Kioti daedong dk751 tractor service repair manual
- 1. TO THE READER 1C34-WOO May. 2005 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.
- 2. DK651/751/801/901 2 C34-WOO May. 2005 SAFETY STARTING 1. Always use the safety start switch to start the en- gine 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 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 regula- tions before you attempt to repair or operate this unit. Read these instructions carefully. 2. SAFETY FIRST SIGNS DANGER WARNING CAUTION IMPORTANT DESCRIPTION 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. This mark indicates potentially hazardous situation which, if not observed, may result in death or moderate injury. 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. 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
- 3. TO THE READER 3C34-WOO May. 2005 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 servic- ing 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. 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 pres- sure 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. C34W003A 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 acci- dental 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
- 4. DK651/751/801/901 4 C34-WOO May. 2005 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 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. PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, clothing and cause blind- ness 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. C34W006A C34W007A
- 5. TO THE READER 5C34-WOO May. 2005 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
- 6. DK651/751/801/901 6 C34-WOO May. 2005 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. C34W010A C34W011A ROPS CABIN
- 7. TO THE READER 7C34-WOO May. 2005 (2) Parts No. : T4837-51181(1) Parts No. : E6500-51101 (4) Parts No. : T4817-52201(3) Parts No. : T4628-52201 (5) Parts No. : T2325-50743
- 8. DK651/751/801/901 8 C34-WOO May. 2005 (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
- 9. TO THE READER 9C34-WOO May. 2005 (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
- 10. DK651/751/801/901 10 C34-WOO May. 2005 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, FUELAND 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
- 11. TO THE READER 11C34-WOO May. 2005 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 INLETAND 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
- 12. DK651/751/801/901 12 C34-WOO May. 2005 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. DISASSEMBLYAND 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
- 13. TO THE READER 13C34-WOO May. 2005 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 INLETAND 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
- 14. DK651/751/801/901 14 C34-WOO May. 2005 CHAPTER 3. CLUTCH.......................................................................................................... 3-1 1. STRUCTURE ...................................................................................................................................3-3 2. TROUBLESHOOTING .....................................................................................................................3-4 3. SPECIFICATIONS ...........................................................................................................................3-5 4. INSPECTION, DISASSEMBLYAND 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. DISASSEMBLYAND 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. DISASSEMBLYAND 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
- 15. TO THE READER 15C34-WOO May. 2005 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. DISASSEMBLINGAND 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, DIASSEMBLYAND 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 FRONTAXLE ...................................................................................................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
- 16. DK651/751/801/901 16 C34-WOO May. 2005 3. INSPECTION, DIASSEMBLYAND 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 VISUALANDAUDIO 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 ANDADJUSTMENTS ..............................................................................................9-15 4.1 CHARGING REFRIGERANT ..............................................................................................9-16 5. INSPECTION, DISASSEMBLYAND 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
- 17. TO THE READER 17C34-WOO May. 2005 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, DISASSEMBLYAND REPAIR ..............................................................................10-18 8.1 BATTERY .........................................................................................................................10-18 8.2 STARTING SYSTEM ........................................................................................................10-20 8-3 LOGHT SYSTEM .............................................................................................................10-25
- 21. GENERAL 1-3C34-WOO May. 2005 1. TRACTOR IDENTIFICATION When contacting your local KIOTI distributor, always specify engine serial number, tractor serial number and hour meter reading. (1) Hour Meter C34W103A 2 1 (1) Identification Number (2) Transmission Serial Number (1) Engine Serial Number C34W101A C34W102A
- 22. CHAPTER 1 DK651/751/801/901 1-4 C34-WOO May. 2005 2. DIMENSIONS C34W104A F 423 (16.6) 443 (17.4) 443 (17.4) 470 (18.5) E 1,406 (55.3) 1,504 (59.2) 1,504 (59.2) 1,534 (60.3) D 1,477 (57.9) 1,534 (60.3) 1,534 (60.3) 1,576 (62.0) C 2,048 (80.6) 2,142 (84.3) 2,142 (84.3) 2,142 (84.3) B 2,650 (104.3) 2,710 (106.6) 2,710 (106.6) 2,754 (108.4) A 3,943 (155.2) 4,142 (163.0) 4,269 (167.9) 4,269 (167.9) DK651 DK751 DK801 DK901 mm (in.)
- 23. GENERAL 1-5C34-WOO May. 2005 3. GENERAL PRECAUTIONS C34W105A (1) Grease (2) Snap Ring for Shaft (3) Snap Ring for Hole (4) Assemble Towards to be Forced (5) Reciprocating (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 stor- age 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 perform- ing any measurement of parts. 9. Disconnect the battery negative (-) cable before re- moving or installing any live electrical components. 10. Use only DAEDONG (KIOTI) genuine parts to main- tain the performance and safety of your KIOTI tractor. • 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 add- ing oil to the sealed parts, if applicable. IMPORTANT 3.1 ASSEMBLY AND DISASSEMBLY 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 asso- ciated packing (gasket), bearing(s), and o-ring(s). Apply grease properly for O-rings and oil seals be- fore assembly. 13. Locate the split portion of any spring pin by refer- encing the direction of force, like the above figure. 14. Replace any split pin with a new one.
- 24. CHAPTER 1 DK651/751/801/901 1-6 C34-WOO May. 2005 C34W108A 3.2 ELECTRICAL SYSTEM 1. Check all electrical connectors daily for any dam- age or short circuit at their junctions. In addition, annually schedule a complete electrical system in- spection 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 connect- ing 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. To ensure safety and prevent damage to the machine and surrounding equipment, heed the following precau- tions in handling electrical parts and wiring. C34W106A • 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 peri- odic check during regular maintenance. • Do not attempt to modify or remodel any electri- cal parts and/or wiring. • When removing the battery cables, disconnect the negative cable first. When installing the bat- tery cables, connect the positive cable first. IMPORTANT 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. C34W107A
- 25. GENERAL 1-7C34-WOO May. 2005 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. 3.4 LUBRICANT During assembly and repair, apply designated lubricant where specified in accordance with this repair manual. C34W109A C34W110A
- 26. CHAPTER 1 DK651/751/801/901 1-8 C34-WOO May. 2005 2,200 100 (26.4) Dry single Synchro shuttle 12F 12R Standard Wet disc type Independent 540/750 (Option 540/1,000) Max. 2,400 (5,291) Position, draft and mixed control Hydrostatic power steering Drawdar 1,990 (78.3) 2,754 (108.4) 470 (18.5) 1,576 (62.0) 1,534 (60.3) 3,557 (7,842) 4. SPECIFICATIONS NOTE: The specifications are subject to change for the purpose of improvement without any notice. DK651 1103C-33T 3-cylinder, water- cooled, tubo diesel Max. 64 (48)/2,200 52 (39)/2,200 3,300 (201) 1st: 41.2 (14.4) 2nd: 31.7 (11.1) Cat.1 & 2 DK751 1104C-44 4-cylinder, water- cooled, diesel Max. 72.4 (54)/2,200 57 (43)/2,200 DK801 1104C-44T (80HP) Max. 80 (60)/2,200 67 (50)/2,200 DK901 1104C-44T (90HP) Max. 90 (67)/2,200 83 (62)/2,200 Engine Model Model Type Engine gross HP (kW)/rpm P.T.O HP (kW)/rpm Displacement cc (cu.in) Rated revolution rpm (min-1) Fuel tank capacity (gal.) Clutch Transmission Speeds Differential lock Brake P.T.O Rear rpm Pump capacity (Max. flow rate) /min (cc) 3-point hitch Maximum lifting capacity (24in. aft of hitch) kg (lbs.) Hydraulic lift control system Steering Drawbar type DrivetrainHydraulicsystem 4-cylinder, water-cooled, Tubo diesel 1st: 0.43 (0.26) 12th: 29.55 (18.36) 1st: 0.42 (0.26) 12th: 28.93 (17.97) 14.9 - 30 1st: 0.45 (0.27) 12th: 31.34 (19.47) 1st: 0.44 (0.27) 12th: 30.68 (19.06) 11.2 - 20 Standardtiresize Front Rear Forward (At rated engine rpm) km/h (mph) Reverse (At rated engine rpm) km/h (mph) Overall length (with 3p) mm (in.) Overall width (minimum tread) mm (in.) Overall height (Cabin) mm (in.) Wheel base mm (in.) Min. ground clearance mm (in.) Tread Front mm (in.) Rear mm (in.) Weight (cabin) kg (lbs.) TravelingspeedsDimensions 4,267 (167.9) 4,400 (269) 1st: 45.3 (20.6) 2nd: 31.7 (14.4) Cat.2 11.2 - 24 16.9 - 3416.9 - 30 1st: 0.42 (0.26) 12th: 28.71 (17.83) 1st: 0.41 (0.25) 12th: 28.11 (17.46) 4,062 (159.9) 1,790 (70.4) 2,650 (104.3) 2,048 (80.6) 4,23 (16.6) 1,473 (57.9) 1,406 (55.3) 3,093 (6,819) 4,234 (166.6) 3,331 (7,341) 1,940 (76.3) 2,710 (106.6) 443 (17.4) 1,534 (60.3) 1,504 (59.2) 2,142 (84.3) 3,421 (7,542)
- 27. GENERAL 1-9C34-WOO May. 2005 Fuel Coolant Engine crankcase Transmission case Front axle case Front axle Greasing 1 2 3 4 5 6 7 100 (26.4 U.S.gal.) 60 (15.85 U.S.gal.) Each 3.5 (0.9 U.S.gal.) 4.5 (1.2 U.S.gal.) As necessary DK651 DK751/801/901 5. LUBRICANTS, FUEL AND COOLANT No. Locations Capacities Lubricants 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 Multi-gradetransmission fuid the fuid listed below or equivalent are recommended. SAE 90 gear oil or transmission case oil Standad type grease Above 25°C (77°F) 0 to 25°C (32 to 77°F) Below 0°C (32°F) SAE30, SAE10W-30 or 10W-40 SAE20, SAE10W-30 or 10W-40 SAE10W, SAE10W-30 or 10W-40 9.1 (2.4 U.S.gal.) 6.9 (1.82 U.S.gal.) 18.5 (4.9 U.S.gal.) 10.5 (2.77 U.S.gal.) To prevent serious equipment damage, use only genuine KIOTI fluids, oils and greases, or equivalents. Exxonmobil shell BP Mobilfluid 423 or 424 Exxon hydraul 560 DONAX-TD/TD Plus Tractran UTH
- 28. CHAPTER 1 DK651/751/801/901 1-10 C34-WOO May. 2005 Diameter 6. TIGHTENING TORQUES M6 (6 mm, 0.24 in.) M8 (8 mm, 0.31 in.) M10 (10 mm, 0.39 in.) M12 (12 mm, 0.47 in.) M14 (14 mm, 0.55 in.) M16 (16 mm, 0.63 in.) M18 (18 mm, 0.71 in.) M20 (20 mm, 0.79 in.) Material of bolt Indication on top of bolt 7T 9T 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. 7 9 N·m 7.85 ~ 9.31 17.7 ~ 20.5 39.3 ~ 45.1 62.8 ~ 72.5 108 ~ 125 167 ~ 191 246 ~ 284 334 ~ 392 kgf·m 0.80 ~ 0.95 1.8 ~ 2.1 4.0 ~ 4.6 6.4 ~ 7.4 11.0 ~ 12.8 17.0 ~ 19.5 25.0 ~ 29.0 34.0 ~ 40.0 lbf·ft 5.79 ~ 6.87 13.1 ~ 15.1 29.0 ~ 33.2 46.3 ~ 53.5 79.6 ~ 92.5 123 ~ 141 181 ~ 209 246 ~ 289 N·m 7.85 ~ 8.82 16.7 ~ 19.6 31.4 ~ 34.3 kgf·m 0.80 ~ 0.90 1.7 ~ 2.0 3.2 ~ 3.5 lbf·ft 5.79 ~ 6.50 12.3 ~ 14.4 23.2 ~ 25.3 N·m 9.81 ~ 11.2 23.6 ~ 27.4 48.1 ~ 55.8 77.5 ~ 90.2 124 ~ 147 197 ~ 225 275 ~ 318 368 ~ 431 kgf·m 1.00 ~ 1.15 2.4 ~ 2.8 4.9 ~ 5.7 7.9 ~ 9.2 12.6 ~ 15.0 20.0 ~ 23.0 28.0 ~ 32.5 37.5 ~ 44.0 lbf·ft 7.24 ~ 8.31 17.4 ~ 20.2 35.5 ~ 41.2 57.2 ~ 66.5 91.2 ~ 108 145 ~ 166 203 ~ 235 272 ~ 318 Material of opponent part No-grade or 4T SS400, S20C Ordinariness Aluminum S43C, S48C Ordinariness Aluminum N·m 7.85 ~ 8.82 17.7 ~ 20.5 39.3 ~ 44.1 62.8 ~ 72.5 kgf·m 0.80 ~ 0.90 1.8 ~ 2.1 4.0 ~ 4.5 6.4 ~ 7.4 lbf·ft 5.79 ~ 6.50 13.1 ~ 15.1 29.0 ~ 32.5 46.3 ~ 53.5 N·m 12.3 ~ 14.2 29.5 ~ 34.3 60.9 ~ 70.6 103 ~ 117 167 ~ 704 260 ~ 304 344 ~ 402 491 ~ 568 kgf·m 1.25 ~ 1.45 3.0 ~ 3.5 6.2 ~ 7.2 10.5 ~ 12.0 17.0 ~ 20.0 26.5 ~ 31.0 35.0 ~ 41.0 50.0 ~ 58.0 SCr435, SCM435 Ordinariness lbf·ft 9.05 ~ 10.4 21.7 ~ 25.3 44.9 ~ 52.0 76.0 ~ 86.7 123 ~ 144 192 ~ 224 254 ~ 296 362 ~ 419 6.2 STUD BOLTS Unit Material of opponent part Diameter Unit M8 (8 mm, 0.31 in.) M10 (10 mm, 0.39 in.) M12 (12 mm, 0.47 in.) Ordinariness Aluminum N·m 11.8 ~ 15.6 24.6 ~ 31.3 29.5 ~ 49.0 lbf·ft 8.68 ~ 11.5 18.1 ~ 23.1 21.7 ~ 36.1 N·m 8.82 ~ 11.8 19.7 ~ 25.4 31.4 kgf·m 0.90 ~ 1.2 2.0 ~ 2.6 3.2 lbf·ft 6.51 ~ 8.67 14.5 ~ 18.8 23.1 kgf·m 1.2 ~ 1.6 2.5 ~ 3.2 3.0 ~ 5.0 4
- 29. GENERAL 1-11C34-WOO May. 2005 Grade Unit Nominal diameter 5/16 3/8 1/2 9/16 5/8 N·m 23.1 ~ 27.8 47.5 ~ 57.0 108.5 ~ 130.2 149.2 ~ 179.0 203.4 ~ 244.1 kgf·m 2.35 ~ 2.84 4.84 ~ 5.82 11.07 ~ 13.29 15.22 ~ 18.27 20.75 ~ 24.91 lbf·ft 17.0 ~ 20.5 35.0 ~ 42.0 80.0 ~ 96.0 110.0 ~ 132.0 150.0 ~ 180.0 kgf·m 3.31 ~ 4.01 6.22 ~ 7.47 15.22 ~ 18.27 22.14 ~ 26.57 30.44 ~ 36.53 N·m 32.5 ~ 39.3 61.0 ~ 73.2 149.2 ~ 179.0 217.0 ~ 260.4 298.3 ~ 358.0 lbf·ft 24.0 ~ 29.0 45.0 ~ 54.0 110.0 ~ 132.0 160.0 ~192.0 220.0 ~ 264.0 6.3 AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS SAE GR.5 SAE GR.8
- 30. CHAPTER 1 DK651/751/801/901 1-12 C34-WOO May. 2005 1 year 2 years No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Change Change Change Change Change Change Adjust Check - Check Check Clean Change Check Change Adjust Adjust Adjust Check Change Check Change Check Change Check Change Adjust Adjust Check Check Clean Change Check Change Change Drain Item Engine oil Engine oil filter Transmission oil filter Hydraulic oil filter Transmission fluid Front axle case oil Front axle pivot Engine start system Greasing Wheel bolt torque Battery condition Air cleaner element Fuel filter element Fan belt Clutch Brake Radiator hose and clamp Power steering oil line Fuel line Intake air line Toe-in Engine valve clearance Fuel injection nozzle injection pressure Injection pump Cooling system Coolant Fuel system Fuse Light bulb Drain moisture from clutch housing Period Indication on Hour Meter After Purchase Important 50 100 150 200 250 800750700650600500450400350300 15003000 *4 *1 *2 *3 7. MAINTENANCE CHECK LIST 550 Service as required Everyday
- 31. GENERAL 1-13C34-WOO May. 2005 No. 31 32 33 34 35 36 37 38 1 year 2 years Clean Check Clean Clean Check Check Check Supple- ment Item Air conditioner condenser net Air conditioner belt tension Intake air filter Ambient air filter Air conditioner hose Heater hose Refrigerant Washer liquid Period Indication On Hour Meter After Purchase Important 50 100 150 200 250 800750700650600500450400350300 15003000550 As necessary Everyday • 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. IMPORTANT
- 32. CHAPTER 1 DK651/751/801/901 1-14 C34-WOO May. 2005 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). 8.1 DAILY CHECK For your own safety and maximum service life of the machine, make a thorough daily inspection before op- erating the machine to start the engine. A. CHECKING AND REFUELING (1) Fuel Tank Cap Fuel tank capacity 100 (26.4 U.S.gal.) 8. CHECK AND MAINIENANCE 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”. CAUTION 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. C34W111A NOTE: • No.2-D is a distillate fuel of lower volatility for en- gines in industrial and heavy mobile service. (SAE J313 JUN 87) • Grade of Diesel Fuel Oil According to ASTM D975 Flash Point °C (°F) Min 52 (125) Water and Sediment, Volume % Max 0.05 Carbon Residue On, 10 Percent Residuum, % Max 0.35 Ash, Weight % Max 0.01 Distillation Temperatures, °C (°F) 90% Point Viscosity Kinematic cSt or mm²/s at 40°C Min 282 (540) Max 338 (640) Min 1.9 Viscosity Saybolt, SUS at 100°F Min 32.6 Max 40.1 Sulfur, Weight % Copper Strip Corrosion Cetane Number Max 4.1 Max 0.50 Max No.3 Min 40 • 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 trac- tor may cause a fire. • To prevent condensation( water) accumulation in the fuel tank, fill the tank before parking the trac- tor overnight. IMPORTANT To avoid personal injury: • Do not smoke while refueling. • Be sure to stop the engine before refueling. CAUTION
- 33. GENERAL 1-15C34-WOO May. 2005 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.) B. CHECKING ENGINE OIL LEVEL (1) Oil Inlet (2) Dipstick (A) Oil Level is Acceptable Within this Range C. CHECKING COOLANT LEVEL (1) Recovery Tank (A) FULL (B) LOW C34W112A C34W113A 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 es- cape before removing the cap completely. CAUTION • 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. IMPORTANT To avoid personal injury: • Be sure to stop the engine before checking the oil level. CAUTION 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) • 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. IMPORTANT
- 34. CHAPTER 1 DK651/751/801/901 1-16 C34-WOO May. 2005 F. CLEANING GRILL, RADIATOR SCREEN AND OIL COOLER SCREEN (1) Radiator 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. C34W114A E. CHECKING SEAT BELT AND ROPS 1. Always check condition of seat belt and ROPS at- taching hardware before operating tractor. 2. Replace if damaged. To avoid personal injury: • Besuretostoptheenginebeforeremovingthescreen. CAUTION • Grill and screen must be clean from debris to keep the engine from overheating and to allow good air intake to the air cleaner. IMPORTANT D. CHECKING HEAD LIGHT, HAZARD LIGHT ETC. 1. Inspect the lights for broken bulbs and lenses. 2. Replace if broken. 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. Re- move the drain plug (1) to remove the deposited water and dirts when necessary. Water infuel results in breakage of injection pump shaft or malfunction of injection nozzle. Drain the water from the fuel pre-filter frequently. CAUTION (1) Drain Plug C34W115A
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