Kioti Daedong CK20J Tractor Service Repair Manual

CONTENTS TO THE READER .............................................................................................................................................................. 1 SAFETY FIRST ................................................................................................................................................................... 2 SAFETY DECALS .............................................................................................................................................................. 6

CHAPTER 1. GENERAL ..................................................................................................................... 1-1 1. TRACTOR IDENTIFICATION ......................................................................................................................... 1-3 2. DIMENSIONS ................................................................................................................................................... 1-4 3. GENERAL PRECAUTIONS ............................................................................................................................ 1-5 3.1 ASSEMBLY AND DISASSEMBLY ......................................................................................................... 1-5 3.2 ELECTRICAL SYSTEM ......................................................................................................................... 1-6 3.3 TUBES AND RUBBERS ........................................................................................................................ 1-7 3.4 LUBRICANT ........................................................................................................................................... 1-7 4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING .................................................. 1-8 5. SPECIFICATIONS ........................................................................................................................................... 1-9 6. LUBRICANTS, FUEL AND COOLANT ........................................................................................................ 1-10 7. TIGHTENING TORQUES ............................................................................................................................. 1-11 7.1 GENERAL USE SCREWS, BOLTS AND NUTS ............................................................................... 1-11 7.2 STUD BOLTS ....................................................................................................................................... 1-11 7.3 AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS ........ 1-12 8. MAINTENANCE CHECK LIST ..................................................................................................................... 1-13 9. CHECK AND MAINIENANCE ....................................................................................................................... 1-15 9.1 DAILY CHECK ...................................................................................................................................... 1-15 9.2 EVERY 50 HOURS .............................................................................................................................. 1-19 9.3 EVERY 100 HOURS ............................................................................................................................ 1-21 9.4 EVERY 200 HOURS ............................................................................................................................ 1-27 9.5 EVERY 400 HOURS ............................................................................................................................ 1-31 9.6 EVERY 600 HOURS ............................................................................................................................ 1-32 9.7 EVERY 800 HOURS ............................................................................................................................ 1-32 9.8 EVERY 1 YEAR .................................................................................................................................... 1-33 9.9 EVERY 2 YEAR .................................................................................................................................... 1-33 9.10 SERVICE AS REQUIRED ................................................................................................................... 1-35 10. TIRES .............................................................................................................................................................. 1-37 10.1 INFLATION PRESSURE ..................................................................................................................... 1-37 10.2 TREAD .................................................................................................................................................. 1-38 10.3 BALLAST ............................................................................................................................................... 1-39 11. IMPLEMENT LIMITATIONS ........................................................................................................................... 1-41

CHAPTER 2. ENGINE ........................................................................................................................ 2-1 1. GENERAL ......................................................................................................................................................... 2-3 1.1 ENGINE IDENTIFICATION ................................................................................................................... 2-3 1.2 SPECIFICATIONS .................................................................................................................................. 2-4

1.3 PERFORMANCE CURVE ..................................................................................................................... 2-5 1.4 DIMENSIONS ......................................................................................................................................... 2-6 2. CONSTRUCTION AND FUNCTION .............................................................................................................. 2-7 2.1 ENGINE ................................................................................................................................................... 2-7 2.2 LUBRICATION SYSTEM ..................................................................................................................... 2-12 2.3 COOLING SYSTEM ............................................................................................................................. 2-15 2.4 FUEL SYSTEM ..................................................................................................................................... 2-17 2.5 INLET AND EXHAUST SYSTEM ........................................................................................................ 2-24 3. DISASSEMBLY AND SERVICING OF ENGINE ......................................................................................... 2-25 3.1 TROUBLESHOOTING ......................................................................................................................... 2-25 3.2 SERVICE DIRECTIONS ..................................................................................................................... 2-28 3.3 CHECKING, DISASSEMBLING AND SERVICING .......................................................................... 2-33 3.4 DISASSEMBLY AND REASSEMBLY .................................................................................................. 2-39 3.5 SERVCING ........................................................................................................................................... 2-55

CHAPTER 3. CLUTCH ....................................................................................................................... 3-1 1. STRUCTURE ................................................................................................................................................... 3-3 2. SERVICING ...................................................................................................................................................... 3-4 2.1 TROUBLESHOOTING ........................................................................................................................... 3-4 2.2 SPECIFICATIONS .................................................................................................................................. 3-5 2.3 CHECKING AND ADJUSTMENT ......................................................................................................... 3-6 2.4 DISASSEMBLING AND ASSEMBLING ................................................................................................ 3-7 2.5 INSPECTION AND REPAIR ................................................................................................................ 3-12

CHAPTER 4. TRANSMISSION ......................................................................................................... 4-1 1. STRUCTURE ................................................................................................................................................... 4-3 1.1 POWER TRAIN DIAGRAM .................................................................................................................... 4-3 1.2 POWER TRAIN ....................................................................................................................................... 4-5 1.3 TRANSMISSION SHIFT LINKAGE STRUCTURE ........................................................................... 4-12 1.4 DIFFERENTIAL GEAR ........................................................................................................................ 4-17 1.5 HST CONTROL LINKAGE .................................................................................................................. 4-20 2. SERVICING .................................................................................................................................................... 4-21 2.1 TORUBLESHOOTING ......................................................................................................................... 4-21 2.2 SPECIFICATIONS ................................................................................................................................ 4-25 2.3 DISASSEMBLING AND ASSEMBLING .............................................................................................. 4-26 2.4 HYDROSTATIC TRANSMISSION(CK20H) ....................................................................................... 4-48

CHAPTER 5. REAR AXLE .................................................................................................................. 5-1 1. STRUCTURE ................................................................................................................................................... 5-3 2. SERVICING ...................................................................................................................................................... 5-4 2.1 TROUBLESHOOTING ........................................................................................................................... 5-4 2.2 SPECIFICATIONS .................................................................................................................................. 5-4 2.3 DISASSEMBLING AND ASSEMBLING ................................................................................................ 5-5

CHAPTER 6. BRAKE .......................................................................................................................... 6-1 1. STRUCTURE ................................................................................................................................................... 6-3 1.1 FEATURES OF WET DISC BRAKES .................................................................................................. 6-3 2. SERVICING ...................................................................................................................................................... 6-5 2.1 TROUBLESHOOTING ........................................................................................................................... 6-5 2.2 SPECIFICATIONS .................................................................................................................................. 6-5 2.3 DISASSEMBLING AND ASSEMBLING ................................................................................................ 6-6 2.4 SERVICING .......................................................................................................................................... 6-10

CHAPTER 7. FRONT AXLE ............................................................................................................... 7-1 1. STRUCTURE ................................................................................................................................................... 7-3 1.1 FRONT AXLE STRUCTURE ................................................................................................................. 7-3 1.2 WHEEL ALIGNMENT ............................................................................................................................. 7-4 2. SERVICING ...................................................................................................................................................... 7-6 2.1 TROUBLESHOOTING ........................................................................................................................... 7-6 2.2 SPECIFICATIONS .................................................................................................................................. 7-7 2.3 CHECKING, DISASSEMBLING AND SERVICING ............................................................................ 7-9 2.4 SERVICING .......................................................................................................................................... 7-18

CHAPTER 8. STEERING SYSYTEM ............................................................................................... 8-1 1. STRUCTURE ................................................................................................................................................... 8-3 1.1 CHARACTERISTICS ............................................................................................................................. 8-3 1.2 HYDRAULIC CIRCUIT OF POWER STEERING SYSTEM ............................................................... 8-4 1.3 GEAR PUMP ........................................................................................................................................... 8-5 1.4 POWER STEERING UNIT .................................................................................................................... 8-6 1.5 STEERING CYLINDER ......................................................................................................................... 8-8 1.6 OIL FLOW ............................................................................................................................................... 8-9 2. SERVICING .................................................................................................................................................... 8-11 2.1 TROUBLESHOOTING ......................................................................................................................... 8-11 2.2 SPECIFICATION .................................................................................................................................. 8-12 2.3 DISASSEMBLY AND ASSEMBLY ....................................................................................................... 8-13

CHAPTER 9. HYDRAULIC SYSTEM ............................................................................................... 9-1 1. STRUCTURE ................................................................................................................................................... 9-3 1.1 HYDRAULIC CIRCUIT DIAGRAM ........................................................................................................ 9-3 1.2 OIL FILTER ............................................................................................................................................. 9-5 1.3 STRUCTURE ......................................................................................................................................... 9-6 1.4 HYDRAULIC CIRCUIT DIAGRAM OF 3-POINT HUDRAULIC SYSTEM ........................................ 9-7 1.5 PRIORITY FLOW CONTROL [HYDRAULIC BLOCK TYPE OUTLET] ............................................ 9-8 1.6 JOYSTICK VALVE ................................................................................................................................ 9-11 1.7 AUXILIARY CONTROL VALVE (IF EQUIPPED) ............................................................................... 9-18 1.8 CONTROL (MLS) VALVE .................................................................................................................... 9-20 1.9 OPERATION OF INTERNAL LEVERS IN CONTROLLED POSITION .......................................... 9-24 1.10 ASSEMBLY MEASUREMENT OF PUSH ROD ................................................................................. 9-26

2. SERVICING .................................................................................................................................................... 9-27 2.1 TROUBLECHOOTING ........................................................................................................................ 9-27 2.2 SPECIFICATION .................................................................................................................................. 9-29 2.3 DISASSEMBLING AND ASSEMPLING .............................................................................................. 9-31

CHAPTER 10. ELECTRIC SYSTEM .............................................................................................. 10-1 1. ELECTRIC SYSTEM ..................................................................................................................................... 10-3 1.1 WIRING DIAGRAM ............................................................................................................................... 10-3 1.2 BATTERY .............................................................................................................................................. 10-5 1.3 STARTING SYSTEM ............................................................................................................................ 10-6 1.4 CHARGING SYSTEM .......................................................................................................................... 10-7 1.5 LIGHTING SYSTEM ............................................................................................................................. 10-8 1.6 COMBINATION METER .................................................................................................................... 10-12 2. SERVICING ................................................................................................................................................. 10-14 2.1 TROUBLESHOOTING ...................................................................................................................... 10-14 3. CHECKING, DISASSEMBLING AND SERVICING ................................................................................. 10-17 3.1 BATTERY ........................................................................................................................................... 10-17 3.2 STARTING SYSTEM ......................................................................................................................... 10-20 3.3 CHARGING SYSTEM ....................................................................................................................... 10-28 3.4 LIGHTING SYSTEM .......................................................................................................................... 10-29 3.5 COMBINATION METER .................................................................................................................... 10-32

TO THE READER

TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of KIOTI tractors CH20, CK20J, CK20H and CK20HJ. It is divided into two parts, “Mechanism” and “Servicing” for each section.

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

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

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

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

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

DESCRIPTION

SIGNS

DANGER

This mark indicates hazardous situation which, if not observed, may result in death or fatal injury.

This mark should be indicated for most dangerous situations only.

WARNING

This mark indicates potentially hazardous situation which, if not observed, may result in death or moderate injury.

CAUTION

This mark indicates potentially hazardous situation which, if not observed, may result in minor or moderate injury. And this mark can be used as a warning against unsafe activities.

IMPORTANT

This mark indicates emphasis on notable characteristics in working procedures or information on working procedures and technology for convenient use.

NOTE

Gives helpful information.

BEFORE SERVICING AND REPAIRING 1. Read all safety instructions in this manual and be aware of the safety decals on your machine itself.

2. Thoroughly clean your work area and the machine.

3. Make sure the machine is on firm and level ground and that the parking brake is set.

4. Lower the implement to the ground.

5. Stop the engine and remove the key.

6. Disconnect the negative battery cable.

7. Place a “DO NOT OPERATE” tag in operator station.

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SAFETY STARTING 1. Always use the safety start switch to start the engine and never by any other means.

2. Do not alter or remove any part of machine safety system.

3. Before starting the engine, make sure that all shift levers are in neutral positions or in disengaged positions.

4. Never start the engine unless you are in the operator’s seat.

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TO THE READER SAFETY WORKING 1. Do not operate or service the machine while under the influence of alcohol, medication, or other substances.

2. Never wear loose fit clothing and always use safety equipment appropriate to the job.

3. Never use improvised tools, parts or procedures.

Use only recommended tools appropriate to the work.

4. Be careful to perform all work safely when servicing is done by two or more people.

5. Always support the machine by safety stands. Never work under the machine that is supported solely by a jack.

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6. Do not touch any rotating or hot parts while the engine is running.

7. Never remove the radiator cap while the engine is running, or immediately after stopping. Only remove radiator cap when cool enough to touch with bare hands. Slowly loosen the cap to relieve pressure before removing completely.

8. Escaping fluid (fuel or hydraulic oil) under pressure can penetrate the skin causing serious injury.

Relieve pressure before disconnecting hydraulic or fuel lines. Tighten all connections before applying pressure.

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AVOID FIRES 1. Never smoke or allow flames or sparks in your working area, as fuel is extremely flammable and explosive under certain conditions.

2. Always disconnect the negative battery cable first and reconnect it last to avoid sparks from an accidental short circuit.

3. Battery gas will ignite. Keep sparks and open flame away from the top of battery, especially while charging.

4. Be careful not to spill fuel on the engine.

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CK20(H) VENTILATE WORK AREA 1. Exhaust contains poisonous carbon monoxide so you should never run the engine in a closed area. If the engine must be running while performing maintenance, make sure the area is well ventilated.

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

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DISPOSE OF FLUIDS PROPERLY 1. Observe relevant environmental protection regulations when disposing of oil, fuel, coolant, electrolyte and other harmful waste. Never pour fluids into the ground, down a drain, or into a stream, pond, or lake.

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TO THE READER PREPARE FOR EMERGENCIES 1. Be sure to keep a first aid kit and fire extinguisher handy at all times.

2. Keep emergency numbers for the nearest fire department, hospital, doctor and ambulance service, near your telephone in case of emergency.

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SAFETY DECALS z

The following safety decals are installed on the machine.

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

(1) Parts No. : T2350-54122 (Optional)

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(2) Parts No. : T4625-52351

(3) Parts No. : T4625-52361

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TO THE READER (4) Parts No. : T2325-50743

(5) Parts No. : T2325-50512

(6) Parts No. : T2445-50724

(7) Parts No. : T2615-53561

(8) Parts No. : T2350-54141

(9) Parts No. : T2615-54112

CARE OF DANGER, WARNING AND CAUTION LABELS 1. Keep danger, warning and caution labels clean and free from obstructing material.

2. Clean danger, warning and caution labels with soap and water, dry with a soft cloth.

3. Replace damaged or missing danger, warning and caution labels with new labels.

4. If a component with danger, warning or caution label(s) is replaced, make sure new label(s) is (are) attached in the same locations(s) as the replaced component.

5. Mount new labels by applying on a clean dry surface and pressing any bubbles to outside edge.

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CHAPTER 1

GENERAL

GENERAL

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

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(1) Statutory Plate

(2) Identification Plate

(3) Engine Serial Number

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(4) Transmission Serial Number

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(5) Hour Meter

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CK20(H)

2. DIMENSIONS mm (in.)

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GENERAL

3. GENERAL PRECAUTIONS 3.1 ASSEMBLY AND DISASSEMBLY

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(1) Grease

(4) Assemble Towards to be Forced

(2) Snap Ring for Shaft

(5) Reciprocating

(3) Snap Ring for Hole

(6) Rotating

1. Place the tractor on the flat surface for adjustment or service.

2. Please work with the engine stop except for the case that must be worked with the engine running.

3. Arrange each part properly on the clean space for disassembly. For bolts and nuts, tighten manually by hand to its original position.

11. For assembling any snap ring for shaft or snap ring for hole, assemble the head by the direction to be forced, like above figure.

12.Insert the split portion of any spring pin by the direction to be forced, like above figure.

13.Replace any split pin as a new one.

4. Use only the approved special tool. For the tool that is not used often, use the tool made by each service workshop.

5. Use only part cleaning agent for manufacturing when any part needs to be clean. Do not use the diesel oil for cleaning to prevent any pollution. Use only approved fluid oil for cleaning any hydraulic part.

IMPORTANT •

Use the packing bond as three bond 1208D or LOCTITE product.

6. Be careful not to attach any dust or metal chip etc. for disassembly and assembly of any hydraulic part.

•

7. For measuring any part, remove any oil or polluted material before performing the measurement.

For using any packing bond, remove any remained bond in the part before apply.

•

Apply the bond in center of the flange between bolt holes of the contact surface and apply the inner surface for bolt hole portion.

•

Perform the assembly within 10 minutes after apply and inject oil after passing 30 minutes above.

8. Disconnet the battery negative (-) cable before removing or installing the live components.

9. Use only the DAEDONG genuine part for replacement to maintain the performance and safety.

10.Replace the packing bearing and O-ring as new part. Apply the grease properly for O-rings and oil seals before assembly.

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CK20(H)

3.2 ELECTRICAL SYSTEM 1. Check electrical wiring daily every year for any damage or short circuit at junction. In addition, undergo onerous inspection via the agency regularly.

2. Do not modify or reorganize the wiring of the electric field parts.

3. When disconnecting battery cable disconnect negative cable first, reinstall the positive cable first when reinstalling.

Disconnect battery negative terminal

NOTE: •

Be sure to turn the starting key OFF when connecting or disconnecting the cable.

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4. Remove the connector by pulling the plastic section not the wiring.

5. When reconnecting the connector, Insert it until it snaps.

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6. When replacing a broken fuse with a new one, be sure to use the fuse of capacity as specified.

7. Be sure not to drop sensors and relays which are fragile.

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GENERAL

3.3 TUBES AND RUBBERS Be cautious of oil or the like on the tubes and rubber parts, which may cause change in quality.

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3.4 LUBRICANT When assembling and fixing, apply designated lubricant where specified in accordance with this repair manual.

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CK20(H)

4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING To ensure safety and prevent damage to the machine and surrounding equipment, heed the following precautions in handling electrical parts and wiring.

IMPORTANT •

Check electrical wiring for damage and loosened connection every year. To this end, educate the customer to do his or her own check and at the same time recommend the dealer to perform periodic check for a fee.

•

Do not attempt to modify or remodel any electrical parts and wiring.

•

When removing the battery cables, disconnect the negative cable first. When installing the battery cables, connect the positive cable first.

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