Page 1


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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CK20(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.

196W001A

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.

196W002A

2

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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.

196W003A

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. 196W004A

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.

196W005A

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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.

196W006A

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.

196W007A

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.

196W008A

4

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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.

196W009A

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CK20(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.

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

6

(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.

196W102A

196W101A

(1) Statutory Plate

(2) Identification Plate

(3) Engine Serial Number

196W103A

196W100A

(4) Transmission Serial Number

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(5) Hour Meter

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CHAPTER 1

CK20(H)

2. DIMENSIONS mm (in.)

196W167A

1-4

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GENERAL

3. GENERAL PRECAUTIONS 3.1 ASSEMBLY AND DISASSEMBLY

196W104A

(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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CHAPTER 1

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.

196W107A

4. Remove the connector by pulling the plastic section not the wiring. 5. When reconnecting the connector, Insert it until it snaps.

196W108A

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.

196W109A

1-6

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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.

196W110A

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

196W111A

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CHAPTER 1

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.

1-8

196W112A

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GENERAL

5. SPECIFICATIONS CK20 Model

HST

MECHANICAL

Model

3C093

Type

Engine

Liquid-cooled, 3-cylinder diesel

Engine gross

HP (kW)

P.T.O

HP (kW)

Displacement

cc (cu.in)

Rated revolution

927 (56.6) 2,800

(gal.)

Clutch

20 (5.28) Dry type single stage

Transmission Speeds

Synchro/constant

Hydrostatic

6F 2R

INF.2

Differential lock

Standard

Brake

Wet disc type Live continuous

Trans

P.T.O Rear

(rpm)

1 speed (540 rpm at 2,646 engine rpm)

Mid

(rpm)

1 speed (2,000 rpm at 2,706 engine rpm)

Pump capacity (Max. flow rate)

29 (7.66)

/min (gpm)

Cat.I

3-point hitch Hydraulic system

15.5 (11.6)

r.p.m min-1

Fuel tank capacity

Drive train

21 (15.7) 16.5 (12.3)

Maximum lifting capacity (24in. aft of hitch) kgf (lbs.) Hydraulic lift control system

503 (1,109) Position control

Steering

Hydrostatic

Standard tire size

Front (AG, TURF, INDUSTRIAL)

6 ~- 12 (23 x 8.50 ~ 12, 23 x 8.50 ~ 12)

Rear (AG, TURF, INDUSTRIAL)

9.5 ~ 16 (33 x 12.5 x 16.5, 12 ~ 16.5)

Traveling speeds

Forward (At rated engine rpm)

km/h (mph) 1.10 ~ 16.24 (0.68 ~ 10.09)

0 ~ 14.97 (0 ~ 9.30)

Reverse (At rated engine rpm)

km/h (mph)

1.36 ~ 6.31 (0.85 ~ 3.92)

0 ~ 9.37 (0 ~ 5.82)

Dimensions

Overall length (with 3p)

mm (in.)

2,684 (105.7)

Overall width (minimum tread)

mm (in.)

1,121 (44.1)

Overall height (Top of ROPS)

mm (in.)

1,970 (77.5)

Wheel base

mm (in.)

1,470 (57.9)

Min. ground clearance

mm (in.)

310 (12.2)

Tread

Front

mm (in.)

910 (35.8)

Rear

mm (in.)

890 ~ 935 (35.0 ~ 36.8)

Min. turning radius (with brake) Weight (with ROPS)

m (Ft.) kgf (lbs.)

2.3 (7.5) 890 (1,962)

904 (1,993)

NOTE: The specifications are subject to change for the purpose of improvement without any notice.

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CK20(H)

6. LUBRICANTS, FUEL AND COOLANT No.

Locations

Capacities CK20H

Lubricants

CK20 No.2-D diesel fuel

1

Fuel

20

(5.28 U.S.gal.)

2

Coolant

5.7

(1.50 U.S.gal.)

No.1-D diesel fuel if temperature is below -10°C (14°F) Fresh clean water with anti-freeze Engine oil: API Service Classification CC or CD Above 25°C (77°F)

3

Engine crankcase

2.6

(0.69 U.S.gal.)

SAE30, SAE10W-30 or 10W-40

0 to 25°C (32 to 77°F) SAE20, SAE10W-30 or 10W-40 Below 0°C (32°F)

SAE10W, SAE10W-30 or 10W-40

Multi-gradetransmission fluid the fluid listed below or equivalent are recommended. 4

5

Transmission case

Front axle case (4WD only) Greasing

6

1-10

Battery terminal

18.5 21.6 (4.89 U.S.gal.) (5.71 U.S.gal.)

3.1

(0.82 U.S.gal.)

Maker

Brand(Standard)

Shell

DONAX-TD,DONAX-TM

Mobil

Mobile Fluid 350

Exxon

Torque Fluid 56

SAE 90 gear oil

No. of greasing points

Capacity

Type of grease

2

Moderate amount

Multipurpose type grease

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GENERAL

7. TIGHTENING TORQUES 7.1 GENERAL USE SCREWS, BOLTS AND NUTS Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be tightened according to the table below. Indication on top of bolt

4

Material of bolt

No-grade or 4T

7

SS400, S20C

9

7T

9T

SCr435, SCM435

S43C, S48C

Material of opponent part

Ordinariness

Aluminum

Ordinariness

Aluminum

Ordinariness

Unit Diameter

N·m kgf·m lbf·ft

N·m kgf·m lbf·ft

N·m kgf·m lbf·ft

N·m kgf·m lbf·ft

N·m kgf·m lbf·ft

7.85 M6 ~ (6 mm, 0.24 in.) 9.31

0.80 ~ 0.95

5.79 ~ 6.87

7.85 0.80 ~ ~ 8.82 0.90

5.79 ~ 6.50

9.81 1.00 ~ ~ 11.2 1.15

7.24 ~ 8.31

7.85 ~ 8.82

0.80 5.79 ~ ~ 0.90 6.50

12.3 ~ 14.2

1.25 9.05 ~ ~ 1.45 10.4

17.7 M8 ~ (8 mm, 0.31 in.) 20.5

1.8 ~ 2.1

13.1 ~ 15.1

16.7 ~ 19.6

1.7 ~ 2.0

12.3 ~ 14.4

23.6 ~ 27.4

2.4 ~ 2.8

17.4 ~ 20.2

17.7 ~ 20.5

1.8 ~ 2.1

13.1 ~ 15.1

29.5 ~ 34.3

3.0 ~ 3.5

21.7 ~ 25.3

39.3 M10 ~ (10 mm, 0.39 in.) 45.1

4.0 ~ 4.6

29.0 ~ 33.2

31.4 ~ 34.3

3.2 ~ 3.5

23.2 ~ 25.3

48.1 ~ 55.8

4.9 ~ 5.7

35.5 ~ 41.2

39.3 ~ 44.1

4.0 ~ 4.5

29.0 ~ 32.5

60.9 ~ 70.6

6.2 ~ 7.2

44.9 ~ 52.0

62.8 M12 ~ (12 mm, 0.47 in.) 72.5

6.4 ~ 7.4

46.3 ~ 53.5

77.5 ~ 90.2

7.9 ~ 9.2

57.2 ~ 66.5

62.8 ~ 72.5

6.4 ~ 7.4

46.3 ~ 53.5

103 ~ 117

10.5 76.0 ~ ~ 12.0 86.7

108 M14 ~ (14 mm, 0.55 in.) 125

11.0 ~ 12.8

79.6 ~ 92.5

124 ~ 147

12.6 ~ 15.0

91.2 ~ 108

167 ~ 196

17.0 ~ 20.0

123 ~ 144

167 M16 ~ (16 mm, 0.63 in.) 191

17.0 ~ 19.5

123 ~ 141

197 ~ 225

20.0 ~ 23.0

145 ~ 166

260 ~ 304

26.5 ~ 31.0

192 ~ 224

246 M18 ~ (18 mm, 0.71 in.) 284

25.0 ~ 29.0

181 ~ 209

275 ~ 318

28.0 ~ 32.5

203 ~ 235

344 ~ 402

35.0 ~ 41.0

254 ~ 296

334 M20 ~ (20 mm, 0.79 in.) 392

34.0 ~ 40.0

246 ~ 289

368 ~ 431

37.5 ~ 44.0

272 ~ 318

491 ~ 568

50.0 ~ 58.0

362 ~ 419

7.2 STUD BOLTS Ordinariness

Material of opponent part Unit

Aluminum

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

M8 (8 mm, 0.31 in.)

11.8 ~ 15.6

1.2 ~ 1.6

8.68 ~ 11.5

8.82 ~ 11.8

0.90 ~ 1.2

6.51 ~ 8.67

M10 (10 mm, 0.39 in.)

24.6 ~ 31.3

2.5 ~ 3.2

18.1 ~ 23.1 19.7 ~ 25.4

2.0 ~ 2.6

14.5 ~ 18.8

M12 (12 mm, 0.47 in.)

29.5 ~ 49.0

3.0 ~ 5.0

21.7 ~ 36.1

3.2

23.1

Diameter

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CHAPTER 1

CK20(H)

7.3 AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS SAE GR.5

Grade

SAE GR.8

Unit

Nominal diameter

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

5/16

23.1 ~ 27.8

2.35 ~ 2.84

17.0 ~ 20.5

32.5 ~ 39.3

3.31 ~ 4.01

24.0 ~ 29.0

3/8

47.5 ~ 57.0

4.84 ~ 5.82

35.0 ~ 42.0

61.0 ~ 73.2

6.22 ~ 7.47

45.0 ~ 54.0

1/2

108.5 ~ 130.2

11.07 ~ 13.29

80.0 ~ 96.0

149.2 ~ 179.0

15.22 ~ 18.27

110.0 ~ 132.0

9/16

149.2 ~ 179.0

15.22 ~ 18.27

110.0 ~ 132.0

217.0 ~ 260.4

22.14 ~ 26.57

160.0 ~192.0

5/8

203.4 ~ 244.1

20.75 ~ 24.91

150.0 ~ 180.0

298.3 ~ 358.0

30.44 ~ 36.53

220.0 ~ 264.0

1-12

S196-WOO

Jul. 2003


GENERAL

8. MAINTENANCE CHECK LIST Period

After Purchase

Indication On Hour Meter

Important

No. 1 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1500 3000

Item 1

Engine oil

Change

€ z

z

2

Engine oil filter

Replace

€

z

z

z z

z

z z

z

z

3

Transmission oil filter

Replace

€

z

z

z

z

Hydraulic oil filter

Replace

€

z

z

z

z

5

Transmission fluid

Change

z

z

6

Front axle case oil

Change

z

z

7

Front axle pivot

Adjust

z

8

Engine start system

Check

z z z z z z z z z z z z z z z z

9

Greasing

-

z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z

z

z

10

Wheel bolt torque

Check

11

Battery condition

Check

z

z

z

z

z

z

z

z

Clean

z

z

z

z

z

z

z

z

12

Air cleaner element

13

Fuel filter element

14

Fan belt

Adjust

z

z

z

z

z

z

z

z

15

HST neutral spring

Adjust

z

z

z

z

z

z

z

z

16

Brake

Adjust

z

z

z

z

z

z

z

z

17

Radiator hose and clamp

Check Replace

18

Power steering oil line

Replace

19

20

z

z

z

z

z

z

z

z

Replace

z

z z

z

z

z z

z

Check

Check Fuel line

z

Replace Check

z

z

z z

z

z

z

z

z

z

z

z z

Replace Check

Intake air line

z

z

z

z z

Replace

21

Toe-in

Adjust

22

Engine valve clearance

Adjust

23

Fuel injection nozzle injection pressure

Check

z z

24

Injection pump

Check

z

25

Cooling system

26

Coolant

27

Fuel system

28

Fuse

Replace

29

Light bulb

Replace

S196-WOO

Jul. 2003

year years

z

4

z

2

z

z

z

z z

Flush

z

Change

z

Bleed

Service as required

1-13


CHAPTER 1

CK20(H)

IMPORTANT •

The jobs indicated by € must be done after the first 50 hours of operation. *1 Air cleaner should be cleaned more often in dusty conditions than in normal conditions. *2 Every year or every 6 times of cleaning. *3 Replace only if necessary. *4 When the battery is used for less than 100 hours per year, check the fluid level annually.

The items listed above (@ marked) are registered as emission related critical parts by KIOTI in the U.S.EPA non-road emission regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the above instruction. Please see the Warranty Statement in detail.

1-14

S196-WOO

Jul. 2003


GENERAL

9. CHECK AND MAINIENANCE 9.1 DAILY CHECK Walk Around Inspection

For your own safety and maximum service life of the machine, make a thorough daily inspection before operating the machine to start the engine.

Look around and under the tractor for such items as loose bolts, trash build-up, oil or coolant leaks, broken or worn parts.

CAUTION To avoid personal injury: • Be sure to check and service the tractor on a flat place with the engine shut off and the parking brake “ON”.

A. CHECKING AND REFUELING Fuel tank capacity

20 (5.28 U.S.gal.)

CAUTION To avoid personal injury: • Do not smoke while refueling. • Be sure to stop the engine before refueling.

1. Turn the key switch to “ON”, check the amount of fuel showing on the fuel gauge. 2. Fill fuel tank when fuel gauge shows 1/4 or less fuel in tank.

196W113A

3. Use grade No.2-Diesel fuel at temperatures above -10°C (14°F).

(1) Fuel Tank Cap

IMPORTANT

NOTE:

Do not permit dirt or trash to get into the fuel system.

Be careful not to let the fuel tank become empty, otherwise air will enter the fuel system, requiring the fuel system to be bled before next engine start.

Be careful not to spill during refueling. If should occur, wipe it off at once, or it may cause a fire.

To prevent condensation (water) accumulation in the fuel tank, fill the tank before parking overnight. Flash Point °C (°F)

Water and Sediment, Volume %

No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE J313 JUN 87)

Grade of Diesel Fuel Oil According to ASTM D975

Carbon Residue On, 10 Percent Residuum, %

Ash, Weight %

Min

Max

Max

Max

52 (125)

0.05

0.35

0.01

Distillation Temperatures, °C (°F) 90% Point

Viscosity Kinematic cSt or mm²/s at 40°C

Viscosity Saybolt, SUS at 100°F

Sulfur, Weight %

Copper Strip Corrosion

Cetane Number

Min

Max

Min

Max

Min

Max

Max

Max

Min

282 (540)

338 (640)

1.9

4.1

32.6

40.1

0.50

No.3

40

S196-WOO

Jul. 2003

1-15


CHAPTER 1

CK20(H)

B. CHECKING ENGINE OIL LEVEL

IMPORTANT •

When using an oil of different maker or viscosity from the previous one, remove all of the old oil. Never mix two different types of oil.

Never run engine is the oil level is low.

CAUTION To avoid personal injury: •

Be sure to stop the engine before checking the oil level.

196W114A

(1) Oil Inlet 1. Park the machine on a flat surface. 2. Check the engine oil before starting the engine or 5 minutes or more after the engine has stopped.

(2) Dipstick (A) Oil Level is Acceptable Within this Range

3. To check the oil level, draw out the dipstick, wipe it clean, replace it, and draw it out again. Check to see that the oil level is between the two notches. If the level is too low, add new oil to the prescribed level at the oil inlet. (See “LUBRICANTS” in Maintenance Section)

C. CHECKING COOLANT LEVEL CAUTION To avoid personal injury: •

Do not remove radiator cap while coolant is hot. When cool, slowly rotate cap to the first stop and allow ample time for excess pressure to escape before removing the cap completely.

1. Make sure to see that the coolant level is between the “FULL” and “LOW” marks of recovery tank. 2. When the coolant level drops due to evaporation, add water only up to the full level. In case of leakage, add anti-freeze and water in the specified mixing ration up to the full level. (See “Flush Cooling System and Changing Coolant” in every 2 yours maintenance.)

196W115A

(1) Recovery Tank

(A) FULL (B) LOW

IMPORTANT •

If the radiator cap has to be removed, follow the caution above and securely retighten the cap.

Use clean, fresh water and anti-freeze to fill the recovery tank.

If water should leak, consult your local KIOTI Dealer.

1-16

S196-WOO

Jul. 2003


GENERAL D. CHECKING HEAD LIGHT, HAZARD LIGHT ETC. 1. Inspect the lights for broken bulbs and lenses. 2. Replace if broken.

E. CHECKING SEAT BELT AND ROPS 1. Always check condition of seat belt and ROPS attaching hardware before operating tractor. 2. Replace if damaged.

F. CLEANING GRILL, RADIATOR SCREEN AND OIL COOLER SCREEN

CK20

CAUTION To avoid personal injury: •

Be sure to stop the engine before removing the screen.

1. Check front grill and side screens to be sure they are clean of any debris. 2. Detach the screen and eliminate all the foreign material. 196W116A

IMPORTANT •

Grill and screen must be clean from debris to avoid engine from overheating and to allow good air intake for the air cleaner.

(1) Radiator Screen (A) DETACH

CK20H

196W117A

(1) Radiator Screen (2) Oil Cooler Screen (A) DETACH

S196-WOO

Jul. 2003

1-17


CHAPTER 1

CK20(H)

G. CHECKING BRAKE PEDALS AND CLUTCH PEDAL 1. Examine the brake and clutch pedals for free travel, and smooth operation. 2. Adjust if incorrect quantity is found: (See “Adjusting Clutch and Brake Pedal” in every 100 hours maintenance.)

NOTE: Brake pedals should be equal when depressed.

H. CHECKING GAUGES, METER AND EASY CHECKER 1. Examine the instrument panel for broken gauge(s), meter(s) and Easy Checker lamps. 2. Replace if broken.

I. CHECKING HEAD LIGHT, HAZARD LIGHT ETC. 1. Inspect the lights for broken bulbs and lenses. 2. Replace when necessary.

J. CHECKING SEAT BELT AND ROPS 1. Always check condition of seat belt and ROPS attaching hardware before operating tractor. 2. Replace when necessary.

1-18

S196-WOO

Jul. 2003


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Kioti Daedong CK20H Tractor Service Repair Manual  
Kioti Daedong CK20H Tractor Service Repair Manual  
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