Page 1

TO THE READER

1. TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of KIOTI tractors DK651/751/801/901. 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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DK651/751/801/901

2. 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.

C34W001A

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.

C34W002A

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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.

C34W003A

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.

C34W004A

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.

C34W005A

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DK651/751/801/901 VENTILATE WORK AREA 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.

C34W006A

PREVENT ACID BURNS 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.

C34W007A

DISPOSE OF FLUIDS PROPERLY 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.

C34W008A

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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.

C34W009A

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DK651/751/801/901

3. SAFETY DECALS The following safety decals are installed on the machine. If a decal becomes damaged, illegible or is not on the machine, replace it. The decal part number is listed in the parts list. ROPS

C34W010A

CABIN

C34W011A

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TO THE READER (1) Parts No. : E6500-51101

(2) Parts No. : T4837-51181

(3) Parts No. : T4628-52201

(4) Parts No. : T4817-52201

(5) Parts No. : T2325-50743

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DK651/751/801/901 (6) Parts No. : T4818-52142

(7) Parts No. : T4625-52351

(8) Parts No. : T2615-53561

(9) Parts No. : T2615-55112

(10) Parts No. : T4837-51191

(11) Parts No. : T2615-54112

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TO THE READER (12) Parts No. : T4837-51093

(13) Parts No. : T4837-52121

MAINTAINING THE SAFETY SIGNS FOR DANGER, WARNING AND CAUTION 1. Make sure that these safety signs are clean and have no foreign and obstacle objects on them. 2. When cleaning, wash them with soup and water and clean using a soft cloth. 3. Immediately replace missing or damaged safety signs. 4. Make sure that new equipment components and repair parts include a new safety sign in its place. 5. Attach a new safety sign on dry surface and rub it outwards to remove bubbles

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DK651/751/801/901

4. CONTENTS CHAPTER 1. GENERAL ....................................................................................................... 1-1 1. TRACTOR IDENTIFICATION ............................................................................................................ 1-3 2. DIMENSIONS .................................................................................................................................. 1-5 3. GENERAL PRECAUTIONS ............................................................................................................. 1-5 3.1 ASSEMBLY AND DISASSEMBLY ....................................................................................... 1-5 3.2 ELECTRICAL SYSTEM ........................................................................................................ 1-7 3.3 TUBES AND RUBBERS ....................................................................................................... 1-7 3.4 LUBRICANT .......................................................................................................................... 1-7 4. SPECIFICATIONS ............................................................................................................................ 1-9 5. LUBRICANTS, FUEL AND COOLANT ............................................................................................. 1-9 6. TIGHTENING TORQUES ................................................................................................................ 1-11 6.1 GENERAL USE SCREWS, BOLTS AND NUTS ................................................................. 1-11 6.2 STUD BOLTS ....................................................................................................................... 1-11 7. MAINTENANCE CHECK LIST ....................................................................................................... 1-13 8. CHECK AND MAINIENANCE ........................................................................................................ 1-15 8.1 DAILY CHECK .................................................................................................................... 1-15 8.2 INITIAL 50 HOURS ............................................................................................................. 1-17 8.3 EVERY 50 HOURS ............................................................................................................. 1-21 8.4 EVERY 100 HOURS .......................................................................................................... 1-23 8.5 EVERY 200 HOURS .......................................................................................................... 1-27 8.6 EVERY 250 HOURS .......................................................................................................... 1-30 8.7 EVERY 400 HOURS .......................................................................................................... 1-30 8.8 EVERY 600 HOURS .......................................................................................................... 1-30 8.9 EVERY 800 HOURS .......................................................................................................... 1-31 8.10 EVERY 1 YEAR ................................................................................................................. 1-31 8.11 EVERY 2 YEAR ................................................................................................................. 1-32 8.12 SERVICE AS REQUIRED .................................................................................................. 1-34 9. TIRES ............................................................................................................................................. 1-37 9.1 INFLATION PRESSURE ..................................................................................................... 1-37 9.2 TREAD ................................................................................................................................ 1-38 9.3 BALLAST ............................................................................................................................ 1-40 9.4 TRAVELING SPEED .......................................................................................................... 1-41

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TO THE READER

CHAPTER 2. ENGINE ........................................................................................................... 2-1 1. SYSTEMS OPERATION SECTION ................................................................................................. 2-3 1.1 ENGINE MODEL VIEWS ...................................................................................................... 2-3 1.2 FUEL SYSTEM ..................................................................................................................... 2-4 1.3 AIR INLET AND EXHAUST SYSTEM ................................................................................... 2-5 1.4 LABRICATION SYSTEM ...................................................................................................... 2-7 1.5 COOLING SYSTEM ............................................................................................................. 2-9 2. SPECIFICATIONS ......................................................................................................................... 2-10 2.1 ENGINE DESIGN ................................................................................................................ 2-10 2.2 FUEL INJECTION LINES .................................................................................................... 2-11 2.3 FUEL INJECTION PUMP .................................................................................................... 2-11 2.4 FUEL INJECTORS .............................................................................................................. 2-13 2.5 FUEL TRANSFER PUMP ................................................................................................... 2-14 2.6 LIFTER GROUP ................................................................................................................. 2-14 2.7 ROCKER SHAFT ............................................................................................................... 2-15 2.8 VALVE MECHANISM COVER ............................................................................................ 2-16 2.9 CYLINDER HEAD VALVES ................................................................................................ 2-17 2.10 CYLINDER HEAD ............................................................................................................... 2-20 2.11 TURBOCHARGER ............................................................................................................. 2-22 2.12 EXHAUST MANIFOLD ........................................................................................................ 2-23 2.13 CAMSHAFT ........................................................................................................................ 2-24 2.14 CAMSHAFT BEARINGS ..................................................................................................... 2-26 2.15 ENGINE OIL FILTER .......................................................................................................... 2-27 2.16 ENGINE OIL PUMP ............................................................................................................. 2-28 2.17 ENGINE OIL PRESSURE ................................................................................................... 2-31 2.18 ENGINE OIL BYPASS VALVE ............................................................................................ 2-31 2.19 ENGINE OIL PAN ................................................................................................................ 2-33 2.20 CRANKCASE BREATHER ................................................................................................. 2-35 2.22 WATER PUMP .................................................................................................................... 2-36 2.21 WATER TEMPERATURE REGULATOR AND HOUSING .................................................. 2-36 2.23 CYLINDER BLOCK ............................................................................................................ 2-37 2.24 CRANKSHAFT .................................................................................................................... 2-41 2.25 CRANKSHAFT SEALS ....................................................................................................... 2-44 2.26 CONNECTING ROD BEARING JOURNAL ........................................................................ 2-45 2.27 MAIN BEARING JOURNAL ................................................................................................. 2-45 2.28 CONNECTING ROD ........................................................................................................... 2-46 2.29 PISTON AND RINGS .......................................................................................................... 2-48

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DK651/751/801/901 2.30 PISTON COOLING JET ..................................................................................................... 2-50 2.31 FRONT HOUSING AND COVERS ..................................................................................... 2-51 2.32 GEAR GROUP (FRONT) ................................................................................................... 2-52 2.33 FLYWHEEL ......................................................................................................................... 2-54 2.34 FLYWHEEL HOUSING ........................................................................................................ 2-55 2.35 CRANKSHAFT PULLEY ..................................................................................................... 2-55 2.36 FAN DRIVE ......................................................................................................................... 2-56 2.37 ENGINE LIFTING BRACKET .............................................................................................. 2-57 2.38 GLOW PLUGS ................................................................................................................... 2-57 3. SEPARATE THE ENGINE .............................................................................................................. 2-58 4. DISASSEMBLY AND ASSEMBLY .................................................................................................. 2-66 4.1 FUEL PRIMING PUMP ........................................................................................................ 2-66 4.2 FUEL FILTER BASE ........................................................................................................... 2-67 4.3 FUEL INJECTION LINES .................................................................................................... 2-68 4.4 FUEL INJECTOR COVER .................................................................................................. 2-69 4.5 FUEL INJECTION PUMP / DELPHI DP210 ........................................................................ 2-70 4.6 FUEL INJECTION PUMP / BOSCH EPVE .......................................................................... 2-74 4.7 FUEL INJECTOR ................................................................................................................ 2-78 4.8 TURBOCHARGER ............................................................................................................. 2-79 4.9 EXHAUST MANIFOLD ........................................................................................................ 2-82 4.10 EXHAUST ELBOW (OPTION FOR FOUR CYLINDER ENGINES ONLY) ......................... 2-84 4.11 INLET AND EXHAUST VALVE SPRINGS .......................................................................... 2-85 4.12 INLET AND EXHAUST VALVES ......................................................................................... 2-88 4.13 INLET AND EXHAUST VALVE GUIDES ............................................................................. 2-91 4.14 INLET AND EXHAUST VALVE SEAT INSERTS ................................................................. 2-93 4.15 ENGINE OIL FILTER BASE ................................................................................................ 2-96 4.16 ENGINE OIL COOLER ....................................................................................................... 2-98 4.17 ENGINE OIL RELIEF VALVE (ENGINE OIL PUMP) ......................................................... 2-102 4.18 ENGINE OIL RELIEF VALVE (BALANCER UNIT FOR THE 1104 ENGINES ONLY) ..... 2-103 4.19 ENGINE OIL PUMP (ENGINES WITHOUT A BALANCER) .............................................. 2-104 4.20 WATER PUMP .................................................................................................................. 2-106 4.21 WATER TEMPERATURE REGULATOR ......................................................................... 2-111 4.22 FLYWHEEL ....................................................................................................................... 2-113 4.23 CRANKSHAFT REAR SEAL ............................................................................................ 2-115 4.24 CRANKSHAFT WEAR SLEEVE (REAR) ......................................................................... 2-118 4.25 FLYWHEEL HOUSING ...................................................................................................... 2-119

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TO THE READER 4.26 CRANKSHAFT PULLEY ................................................................................................... 2-121 4.27 CRANKSHAFT FRONT SEAL ......................................................................................... 2-122 4.28 CRANKSHAFT WEAR SLEEVE (FRONT) ...................................................................... 2-124 4.29 FRONT COVER ............................................................................................................... 2-125 4.30 GEAR GROUP (FRONT) ................................................................................................. 2-127 4.31 IDLER GEAR .................................................................................................................... 2-130 4.32 HOUSING (FRONT) ......................................................................................................... 2-134 4.33 ACCESSORY DRIVE ....................................................................................................... 2-137 4.34 CRANKCASE BREATHER ............................................................................................... 2-139 4.35 VALVE MECHANISM COVER .......................................................................................... 2-141 4.36 ROCKER SHAFT AND PUSHROD .................................................................................. 2-143 4.37 CYLINDER HEAD ............................................................................................................. 2-147 4.38 LIFTER GROUP - INSTALL ............................................................................................. 2-153 4.39 CAMSHAFT ...................................................................................................................... 2-154 4.40 CAMSHAFT GEAR ........................................................................................................... 2-155 4.41 CAMSHAFT BEARINGS ................................................................................................... 2-156 4.42 ENGINE OIL PAN .............................................................................................................. 2-157 4.43 BALANCER (4 CYLINDER ENGINS ONLY) ..................................................................... 2-160 4.44 PISTON COOLING JETS ................................................................................................. 2-161 4.45 PISTONS AND CONNECTING RODS.............................................................................. 2-164 4.46 CONNECTING ROD BEARINGS ..................................................................................... 2-169 4.47 CRANKSHAFT MAIN BEARINGS ..................................................................................... 2-171 4.48 CRANKSHAFT .................................................................................................................. 2-176 4.49 CRANKSHAFT GEAR ...................................................................................................... 2-183 4.50 BEARING CLEARANCE ................................................................................................... 2-184 4.51 GLOW PLUGS ................................................................................................................. 2-186 3.52 V-BELTS ........................................................................................................................... 2-187 4.53 FAN ................................................................................................................................... 2-188 4.54 FAN DRIVE ....................................................................................................................... 2-188 5. TESTING AND ADJUSTING SECTION ....................................................................................... 2-189 5.1 FUEL SYSTEM ................................................................................................................. 2-189 5.2 AIR INLET AND EXHAUST SYSTEM ............................................................................... 2-198 5.3 LUBRICATION SYSTEM ..................................................................................................2-206 5.4. COOLING SYSTEM ......................................................................................................... 2-209 5.5 BASIC ENGINE ................................................................................................................. 2-215 6. LIST OF SPECIAL TOOLS ......................................................................................................... 2-221

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DK651/751/801/901

CHAPTER 3. CLUTCH .......................................................................................................... 3-1 1. STRUCTURE ................................................................................................................................... 3-3 2. TROUBLESHOOTING ..................................................................................................................... 3-4 3. SPECIFICATIONS ........................................................................................................................... 3-5 4. INSPECTION, DISASSEMBLY AND REPAIR .................................................................................. 3-6 4.1 INSPECTION ........................................................................................................................ 3-6 4.2 DISASSEMBLING AND ASSEMBLING ................................................................................. 3-8 4.3 INSPECTION AND REPAIR ................................................................................................ 3-16

CHAPTER 4. TRANSMISSION ............................................................................................. 3-1 1. STRUCTURE ................................................................................................................................... 4-3 1.1 POWER TRAIN DIAGRAM ................................................................................................... 4-3 1.2 POWER TRAIN .................................................................................................................... 4-4 2. TROUBLESHOOTING ................................................................................................................... 4-10 3. DISASSEMBLY AND SERVICE ..................................................................................................... 4-13 3.1 REMOVING TRANSMISSION ............................................................................................. 4-13 3.2 REMOVING CLUTCH HOUSING ........................................................................................ 4-27 3.3 REMOVING TRANSMISSION ............................................................................................. 4-32 3.4 MAINTENANCE .................................................................................................................. 4-40

CHAPTER 5. REAR AXLE .................................................................................................... 5-1 1. STRUCTURE ................................................................................................................................... 5-3 2. TROUBLESHOOTING ..................................................................................................................... 5-4 3. TIGHTENING TORQUES ................................................................................................................ 5-5 4. DISASSEMBLY AND REPAIR .......................................................................................................... 5-6 4.1 REMOVING REAR AXLE ...................................................................................................... 5-6 4.2 MAINTENANCE .................................................................................................................. 5-10

CHAPTER 6. BRAKE ............................................................................................................ 6-1 1. STRUCTURE ................................................................................................................................... 6-3 1.1 OPERATIONAL PRINCIPLE ................................................................................................. 6-3 2. TROUBLESHOOTING ..................................................................................................................... 6-4 3. SPECIFICATIONS ........................................................................................................................... 6-5 4. TIGHTENING TORQUE ................................................................................................................... 6-6

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TO THE READER 5. CHECK AND ADJUSTMENT ............................................................................................................ 6-7 5.1 BRAKE PEDAL FREE PLAY ................................................................................................ 6-7 5.2 DIFFERENCE BETWEEN RIGHT AND LEFT BRAKE PEDAL ........................................... 6-7 5.3 ADJUSTING PARKING BRAKE WIRE.................................................................................. 6-8 5.4 AIR BLEEDING FROM BRAKE SYSTEM ............................................................................ 6-9 6. DISASSEMBLING AND SERVICING ............................................................................................. 6-10 6.1 REMOVING REAR AXLE .................................................................................................... 6-10

CHAPTER 7. FRONT AXLE .................................................................................................. 7-1 1. STRUCTURE ................................................................................................................................... 7-3 2. TROUBLESHOOTING ..................................................................................................................... 7-4 2.1 TROUBLESHOOTING FOR FRONT DIFFERENTIAL CLUTCH ......................................... 7-4 2.2 TROUBLESHOOTING FOR OIL LEAKAGE AT FRONT AXLE ........................................... 7-4 3. INSPECTION, DIASSEMBLY AND REPAIR..................................................................................... 7-5 3.1 TOE-IN .................................................................................................................................. 7-5 3.2 FRONT WHEEL STEERING ANGLE ................................................................................... 7-6 3.3 ROCKING FORCE OF FRONT AXLE ................................................................................. 7-7 3.4 AXLE SWAY OF FRONT WHEEL ........................................................................................ 7-7 4. DISASSEMBLY AND SERVICE ....................................................................................................... 7-8 4.1 REMOVING FRONT AXLE ................................................................................................... 7-8 4.2 SERVICING ........................................................................................................................ 7-17

CHAPTER 8. HYDRAULIC SYSTEM ................................................................................... 8-1 1. STRUCTURE ................................................................................................................................... 8-3 1.1 HYDRAULIC SYSTEM DIAGRAM ........................................................................................ 8-3 1.2 HYDRAULIC CIRCUIT .......................................................................................................... 8-4 1.3 OIL FILTER ........................................................................................................................... 8-5 1.4 HYDRAULIC PUMP .............................................................................................................. 8-6 1.5 POWER STEERING SYSTEM ............................................................................................. 8-7 1.6 PTO CLUTCH SYSTEM ....................................................................................................... 8-9 1.7 JOYSTICK VALVE .............................................................................................................. 8-10 1.8 HORIZONTAL CONTROL SYSTEM ................................................................................... 8-10 1.9 HYDRAULIC POWER ELEVATION SYSTEM .................................................................... 8-12 2. TROUBLESHOOTING ................................................................................................................... 8-14 2.1 POWER STEERING SYSTEM ........................................................................................... 8-14 2.2 HYDRAULIC LIFT SYLINDER SYSTEM ............................................................................ 8-15

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DK651/751/801/901 3. INSPECTION, DIASSEMBLY AND REPAIR................................................................................... 8-16 3.1 HYDRAULIC FILTER .......................................................................................................... 8-16 3.2 HYDRAULIC PUMP ............................................................................................................ 8-16 3.3 STEERING SYSTEM .......................................................................................................... 8-18 3.4 PTO CLUTCH ..................................................................................................................... 8-21

CHAPTER 9. CABIN SYSTEM ............................................................................................. 8-1 1. AIR CONDITIONER/HEATER STRUCTURE .................................................................................. 9-3 1.1 AIR CONDITIONER SYSTEM LAYOUT ............................................................................... 9-3 1.2 CIRCUIT DIAGRAM .............................................................................................................. 9-4 1.3 AIR CONDITIONER/HEATER SPECIFICATIONS ................................................................ 9-5 2. TROUBLE SHOOTING .................................................................................................................... 9-6 2.1 VISUAL AND AUDIO CHECK ................................................................................................ 9-6 2.2 TROUBLE DIAGNOSIS ........................................................................................................ 9-7 2.3 ADVANCED TROUBLESHOOTING ..................................................................................... 9-8 3. CHECKING AND CHARGING GAS ............................................................................................... 9-11 3.1 TROUBLESHOOTING BY MANIFOLD GAUGE ................................................................ 9-11 4. INSPECTION AND ADJUSTMENTS .............................................................................................. 9-15 4.1 CHARGING REFRIGERANT .............................................................................................. 9-16 5. INSPECTION, DISASSEMBLY AND REPAIR ................................................................................ 9-19 5.1 REMOVING CABIN ............................................................................................................. 9-19 5.2 REMOVING AIR CONDITIONER UNIT ............................................................................... 9-25 5.3 REMOVING COMPRESSOR .............................................................................................. 9-26

CHAPTER 10. ELECTRIC SYSTEM .................................................................................. 10-1 1. WIRING DIAGRAM ........................................................................................................................ 10-3 1.1 GENERAL ........................................................................................................................... 10-3 1.2 FITTING SPECIFICATIONS OF TRANSVERSE CONTOL CYLINDER ............................ 10-4 2. BATTERY ...................................................................................................................................... 10-5 3. STARTING SYSTEM ..................................................................................................................... 10-6 4. CHARGING SYSTEM .................................................................................................................... 10-7 5. LIGHTING SYSTEM ...................................................................................................................... 10-8 5.1 LIGHT SWITCH .................................................................................................................. 10-9 5.2 HAZARD WARNING SWITCH ............................................................................................ 10-9 5.3 FLASHER UNIT .................................................................................................................. 10-9 5.4 LAMPS .............................................................................................................................. 10-10 5.5 HEAD LIGHTS .................................................................................................................. 10-11

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TO THE READER 6. COMBINATION METER ............................................................................................................... 10-12 6.1 TACHOMETER AND HOURMETER (1) .......................................................................... 10-13 6.2 ENGINE COOLANT TEMP. GAUGE (2), FUEL GAUGE (3) .......................................... 10-13 6.3 GAUGES AND INDICATORS (BULB STANDARD: 14V, 1.4W) ...................................... 10-14 6.4 SENSORS ......................................................................................................................... 10-15 7. TROUBLESHOOTING10-16 8. INSPECTION, DISASSEMBLY AND REPAIR .............................................................................. 10-18 8.1 BATTERY ......................................................................................................................... 10-18 8.2 STARTING SYSTEM ........................................................................................................ 10-20 8-3 LOGHT SYSTEM ............................................................................................................. 10-25

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MEMO ......................................................................................................................................................................................................................................................................................................................................................................................................................................................

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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.

2 1

C34W101A

(1) Identification Number

C34W102A

(1) Engine Serial Number

(2) Transmission Serial Number

C34W103A

(1) Hour Meter

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DK651/751/801/901

2. DIMENSIONS

C34W104A

mm (in.) A

B

C

D

E

F

DK651

3,943 (155.2)

2,650 (104.3)

2,048 (80.6)

1,477 (57.9)

1,406 (55.3)

423 (16.6)

DK751

4,142 (163.0)

2,710 (106.6)

2,142 (84.3)

1,534 (60.3)

1,504 (59.2)

443 (17.4)

DK801

4,269 (167.9)

2,710 (106.6)

2,142 (84.3)

1,534 (60.3)

1,504 (59.2)

443 (17.4)

DK901

4,269 (167.9)

2,754 (108.4)

2,142 (84.3)

1,576 (62.0)

1,534 (60.3)

470 (18.5)

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GENERAL

3. GENERAL PRECAUTIONS 3.1 ASSEMBLY AND DISASSEMBLY

C34W105A

(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 (KIOTI) approved special tools. Servicing dealers may machine tools to DAEDONG (KIOTI) 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. 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. 10. Use only DAEDONG (KIOTI) genuine parts to maintain the performance and safety of your KIOTI tractor.

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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.

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.

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CHAPTER 1

DK651/751/801/901

3.2 ELECTRICAL SYSTEM 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.

C34W106A

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: •

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. C34W107A

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.

C34W108A

1-6

C34-WOO May. 2005


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.

C34W109A

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

C34W110A

C34-WOO May. 2005

1-7


CHAPTER 1

DK651/751/801/901

4. SPECIFICATIONS Model

Model

Engine

Type Engine gross

HP (kW)/rpm

P.T.O

HP (kW)/rpm

Displacement Rated revolution

cc (cu.in)

DK651

DK751

DK801

DK901

1103C-33T

1104C-44

1104C-44T (80HP)

1104C-44T (90HP)

3-cylinder, water-

4-cylinder, water-

cooled, tubo diesel

cooled, diesel

Max. 64 (48)/2,200 Max. 72.4 (54)/2,200 Max. 80 (60)/2,200 52 (39)/2,200

Dry single Synchro shuttle

Drive train

Speeds

12F 12R Standard

Differential lock

Wet disc type

Brake P.T.O

Independent

Hydraulic system

Rear

1st: 41.2 (14.4)

540/750 (Option 540/1,000) 1st: 45.3 (20.6)

2nd: 31.7 (11.1)

2nd: 31.7 (14.4)

Cat.1 & 2

Cat.2

rpm

Pump capacity (Max. flow rate) /min (cc) 3-point hitch Maximum lifting capacity (24in. aft of hitch)

Max. 2,400 (5,291)

kg (lbs.)

Hydraulic lift control system

Position, draft and mixed control

Steering

Hydrostatic power steering

Drawbar type Standard tire size

83 (62)/2,200

100 (26.4)

Clutch

Traveling speeds

Max. 90 (67)/2,200

2,200

(gal.)

Transmission

Drawdar

Front

11.2 - 24

11.2 - 20

Rear

14.9 - 30

16.9 - 30

16.9 - 34

1st: 0.42 (0.26) Forward (At rated engine rpm) km/h (mph) 12th: 28.71 (17.83)

1st: 0.43 (0.26)

1st: 0.45 (0.27)

12th: 29.55 (18.36)

12th: 31.34 (19.47)

Reverse (At rated engine rpm) 1st: 0.41 (0.25) km/h (mph) 12th: 28.11 (17.46)

1st: 0.42 (0.26)

1st: 0.44 (0.27)

12th: 28.93 (17.97)

12th: 30.68 (19.06)

Overall length (with 3p)

Dimensions

67 (50)/2,200 4,400 (269)

57 (43)/2,200

3,300 (201)

rpm (min-1)

Fuel tank capacity

4-cylinder, water-cooled, Tubo diesel

mm (in.)

4,062 (159.9)

Overall width (minimum tread) mm (in.)

1,790 (70.4)

1,940 (76.3)

1,990 (78.3)

2,650 (104.3)

2,710 (106.6)

2,754 (108.4)

Overall height (Cabin) Wheel base

mm (in.) mm (in.)

Min. ground clearance

mm (in.)

Tread

4,234 (166.6)

2,048 (80.6)

4,267 (167.9)

2,142 (84.3)

4,23 (16.6)

443 (17.4)

1,576 (62.0) 1,534 (60.3)

Front

mm (in.)

1,473 (57.9)

1,534 (60.3)

Rear

mm (in.)

1,406 (55.3)

1,504 (59.2)

kg (lbs.)

3,093 (6,819)

Weight (cabin)

3,331 (7,341)

470 (18.5)

3,421 (7,542)

3,557 (7,842)

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

1-8

C34-WOO May. 2005


GENERAL

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

Locations

1

Fuel

2

Coolant

Capacities

DK651

Lubricants

DK751/801/901

100 (26.4 U.S.gal.) 9.1

18.5

(2.4 U.S.gal.)

(4.9 U.S.gal.)

No.2-D diesel fuel No.1-D diesel fuel if temperature is below -10°C (14°F) Fresh clean water with anti-freeze (50:50) Engine oil: API Service Classification CC or CD

3

Engine crankcase

6.9

10.5

(1.82 U.S.gal.)

(2.77 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

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

Transmission case

60 (15.85 U.S.gal.)

Each 3.5 (0.9 U.S.gal.)

5

Front axle case

6

Front axle

4.5 (1.2 U.S.gal.)

7

Greasing

As necessary

C34-WOO May. 2005

Exxonmobil

Mobilfluid 423 or 424 Exxon hydraul 560

shell

DONAX-TD/TD Plus

BP

Tractran UTH

SAE 90 gear oil or transmission case oil Standad type grease

1-9


CHAPTER 1

DK651/751/801/901

6. TIGHTENING TORQUES 6.1 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 Material of opponent part Unit Diameter

7

No-grade or 4T

SS400, S20C

9

7T

9T

SCr435, SCM435

S43C, S48C

Ordinariness

Aluminum

Ordinariness

Aluminum

Ordinariness

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 ~ 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

12.3 ~ 14.2

1.25 ~ 1.45

9.05 ~ 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 ~ 12.0

76.0 ~ 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 ~ 704

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

6.2 STUD BOLTS Ordinariness

Material of opponent part Unit

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

1-10

Aluminum

31.4

C34-WOO May. 2005


GENERAL

6.3 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

C34-WOO May. 2005

1-11


CHAPTER 1

DK651/751/801/901

7. 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

z

2

Engine oil filter

Change

€

z

z

z

3

Transmission oil filter

Change

€

z

z

z

z

4

Hydraulic oil filter

Change

€

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

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

Clutch

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 Change

18

Power steering oil line

Change

19

Fuel line

20

Intake air line

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

Change

29

Light bulb

Change

30

Drain moisture from

z

z z z z

z

z

z z z z z z z z z z z

*4 *1 z

Change Check

1-12

z

z

z

z

z z

z

Check

z

z

z z

z

z

z

z

z

z

z

z z

Change Check

clutch housing

Everyday

Change

Check

*2

z

z

z

z z

Change z

z

z

*3

z z

Clean

z

Change

z

Check Service as required

Drain

C34-WOO May. 2005


GENERAL 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 31

Air conditioner

Clean

Everyday

condenser net 32

Air conditioner belt

Check

z

z

z

z

Clean

z

z

z

z

z

z

z

z

tension 33

Intake air filter

34

Ambient air filter

Clean

35

Air conditioner hose

Check

z

36

Heater hose

Check

z

37

Refrigerant

Check

As

38

Washer liquid

Supple-

necessary

ment

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.

C34-WOO May. 2005

1-13


CHAPTER 1

DK651/751/801/901

8. CHECK AND MAINIENANCE 8.1 DAILY CHECK Walk Around Inspection Look around and under the tractor for such items as loose bolts, trash build-up, oil or coolant leaks, broken or worn parts.

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

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 100 (26.4 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. 3. Use No.2-Diesel fuel at all temperatures above -10°C (14°F).

C34W111A

(1) Fuel Tank Cap

NOTE:

IMPORTANT • •

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

1-14

C34-WOO May. 2005


GENERAL 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.

C34W112A

(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. 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 page 1-9)

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

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.)

C34W113A

(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.

C34-WOO May. 2005

1-15


CHAPTER 1

DK651/751/801/901

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.

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.

C34W114A

(1) Radiator Screen

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.

I. DRAINING WATER FROM FUEL PRE-FILTER Water and dirts in fuel are deposited at fuel filter. Remove the drain plug (1) to remove the deposited water and dirts when necessary.

CAUTION Water infuel results in breakage of injection pump shaft or malfunction of injection nozzle. Drain the water from the fuel pre-filter frequently.

1-16

C34W115A

(1) Drain Plug C34-WOO May. 2005


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