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 MAINTENANCE ...................................................................................................................... 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 ............................................................................................................................................... 1-40 10.4 TRAVELING SPEED ............................................................................................................................ 1-41 11. IMPLEMENT LIMITATIONS ........................................................................................................................... 1-42
CHAPTER 2. ENGINE SYSTEM ....................................................................................................... 2-1 1. FEATURE .......................................................................................................................................................... 2-3 2. LUBRICATING SYSTEM ................................................................................................................................. 2-4 3. COOLING SYSTEM ......................................................................................................................................... 2-5 4. FUEL SYSTEM ................................................................................................................................................. 2-6 5. TROUBLESHOOTING .................................................................................................................................... 2-7 6. SERVICING SPECIFICATIONS ................................................................................................................... 2-10 7. DISASSEMBLING AND MAINTENANCE .................................................................................................... 2-22 7.1 DISASSEMBLING ENGINE ................................................................................................................ 2-22 7.2 ENGINE DISASSEMBLED VIEW ....................................................................................................... 2-29 7.3 ENGINE BODY ..................................................................................................................................... 2-31 7.4 LUBRICATING SYSTEM ..................................................................................................................... 2-56 7.5 COOLING SYSTEM ............................................................................................................................. 2-59 7.6 FUEL SYSTEM ..................................................................................................................................... 2-61
CHAPTER 3. CLUTCH ....................................................................................................................... 3-1 1. STRUCTURE ................................................................................................................................................... 3-3 2. TROUBLESHOOTING .................................................................................................................................... 3-4 3. SPECIFICATIONS ........................................................................................................................................... 3-5 4. DISASSEMBLING AND MAINTENANCE ...................................................................................................... 3-6 4.1 CHECKING AND ADJUSTMENT ......................................................................................................... 3-6 4.2 DISASSEMBLING AND ASSEMBLING OF THE CLUTCH HOUSING ............................................ 3-7 4.3 SERVICING .......................................................................................................................................... 3-12
CHAPTER 4. TRANSMISSION ......................................................................................................... 4-1 1. MANUAL TRANSMISSION MODEL ............................................................................................................... 4-3 1.1 POWER TRAIN DIAGRAM .................................................................................................................... 4-3 1.2 POWER TRAIN ....................................................................................................................................... 4-5 1.3 TRANSMISSION SHIFT LINKAGE STRUCTURE ........................................................................... 4-11 2. HST TRANSMISSION MODEL ..................................................................................................................... 4-16 2.1 POWER TRAIN DIAGRAM .................................................................................................................. 4-16 2.2 POWER TRAIN ..................................................................................................................................... 4-17 2.3 TRANSMISSION SHIFT LINKAGE STRUCTURE ........................................................................... 4-26 3. PTO EJECTION ............................................................................................................................................. 4-27 3.1 POWER TRAIN DIAGRAM .................................................................................................................. 4-27 3.2 POWER TRAIN ..................................................................................................................................... 4-28 3.3 PTO SHIFT LINKAGE .......................................................................................................................... 4-29 4. DIFFERENTIAL GEAR .................................................................................................................................. 4-30 4.1 STRUCTURE ....................................................................................................................................... 4-30 5. TROUBLESHOOTING .................................................................................................................................. 4-33 5.1 HYDROSTATIC TRANSMISSION ....................................................................................................... 4-33 5.2 MANUAL TRANSMISSION .................................................................................................................. 4-36 6. SPECIFICATIONS ......................................................................................................................................... 4-37
7. DISASSEMBLING AND MAINTENANCE .................................................................................................... 4-38 7.1 DISASSEMBLING TRANSMISSION MANUAL MODEL (CK25/30) ............................................... 4-38 7.2 DISASSEMBLING TRANSMISSION HST MODEL (CK25H/30H) ................................................. 4-59 7.3 CHECK AND SERVICE ....................................................................................................................... 4-74
CHAPTER 5. REAR AXLE .................................................................................................................. 5-1 1. STRUCTURE ................................................................................................................................................... 5-3 2. TROUBLESHOOTING .................................................................................................................................... 5-4 3. SPECIFICATIONS ........................................................................................................................................... 5-5 4. DISASSEMBLING AND MAINTENANCE ...................................................................................................... 5-6 4.1 DISASSEMBLING THE REAR AXLE ................................................................................................... 5-6 4.2 DISASSEMBLING THE REAR AXLE CASE ........................................................................................ 5-8
CHAPTER 6. BRAKE .......................................................................................................................... 6-1 1. STRUCTURE ................................................................................................................................................... 6-3 2. TROUBLESHOOTING .................................................................................................................................... 6-4 3. SPECIFICATION .............................................................................................................................................. 6-5 4. DISASSEMBLING AND MAINTENANCE ...................................................................................................... 6-6 4.1 CHECK AND ADJUSTMENT ................................................................................................................ 6-6 4.2 DISASSEMBLING THE BRAKE CASE ................................................................................................ 6-8 4.3 BRAKE CASE DISASSEMBLY ............................................................................................................ 6-12 4.4 CHECK AND SERVICE ....................................................................................................................... 6-13
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 SYSTEM .................................................................................................. 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. TROUBLESHOOTING .................................................................................................................................. 8-11 3. SPECIFICATION ............................................................................................................................................ 8-12 4. DISASSEMBLY AND MAINTENANCE ......................................................................................................... 8-13
4.1 DISASSEMBLY THE HYDRAULIC PUMP ......................................................................................... 8-13 4.2 DISASSEMBLING THE POWER STEERING UNIT ......................................................................... 8-15 4.3 DISASSEMBLING THE STEERING CYLINDER ............................................................................. 8-25 4.4 SERVICING .......................................................................................................................................... 8-26
CHAPTER 9. HYDRAULIC SYSTEM ............................................................................................... 9-1 1. STRUCTURE ................................................................................................................................................... 9-3 1.1 HYDRAULIC CIRCUIT DIAGRAM ........................................................................................................ 9-3 1.2 HYDRAULIC CIRCUIT DIAGRAM OF 3-POINT HYDRAULIC SYSTEM ......................................... 9-4 1.3 HYDRAULIC SCHEME ......................................................................................................................... 9-7 1.4 OIL FILTER ............................................................................................................................................. 9-8 1.5 JOYSTICK VALVE .................................................................................................................................. 9-9 1.6 AUXILIARY CONTROL VALVE (IF EQUIPPED) ............................................................................... 9-17 1.7 CONTROL (MLS) VALVE .................................................................................................................... 9-18 2. OPERATION ................................................................................................................................................... 9-24 2.1 PRINCIPLE OF CONTROL ................................................................................................................ 9-24 3. TOP LINK BRACKET DEVICE ..................................................................................................................... 9-27 3.1 STRUCTURE (IF DRAFT EQUIPPED) ............................................................................................. 9-27 3.2 OPERATION ......................................................................................................................................... 9-27 4. TROUBLESHOOTING .................................................................................................................................. 9-28 4.1 POWER LIFT ASSEMBLY ................................................................................................................... 9-28 4.2 JOYSTICK VALVE ................................................................................................................................. 9-29 5. SPECIFICATION ............................................................................................................................................ 9-30 6. DISASSEMBLING AND MAINTENANCE .................................................................................................... 9-31 6.1 HYDRAULIC PUMP ............................................................................................................................. 9-31 6.2 JOY-STICK VALVE ............................................................................................................................... 9-32 6.3 SEPARATE THE HYDRAULIC CYLINDER ....................................................................................... 9-36 6.4 CHECK AND ADJUSTMENT .............................................................................................................. 9-51
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. 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 CK25/30 and CK25H/30H. It is divided into two parts, “Mechanism” and “Servicing”.
MECHANISM Information on the construction and functions are included. The part should be completely understood before proceeding with troubleshooting, disassembling or servicing.
SERVICING In this section you will find general precautions, maintenance and special tools. The are other sections which include troubleshooting, servicing, specifications lists, disassembling, assembling and servicing that explains in detail procedures, precautions, factory specifications and acceptable limits. This manual contains the latest production information on illustrations and specifications based on the most up to date production information available at the time of publication. We reserve the right to make changes throughout the entire manual at any time without notice.
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CK25(H)/30(H)
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 the 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 fitting clothing and always use safety equipment appropriate to the job. 3. Never use improvised tools, parts or procedures. Use only recommended tools appropriate to the work. 4. Be careful to perform all work safely when servicing is done by two or more people. 5. Always support the machine by safety stands. Never work under the machine that is supported solely by a jack.
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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 it is 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. 704W004A
AVOID FIRES 1. Never smoke or allow flames or sparks in your work area, as fuel is extremely flammable and explosive under certain conditions. 2. Always disconnect the negative battery cable first and reconnect it last to avoid sparks from an 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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CK25(H)/30(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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CK25(H)/30(H)
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.
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(1) Parts No. : T2181-54121 (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. : T2615-55111
(8) Parts No. : T2350-54141
(10) Parts No. : T2615-53561
(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. D704-WOO
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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 NO(EU)
(4) Transmission Serial Number(HST TYPE)
(3) Engine Serial Number (5) Transmission Serial Number(MANUAL TYPE)
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(6) Hour Meter
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CHAPTER 1
CK25(H)/30(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 firm and level ground prior to any service or adjustment. 2. Work with the engine stopped whenever possible. Be careful when doing any testing that requires the engine to be running. 3. Use only DAEDONG approved special tools. Servicing dealers may machine tools to DEADONG specifications, if the tool will not be used often. 4. Keep your work area and the tractor clean during all phases of the disassembly and reassembly process.
11. When assembling an outside snap ring, on a shaft, or an inside snap ring, in a hole, assemble with the head in the direction of force. Reference the above figure. 12.When replacing a new part also replace the associated packing (gasket), bearing(s), and o-ring(s). Apply grease properly for O-rings and oil seals before assembly. 13.Locate the split portion of any spring pin by referencing the direction of force, like the above figure. 14.Replace any split pin with a new one.
5. After removal, keep parts clean and organized. Tighten nuts to mating bolts by hand to keep matched sets together. 6. Be careful during disassembly, assembly, and storage of hydraulic parts. Dust and metal chips can contaminate the whole hydraulic system. Keep parts covered whenever possible. 7. Use only approved manufactures cleaning agents for parts cleaning. Hydraulic parts should be cleaned with an approved cleaning oil. Diesel fuel should never be used for cleaning. 8. Remove all oil and contaminates before performing any measurement of parts. 9. Disconnect the battery negative (-) cable before removing or installing any live electrical components.
IMPORTANT •
Use packing bond, gasket sealer, equivalent to Three Bond 1208D.
•
Remove all existing sealer before applying new sealer to the part.
•
Apply the bond, sealer, in a bead centered on the sealing flange area. If a bolt hole is encountered, continue bead to the center of the inner sealing surface.
•
Assemble the parts within 10 minutes of bond, sealer, application. Wait 30 minutes before adding oil to the sealed parts, if applicable.
10.Use only DAEDONG ( KIOTI) genuine parts to maintain the performance and safety of your KIOTI tractor.
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CHAPTER 1
CK25(H)/30(H)
3.2 ELECTRICAL SYSTEM 1. Check all electrical connectors daily for any damage or short circuit at their junctions. In addition, annually schedule a complete electrical system inspection with your local KIOTI dealer. 2. Do not modify or reorganize the wiring harness or the electric field parts. 3. When disconnecting battery cables, disconnect the negative cable first. Reinstall the positive cable first when reinstalling. DISCONNECTING BATTERY NEGATIVE CABLE
NOTE: •
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Be sure to turn the starting key OFF when connecting or disconnecting the cable.
4. When disconnecting a connector, grasp 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 on, be sure to use the fuse with the correct amperage capacity. Use your owner’s manual to establish the correct capacity. 7. Be sure not to drop sensors and relays. They are fragile.
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3.3 TUBES AND RUBBERS Keep the tubes (hoses) and rubber parts free from oil and other petroleum products. This may cause a change in quality in these parts, and may shorten product life.
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3.4 LUBRICANT During assembly and repair, apply designated lubricant where specified in accordance with this repair manual.
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