylinder and
BRAKE
Valve clearance (3, 4 cylinders) the exhaust valve of the No. 3 cylinder. Adjust the
clearance if necessary.
IN EX
FRONT AXLE
A series 0.25 mm 0.30 mm

After one turn
B series (0.0098 in.) (0.0118 in.)
1 2 3
IN EX IN EX IN EX
STEERING
: closed, : open
HYDRAULIC
ELECTRIC
CABIN
A/C & HEATER
2-46 DH14-W00 Jul. 2008

5.4 Valve lift (deflection and worn 5.5. injection timing measurement
SAFETY FIRST
condition of valve cam, tappet, and adjustment
push rod, rocker arm, etc.)
Notes
GENERAL
2. Adjust the valve clearance according to the section
5.3. Perform the work with the engine installed in the
tractor.
3. Set the dial gauge so that its pointer is on the valve.
The valve should be closed and the rocker arm
ENGINE
should move as much as the free play.
4. Measure the max. valve movement while turning
the crankshaft.
5. Measure the max. vertical movement of other
CLUTCH
valves according to the above process.
6. The vertical movement for all valves should be in
the tolerance range of 0.5 mm (0.02 in.). If the mea-
TRANSMISSION
sured value is out of the tolerance, check the cor-
responding valve for the deflection of the pushrod,
worn condition, engagement with the tappet, worn
tappet and worn valve cam.
HST
T46W256A
T46W257A REAR AXLE

BRAKE
FRONT AXLE
STEERING
2. Remove the timing check window cover of the fly-

HYDRAULIC
wheel housing.
3. Turn the flywheel to find 1, 4 FI mark for 4-cylin-
der engine or 1 FI mark for 3-cylinder engine on the
flywheel.
ELECTRIC
4. When the mark was found, turn the crankshaft coun-

of the engine).
- "1, 4 FI" means the injection timing of the No. 1
CABIN
or 4 cylinders.
- For 4B243 engine equipped with the CTD pump,
it is marked on 18 and 22 of the flywheel.
A/C & HEATER
DH14-W00 Jul. 2008 2-47

SAFETY FIRST
Fuel

GENERAL
ENGINE
CLUTCH
T46W258A T46W261A
6. Remove the fuel in the nozzle holder with clean

- When turning the crankshaft, use a special ser-
cloth and leave only small amount of fuel.
vice tool (socket) for turning the crankshaft by
TRANSMISSION
engaging it with the socket wrench.

Notes of the engine) slowly.
8. When the amount of the fuel in the nozzle holder in-
How to make the crankshaft turning socket
creases abruptly, that moment is the injection timing.
HST

REAR AXLE

the exhaust cycle. Therefore, turn the crankshaft
360 to find the compression cycle and repeat the
above procedures.
BRAKE
T46W259A
through the timing window and measure the distance
a. Cut the coupler (DAEDONG part No.: between the "1, 4 FI" or "1 FI" and the mark you made.
37805-4452-1) in half.
FRONT AXLE
10. To advance the injection timing, reduce the amount

c. You can use DAEDONG speical tool kit amount of shims.
(part No.: G0611-B0010).
STEERING
HYDRAULIC
ELECTRIC
CABIN
T46W260A

A/C & HEATER

2-48 DH14-W00 Jul. 2008

5.6 oil pressure measurement
SAFETY FIRST
Flywheel
Injection Diameter of Amount of shims
Model circumfer-
timing flywheel to adjust 1
ence for 1
3B183
4B243
GENERAL
BTDC 315 mm 2.74 mm 0.1 mm
(for do- 18 (12.4 in.) (0.108 in.) (0.004 in.)
mestic
model)
4A200, BTDC 321 mm 2.8 mm 0.1 mm
ENGINE
4A220 18 (12.64 in.) (0.11 in.) (0.004 in.)
4B243
(for BTDC 321 mm 2.8 mm 0.1 mm
CLUTCH
export 22 (12.64 in.) (0.11 in.) (0.004 in.)
model)
T46W262A
- BTDC: Before top dead center 1. Remove the oil pressure switch and install the
TRANSMISSION
adapter and the pressure tester.
Example)
2. Start and warm up the engine. Then, measure the
For 4A200, if the measured injection timing is on the 2.8
oil pressure at idle and rated speed.
mm (2.74 mm for 3B183) above the FI mark, it means
that the injection timing is 1 advanced. Therefore, the 3. If the oil pressure is less than the allowable limit,
HST
measured injection timing is BTDC 19. In this case, check the oil level, oil filter, oil pump relief valve, oil
the injection is adjusted to 18 if adding 0.1 mm of shim passages and oil clearance.
under the fuel injection pump.
REAR AXLE
Engine oil At idle Specified over 49 kPa
pressure speed value 0.5 kgf/cm
7.11 psi
At rated Specified 294 ~ 441 mm
speed value 2.5 ~ 4.5 kgf/cm
BRAKE
35.6 ~ 64.0 psi
Allowable 245 kPa
FRONT AXLE
limit 2.5 kgf/cm
(lower limit)
35.6 psi
Oil pressure switch
STEERING
Tightening torque............14.7 ~ 19.6 Nm
1.5 ~ 2.0 kgf-m
10.8 ~ 14.5 lb-ft
HYDRAULIC
ELECTRIC
CABIN
A/C & HEATER
DH14-W00 Jul. 2008 2-49

5.7 Bubble test for radiator 5.8 injection nozzle Inspection

SAFETY FIRST
Notes CAUTION
Checking if air is leaked through the crack on the Never contact with spraying diesel under
GENERAL
cylinder wall pressure. It may penetrate the skin and cause the
serious injury.
Be sure nobody is in direction of the spray.
1. Check the coolant level of the radiator and the res-
ervoir tank. Add the coolant if necessary.
ENGINE
2. Start the engine with the radiator cap closed and

A. Fuel injection pressure
the reservoir tank cap open.
3. Check if any bubble can be seen in the overflow
hose on the bottom of the reservoir tank around 5
CLUTCH
minutes later.
4. If any bubble can be seen, remove the engine cyl-
inder head to check the head gasket for damage,
TRANSMISSION
the cylinder bore for crack and the cylinder head for
crack. Replace the components if necessary.
HST
T46W263A
REAR AXLE

3. If the measurements are not within the specified
range, replace the injection nozzle.
BRAKE
Specified value of fuel

injection pressure............14.70 ~ 15.68 MPa
FRONT AXLE
150 ~ 160 kgf/cm

2,133 ~ 2,275 psi
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C & HEATER
2-50 DH14-W00 Jul. 2008

SAFETY FIRST
GENERAL
ENGINE
B. Fuel tightness of needle valve seat
CLUTCH
TRANSMISSION
HST
T46W264A
REAR AXLE
2. Apply 130 kgf/cm of pressure consistently for 10
seconds and check if the fuel is leaked from the
nozzle.
BRAKE
3. If the fuel is leaked, replace the nozzle.
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C & HEATER
DH14-W00 Jul. 2008 2-51

ENGINE - EXPLODED VIEW DK35/40(C)/45(C)SE
6. Exploded view
SAFETY FIRST
Notes
The manufacturing parts are subject to change without notice. Therefore, check the parts catalog or electronic
GENERAL
manual for latest information.
6.1 E010 cylinder block

ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BRAKE
FRONT AXLE
STEERING
HYDRAULIC
T46W2F9B
ELECTRIC
Components
(1) Cylinder block assembly (10) Straight pin (19) Oil pump gasket
(2) Cylinder block (11) Straight pin (20) Bolt with captive washer
(3) Plug (12) Straight pin (21) Oil pump drive gear
CABIN
(4) Plug (13) Pipe pin (22) Key

(5) Plug (14) Coolant return pipe (23) Flange nut
(6) Plug (15) Plug (24) Oil switch
(7) Plug (16) Gasket (25) Oil gauge guide
A/C & HEATER
(8) Plug (17) Pipe pin

(9) Straight pin (18) Oil pump assembly
2-52 DH14-W00 Jul. 2008

DK35/40(C)/45(C)SE ENGINE - EXPLODED VIEW
6.2 E020 oil pan
SAFETY FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BRAKE
FRONT AXLE
STEERING
HYDRAULIC
T46W2H0B
ELECTRIC
Components
(1) Oil pan assembly (5) Drain plug (9) O-ring

(2) Oil pan gasket (6) Seal washer (10) Oil gauge
CABIN
(3) Flange bolt with captive pin (7) Oil filter 1 (11) Oil gauge guiding pipe
(4) Bolt with captive washer (8) Flange bolt with captive pin (12) Packing
A/C & HEATER
DH14-W00 Jul. 2008 2-53

6.3 E030 cylinder head

SAFETY FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BRAKE
FRONT AXLE
STEERING
HYDRAULIC
T46W2H1B
ELECTRIC
Components
(1) Cylinder hear assembly (7) Exhaust valve guide (13) Nut
(2) Cylinder head (8) Combustion chamber (14) Engine hook
CABIN
(3) Plug (9) Plug (15) Bolt with captive washer

(4) Plug (10) Stud bolt (16) Head gasket
(5) Plug (11) Engine hook (17) Head bolt
A/C & HEATER
(6) Intake valve guide (12) Spring washer
2-54 DH14-W00 Jul. 2008

6.4 E040 gear case
SAFETY FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BRAKE
FRONT AXLE
STEERING
T46W2H2B
HYDRAULIC
Components
(1) Gear case assembly (13) Belt seat (25) Bolt with captive washer
(2) Gear case (14) Steel ball (26) Plain washer
ELECTRIC
(3) Plug (15) Cover (27) Coolant return flange

(4) O-ring (16) Cover bolt (28) Gaske
(5) O-ring (17) O-ring (29) Bolt with captive washer
(6) O-ring (18) O-ring (30) Stud bolt
(7) Straight pin (19) Flange bolt (31) Nut
CABIN
(8) Oil filter support (20) Gear case gasket (32) Spring washer
(9) O-ring (21) Bolt with captive washer (33) Oil filter
(10) Bolt with captive washer (22) Bolt with captive washer (34) Oil filter
A/C & HEATER
(11) Connecting pipe (23) Bolt with captive washer

(12) Spring (24) Bolt with captive washer
DH14-W00 Jul. 2008 2-55

6.5 E050 main bearing case

SAFETY FIRST
GENERAL
ENGINE
DK 35
4 6
CLUTCH
5
7
6
3
TRANSMISSION
2
HST
2
REAR AXLE
2 1
2 10
BRAKE
2
9
FRONT AXLE
13
8
STEERING
13
11
HYDRAULIC
12
T46W2H3A
ELECTRIC
Components
(1) Main bearing case assembly (6) Flange bolt with captive pin (11) Washer
(2) Bearing case bolt 1 (7) Oil seal (12) Bearing case bolt 2
CABIN
(3) Bearing case gasket (8) Main bearing case assembly 1 (13) Straight pin
(4) Main bearing case cover (9) Main bearing case assembly 2
(5) Bearing case cover gasket (10) Main bearing case assembly 3
A/C & HEATER
2-56 DH14-W00 Jul. 2008

6.6 E080 valve rocker arm
SAFETY FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BRAKE
FRONT AXLE
STEERING
HYDRAULIC
T46W2H4B
ELECTRIC
Components
(1) Intake valve (7) Rocker arm shaft assembly (13) Snap ring
(2) Exhaust valve (8) Rocker arm shaft (14) Rocker arm
CABIN
(3) Valve spring (9) Sealing cap (15) Control nut

(4) Valve spring support (10) Rocker arm support (16) Control screw
(5) Valve spring collet (11) Plain washer (17) Rocker arm support bolt
A/C & HEATER
(6) Valve stem seal (12) Rocker arm spring
DH14-W00 Jul. 2008 2-57

6.7 E030 cylinder head cover

SAFETY FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BRAKE
FRONT AXLE
STEERING
HYDRAULIC
T46W2H5B
ELECTRIC
Components
(1) Cylinder hear cover assembly (6) Screw with captive washer (11) Head cover bolt
(2) Cylinder head cover (7) Bleeding connection
CABIN
(3) Valve cover (8) Cylinder head cover gasket

(4) O-ring (9) Blowby hose
(5) Oil baffle plate (10) Band
A/C & HEATER
2-58 DH14-W00 Jul. 2008

6.8 E100 camshaft
SAFETY FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BRAKE
DK 35
FRONT AXLE
STEERING
HYDRAULIC
T46W2H6B
ELECTRIC
Components
(1) Tappet (7) Key (13) Spacer 2

(2) Push rod (8) Camshaft stopper (14) Snap ring
CABIN
(3) Camshaft assembly (9) Bolt with captive washer (15) Idle gear shaft
(4) Camshaft (10) Idle gear assembly (16) Flange bolt with captive pin
(5) Filler plug (11) Idle gear
A/C & HEATER
(6) Camshaft gear (12) Idle gear bushing
DH14-W00 Jul. 2008 2-59

6.9 E110 piston crankshaft

SAFETY FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
series A
HST
REAR AXLE
BRAKE
series B
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
T46w2H7B
Components
(1) Piston assembly (9) Connecting rod assembly (17) Crankshaft metal 1 (25) Space cylinder
(2) Piston (10) Connecting rod (18) Crankshaft metal 2 (26) Oil seal
CABIN
(3) Piston pin (11) Piston pin bushing (19) Side metal 1 (27) Crankshaft nut
(4) Piston ring assembly (12) Connecting rod bolt (20) Side metal 2 (28) Oil pump drive gear
(5) Piston ring 1 (13) Crank pin metal (21) Key
A/C & HEATER
(6) Piston ring 2 (14) Crankshaft assembly (22) Crankshaft gear

(7) Oil ring assembly (15) Crankshaft (23) Oil slinger
(8) Piston pin snap ring (16) Filling plug (24) O-ring
2-60 DH14-W00 Jul. 2008

6.10 E120 flywheel
SAFETY FIRST
HST
GENERAL
mechanical
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BRAKE
FRONT AXLE
STEERING
HYDRAULIC
T46W2H8A
ELECTRIC
Components
(1) Flywheel assembly (8) Cover gasket (15) Nut

(2) Flywheel (9) Timing mark cover (16) Spring washer
CABIN
(3) Ring gear (10) Bolt with captive washer (17) Starter
(4) Flywheel bolt (11) Flange bolt with captive pin (18) Stud bolt
(5) Flywheel housing (12) Bolt with captive washer (19) Nut
A/C & HEATER
(6) Plug (13) Starter assembly (20) Spring washer

(7) Straight pin (14) Starter gasket (21) Spline hub(DK35)
DH14-W00 Jul. 2008 2-61

6.11 E130 nozzle holder

SAFETY FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BRAKE
FRONT AXLE
STEERING
HYDRAULIC
The DK35 is 3-cylinder engine which has three nozzles and three glow plugs.
T46W2H9B
ELECTRIC
Components
(1) Nozzle holder assembly (6) Injection pipe 3 (11) Glow plug
(2) Heat seal (7) Injection pipe 4 (12) Glow plug powerstrip
CABIN
(3) Gasket (8) Pipe clamp 1 (13) Overflow pipe assembly

(4) Injection pipe 1 (9) Pipe holder (14) Fuel tube
(5) Injection pipe 2 (10) Screw with captive washer (15) Hose clamp
A/C & HEATER
2-62 DH14-W00 Jul. 2008

6.12 E140 fuel camshaft
SAFETY FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BRAKE
FRONT AXLE
STEERING
T46W2i1B
HYDRAULIC
Components
(1) Fuel injection camshaft assembly (12) Ball case clip (23) Spring washer
(2) Fuel injection camshaft (13) Clip (24) Nut
ELECTRIC
(3) Ball bearing (14) Snap ring (25) Bolt with captive washer
(4) Ball bearing (15) Fuel camshaft stopper (26) Fuel pipe joint
(5) Key (16) Bolt with captive washer (27) Eye bolt
(6) Injection pump gear assembly (17) Stud bolt (28) Stud bolt
(7) Injection pump gear (18) Injection pump shim (T0.45) (29) Fuel pump gasket
CABIN
(8) Steel ball (19) Injection pump shim 1 (T0.3) (30) Fuel pump assembly
(9) Governor sleeve (20) Injection pump shim 2 (T0.15) (31) Spring washer
(10) Steel ball (21) Injection pump shim 3 (T0.1) (32) Nut
A/C & HEATER
(11) Governor ball case (22) Injection pump assembly
DH14-W00 Jul. 2008 2-63

6.13 E150 speed control plate

SAFETY FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BRAKE
FRONT AXLE
STEERING
HYDRAULIC
T46W2i2B
ELECTRIC
Components
(1) Fuel control bolt (8) Speed control plate (15) Flange nut
(2) Control nut (9) Speed control gasket (16) Stop screw
CABIN
(3) Gasket (10) Spring (17) Nut

(4) Cap nut (11) Spring pin (18) Wire
(5) Snap ring (12) Oil seal (19) Seal copper
A/C & HEATER
(6) Cap (13) Bolt with captive washer

(7) Speed control lever (14) Stud bolt
2-64 DH14-W00 Jul. 2008

6.14 E160 engine stop lever
SAFETY FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BRAKE
FRONT AXLE
STEERING
T46W2i3B
HYDRAULIC
Components
(1) Idle limit system assembly (12) Speed control plate (23) Engine stop solenoid guide
(2) Spring (13) Engine stop lever 2 assembly (24) O-ring
ELECTRIC
(3) Idle control shaft (14) Oil seal (25) Stud bolt
(4) Bushing (15) Spring (26) Flange nut
(5) Idle control body (16) Engine stop lever 1 (27) Oil filler plug cover
(6) Idle control bolt (17) Spring pin (28) Gasket
(7) Spring (18) Speed control plate gasket (29) Bolt with captive washer
CABIN
(8) Nut (19) Bolt with captive washer (30) Bolt with captive washer
(9) O-ring (20) Stud bolt (31) Cable bracket
(10) Packing (21) Flange nut (32) Oil filler plug
A/C & HEATER
(11) Cap (22) Solenoid assembly
DH14-W00 Jul. 2008 2-65

6.15 E170 governor

SAFETY FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BRAKE
FRONT AXLE
STEERING
HYDRAULIC
T46W2i4B
ELECTRIC
Components
(1) Governor lever assembly (8) Fork lever shaft (15) Bolt with captive washer
(2) Fork lever assembly (9) Fork lever 2 (16) Governor spring 1r
CABIN
(3) Fork lever 1 (10) Bolt (17) Governor spring 2

(4) Fork lever pin 1 (11) Spring washer
(5) Fuel limit pin (12) Fork lever holder
A/C & HEATER
(6) Fuel control spring (13) Bolt

(7) Mounting screw (14) Bolt with captive washer
2-66 DH14-W00 Jul. 2008

6.16 E180 water pump
SAFETY FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
11
2 8
1
2
6
13
HST
12
5 4
REAR AXLE
6 3
7
14
BRAKE
16
15
FRONT AXLE
10
17
STEERING
HYDRAULIC
T46W2i5A
ELECTRIC
Components
(1) Water pump assembly (7) Fan pulley (13) Spring washer
(2) Water pump body (8) Water pump body gasket (14) Stud bolt
CABIN
(3) Water pump bearing (9) Bolt with captive washer (15) Spring washer
(4) Impeller (10) Bolt (16) Nut
(5) Mechanical seal assembly (11) Stud bolt (17) Timing screw
A/C & HEATER
(6) Flange (12) Nut
DH14-W00 Jul. 2008 2-67

6.17 E190 coolant pipe

SAFETY FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BRAKE
FRONT AXLE
STEERING
HYDRAULIC
T46W2i6C
ELECTRIC
Components
(1) Coolant flange (8) Coolant return pipe (15) Dual sensor
(2) Coolant flange gasket (9) Pipe (16) Nut
CABIN
(3) Bolt with captive washer (10) Pipe band (17) Pipe
(4) Stud bolt (11) Thermostat (18) Pipe band
(5) Bolt with captive washer (12) Gasket
A/C & HEATER
(6) Nut (13) Thermostat cover

(7) Spring washer (14) Bolt with captive washer
2-68 DH14-W00 Jul. 2008

6.18 E200 AC generator
SAFETY FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BRAKE
FRONT AXLE
STEERING
HYDRAULIC
T46W2i7B
ELECTRIC
Components
(1) AC generator assembly (8) Plain washer (15) Key

(2) Spacer (9) Bolt with captive washer (16) Fan belt
CABIN
(3) Bolt (10) Cooling fan (17) Plain washer

(4) Plain washer (11) Fan collar (18) Spring washer
(5) Spring washer (12) Bolt with captive washer (19) Nut
A/C & HEATER
(6) Nut (13) Plain washer

(7) Generator support (14) Fan drive pulley
DH14-W00 Jul. 2008 2-69

6.19 E220 manifold

SAFETY FIRST
GENERAL
ENGINE
CLUTCH
TRANSMISSION
HST
REAR AXLE
BRAKE
FRONT AXLE
STEERING
HYDRAULIC
T46W2i8B
ELECTRIC
Components
(1) Inlet manifold (4) Stud bolt (7) Flange nut

(2) Inlet manifold gasket (5) Exhaust Manifold gasket (8) Bolt with captive washer
CABIN
(3) Bolt with captive washer (6) Exhaust manifold (9) Exhaust pipe
A/C & HEATER
2-70 DH14-W00 Jul. 2008

DK35/40(C)/45(C)SE ENGINE - SERVICING
7. SERVICING
SAFETY FIRST
7.1 engine assembly Removal and installation
GENERAL
1
ENGINE
4
CLUTCH
3
T46W265A T46W268A
TRANSMISSION
1. Park the tractor on level ground and disconnect the 8. Disconnect or remove the accelerator cables (1).
negative battery cable. Drain the coolant, engine 9. Remove the rubber hose of hydraulic suction pipe
oil, hydraulic fluid and fuel if necessary. connection (2).
* Drain the transmission fluid before removing any
hydraulic parts.
HST
10. Separate two hydraulic pipes (3) from the hydraulic
pump or remove them from the tractor.
11. Disconnect two steering hoses (LH, RH) (4) from
REAR AXLE
the left and right steering cylinders and disconnect
the steering return hose and steering supply hose.
(See Steering for details.)
Symbols for 4 types of
BRAKE
steering hoses
P (Pump):
T46W266A
This is the hydraulic supply hose installed
2. Remove the hood (1) and side covers (LH/RH) (2).
FRONT AXLE
between modulator valve and steering unit. It is
indicated by red tape on both ends.
T (Return):
This is the return hose installed between the
STEERING
steering unit and the hydraulic block on the gear
pump. It doesn't have any mark. For the HST
tractor, this hose comes out of the steering unit
and is connected to the HST oil cooler.
HYDRAULIC
2 4 R (Right turn):
This hose is installed between steering unit and
RH steering cylinder. It is indicated by white tape
on both ends.
ELECTRIC
1
3
T46W267A
L (Left turn):
This hose is installed between steering unit and
3. Remove the floor mat (1).
LH steering cylinder. It is indicated by yellow tape
4. Remove the clutch link pin (2) to disconnect the link. on both ends.
CABIN
5. Remove the LH/RH brake rod pins (3) under the

floor deck to separate the rod and link.
6. Disconnect the shuttle lever rod connection (4).
A/C & HEATER
7. Disconnect the connectors of wiring between the

panel and engine and wiring harness between the
panel and transmission.
DH14-W00 Jul. 2008 2-71

ENGINE - SERVICING DK35/40(C)/45(C)SE
17. Remove the docking bolts and nuts from the clutch
SAFETY FIRST
housing and flywheel housing.

* M12 tightening torque.. 77.4 ~ 90.2 Nm
7.9 ~ 9.2 kgf-m
57.1 ~ 66.5 lb-ft
GENERAL
1 18. Chock the rear wheels.

19. Separate the mating section by rolling the front
wheels to forward direction.
* Liquid gasket for contact surface of mating sec-
ENGINE
tion: Three Bond 1206D

2 * For detailed installation procedures, refer to the
T46W269A chapter "Clutch".
CLUTCH
20. Drain the fuel in the fuel tank by disconnecting the

12. Remove the panel mounting bolts (1) at both sides. inlet hose of the fuel feed pump.
13. Remove all mounting bolts (2) from floor deck. 21. Remove the fuel tank (1).
TRANSMISSION
14. Remove the steering column by lifting it slowly with

a hoist. 2
* Be careful not to damage the hoses, wirings and
cables.
1
HST
REAR AXLE
BRAKE
3 T46W272A
22. Remove the muffler (1), air filter hose (2) and radia-
tor hose (3).
FRONT AXLE
1
T46W270A
15. Remove the shaft cover to remove the front wheel

drive shaft (1).
STEERING
HYDRAULIC
1
ELECTRIC
T46W273A
23. Hook the chain on the engine towing eyes and lift
the engine slightly using a hoist.
CABIN
T46W271A
WARNING
Support the front frame with a stand so that the
16. Place two hydraulic jacks on the rail as shown in
A/C & HEATER
tractor does not fall forward when the engine is

the figure and position them under the transmission
removed from it.
housing and engine oil pan.
2-72 DH14-W00 Jul. 2008

7.2 PCV valve
SAFETY FIRST
24. Remove the engine frame mounting bolts.
* M12(9T) tightening torque 77.4 ~ 100.0 Nm
7.9 ~ 10.2 kgf.m
GENERAL
57.1 ~ 73.7 lb-ft
* The engine cylinder block is made by casting.
Therefore, the 9T bolt should be tightened to the
torque specified for the 7T bolt.
ENGINE
25. Remove the engine by lifting it gently.
CLUTCH
TRANSMISSION
HST
T46W275B
1. Remove the blow-by hose (1).

2. Remove the cylinder head cover bolts (2).
REAR AXLE
T46W274A
3. Remove the head cover (3) and gasket (4).

26. Remove the cooling fan, fuel filter, alternator, gear
4. Remove the PCV valve cover (5) or oil baffle plate (6)
pump, clutch cover, starter motor and reservoir tank
if necessary.
if necessary.
27. Install in the reverse order of removal.
BRAKE
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C & HEATER
DH14-W00 Jul. 2008 2-73

7.3 head cover installation 7.5 heat seal Removal

SAFETY FIRST
2
GENERAL
3
ENGINE
4
CLUTCH
T46W276b T46W278A
1. Make sure that the head cover gasket is well seat- (1) Philips screwdriver (3) Injection nozzle gasket
TRANSMISSION
ed on the groove of the cylinder head cover. (2) Nozzle (4) Heat seal
2. When installing the head cover, keep the specified

1. Drive the Philips screwdriver lightly into the heat seal
tightening torque and tighten the bolts gradually
hole.
into 3 ~ 4 steps.
2. Turn the Philips screwdriver three or four times each
HST
3. Ensure that the cylinder head cover gasket (1) is

way.
not defective.
3. While turning the Philips screwdriver, slowly pull out
Cylinder head cover bolt (M8)
the heat seal together with the injection nozzle gas-
REAR AXLE
..........................................8.8 ~ 11.8 Nm
ket. If the heat seal drops, repeat the above proce-
0.9 ~ 1.2 kgf-m
dure.
6.5 ~ 8.7 lb-ft
4. The heat seal and injection nozzle gasket must be
replaced once the injection nozzle has been re-
BRAKE
moved for cleaning or service.

7.4 Glow plug and fuel overflow pipe
Notes
FRONT AXLE
Use a Philips screwdriver with the size of 0.6

4 mm. This is slightly larger than the hole diameter
5 of heat seal.
6
STEERING
1
2
3
HYDRAULIC
ELECTRIC
T46W277A
1. Disconnect the high-pressure injection pipe (5) and

CABIN
the overflow pipe (6).

2. Remove the glow plugs (4).
3. Remove the injection nozzle (1), gasket (2) and
A/C & HEATER
heat seal (3).

Refer to "7.5 Removal of heat seal".
2-74 DH14-W00 Jul. 2008

7.6 Rocker arm assembly
SAFETY FIRST
7.6.1 Removal and installation
GENERAL
1
ENGINE
4
CLUTCH
3
TRANSMISSION
2
HST
REAR AXLE
T46W280A
Components
(1) Rocker arm shaft (3) Rocker arm support
BRAKE
(2) Rocker arm (4) Rocker arm support bolt
FRONT AXLE
A. Removal B. Installation
1. Remove the rocker arm mounting bolts (4) by loos-
ening them in several steps.
2. Remove the rocker arm assembly and the push
STEERING
rod.
Push rod
#
HYDRAULIC
Tappet

ELECTRIC
T46W281A
1. Make sure that the push rod is seated on the con-

CABIN
caved area of the tappet.

A/C & HEATER
DH14-W00 Jul. 2008 2-75

SAFETY FIRST
7.6.2 rocker arm assembly check
3 cylinders
GENERAL
ENGINE
Installation
order
4 cylinders
CLUTCH
9
10
11
Installation
order
TRANSMISSION
T46W279A T46W282A
2. Tighten the rocker arm support bolts to the speci- 1. Measure the rocker arm I.D. with an inside microm-
fied torque in several steps with the specified se- eter.
quence as shown in the figure. 2. Measure the rocker arm shaft O.D. with an outside
3. Adjust the valve clearance after assembling the micrometer.
HST
rocker arm assembly. 3. If the clearance exceeds the allowable limit, replace
the rocker arm.
Important
REAR AXLE
4. If the clearance still exceeds the allowable limit af-

Bolt ter replacing the rocker arm, replace the rocker arm
shaft.
Clearance Specified 0.020 ~ 0.070 mm

BRAKE
size (0.00079 ~ 0.00276 in.)
Rocker arm shaft Allowable 0.15 mm

T46W2J0A
limit (0.0059 in.)
FRONT AXLE
Rocker arm Specified 18.955 ~ 18.980 mm

To tighten the rocker arm support bolt, the groove
shaft O.D. size (0.74626 ~ 0.74724 in.)
on the rocker arm shaft should face the bolt.
Rocker arm Specified 19.000 ~ 19.025 mm
STEERING
Rocker arm mounting bolt I.D. size (0.74803 ~ 0.74902 in.)

(M10).................................60.8 ~ 73.5 Nm
6.2 ~ 7.2 kgf-m
44.8 ~ 54.2 lb-ft
HYDRAULIC
ELECTRIC
CABIN
A/C & HEATER
2-76 DH14-W00 Jul. 2008

7.7 cylinder head
SAFETY FIRST
7.7.1 Cylinder head removal 7.7.2 cylinder head installation
1. Apply the liquid gasket (Three bond 1215 or equiv-
alent) on both sides of coolant flange gasket.
GENERAL
2. Always replace the head gasket with a new one. Pay
particular attention to its direction and orientation.
3. Remove any gasket residue out of mating surfaces
ENGINE
of the cylinder head and cylinder block before in-
stalling the new cylinder head gasket. Be careful
not to get the residue enter into the block or the
head. (Use a vacuum cleaner to clean the residue.)
CLUTCH
4. Before installing the tappets, apply engine oil
around them.
Important
TRANSMISSION
T46W283A
Installation sequence for head bolts Apply the oil to the thread of head bolts and tighten
them to the specified torque in several steps and
the specified sequence shown in the figure.
Unscrew
47# from
No. 14 to No. 1 Retighten them in 30 minutes after running the
4##
HST
Tighten from engine and adjust the valve clearance.
4#
No. 1 to No. 14
47#
# Cylinder head bolts
Flywheel Gear case
REAR AXLE
#
side
side
Unscrew from
10.5 ~ 11.0 kgf-m
4;#
No. 18 to No. 1 75.9 ~ 79.6 lb-ft
4##
Tighten from
4#
No. 1 to No. 18
4;# 7.7.3 Cylinder head surface flatness
check
BRAKE
T46W284A
(1) Cylinder head (2) Coolant flange
FRONT AXLE
1. Loosen the head bolts in the reverse sequence as
shown in the figure.
(Follow the sequence in the figure when tightening
them.)
STEERING
2. Lift it slightly with a hoist by using the hook.
3. Remove the coolant flange (2) if necessary.
4. Remove the tappets from the cylinder block.
HYDRAULIC
T46W285A
CAUTION
Mark the cylinder number to the tappets to
2. Place a straight edge on the cylinder head and
prevent them from interchanging.
measure the clearance with a feeler gage as shown
ELECTRIC
in the figure.
3. If the measured value exceeds the allowable limit,
replace the cylinder head.
CABIN
Important
Do not place the straight edge on the combustion
chamber.
A/C & HEATER
Allowable limit.................0.05 mm
0.0019 in.
DH14-W00 Jul. 2008 2-77

7.8 intake and exhaust valves

SAFETY FIRST
7.8.1 valve Removal 7.8.3 Valve recess check
12
11
GENERAL
10
9
8
7
6
5
4
ENGINE
3
2
1
0
3
1
CLUTCH
2 T46W287A
5
4
1. Clean the cylinder head, the valve face and the
TRANSMISSION
T46W286A valve seat.

2. Insert the valve into the valve guide.
(1) Valve (4) Valve spring
(2) Collet (5) Valve stem seal
3. Measure the valve recess with a depth gauge.
(3) Retainer 4. If the recess value exceeds the allowable limit, re-
place the valve and check the valve seat.
1. Compress the valve spring with the replacer and
HST
remove the collet (2). Valve recess Specified 0.2 ~ 0.5 mm

value 0.0078 ~ 0.0197 in.
2. Remove the retainer (3), valve spring (4), valve
REAR AXLE
stem seal (5) and the valve (1). Allowable 0.8 mm

limit 0.0315 in.
Important
Be careful not to interchange the valves and
related components.
7.8.4 Valve seat check
BRAKE
Mark the cylinder number on the valve and the

parts to prevent interchanging.
FRONT AXLE
7.8.2 valve Installation

1. Apply oil to the stem of valve and install it into the
STEERING
cylinder head.
2. Lubricate the valve and its related parts after instal-
lation.
HYDRAULIC
T46W288A
1. Coat the valve face lightly with red lead and put the
valve on its seat to check the contact.
2. If the valve does not seat all the way around the
ELECTRIC
valve seat or the valve contact is less than 70%,

correct the valve seating as follows.
3. Apply compound on the valve face evenly.
4. Put the valve on its seat and hold it with the valve
flapper.
CABIN
5. Turn the valve back and forth on the valve seat to lap.
6. Remove the compound and clean the valve and the
seat.
A/C & HEATER
7. Apply oil on the valve face and finish to complete

fitting.
8. Repeat lapping until the valve seats correctly.
2-78 DH14-W00 Jul. 2008

SAFETY FIRST
7.8.5 Valve spring check 7.8.6 Valve spring squareness (Tilt)
GENERAL
ENGINE
CLUTCH
T46W289A T46W290A
1. Measure the free length of the spring with vernier 1. Place the spring on the flat plate and then put a
TRANSMISSION
calipers. square at its side.
2. Place the spring on a spring compression tester 2. Measure the maximum distance "A" while rotating
and compress to the specified length to measure the spring.
the tension. 3. If the measurement exceeds the allowable limit, re-
3. If the measured value is less than the allowable place the spring.
HST
limit, replace the valve spring.
Valve spring Allowable 1.0 mm
squareness limit
REAR AXLE
Tension Specified 117 N / 35.15 mm 0.039 in.
value 12.0 kgf / 35.15 mm
26.5 lbs / 1.3839 in.
Allowable 100 N / 35.15 mm
limit 10.2 kgf / 35.15 mm
22.5 lbs / 1.3839 in.
BRAKE
Free length Specified 41.7 ~ 42.2 mm
value 1.6417 ~ 1.6614 in.
FRONT AXLE
Allowable 41.2 mm
limit 1.622 in
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C & HEATER
DH14-W00 Jul. 2008 2-79

7.9 injection pump

SAFETY FIRST
7.9.1 injection pump Removal 7.9.2 injection pump Installation

1. Apply the liquid gasket (Three bond 1215, 1104 or
1
equivalent) on the pump installation surface of the
GENERAL
cylinder block.
2. Install the shims as they were.

Injection pump
ENGINE
3 #
control rack lever
2
Fork lever 1
4#
CLUTCH
4
TRANSMISSION
T46W291A T46W294A
1. Remove the injection pipes (1) and the intake mani- 3. Make sure that the lever of the pump control rack is
fold (2). on the outer side from the fork lever 1 when install-
2. Remove the overflow pipe (3). ing the pump.
HST
3. Remove the oil filler flange (4).
Tightening sequence of bolt or nut:

123456
REAR AXLE
1
BRAKE
FRONT AXLE
T46W293B
T46W292A
STEERING
4. Remove the idle limit spring mounting bolt (1).
WARNING
HYDRAULIC
Never remove the idle limit spring seal (2).

Otherwise, it could negatively affect the emission
control and the engine may not be covered by
warranty any more.
ELECTRIC
5. Remove the fuel injection pump.

T46W295B
6. Keep the shims just like they were.
4. Tighten the nuts to the specified torque in several
CABIN
steps in the correct sequence as shown in the figure.

M8......................................23.5 ~ 27.4 Nm
2.4 ~ 2.8 kgf-m
A/C & HEATER
17.3 ~ 20.2 lb-ft

5. Tighten the idle limit spring mounting bolt.
2-80 DH14-W00 Jul. 2008

SAFETY FIRST
7.9.3 injection pump disassembly 7.9.4 nozzle holder disassembly
GENERAL
3
ENGINE
4
1
5
CLUTCH
1
7 2
TRANSMISSION
2
8
4
5
HST
7
6
REAR AXLE
T46W296A T46W297A
(1) Pump body (5) Delivery valve (1) Nozzle holder (5) Distance piece
(2) Control rack (6) Tappet roller (2) Adjusting washer (6) Nozzle
(3) Delivery valve holder (7) Plunger (3) Nozzle spring (7) Nozzle nut
BRAKE
(4) Delivery valve spring (8) Cylinder (4) Push rod

Important
FRONT AXLE
2. Remove the nozzle holder (1) and take out the in-
When disassembling the pump components, the ternal components.
amount of fuel injection should be adjusted on a
designated bench. Installation
STEERING
Only authorized service personnel should Before installing the nozzle, soak it in clean fuel.
disassemble or reassemble the fuel injection
When installing the push rod (4), be careful of its
pump.
direction.
HYDRAULIC
ELECTRIC
CABIN
A/C & HEATER
DH14-W00 Jul. 2008 2-81

7.10 governor spring and stop solenoid

SAFETY FIRST
Removal installation
GENERAL
ENGINE
1
CLUTCH
T46W298A
1. Remove the idle adjusting bolt (1), fuel injection

TRANSMISSION
pump (2) and oil filler flange (3).

1
HST
2
REAR AXLE
T46W2A5A
(1) Governor spring 1 (3) Fork lever 2

(2) Governor spring 2 (4) Governor lever
BRAKE
T46W299A
1. When installing the governor spring, make sure that
3. Remove the stop solenoid (1). Be careful not to the governor spring 2 is installed on the inside of
governor spring 1.
FRONT AXLE
drop the stop solenoid guide (2).
CAUTION
Be careful of the direction of the governor spring
STEERING
1. The longer side should face the governor fork.

If the governor spring is dropped during the
installation, the crankcase should be disassembled
again. Therefore, use a hook not to drop the
HYDRAULIC
governor spring.
2. The governor spring can also be installed by install-

ing one end to the throttle lever first and then the
ELECTRIC
T46W2A0A other end to the long hole of the governor fork.
4. Remove the governor spring using a hook after re-

moving the throttle cover (1).
Be careful not to pop out the governor spring.
CABIN
- The governor spring can also be removed by dis-

engaging it from the fork lever and then removing
it engaged with the throttle lever.
A/C & HEATER
2-82 DH14-W00 Jul. 2008

7.11 Gear case
SAFETY FIRST
removal installation
GENERAL
ENGINE
1
CLUTCH
2
TRANSMISSION
T46W2A2b T46W2A4A
(1) Crankshaft nut (2) Fan drive pulley 1. Apply the grease to the crankshaft oil seal (1) lip on
the gear case and take care not to damage it when
1. Remove the crankshaft nut (1).
installing.
2. Remove the fan drive pulley (2).
2. Apply the grease on the O-ring (2) and attach it to
HST
Crankshaft nut the gear case to prevent it from coming off during
Tightening torque............137.3 ~ 156.9 Nm reassembling.
14.0 ~ 16.0 kgf-m
3. Make sure that the gear case mounting bolts are
REAR AXLE
101.3 ~ 115.7 lb-ft
installed at correct locations.
Important
BRAKE
In general, the bolt should be screwed as 1.5
times as the diameter of the bolt in length.
FRONT AXLE
5. Install all bolts and increase the tightening torque
gradually (in 2 to 3 steps).
M8 tightening torque.......23.5 ~ 27.4 Nm
2.4 ~ 2.8 kgf-m
STEERING
17.3 ~ 20.2 lb-ft
HYDRAULIC
T46W2A3A
3. Unscrew the crankcase mounting bolts to remove

the gear case.
ELECTRIC
CABIN
A/C & HEATER
DH14-W00 Jul. 2008 2-83

7.12 Idle gear and crank gear

SAFETY FIRST
Removal Installation
1. If necessary, heat the crankshaft (2) gear up to ap-
prox. 80C (176F) and insert it to the crankshaft.
GENERAL
2. Apply the oil to the O-ring (5) on the left figure.

3. The tapered face of the crankshaft collar should be
first to contact with the O-ring.
ENGINE
4. Install the idle gear while aligning the marks on the

all gears as shown in the figure.
CLUTCH
TRANSMISSION
T46W2A6A
(1) Idle gear (4) Oil slinger

(2) Crankshaft gear (5) O-ring
(3) Oil pump drive gear 1 (6) Crankshaft collar
HST
1. Remove the crankshaft collar (6), O-ring (5), oil

slinger (4) and oil pump drive gear 1 (3) in order.
2. Remove the idle gear (1).
REAR AXLE
T46W2A7A
3. Remove the crankshaft gear (2) with a puller set.
(1) Idle gear (4) Fuel camshaft gear
Notes (2) Crankshaft gear (5) Valve camshaft gear
(3) Oil pump gear
The oil pump drive gear (3) is only for the B series
BRAKE
engine. It is not installed to the A series engine.

Important
Instead, the crankshaft gear (2) of the A series
engine is longer than that of the B series as much Even the one misalignment of these marks on the
gears can lead to fatal failure of the engine.
FRONT AXLE
as the thickness of the oil pump drive gear (3).

STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C & HEATER
2-84 DH14-W00 Jul. 2008

7.13 Valve camshaft 7.14 Fuel camshaft
SAFETY FIRST
Removal Removal
GENERAL
ENGINE
Service

hole
CLUTCH
TRANSMISSION
T46W2A8A T46W2F5A
(1) Camshaft (2) Cam gear 1. Remove the fuel camshaft stopper (1).
1. Align the holes on the cam gear (2) with the bolt
holes and unscrew the bolts through the service
HST
hole with a T handle wrench.
2. Remove the camshaft (1).
3. Remove the cam gear (2).
REAR AXLE
Installation
If necessary, heat the cam gear up to approx. 80C
(176F) and insert it to the camshaft (1).
BRAKE
FRONT AXLE
T46W2A9A
(1) Fork lever 1 (4) Camshaft

(2) Fork lever 2 (5) Fork lever holder
(3) Fuel injection pump gear
2. Unscrew the fork lever holder screws and remove STEERING

the fuel camshaft (4), fork lever holder (5), fork le-
ver 1 (1) and fork lever 2 (2) at the same time.
HYDRAULIC
3. Remove the fuel camshaft gear (3) from the fuel

camshaft if necessary.
Installation
ELECTRIC
If necessary, heat the fuel camshaft gear up to ap-

prox. 80C (176F) and insert it to the camshaft.
CABIN
A/C & HEATER
DH14-W00 Jul. 2008 2-85

7.15 crank gears and shafts check

SAFETY FIRST
7.15.1 Timing gear backlash 7.15.3 Valve camshaft gear side clearance
GENERAL
ENGINE
CLUTCH
T46W2B0A
T46W2B2A
1. Set a dial indicator (lever type) with its tip on the
TRANSMISSION
gear tooth. (1) Camshaft (3) Camshaft stopper

2. Move the timing gear to measure its backlash while (2) Camshaft gear
holding the engaged gear to it.
1. Pull the cam gear (2) and the camshaft (1).
3. If the backlash exceeds the allowable limit, check the
oil clearance of the shafts and the gear. (See 7.15.7) 2. Measure the clearance (A) between cam gear (2)
4. If the oil clearance is OK but the backlash is over and camshaft stopper (3).
HST
the allowable limit, replace the gear. 3. If the clearance exceeds the allowable limit, replace
Backlash Specified value 0.04 ~ 0.11 mm
REAR AXLE
0.0016 ~ 0.004 in. Side clear- Specified value 0.07 ~ 0.22 mm

Allowable limit 0.15 mm ance 0.028 ~ 0.0781 in.
0.0059 in. Allowable limit 0.3 mm
0.0118 in.
7.15.2 Idle gear side clearance

BRAKE
7.15.4 Fuel camshaft gear side clearance

FRONT AXLE
STEERING
HYDRAULIC
T46W2B1B
(1) Idle gear collar 2 (2) Idle gear

T46W2B3A
1. Pull the idle gear collar 2 (1) and push the idle gear (1) Fuel injection pump gear (2) Snap ring
ELECTRIC
(2) at its end.

2. Measure the clearance (A) between idle gear and 1. Measure the clearance (A) between fuel injection
idle gear collar 2 with a feeler gauge. pump gear (1) and snap ring (2) on the fuel camshaft.
3. If the clearance exceeds the allowable limit, replace 2. If the clearance exceeds the allowable limit, check
the idle gear (2). the gear, the bearing and the key.
CABIN
Side clear- Specified value 0.20 ~ 0.51 mm Side clear- Specified value 0.15 ~ 0.57 mm
ance 0.0079 ~ 0.0201 in. ance 0.0059 ~ 0.0224 in.
A/C & HEATER
Allowable limit 0.9 mm Allowable limit 0.9 mm

0.035 in. 0.035 in.
2-86 DH14-W00 Jul. 2008

SAFETY FIRST
7.15.5 Idle gear oil clearance mea- 7.15.7 Valve camshaft oil clearance
surement measurement
GENERAL
ENGINE
9
10
11
CLUTCH
TRANSMISSION
T46W2B4A T46W2B6A
1. Measure the idle gear shaft O.D. with an outside 1. Measure the I.D. of the camshaft bore on the crankcase
micrometer. with an inside micrometer.
2. Measure the idle gear bushings I.D. with an inside 2. Measure the O.D. of the camshaft journal with an
micrometer. outside micrometer.
HST
3. If the clearance exceeds the allowable limit, replace 3. If the clearance exceeds the allowable limit, replace
the bushing. the shaft.
REAR AXLE
Oil Specified 0.025 ~ 0.066 mm Oil Specified 0.050 ~ 0.091 mm
clearance value 0.00098 ~ 0.00259 in. clearance value 0.00197 ~ 0.00358 in.
Allowable 0.1 mm Allowable 0.15 mm
limit 0.004 in. limit 0.0059 in.
Shaft Specified 37.959 ~ 37.975 mm Journal Specified 39.934 ~ 39.950 mm
BRAKE
O.D. value 1.4944 ~ 1.4950 in. O.D. value 1.57221 ~ 1.57284 in.
Bushing Specified 38.000 ~ 38.025 mm Bore I.D. Specified 40.000 ~ 40.025 mm
I.D. value 1.4961 ~ 1.4970 in. value 1.57480 ~ 1.57579 in.
FRONT AXLE
7.15.6 idle gear bushing replacement
STEERING
HYDRAULIC
ELECTRIC
T46W2B5A
1. Press out the bushing using replacing tool.

CABIN
2. Clean the bore, and apply the oil on it.

3. Press in the new bushing using the replacing tool.
A/C & HEATER
DH14-W00 Jul. 2008 2-87

7.15.8 valve Camshaft deflection 7.16 piston and connecting rod

SAFETY FIRST
check
Removal
GENERAL
ENGINE
CLUTCH
T46W2b9A
T46W2B7A
1. Remove the oil pan and oil pan gasket.

1. Place the camshaft on V blocks with its journals
TRANSMISSION
supported and set a dial indicator with its tip on the 2. Remove the oil strainer (1).
intermediate journal. Installation
2. Measure the eccentricity (half of the measured Be sure to install the O-ring (2) between oil
value) while turning the camshaft on the V blocks. strainer and cylinder block.
HST
place the camshaft.

REAR AXLE
limit 0.002 in.
7.15.9 valve Cam height measurement

BRAKE
T46W2C0A
FRONT AXLE
3. Rotate the crankshaft so that the connecting rod

cap (4) comes to the bottom. Then, remove the bolt
(3) and the cap (4).
4. Rotate the crankshaft so that the piston (5) comes to
STEERING
the top. Then, tap the connecting rod with a rubber

hammer to pop the piston out of the top of the block.
HYDRAULIC
T46W2B8A
1. Measure the height of the camshaft lobe at largest

1
O.D. with an outside micrometer.
2
2. If the measured value is below the allowable limit,
ELECTRIC
replace the camshaft.
Cam 3A183 IN. Specification 33.59 mm 1

height 4A200 1.322 in.
CABIN
4A220 Allowable 33.54 mm

limit 1.320 in.
4B243 T46W2C2A
EX. Specification 33.69 mm
1.326 in. 5. Remove the piston rings with a piston ring replacing tool.
A/C & HEATER
Allowable 33.64 mm 6. Remove the piston pin snap ring (1) and then re-
limit 1.324 in. move the piston pin (2).
2-88 DH14-W00 Jul. 2008

Installation
SAFETY FIRST
GENERAL
Top
ring
end (Y
Mark (Y
or R)R)
Exhaust
manifold
side gap
Undercut
#
ENGINE
Side 2nd
2 ring
Oil ring

mark
Injection pump side end
gap
end gap
T46W2C5A

(1) Top ring (2) 2nd ring (3) Ring
CLUTCH
T46W2C3A
8. Make sure that the undercut of the 2nd ring faces
downward.
9. Apply the oil on the crankpin bearing, cylinder wall
TRANSMISSION
1 and connecting rod cap screw.
HST
1
REAR AXLE
3 T46W2F6A
2
T46W2C4A
1. Clean all the parts before installation.
BRAKE
2. Warm up the piston by soaking it in hot oil (approx.
80 C) for 10 to 15 minutes before inserting the pis-
ton pin into the piston.
FRONT AXLE
3. Install the piston and connecting rod with the mark 2
FW on the piston facing the flywheel and the side T46W2C1A
marks on the connecting rod facing the fuel injec-

10. Insert the connecting rod and piston assembly with
tion pump.
STEERING
the arrow mark (1) on the piston and the stamped
4. The manufacturer mark (Y or R) (3) on the top ring number (2) on the connecting rod facing the fuel
should face the top of the piston. injection pump using a piston ring compressor.
5. The cutout of expander (1) should face the opposite 11. Apply the engine oil to the connecting rod cover
HYDRAULIC
side of the oil ring (2) end gap. bolts and hand tighten them all the way down.
Then, tighten them with a torque wrench. If they
6. The top ring end gap ring should be on the opposite
would not be tightened to the specified torque, re-
side of the combustion chamber on piston.
place the bolts. The both stamped numbers should
7. The 2nd ring end gap and the oil ring end gap be seen from one side.
ELECTRIC
should be 120 far from the top ring end gap. Connecting rod cover bolt 44.1 ~ 49.0 Nm
4.5 ~ 5.0 kgf-m
32.5 ~ 36.1 lb-ft
Important
CABIN
Mark the cylinder number on the piston and

connecting rod to prevent them from interchanging.
Be careful not to damage the chrome-plate area
A/C & HEATER
on the piston ring when pressing the piston and

ring assembly into the cylinder.
DH14-W00 Jul. 2008 2-89

7.17 piston and connecting rod check

SAFETY FIRST
7.17.1 Piston pin bore 7.17.2 piston pin and bushing Clearance
GENERAL
ENGINE
9
10
11
CLUTCH
T46W2C8A
1. Measure the piston pin O.D. with an outside micrometer.

TRANSMISSION
T46W2C7A
1. Measure the I.D. of piston pin bore (lengthwise and micrometer.
widthwise of the piston) with a cylinder gauge. 3. If the clearance still exceeds the allowable limit af-
2. If the measured value exceeds the allowable limit, ter replacing the bushing with new one, replace the
replace the piston. piston pin.
HST
Piston pin Specified 25.000 ~ 25.006 mm Clearance Specified 0.014 ~ 0.038 mm

bore I.D. value (0.9843 ~ 0.9845 in.) between value (0.00055 ~ 0.00150 in.)
REAR AXLE
piston pin Allowable 0.15 mm

Allowable 25.03 mm
and bushing limit (0.0059 in.)
limit (0.9854 in.)
Piston pin Specified 25.002 ~ 25.011 mm
O.D. value (0.98433 ~ 0.98469 in.)
Bushing Specified 25.025 ~ 25.040 mm
BRAKE
I.D. value (0.98524 ~ 0.98583 in.)
7.17.3 piston pin bushing replacement

FRONT AXLE
STEERING
HYDRAULIC
Removal
Press
in
T46W2C9A
ELECTRIC
1. Press out the bushing using a bushing replacing tool.

2. Clean the new bushing and the bore and apply the
oil to them.
CABIN
Important
Align the oil holes (1) of the connecting rod and
A/C & HEATER
the bushing.
2-90 DH14-W00 Jul. 2008

7.18 piston ring measurement
SAFETY FIRST
7.18.1 Piston ring end gap 7.18.2 Piston ring clearance
GENERAL
ENGINE
CLUTCH
TRANSMISSION
T46W2D0A T46W2D1A
1. Place the piston ring to be measured on the top 1. Clean the ring and ring grooves, and install each
face of piston in cylinder block and slightly push in ring in its groove.
the piston and piston ring. (Do not put the piston 2. Measure the clearance between the ring and the
ring on the carbon layer.) ring groove with a feeler gauge.
HST
2. Measure the ring end gap with a feeler gauge. 3. If the clearance exceeds the allowable limit, replace
3. If the gap exceed the allowable limit, replace the the piston ring.
piston ring.
REAR AXLE
4. If the clearance still exceeds the allowable limit
after removing the ring with new one, replace the
Piston ring 2nd Specified 0.55 ~ 0.70 mm piston.
end gap ring value (0.0217 ~ 0.0276 in.)
Allowable 1.25 mm Piston ring 2nd Specified 0.04 ~ 0.08 mm
BRAKE
limit (0.0492 in.) clearance ring value (0.00157 ~ 0.00314 in.)
Top ring, Specified 0.25 ~ 0.40 mm Allowable 0.15 mm

oil ring value (0.0098 ~ 0.0157 in.) limit (0.0059 in.)
FRONT AXLE
Allowable 1.25 mm Oil ring Specified 0.02 ~ 0.06 mm
limit (0.0492 in.) value (0.00079 ~ 0.00236 in.)
Allowable 0.15 mm
4. If the gap is still over the allowable limit with even limit (0.0059 in.)
STEERING
new ring, measure the diameter of bore (see page
2-97). HYDRAULIC
ELECTRIC
CABIN
A/C & HEATER
DH14-W00 Jul. 2008 2-91

7.19 crankshaft and flywheel

SAFETY FIRST
Removal
GENERAL
ENGINE
CLUTCH
TRANSMISSION
T46W2D2A T46W2D4A
1. Install the stopper on the flywheel and unscrew the 3. Remove all main bearing case bolts (1).
bolts. 4. Remove the crankshaft by tapping it to the flywheel
direction with a rubber hammer.
Notes
HST
The crankshaft wrench or the ring gear can be used CAUTION

as a flywheel stopper.
Securely hold the main bearing so that it does
REAR AXLE
not strike the cylinder block or crankshaft when

removing it.
Installation
BRAKE
FRONT AXLE
STEERING
3
HYDRAULIC
up
T46W2D5A
ELECTRIC
2 1. Install the main bearing case with its "Flywheel"

mark facing flywheel side. Apply the oil on the metal
T46W2D3A
bearing.
2. Loosen the inner bolts (2) first and then outer bolts
(3) on the main bearing cover (1). Important
CABIN
If the main bearing case is installed backwards,

its oil delivery hole will not be aligned with the
hole of the cylinder block which can cause
A/C & HEATER
engine stall.
2-92 DH14-W00 Jul. 2008

SAFETY FIRST
2. The number of lines (1) on the edge indicates the
main bearing case number.
The first bearing from the crankcase - 1 line
GENERAL
The second bearing from the crankcase - 2 lines
The third bearing from the crankcase
- No line. different in shape for 3-cylinder type
ENGINE
The fourth bearing from the crankcase
- No line, different in shape
* For some models, the number is stamped on the
edge.
CLUTCH
T46W2D7A
5. Align the main bearing mounting bolt hole with

the hole on the cylinder block. Apply the sufficient
TRANSMISSION
amount of oil to the mounting bolt and tighten it with
a hand completely.
6. Tighten them with the torque wrench.
Main bearing mounting bolt torque
HST
(A, B series)......................68.6 ~ 73.5 Nm
7.0 ~ 7.5 kgf-m
50.6 ~ 54.2 lb-ft
REAR AXLE
T46W2D6A
3. When installing the main bearing case cover bolts,

apply the oil on them and tighten them with a hand
BRAKE
until they are not screwed in. Then, tighten them
with the torque wrench in several steps. 1 2
3
FRONT AXLE
Main bearing cover bolt 4
(A, B series)......................46.1 ~ 50.9 Nm
4.7 ~ 5.2 kgf-m
33.9 ~ 37.6 lb-ft
STEERING
4. Insert the crankshaft with the main bearing cases
assembled into the cylinder block. Apply the suffi-
T46W4J2A
cient amount of oil on the main bearing.
7. Assemble the main bearing case cover (1) with the
HYDRAULIC
oil seal (2).

* Be sure to assemble the bearing cover gasket (3)
and bearing case cover gasket (4).
ELECTRIC
CABIN
A/C & HEATER
DH14-W00 Jul. 2008 2-93

SAFETY FIRST
9. Crankshaft and flywheel have their own reference

hole on the mating surface. When installing the
crankshaft and the flywheel, align the holes.
GENERAL
Notes
ENGINE
CLUTCH
TRANSMISSION
up
HST
2
T46W2D3A
Notes
REAR AXLE
When installing the main bearing case cover, the

"UP" mark on it should be at the highest position
so that its holes are aligned with the holes of the
cylinder block.
BRAKE
T46W2F8A
8. Tighten the outer bolts (3) first, then tighten the in- If the flywheel is turned from the original position and
ner bolts (2). then installed, the bolts cannot be tightened.
FRONT AXLE
Align the installation reference holes (arrow in the

M8......................................23.6 ~ 27.4 Nm
figure) before installation.
2.4 ~ 2.8 kgf-m
17.4 ~ 20.2 lb-ft
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C & HEATER
2-94 DH14-W00 Jul. 2008

SAFETY FIRST
10. When installing the flywheel bolts, apply the oil on
them and tighten them with a hand until they are
hand-tightened. Then, tighten them with a torque
GENERAL
wrench to the specified torque. Tighten the bolts
diagonally in several steps.
Notes
ENGINE
CLUTCH
TRANSMISSION
HST
T46W2D2A
It is recommended to insert a long bolt (M8, pich 1.25)
REAR AXLE
into the flywheel for easier installation.
Flywheel bolt
10.0 ~ 11.0 kgf-m
BRAKE
72.3 ~ 79.6 lb-ft
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C & HEATER
DH14-W00 Jul. 2008 2-95

7.20 metal journal bearings

SAFETY FIRST
GENERAL
2
ENGINE
Mating notch

3
CLUTCH
1
TRANSMISSION
21 19
HST
REAR AXLE
20
4
BRAKE
T46W2F7A
FRONT AXLE
1. The crank pin metal bearing (1) should be aligned

Important
with the mating notch of the connecting rod (2) or
connecting rod cap (3) before installation. The oil groove of the side metal 1, 2 should face
STEERING
outward. In other words, the oil groove should be

Apply sufficient amount of oil to the bearing be-
seen after the side metal is installed to the main
fore and after the installation.
bearing case.
2. The crankshaft metal bearing 2 (4) should be
If it is installed backwards, it can cause engine stall.
aligned with the notch of the main bearing case and
HYDRAULIC
main bearing case cap (6). The protrusion part of the side metal 2 (20) should
face doward.
Apply sufficient amount of oil to the bearing be-
fore and after the installation.
3. The side metal 1 (19) and side metal 2 (20) can Notes
ELECTRIC
only be installed to the main bearing case cover as-

Install the bearing case and cap to the crankshaft
sembly (21), which is right next to the flywheel.
immediately after installing the crankshaft bearing
Apply sufficient amount of oil before and after the and side metal to prevent the misplace of the
installation. bearing.
CABIN
A/C & HEATER
2-96 DH14-W00 Jul. 2008

7.21 flywheel and crankshaft check
SAFETY FIRST
7.21.1 Flywheel deflection and 7.21.3 crankshaft journal and bear-
crankshaft end play ing 1 Oil clearance
GENERAL
ENGINE
9
10
11
CLUTCH
T46W2D8A
TRANSMISSION
1. Set a dial indicator with its tip on the rear friction
face of the flywheel near the edge. T46W2E0A
2. Turn the flywheel to measure the deflection or the

uneven wear. 1. Measure the I.D. of the crankshaft bearing 1 with
an inside micrometer.
3. If the measured value exceeds the allowable limit,
remove the flywheel and check the mating faces of 2. Measure the O.D. of the crankshaft journal with an
HST
the crankshaft and flywheel. outside micrometer.
4. If it is scored or worn excessively, regrind the sur- 3. If the clearance exceeds the allowable limit, replace
face of the flywheel or replace the flywheel. the crankshaft metal bearing.
REAR AXLE
5. Measure the end play while moving the crankshaft
with flywheel back and forth to each end. A series engine (4A200, 4A220)
6. If the end play exceeds the allowable limit, replace
the side bearing. Oil Specified 0.040 ~ 0.118 mm
clearance value (0.00157 ~ 0.00465 in.)
Deflection Allowable 0.05 mm
BRAKE
Allowable 0.20 mm
limit (0.0020 in.)
limit (0.0079 in.)
End play Specified 0.15 ~ 0.31 mm
Journal Specified 51.921 ~ 51.940 mm
value (0.0059 ~ 0.0122 in.)
O.D. value (2.04414 ~ 2.04488 in.)
FRONT AXLE
Allowable 0.5 mm
Bearing 1 Specified 51.980 ~ 52.039 mm
limit (0.020 in.)
I.D. value (2.04646 ~ 20.4878 in.)
7.21.2 Crankshaft deflection
STEERING
B series engine (3B183, 4B243)
Oil Specified 0.050 ~ 0.122 mm

Allowable 0.20 mm
HYDRAULIC
limit (0.0079 in.)

O.D. value (2.35909 ~ 2.35934 in.)
T46W2D9A
ELECTRIC
1. Place the crankshaft on V blocks with its journals I.D. value (2.362 ~ 2.364 in.)
supported and set a dial indicator with its tip on the
intermediate journal.
2. Measure the eccentricity (half of the measured
CABIN
value) while turning the crankshaft on the V blocks.

A/C & HEATER

limit (0.0031 in.)
DH14-W00 Jul. 2008 2-97

SAFETY FIRST
7.21.4 crankshaft metal bearing 1 7.21.5 crankshaft journal and bear-

replacement ing 2 Oil clearance
GENERAL
ENGINE
CLUTCH
TRANSMISSION
T46W2E1A T46W2E2A
(1) Seam 1. Place a plastigauge in lengthwise on the center of

the journal.
1. Press out the crankshaft metal bearing 1 (1) using
the replacing tool. 2. Install the bearing cap, tighten the bolts to the
HST
specified torque once and remove the cap again.

2. Clean a new crankshaft metal bearing 1 (1) and
bore and apply the engine oil on them. 3. Measure the amount of the flatness with a scale
REAR AXLE
3. Press in a new bearing 1 (1) using a pressing-in

tool while checking the seam of the metal bearing (1) 4. If the clearance exceeds the allowable limit, replace
is facing the exhaust manifold. the bearing.
4. Press in the metal bearing for 4.2 ~ 4.5 mm (A) A series engine (4A200, 4A220)
deeper than the cylinder block.
BRAKE

Allowable 0.20 mm
FRONT AXLE
limit (0.0079 in.)

O.D. value (2.04414 ~ 2.04488 in.)
STEERING
I.D. value (2.04646 ~ 2.04823 in.)

HYDRAULIC

Allowable 0.20 mm
limit (0.0079 in.)
ELECTRIC

O.D. value (2.35909 ~ 2.35934 in.)
I.D. value (2.361 ~ 2.363 in.)
CABIN
A/C & HEATER
2-98 DH14-W00 Jul. 2008

7.22 cylinder bore check
SAFETY FIRST
7.21.6 crank pin and connecting rod 1. Check the worn condition of the honing groove on
bearing 2 Oil clearance the bore.
2. Check the bore for scuffing or scoring.
GENERAL
ENGINE
CLUTCH
TRANSMISSION
T46W2E4A
T46W2E3A
1. Place a plastigauge in lengthwise on the center of

the crankpin.
2. Install the connecting rod, tighten the bolts to the
HST
specified torque once and remove the cap again.
3. Measure the amount of the flatness with the scale
REAR AXLE
the bearing.
T46W2E5A
A series engine (4A200, 4A220)
(A) Axial direction (B) Transverse direction
BRAKE
clearance value (0.00098 ~ 0.00343 in.) 1,2,3 Measuring Points
Allowable 0.20 mm 3. Measure the cylinder liner I.D. at six locations as
FRONT AXLE
limit (0.0079 in.) shown in the figure to find the largest worn area.
Crankshaft Specified 46.959 ~ 46.975 mm
4A200 83.000 ~ 83.022 mm
pin O.D. value (1.84876 ~ 1.84947 in.)
(3.2677 ~ 3.269 in.)
STEERING
pin Bearing value (1.85040 ~ 1.85221 in.) 4A220 87.000 ~ 87.022 mm
I.D. 3B183 (3.425 ~ 3.4261 in.)
4B243
HYDRAULIC

ELECTRIC
Allowable 0.20 mm
limit (0.0079 in.)
pin O.D. value (1.84876 ~ 1.84947 in.)
CABIN

pin Bearing value (1.85040 ~ 1.85221 in.)
I.D.
A/C & HEATER
DH14-W00 Jul. 2008 2-99

7.23 oil pump, oil filter, relief valve and oil strainer
SAFETY FIRST
7.23.1 relief valve of engine oil 7.23.2 oil pump check
Clearance between rotor and

GENERAL
lobe clearance of oil pump

ENGINE
CLUTCH
TRANSMISSION
T46W2E6B
(1) Relief valve ball (3) Relief valve spring T46W2E8A

(2) Relief valve seat
1. Remove the oil pump.

HST
2. Drain the engine oil and remove the oil filter to

check it.
3. Check the relief valve for dirt. Check the seat (2)
REAR AXLE
and ball (1) for damage.

4. If they are damaged, replace them.
5. Check the free length of the spring (3).
6. If it is less than the allowable limit, replace the
BRAKE
spring.
T46W2E9A
Spring free Specified 35 mm

length value (1.38 in.) 1. Measure the clearance between the outer rotor and
FRONT AXLE
inner rotor with a feeler gauge.

Allowable 30 mm
limit (1.18 in.) 2. Measure the clearance between the outer rotor and
the housing with a feeler gauge.
STEERING
CAUTION
the pump.
Install the relief valve cover
with the mark () faces Clearance Specified 0.10 ~ 0.16 mm
upside. between outer value (0.0039 ~ 0.0063 in.)
HYDRAULIC
rotor and inner

rotor
(0.0079 in.)
Clearance Specified 0.11 ~ 0.19 mm
between value (0.0043 ~ 0.0075 in.)
ELECTRIC
outer rotor and

housing
(0.0098 in.)
CABIN
Tightening torque of relief cover

bolt....................................32.4 ~ 36.3 Nm
3.3 ~ 3.7 kgf-m
A/C & HEATER
23.9 ~ 36.8 lb-ft
2-100 DH14-W00 Jul. 2008

End clearance of rotor in oil pump
SAFETY FIRST
GENERAL
ENGINE
CLUTCH
T46W2F0A
1. Place a plastigauge on the rotor and assemble the
TRANSMISSION
pump.
2. Disassemble the pump and measure the amount of
the flatness with a scale to get the clearance.
HST
the pump.
End clearance Specified 0.105 ~ 0.150 mm

value (0.00423 ~ 0.00591 in.)
REAR AXLE
(0.0079 in.)
BRAKE
FRONT AXLE
STEERING
HYDRAULIC
ELECTRIC
CABIN
A/C & HEATER
DH14-W00 Jul. 2008 2-101

7.24 thermostat 7.25 water pump

SAFETY FIRST
GENERAL
ENGINE
CLUTCH
T46W2F1A S76W2P9B
(1) Thermostat (2) Thermostat cover
Removal
TRANSMISSION

2. Pull out the thermostat (1).
Installation
HST
Apply the liquid gasket (Three Bond 1215 or equiv-

alent) on the gasket.
(The paper gasket can be used for some models.)
REAR AXLE
T46W2F4A
Opening temperature of thermo-
(1) Water pump flange (4) Mechanical seal
stat valve (2) Water pump bearing (5) Impeller
(3) Water pump body
BRAKE
Notes
If the coolant is leaked from the hole indicated
FRONT AXLE
by the arrow in the figure, it means that the

mechanical seal is damaged.
Removal
STEERING
1. Remove the fan and fan pulley.

2. Remove the water pump body from the gear case
cover.
HYDRAULIC
T46W2F2A
4. Remove the impeller and water pump body (3).
1. Suspend the thermostat in the water by a string 5. Remove the impeller from the water pump shaft.
with its end inserted between valve and seat. 6. Remove the mechanical seal (4).
ELECTRIC
2. While heating the water slowly, read the tempera-

tures when the valve starts to open and when the Installation
valve opens for approx. 8 mm.
3. If the measured values are not within the specified
value, replace the thermostat. CAUTION
CABIN
Opening Specified Initial opening temperature: The components of the water pump is firmly
temperature value 71 1.5 C (160 3 F) assembled together and they cannot be easily
disassembled or assembled without a special
A/C & HEATER
Below 85 C (185 F) at equipement. Therefore, it is recommended to replace

opening by 8 mm (0.315 in.) the whole water pump assembly.
2-102 DH14-W00 Jul. 2008

MEMO
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Daedong Workshop Manual Production Release 1.0

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What are the different sections covered in the workshop manual?

What are the different sections covered in the workshop manual?

What information is included on the engine identification plate?

What information is included on the engine identification plate?

DAEDONG

1. 3C Series Workshop Manual

2. 3A Series Workshop Manual

3. 4A, 3B, 4B Series Workshop Manual

The 3C100A is a vertical, water-cooled, 4-cycle diesel

tion due to the DAEDONGs circular combustion

SS30-W00 May. 2007 2-3

1.2 ENGINE EPA DECAL

This aluminum decal is riveted on the engine cylinder

Adjustments should be made when the engine is at normal operating

The bar code for the DAEDONG engine number is

1.4 ENGINE NUMBER ASSIGNMENT

tractor serial number and the amount of time used.

For example, FD4000001 means that this engine is F D 4 0 0 0 0 0 1

2-4 SS30-W00 May. 2007

Item Factory Specification

Direction of rotation Counterclockwise (wiewed from flywheel side)

SS30-W00 May. 2007 2-5

2.2 PERFORMANCE CURVE

Performance curve, obtained in accordance with SAE J 1995.

197g/Hp-hr X 22 HP = 4,334 kg/hr

2-6 SS30-W00 May. 2007

SS30-W00 May. 2007 2-7

2.4 SERVICE SPECIFICATIONS

2.4.1 CYLINDER HEAD

Item Reference Value Allowable Limit

100 mm (4 in.) of cylinder head -

Tightness of head bolts 58.8 ~ 63.7 Nm

Item Reference Value Allowable Limit

Valve seat angle (intake, exhaust) 1.047, 0.785 rad. -

0.2740 ~ 0.2746 in.

Valve recessing -0.05 ~ +0.15 mm 1.3 mm

2.4.3 VALVE SPRINGS

Item Reference Value Allowable Limit

Free length 35.1 ~ 35.6 mm 34.8 mm

Load to compress to fitted length 74 N / 31 mm 63 N / 31 mm

2-8 SS30-W00 May. 2007

Item Reference Value Allowable Limit

Item Reference Value Allowable Limit

Item Reference Value Allowable Limit

Oil ring 0.20 ~ 0.35 mm 1.25 mm

0.0016 ~ 0.0031 in.

SS30-W00 May. 2007 2-9

Item Reference Value Allowable Limit

0.7875 ~ 0.7878 in.

Connecting rod alignment 0.02 mm 0.05 mm

Item Reference Value Allowable Limit

O.D. of crankshaft journals 47.934 ~ 47.950 mm

I.D. of crankshaft bearing 2 47.980 ~ 48.006 mm

journals and bearing 2 0.0012 ~ 0.0028 in. 0.0079 in.

1.5746 ~ 1.5756 in.

2.4.9 FUEL INJECTION NOZZLES

Item Reference Value Allowable Limit

Opening pressure 14.2 ~ 15.2 MPa

2-10 SS30-W00 May. 2007

2.4.10 INJECTION PUMP