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 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.

704W001A

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.

704W002A

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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.

704W003A

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.

704W005A

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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.

704W006A

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.

704W007A

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.

704W008A

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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.

704W009A

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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.

704W010A

(1) Parts No. : T2181-54121 (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. : T2615-55111

(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.

704W101A

(1) Statutory Plate

(2) Identification NO(EU)

(4) Transmission Serial Number(HST TYPE)

(3) Engine Serial Number (5) Transmission Serial Number(MANUAL TYPE)

704W103A

(6) Hour Meter

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CHAPTER 1

CK25(H)/30(H)

2. DIMENSIONS mm (in.)

704W102A

1-4

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GENERAL

3. GENERAL PRECAUTIONS 3.1 ASSEMBLY AND DISASSEMBLY

704W103A

(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: •

704W104A

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.

704W105A

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.

704W106A

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GENERAL

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.

704W107A

3.4 LUBRICANT During assembly and repair, apply designated lubricant where specified in accordance with this repair manual.

704W108A

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CK25(H)/30(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. At the same time recommend the dealer to performs a periodic check during regular maintenance.

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

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

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704W109A

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GENERAL

5. SPECIFICATIONS CK25

Model Model

HST

MANUAL

HST

TD1300A

TD1300E

3A150D

3A150E

Engine

Type Engine gross P.T.O

HP (kW)/rpm

Rated revolution

cc (cu.in)

Transmission Speeds

2,600 Dry dual

Dry single

Synchro shuttle

Hydrostatic Drive

8F 8R (CR:16F16R)

Standard tire size Traveling speeds

Dry dual

Dry single

Synchro shuttle

Hydrostatic Drive

8F 8R(CR:16F16R) Standard

Differential lock

Wet disc type

Brake

Live

P.T.O Rear

(rpm)

540 rpm at 2,520 engine rpm / (Option 1000rpm)

Mid

(rpm)

(Option 2,000 rpm at 2,499 engine rpm)

Pump capacity (Max. flow rate) /min (gpm)

48.1 (12.7)

3-point hitch

Cat.I

Maximum lifting capacity (24in. aft of hitch)

800 (1,764)

kg (lbs)

Hydraulic lift control system

Position control

Steering

Hydrostatic Power Steering

Front

6-14

7-14

Rear

9.5-24

11.2-24

Forward (At rated engine rpm) km/h (mph)

1.4-21.64

0-19.95

1.5-22.9

0-21.1

(0.86-13.45)

(0-12.39)

(0.93-14.22)

(0-13.11)

Reverse (At rated engine rpm) km/h (mph)

1.25-19.07

0-13.3

1.32-20.18

0-14.0

(0.77-11.85)

(0-8.26)

(0.82-12.53)

(0-8.69)

Overall length (with 3p)

Dimensions

23 (17.2)/2600 22 (16.4)/2600 1,500 (91.5)

30(7.9)

(gal.)

Clutch

Drive train

19 (14.2)/2600 18 (13.4)/2600 1,299 (79.3)

r.p.m min-1

Fuel tank capacity

Hydraulic system

Vertical, water-cooled, 3-cylinder diesel 30(22.3) 25(18.6)

HP (kW)

Displacement

CK30

MANUAL

mm (in.)

3,103 (122.2)

Overall width (minimum tread) mm (in.)

1,302 (51.2)

1,387 (54.6)

Overall height (from top of ROPS) mm (in.)

2,432 (95.7)

2,460 (96.8)

Wheel base

mm (in.)

Min. ground clearance

mm (in.)

320 (12.59)

Tread

Front

mm (in.)

1,107(43.6)

1,105(43.5)

Rear

mm (in.)

978-1,294 (38.5-50.9)

970-1,302 (38.2-51.3)

3.4(11.2)

3.5(11.5)

Min. turning radius (without brake)

m (Ft.)

Weight (with rops)

kg (lbs.)

1,680 (66.1)

1,364 (3,007)

1,370 (3,020)

351 (13.82)

1,380 (3,042)

1,386 (3,055)

NOTE) 1.The specifications are subject to change for the purpose of improvement without any notice. 2. CR : Only EU option.

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CHAPTER 1

CK25(H)/30(H)

6. LUBRICANTS, FUEL AND COOLANT To prevent serious equipment damage, use only genuine KIOTI fluids, oils and greases, or equivalents. No.

Locations

Capacities CK25/30

Lubricants

CK25H/30H No.2-D diesel fuel

1

Fuel

30 (7.9 U.S.gal.)

No.1-D diesel fuel if temperature is below -10°C (14°F)

CK25 : 7.4 (2.0 U.S.gal.) 2

Coolant

Fresh clean water with anti-freeze

CK30 : 7.8 (2.1 U.S.gal.) Engine oil: API Service Classification CC or CD

3

Engine crankcase

5.8 (1.53 U.S.gal.)

Above 25°C (77°F)

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 Mobilfluid 423 or 424

Exxonmobil

4

5

Transmission case

Front axle case Greasing

6

Battery terminal

30

27

(7.93 U.S.gal.)

(7.13 U.S.gal.)

4.5 (1.19 U.S.gal.) No. of greasing points

Shell

DONAX-TD/TD Plus

BP

Tractran UTH

SAE 90 gear oil or transmission case oil Capacity Moderate amount

2

Exxon Hydraul 560

Type of grease Multipurpose type grease

WARNING Check the oil level regularly. Correct the oil level, if needed, before operating. Always check and add oil with the tractor on a flat, level surface. To prevent personal injury, always stop the engine and set the parking brake before performing any kind of service.

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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

7

No-grade or 4T

SS400, S20C

Material of opponent part Unit

Ordinariness

9

7T

SCr435, SCM435

S43C, S48C

Ordinariness

Aluminum

Ordinariness

Aluminum N·m kgf·m lb·ft

N·m kgf·m

lb·ft

12.3 ~ 14.2

1.25 ~ 1.45

9.05 ~ 10.4

13.1 ~ 15.1

29.5 ~ 34.3

3.0 ~ 3.5

21.7 ~ 25.3

4.0 ~ 4.5

29.0 ~ 32.5

60.9 ~ 70.6

6.2 ~ 7.2

44.9 ~ 52.0

6.4 ~ 7.4

46.3 ~ 53.5

103 ~ 117

10.5 ~ 12.0

76.0 ~ 86.7

91.2 ~ 108

167 ~ 704

17.0 ~ 20.0

123 ~ 144

20.0 ~ 23.0

145 ~ 166

260 ~ 304

26.5 ~ 31.0

192 ~ 224

275 ~ 318

28.0 ~ 32.5

203 ~ 235

344 ~ 402

35.0 ~ 41.0

254 ~ 296

368 ~ 431

37.5 ~ 44.0

272 ~ 318

491 ~ 568

50.0 ~ 58.0

362 ~ 419

N·m kgf·m

lb·ft

N·m kgf·m lb·ft

N·m kgf·m lb·ft

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

0.80 ~ 0.95

5.79 ~ 6.87

7.85 ~ 8.82

0.80 ~ 0.90

5.79 ~ 6.50

9.81 ~ 11.2

1.00 ~ 1.15

7.24 ~ 8.31

7.85 ~ 8.82

0.80 ~ 0.90

5.79 ~ 6.50

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

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

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

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

11.0 ~ 12.8

79.6 ~ 92.5

124 ~ 147

12.6 ~ 15.0

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

17.0 ~ 19.5

123 ~ 141

197 ~ 225

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

25.0 ~ 29.0

181 ~ 209

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

34.0 ~ 40.0

246 ~ 289

Diameter

9T

7.2 STUD BOLTS Ordinariness

Material of opponent part Unit

Aluminum

N·m

kgf·m

lb·ft

N·m

kgf·m

lb·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

D704-WOO

Dec. 2004

31.4

1-11


CHAPTER 1

CK25(H)/30(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

lb·ft

N·m

kgf·m

lb·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

D704-WOO

Dec. 2004


GENERAL

8. MAINTENANCE CHECK LIST Period

After Purchase

Indication On Hour Meter

Important

No. 1 2 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 15003000 year years

Item 1

Engine oil

Change

€ z

z

2

Engine oil filter

Replace

€

z

z

z z

z

z z

z

z z

3

Transmission oil filter

Replace

€

z

z

z

z

4

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

10

Wheel bolt torque

Check

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

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

Clutch

Adjust

€ z

z

z

z

z

z

z

z

Brake

Adjust

€ z

z

z

z

z

z

z

z

Radiator hose and clamp

Check

18

19

Power steering oil line Fuel line

z

z z

z

z

z

z

z

z

z

Replace

z z

z

z

z

z

z

z

z

z

z

z

z

Replace Check

z

Replace Check

20

z

Replace Check

17

z

z

z

z

z

z

z z

Replace Check

z

z

z

z

21

Intake air line

22

Toe-in

Adjust

23

Engine valve clearance

Adjust

24

Fuel injection nozzle injection pressure

Check

z z

25

Injection pump

Check

z

26

Cooling system

Flush

z

27

Coolant

Change

z

28

Fuel system

29

Fuse

Replace

30

Light bulb

Replace

D704-WOO

Dec. 2004

z

Replace

Bleed

z

z

z

z z

Service as required

1-13


CHAPTER 1

CK25(H)/30(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

D704-WOO

Dec. 2004


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 30 (7.9 U.S.gal.)

Fuel tank capacity

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 the fuel gauge shows 1/4 or less fuel in the tank.

704W110A

3. Use No.2-Diesel fuel at all 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 a spill should occur, wipe it off at once. Fuel on the tractor may cause a fire.

To prevent condensation( water) accumulation in the fuel tank, fill the tank before parking the tractor overnight.

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

Flash Point °C (°F)

Water and Sediment, Volume %

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

D704-WOO

Dec. 2004

1-15


CHAPTER 1

CK25(H)/30(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.

704W111A

(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 the 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.)

704W112A

(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

D704-WOO

Dec. 2004


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 CAUTION To avoid personal injury: •

Be sure to stop the engine before removing the screen.

1. Check the front grill and the side screens to be sure they are clean of any debris. 2. Detach the screen and eliminate all the foreign material. 704W113A

(1) Radiator Screen

IMPORTANT •

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

D704-WOO

Dec. 2004

(2) Oil Cooler Screen (A) DETACH

1-17


CHAPTER 1

CK25(H)/30(H)

G. CHECKING BRAKE PEDALS AND CLUTCH PEDAL 1. Examine the brake and clutch pedals for free travel, and smooth operation. 2. Adjust if free travel is not within specifications: (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.

1-18

D704-WOO

Dec. 2004


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