service repair manual

1. CONTENTS
TO THE READER .............................................................................................................................................................. 1
SAFETY FIRST ................................................................................................................................................................... 2
SAFETY DECALS .............................................................................................................................................................. 6
CHAPTER 1. GENERAL.....................................................................................................................1-1
1. TRACTOR IDENTIFICATION ......................................................................................................................... 1-3
2. DIMENSIONS................................................................................................................................................... 1-4
3. GENERAL PRECAUTIONS ............................................................................................................................ 1-5
3.1 ASSEMBLY AND DISASSEMBLY ......................................................................................................... 1-5
3.2 ELECTRICAL SYSTEM ......................................................................................................................... 1-6
3.3 TUBES AND RUBBERS........................................................................................................................ 1-7
3.4 LUBRICANT ........................................................................................................................................... 1-7
4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING .................................................. 1-8
5. SPECIFICATIONS ........................................................................................................................................... 1-9
6. LUBRICANTS, FUEL AND COOLANT ........................................................................................................ 1-10
7. TIGHTENING TORQUES ............................................................................................................................. 1-11
7.1 GENERAL USE SCREWS, BOLTS AND NUTS............................................................................... 1-11
7.2 STUD BOLTS ....................................................................................................................................... 1-11
7.3 AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS ........ 1-12
8. MAINTENANCE CHECK LIST ..................................................................................................................... 1-13
9. CHECK AND MAINTENANCE...................................................................................................................... 1-15
9.1 DAILY CHECK ...................................................................................................................................... 1-15
9.2 EVERY 50 HOURS .............................................................................................................................. 1-19
9.3 EVERY 100 HOURS............................................................................................................................ 1-21
9.4 EVERY 200 HOURS............................................................................................................................ 1-27
9.5 EVERY 400 HOURS............................................................................................................................ 1-31
9.6 EVERY 600 HOURS............................................................................................................................ 1-32
9.7 EVERY 800 HOURS............................................................................................................................ 1-32
9.8 EVERY 1 YEAR .................................................................................................................................... 1-33
9.9 EVERY 2 YEAR .................................................................................................................................... 1-33
9.10 SERVICE AS REQUIRED ...................................................................................................................1-35
10. TIRES.............................................................................................................................................................. 1-37
10.1 INFLATION PRESSURE ..................................................................................................................... 1-37
10.2 TREAD .................................................................................................................................................. 1-38
10.3 BALLAST ............................................................................................................................................... 1-40
10.4 TRAVELING SPEED ............................................................................................................................ 1-41
11. IMPLEMENT LIMITATIONS ........................................................................................................................... 1-42

2. CHAPTER 2. ENGINE SYSTEM .......................................................................................................2-1
1. FEATURE.......................................................................................................................................................... 2-3
2. LUBRICATING SYSTEM ................................................................................................................................. 2-4
3. COOLING SYSTEM ......................................................................................................................................... 2-5
4. FUEL SYSTEM ................................................................................................................................................. 2-6
5. TROUBLESHOOTING .................................................................................................................................... 2-7
6. SERVICING SPECIFICATIONS ...................................................................................................................2-10
7. DISASSEMBLING AND MAINTENANCE .................................................................................................... 2-22
7.1 DISASSEMBLING ENGINE ................................................................................................................ 2-22
7.2 ENGINE DISASSEMBLED VIEW ....................................................................................................... 2-29
7.3 ENGINE BODY ..................................................................................................................................... 2-31
7.4 LUBRICATING SYSTEM ..................................................................................................................... 2-56
7.5 COOLING SYSTEM ............................................................................................................................. 2-59
7.6 FUEL SYSTEM ..................................................................................................................................... 2-61
CHAPTER 3. CLUTCH .......................................................................................................................3-1
1. STRUCTURE ................................................................................................................................................... 3-3
2. TROUBLESHOOTING .................................................................................................................................... 3-4
3. SPECIFICATIONS ........................................................................................................................................... 3-5
4. DISASSEMBLING AND MAINTENANCE ...................................................................................................... 3-6
4.1 CHECKING AND ADJUSTMENT ......................................................................................................... 3-6
4.2 DISASSEMBLING AND ASSEMBLING OF THE CLUTCH HOUSING ............................................ 3-7
4.3 SERVICING .......................................................................................................................................... 3-12
CHAPTER 4. TRANSMISSION .........................................................................................................4-1
1. MANUAL TRANSMISSION MODEL ............................................................................................................... 4-3
1.1 POWER TRAIN DIAGRAM .................................................................................................................... 4-3
1.2 POWER TRAIN....................................................................................................................................... 4-5
1.3 TRANSMISSION SHIFT LINKAGE STRUCTURE ........................................................................... 4-11
2. HST TRANSMISSION MODEL ..................................................................................................................... 4-16
2.1 POWER TRAIN DIAGRAM .................................................................................................................. 4-16
2.2 POWER TRAIN..................................................................................................................................... 4-17
2.3 TRANSMISSION SHIFT LINKAGE STRUCTURE ........................................................................... 4-26
3. PTO EJECTION ............................................................................................................................................. 4-27
3.1 POWER TRAIN DIAGRAM .................................................................................................................. 4-27
3.2 POWER TRAIN..................................................................................................................................... 4-28
3.3 PTO SHIFT LINKAGE .......................................................................................................................... 4-29
4. DIFFERENTIAL GEAR .................................................................................................................................. 4-30
4.1 STRUCTURE ....................................................................................................................................... 4-30
5. TROUBLESHOOTING .................................................................................................................................. 4-33
5.1 HYDROSTATIC TRANSMISSION....................................................................................................... 4-33
5.2 MANUAL TRANSMISSION .................................................................................................................. 4-36
6. SPECIFICATIONS ......................................................................................................................................... 4-37

3. 7. DISASSEMBLING AND MAINTENANCE .................................................................................................... 4-38
7.1 DISASSEMBLING TRANSMISSION MANUAL MODEL (CK25/30) ............................................... 4-38
7.2 DISASSEMBLING TRANSMISSION HST MODEL (CK25H/30H) ................................................. 4-59
7.3 CHECK AND SERVICE ....................................................................................................................... 4-74
CHAPTER 5. REAR AXLE ..................................................................................................................5-1
1. STRUCTURE ................................................................................................................................................... 5-3
2. TROUBLESHOOTING .................................................................................................................................... 5-4
3. SPECIFICATIONS ........................................................................................................................................... 5-5
4. DISASSEMBLING AND MAINTENANCE ...................................................................................................... 5-6
4.1 DISASSEMBLING THE REAR AXLE ................................................................................................... 5-6
4.2 DISASSEMBLING THE REAR AXLE CASE ........................................................................................ 5-8
CHAPTER 6. BRAKE..........................................................................................................................6-1
1. STRUCTURE ................................................................................................................................................... 6-3
2. TROUBLESHOOTING .................................................................................................................................... 6-4
3. SPECIFICATION .............................................................................................................................................. 6-5
4. DISASSEMBLING AND MAINTENANCE ...................................................................................................... 6-6
4.1 CHECK AND ADJUSTMENT ................................................................................................................ 6-6
4.2 DISASSEMBLING THE BRAKE CASE ................................................................................................ 6-8
4.3 BRAKE CASE DISASSEMBLY ............................................................................................................ 6-12
4.4 CHECK AND SERVICE ....................................................................................................................... 6-13
CHAPTER 7. FRONT AXLE ...............................................................................................................7-1
1. STRUCTURE ................................................................................................................................................... 7-3
1.1 FRONT AXLE STRUCTURE ................................................................................................................. 7-3
1.2 WHEEL ALIGNMENT ............................................................................................................................. 7-4
2. SERVICING ...................................................................................................................................................... 7-6
2.1 TROUBLESHOOTING........................................................................................................................... 7-6
2.2 SPECIFICATIONS .................................................................................................................................. 7-7
2.3 CHECKING, DISASSEMBLING AND SERVICING ............................................................................ 7-9
2.4 SERVICING .......................................................................................................................................... 7-18
CHAPTER 8. STEERING SYSTEM ..................................................................................................8-1
1. STRUCTURE ................................................................................................................................................... 8-3
1.1 CHARACTERISTICS ............................................................................................................................. 8-3
1.2 HYDRAULIC CIRCUIT OF POWER STEERING SYSTEM ............................................................... 8-4
1.3 GEAR PUMP ........................................................................................................................................... 8-5
1.4 POWER STEERING UNIT .................................................................................................................... 8-6
1.5 STEERING CYLINDER ......................................................................................................................... 8-8
1.6 OIL FLOW ............................................................................................................................................... 8-9
2. TROUBLESHOOTING .................................................................................................................................. 8-11
3. SPECIFICATION ............................................................................................................................................ 8-12
4. DISASSEMBLY AND MAINTENANCE ......................................................................................................... 8-13

4. 4.1 DISASSEMBLY THE HYDRAULIC PUMP ......................................................................................... 8-13
4.2 DISASSEMBLING THE POWER STEERING UNIT......................................................................... 8-15
4.3 DISASSEMBLING THE STEERING CYLINDER ............................................................................. 8-25
4.4 SERVICING .......................................................................................................................................... 8-26
CHAPTER 9. HYDRAULIC SYSTEM ...............................................................................................9-1
1. STRUCTURE ................................................................................................................................................... 9-3
1.1 HYDRAULIC CIRCUIT DIAGRAM ........................................................................................................ 9-3
1.2 HYDRAULIC CIRCUIT DIAGRAM OF 3-POINT HYDRAULIC SYSTEM ......................................... 9-4
1.3 HYDRAULIC SCHEME ......................................................................................................................... 9-7
1.4 OIL FILTER ............................................................................................................................................. 9-8
1.5 JOYSTICK VALVE .................................................................................................................................. 9-9
1.6 AUXILIARY CONTROL VALVE (IF EQUIPPED) ............................................................................... 9-17
1.7 CONTROL (MLS) VALVE .................................................................................................................... 9-18
2. OPERATION ................................................................................................................................................... 9-24
2.1 PRINCIPLE OF CONTROL ................................................................................................................ 9-24
3. TOP LINK BRACKET DEVICE ..................................................................................................................... 9-27
3.1 STRUCTURE (IF DRAFT EQUIPPED) ............................................................................................. 9-27
3.2 OPERATION ......................................................................................................................................... 9-27
4. TROUBLESHOOTING .................................................................................................................................. 9-28
4.1 POWER LIFT ASSEMBLY ...................................................................................................................9-28
4.2 JOYSTICK VALVE ................................................................................................................................. 9-29
5. SPECIFICATION ............................................................................................................................................ 9-30
6. DISASSEMBLING AND MAINTENANCE .................................................................................................... 9-31
6.1 HYDRAULIC PUMP ............................................................................................................................. 9-31
6.2 JOY-STICK VALVE ...............................................................................................................................9-32
6.3 SEPARATE THE HYDRAULIC CYLINDER ....................................................................................... 9-36
6.4 CHECK AND ADJUSTMENT .............................................................................................................. 9-51
CHAPTER 10. ELECTRIC SYSTEM .............................................................................................. 10-1
1. ELECTRIC SYSTEM ..................................................................................................................................... 10-3
1.1 WIRING DIAGRAM ...............................................................................................................................10-3
1.2 BATTERY .............................................................................................................................................. 10-5
1.3 STARTING SYSTEM ............................................................................................................................ 10-6
1.4 CHARGING SYSTEM .......................................................................................................................... 10-7
1.5 LIGHTING SYSTEM ............................................................................................................................. 10-8
1.6 COMBINATION METER .................................................................................................................... 10-12
2. TROUBLESHOOTING ............................................................................................................................... 10-14
3. CHECKING, DISASSEMBLING AND SERVICING ................................................................................. 10-17
3.1 BATTERY ........................................................................................................................................... 10-17
3.2 STARTING SYSTEM ......................................................................................................................... 10-20
3.3 CHARGING SYSTEM ....................................................................................................................... 10-28
3.4 LIGHTING SYSTEM .......................................................................................................................... 10-29
3.5 COMBINATION METER .................................................................................................................... 10-32

5. TO THE READER
1
D704-WOO Dec. 2004
TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism,
service and maintenance of KIOTI tractors CK25/30 and CK25H/30H. It is divided into two parts, “Mechanism” and
“Servicing”.
„
„
„
„
„ MECHANISM
Information on the construction and functions are included. The part should be completely understood before
proceeding with troubleshooting, disassembling or servicing.
„
„
„
„
„ SERVICING
In this section you will find general precautions, maintenance and special tools. The are other sections which
include troubleshooting, servicing, specifications lists, disassembling, assembling and servicing that explains in
detail procedures, precautions, factory specifications and acceptable limits.
This manual contains the latest production information on illustrations and specifications based on the most up to
date production information available at the time of publication.
We reserve the right to make changes throughout the entire manual at any time without notice.

6. CK25(H)/30(H)
2 D704-WOO Dec. 2004
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.
704W002A
This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and the decals on the machine
itself to warn of the possibility of personal injury. It is essential that you read the instructions and safety regulations
before you attempt to repair or operate this unit. Read these instructions carefully.
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.
704W001A

7. TO THE READER
3
D704-WOO Dec. 2004
SAFETY WORKING
1. Do not operate or service the machine while under
the influence of alcohol, medication, or other
substances.
2. Never wear loose fitting clothing and always use
safety equipment appropriate to the job.
3. Never use improvised tools, parts or procedures.
Use only recommended tools appropriate to the
work.
4. Be careful to perform all work safely when servicing
is done by two or more people.
5. Always support the machine by safety stands. Never
work under the machine that is supported solely by
a jack.
6. Do not touch any rotating or hot parts while the en-
gine 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.
704W003A
704W004A
AVOID FIRES
1. Never smoke or allow flames or sparks in your work
area, as fuel is extremely flammable and explosive
under certain conditions.
2. Always disconnect the negative battery cable first
and reconnect it last to avoid sparks from an 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.
704W005A

8. CK25(H)/30(H)
4 D704-WOO Dec. 2004
DISPOSE OF FLUIDS PROPERLY
1. Observe relevant environmental protection regula-
tions when disposing of oil, fuel, coolant, electro-
lyte and other harmful waste. Never pour fluids into
the ground, down a drain, or into a stream, pond, or
lake.
704W008A
VENTILATE WORK AREA
1. Exhaust contains poisonous carbon monoxide, so
you should never run the engine in a closed area. If
the engine must be running while performing
maintenance, make sure the area is well ventilated.
PREVENT ACID BURNS
1. Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill elec-
trolyte on yourself, flush with water, and get medi-
cal attention immediately.
704W006A
704W007A

9. TO THE READER
5
D704-WOO Dec. 2004
PREPARE FOR EMERGENCIES
1. Be sure to keep a first aid kit and fire extinguisher
handy at all times.
2. Keep emergency numbers for the nearest fire
department, hospital, doctor and ambulance
service, near your telephone in case of emergency.
704W009A

10. CK25(H)/30(H)
6 D704-WOO Dec. 2004
(1) Parts No. : T2181-54121 (Optional)
SAFETY DECALS
z The following safety decals are installed on the machine.
If a decal becomes damaged, illegible or is not on the machine, replace it. The decal part number is listed in the
parts list.
(3) Parts No. : T4625-52361
(2) Parts No. : T4625-52351
704W010A

11. TO THE READER
7
D704-WOO Dec. 2004
CARE OF DANGER, WARNING AND CAUTION LABELS
1. Keep danger, warning and caution labels clean and free from obstructing material.
2. Clean danger, warning and caution labels with soap and water, dry with a soft cloth.
3. Replace damaged or missing danger, warning and caution labels with new labels.
4. If a component with danger, warning or caution label(s) is replaced, make sure new label(s) is (are) attached
in the same locations(s) as the replaced component.
5. Mount new labels by applying on a clean dry surface and pressing any bubbles to outside edge.
(6) Parts No. : T2445-50724
(5) Parts No. : T2325-50512
(4) Parts No. : T2325-50743
(9) Parts No. : T2615-54112
(7) Parts No. : T2615-55111
(8) Parts No. : T2350-54141
(10) Parts No. : T2615-53561

12. CHAPTER 1
GENERAL

13. GENERAL
1-3
D704-WOO Dec. 2004
704W101A
1. TRACTOR IDENTIFICATION
When contacting your local KIOTI distributor, always specify engine serial number, tractor serial number and hour
meter reading.
(1) Statutory Plate (2) Identification NO(EU) (3) Engine Serial Number
(4) Transmission Serial Number(HST TYPE) (5) Transmission Serial Number(MANUAL TYPE)
(6) Hour Meter
704W103A

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15. CHAPTER 1 CK25(H)/30(H)
1-4 D704-WOO Dec. 2004
704W102A
2. DIMENSIONS
mm (in.)

16. GENERAL
1-5
D704-WOO Dec. 2004
3. GENERAL PRECAUTIONS
704W103A
(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 approved special tools. Ser-
vicing dealers may machine tools to DEADONG
specifications, if the tool will not be used often.
4. Keep your work area and the tractor clean during all
phases of the disassembly and reassembly
process.
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 associ-
ated 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.

17. CHAPTER 1 CK25(H)/30(H)
1-6 D704-WOO Dec. 2004
704W106A
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.
704W105A
704W104A
5. When reconnecting the connector, insert it until it
snaps.
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.

18. GENERAL
1-7
D704-WOO Dec. 2004
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 prod-
uct life.
3.4 LUBRICANT
During assembly and repair, apply designated lubri-
cant where specified in accordance with this repair
manual.
704W107A
704W108A