Kioti Daedong DK501 Tractor Service Repair Manual by 16310524

CONTENTS CHAPTER 1 GENERAL ..................................................................................................................... 1-1 1. TRACTOR INDENTIFICATION ....................................................................................................................... 1-3 2. TRACTOR VIEW ............................................................................................................................................... 1-4 3. GENERTAL PRECATIONS 3.1 ASSEMBLY AND DISASSEMBLY ......................................................................................................... 1-5 3.2 ELECTRICAL SYSTEM ......................................................................................................................... 1-6 3.3 TUBE AND RUBBERS .......................................................................................................................... 1-7 3.4 LUBICANT .............................................................................................................................................. 1-7 4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING ................................................... 1-8 5. SPECIFICATION .............................................................................................................................................. 1-9 6. LUBRICANTS,FUEL AND COOLANT ......................................................................................................... 1-10 7. TIGHTENING TORQUE ................................................................................................................................ 1-11 7.1 GENERAL USE SCREW,BOLTS AND NUTS .................................................................................. 1-11 7.2 STUD BOLTS ....................................................................................................................................... 1-11 7.3 AMERICAN STANDARD SCREW,BOLTS AND NUTS WITH UNC OR UNF THREADS ............ 1-12 8. MAINTENANCE CHECK LIST ...................................................................................................................... 1-13 9. CHECK AND MAINTENANCE ...................................................................................................................... 1-15 9.1 DAILY CHECK ...................................................................................................................................... 1-15 9.2 EVERY 50 HOURS .............................................................................................................................. 1-19 9.3 EVERY 100 HOURS ........................................................................................................................... 1-21 9.4 EVERY 200 HOURS ........................................................................................................................... 1-26 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 .................................................................................................................................... 1-32 9.9 EVERY 2 YEARS ................................................................................................................................. 1-33 9.10 SERVICE AS REQUIRED ................................................................................................................... 1-35 10.TIRES .............................................................................................................................................................. 1-38

CHAPTER 2 ENGINE ........................................................................................................................ 2-1 1. FEATURE .......................................................................................................................................................... 2-3 2. LUBRICATING SYSTEM ................................................................................................................................. 2-4 3. COOLING SYSTEM .......................................................................................................................................... 2-5 4. FUEL SYSTEM ................................................................................................................................................. 2-6 5. TROUBLESHOOTING ..................................................................................................................................... 2-7 6. SERVICING SPECIFICATION ...................................................................................................................... 2-10 6.1 ENGINE BODY .................................................................................................................................... 2-10 6.2 LUBRICATING SYSTEM ..................................................................................................................... 2-13 6.3 COOLING SYSTEM ............................................................................................................................. 2-14

6.4 FUEL SYSTEM ..................................................................................................................................... 2-14 6.5 TIGHTENING TORQUE ...................................................................................................................... 2-15 7. DISASSEMBLING AND MAINTENANCE ..................................................................................................... 2-16 7.1 SEAPRATING THE ENGINE .............................................................................................................. 2-16 7.2 ENGINE DISASSEMBLED VIEW ...................................................................................................... 2-25 7.3 ENGINE BODY .................................................................................................................................... 2-27 7.4 LUBRICATING SYSTEM ..................................................................................................................... 2-50 7.5 COOLING SYSTEM ............................................................................................................................. 2-52 7.6 FUEL SYSTEM ..................................................................................................................................... 2-54

CHAPTER 3 CLUTCH ....................................................................................................................... 3-1 1. FEATURES ........................................................................................................................................................ 3-3 2. TROBLESHOOTING ........................................................................................................................................ 3-4 3. SPECIFICATIONS,TIGHTENING TROQUES AND SPECIAL TOOLS ...................................................... 3-5 3.1 SPECIFICATIONS ................................................................................................................................. 3-5 3.2 TIGHTENING TORQUES ..................................................................................................................... 3-5 3.3 SPECIAL TOOLS ................................................................................................................................... 3-5 4. CHECK, DISASSEMBLYING AND MAINTENANCE ..................................................................................... 3-6 4.1 ADJUSTMENT OF PEDAL .................................................................................................................... 3-6 4.2 DISASSEMBLING AND ASSEMBLY OF CLUTCH ............................................................................. 3-7 4.3 INSPECTION AND REPAIR ............................................................................................................... 3-13

CHAPTER 4 TRANSMISSION SYSTEM ........................................................................................ 4-1 1. STRUCTURE ................................................................................................................................................... 4-3 1.1 POWER TRAIN DIAGRAM .................................................................................................................... 4-3 1.2 POWER TRAIN ...................................................................................................................................... 4-4 1.3 TRANSMISSION SHIFT LINKAGE STRUCTURE ........................................................................... 4-10 2. TROUBLESHOOTING ................................................................................................................................... 4-15 2.1 TROUBLESHOOTING FOR SHUTTLE SHIFT ................................................................................ 4-15 2.2 TROUBLESHOOTING FOR MAIN SHIFTS SECTION IN OPERATION ERROR ........................ 4-15 2.3 TROUBLESHOOTING FOR AUXILIARY AND CREEP SHIFTS IN OPERATION ERROR ......... 4-16 2.4 TROUBLESHOOTING FOR REAR DIFFERENTIAL GEAR IN OPERATION ERROR ............... 4-16 2.5 TROUBLESHOOTING FOR FRONT WHEEL DRIVE IN OPERATION ERROR ......................... 4-17 2.6 TROUBLESHOOTING FOR PTO CLUTCH IN OPERATION ERROR ......................................... 4-17 2.7 TROUBLESHOOTING FOR PTO IN OPERATION ERROR ........................................................... 4-17 2.8 TROUBLESHOOTING FOR PARKING BRAKE IN OPERATION ERROR .................................... 4-17 3. SPECIFICATIONS .......................................................................................................................................... 4-18 3.1 TIGHTENING TORQUES ................................................................................................................... 4-18 4. DISASSEMBLING AND MAINTENANCE ..................................................................................................... 4-19 4.1 DISASSEMBLING TRANSMISSION .................................................................................................. 4-19 4.2 SERVICING .......................................................................................................................................... 4-54

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

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

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

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 ........................................................................................................................ 8-7 1.6 OIL FLOW ............................................................................................................................................... 8-8 2. TROUBELSHOOTING ................................................................................................................................... 8-10 3. SPECIFICATIONS .......................................................................................................................................... 8-11 4. DISASSEMBLING AND MAINTENANCE ..................................................................................................... 8-12

4.1 SEPARATING THE HYDRAULIC PUMP ........................................................................................... 8-12 4.2 SEPARATING THE STEERING UNIT ............................................................................................... 8-14 4.3 DISASSEMBLING OF THE STEERING CYLINDER ....................................................................... 8-23 4.4 SERVICING .......................................................................................................................................... 8-24

CHAPTER 9 HYDRAULIC SYSTEM ............................................................................................... 9-1 1. STRUCTURE ................................................................................................................................................... 9-3 1.1 HYDRAULIC OIL FLOW SHEMATIC ................................................................................................... 9-3 1.2 HYDRAULIC CIRCUIT SHEMATIC ..................................................................................................... 9-4 1.3 HYDRAULIC FILTER SHEMATIC ........................................................................................................ 9-5 1.4 HYDRAULICPUMP SHEMATIC ........................................................................................................... 9-5 1.5 POWER STEERING SYSTEM ............................................................................................................. 9-6 1.6 PTO CLUTCH VALVE SYSTEM ........................................................................................................... 9-8 1.7 4WD,Q/T AND Q/T (AB) SYSTEM ........................................................................................................ 9-9 1.8 JOYSTICK VALVE ................................................................................................................................ 9-10 1.9 HORIZONTAL CONTROL SYSTEM (ONLY JP) .............................................................................. 9-11 1.10 HYDRAULIC POWER LIFT SYSTEM ................................................................................................ 9-12 1.11 AUXILIARY CONTROL VALVE (IF EQUIPPED) ............................................................................... 9-13 2. TROUBLINGSHOOTING ............................................................................................................................... 9-14 2.1 JOYSTICK VALVE ................................................................................................................................ 9-14 2.2 HYDRAULIC LIFT SYSTEM ............................................................................................................... 9-15 3. CHECKING,DISASSEMBLING AND MAINTENANCE ............................................................................... 9-16 3.1 HYDRAULIC FILTER .......................................................................................................................... 9-16 3.2 HYDRAULIC PUMP ............................................................................................................................. 9-16 3.3 POWER STEERING UNIT .................................................................................................................. 9-18 3.4 PTO CLUTCH VALVE .......................................................................................................................... 9-19 3.5 4WA,Q/T AND Q/T(AB) VALVE ............................................................................................................ 9-23 3.6 JOYSTICK VALV ................................................................................................................................... 9-27 3.7 HORIZONTAL CONTROL VALVE ...................................................................................................... 9-28 3.8 HYDRAULIC LIFT SYSTEM ............................................................................................................... 9-30

CHAPTER 10 CABIN SYSTEM ...................................................................................................... 10-1 1. STRUCTURE ................................................................................................................................................. 10-3 1.1 HEATER ................................................................................................................................................ 10-3 1.2 AIR-CONDITIONER ............................................................................................................................ 10-4 2. TROUBLESHOOTING ................................................................................................................................... 10-6 3. INSPECTION AND ADJUSTMENTS ......................................................................................................... 10-14

CHAPTER11 ELECTRIC SYSTEM .................................................................................................. 11-1 1. HOW TO WIRING DIAGRAM ........................................................................................................................ 11-3 1.1 WIRE CODE ......................................................................................................................................... 11-3 1.2 WIRE SIZEW ........................................................................................................................................ 11-3 1.3 INSTRUMENT PANEL BULBS .......................................................................................................... 11-4 1.4 RELAY AND SWITCH .......................................................................................................................... 11-5 1.5 MULTIPLE SWITCH ............................................................................................................................ 11-5 1.6 RELAY BOX .......................................................................................................................................... 11-6 1.7 FUSE CHECK ...................................................................................................................................... 11-7 1.8 WIRING DIAGRAM .............................................................................................................................. 11-9 2. INSTRMENT PANEL .................................................................................................................................... 11-11 2.1 SYMBOL DESCRIPTION .................................................................................................................. 11-11 2.2 CIRCUIT DIAGRAM OF INSTRUMENT(USA) ............................................................................... 11-14 3. STSRTING SYSTEM .................................................................................................................................... 11-15 3.1 IGNITION CIRCUIT(WITHOUT THE INSTALLATION OF HORIZONTAL CONTROLLER ....... 11-15 3.2 IGNITION CIRCUIT(HORIZONTAL CONTROL INSTALLATION EXPECTATION ONLY JP ..... 11-16 3.3 MAJOR COMPONENTS ................................................................................................................... 11-17 4. CHARGING SYSTEM ................................................................................................................................... 11-22 4.1 CIRCUIT DIAGRAM ........................................................................................................................... 11-22 4.2 AC (ALTERNATING CURRENT)ALTERNATOR ............................................................................ 11-23 5. ENGINE GLOW PLUG SYSTEM ................................................................................................................ 11-25 5.1 CIRCUIT DIAGRAM ........................................................................................................................... 11-25 5.2 MAJOR COMPONENTS ................................................................................................................... 11-26 6. PTO SYSTEM(ONLY USA) .......................................................................................................................... 11-29 6.1 CIRCUIT DIAGRAM ........................................................................................................................... 11-29 6.2 CIRCUIT DESCRIPTION ................................................................................................................. 11-30 6.3 TROUBLESHOOTING ...................................................................................................................... 11-30 7. ROTARY LEVEL CONTROL INSTALLATION(ONLY JP) ......................................................................... 11-31 7.1 SYSTEM COMPOSITION PARTS .................................................................................................... 11-31 7.2 OUTLINE ............................................................................................................................................ 11-32 7.3 LEVEL CONTROL INSTALLATION FUCTION ............................................................................... 11-34 7.4 ELECTRIC CIRCUIT ........................................................................................................................ 11-36 7.5 TERMINAL ARRANGEMENT TABLE ............................................................................................... 11-37 8. QUECK TURN(ONLY JP) ........................................................................................................................... 11-38 8.1 ELECTRIC CIRCUIT ........................................................................................................................ 11-38 8.2 MAIN PARTS COMPOSITION .......................................................................................................... 11-40 8.3 REPAIRS FOR QUECK TURN1 MALFUCTION ............................................................................ 11-42 9. AIR CONDITIONING SYTEM ...................................................................................................................... 11-43 9.1 CIRCUIT DIAGRAM ........................................................................................................................... 11-43 9.2 MAJPR COMPONENTS .................................................................................................................... 11-44 10.HEATER SYSTEM ........................................................................................................................................ 11-46

TO THE READER

TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of KIOTI (DAEDONG) tractors DK50S/55(DK501/551). 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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DK50S/55(DK501/551)

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.

A13W001A

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. A13W004A

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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DK50S/55(DK501/551) 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.

A13W006A

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.

A13W007A

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.

A13W009A

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DK50S/55(DK501/551)

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.

ROPS

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TO THE READER

CABIN

A13W011A

(1) Parts No. : T4625-52191

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(2) Parts No. : T4837-51181

DK50S/55(DK501/551) (3) Parts No. : T4685-52311

(4) Parts No. : T4818-52142

(5) Parts No. : T2325-50743

(6) Parts No. : T4625-52351

(7) Parts No. : T4625-52361

(8) Parts No. : T4625-53191

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NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.

TO THE READER (9) Parts No. : T2241-50702

(10) Parts No. : T2445-50724

(11) Parts No. : T4837-51093

(12) Parts No. : T2615-54112

(13) Parts No. : T4818-52132

(14) Parts No. : T2615-55112

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DK50S/55(DK501/551) (15) Parts No. : T4817-52201

(16) Parts No. : T2615-53561

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

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CHAPTER 1

GENERAL

1. TRACTOR IDENTIFICATION When contacting your local KIOTI (DAEDONG) 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) Hour Meter

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