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”.
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„
„
„
„ 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
3
C34-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
5
C34-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
7
C34-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
9
C34-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
11
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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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

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14. TO THE READER
13
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

16. TO THE READER
15
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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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