service repair manual

1. TO THE READER
1
C34-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
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

3. TO THE READER
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C34-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

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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

5. TO THE READER
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C34-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

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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

7. TO THE READER
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C34-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

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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

9. TO THE READER
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C34-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

10. CHAPTER 1
GENERAL

11. GENERAL
1-3
C34-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

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13. 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.)

14. GENERAL
1-5
C34-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.

15. 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

16. GENERAL
1-7
C34-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