Kioti Daedong DK65 Tractor Complete Workshop Service Repair Manual
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CONTENTS
CHAPTER 1. GENERAL INFORMATION ........................................................................................ 1-1
1. OUTSIDE DIAGRAM ........................................................................................................................................ 1-3
2. TIGHTENING TORQUE FOR STANDARD BOLTS AND NUTS ................................................................. 1-4
2.1 TIGHTENING TORQUE ......................................................................................................................... 1-4
3. SPECIFICATIONS ............................................................................................................................................ 1-6
4. IDENTIFICATION ............................................................................................................................................. 1-8
4.1 ENGINE NUMBER ................................................................................................................................. 1-8
4.2 CHASSIS NUMBER OF THE TRACTOR(CHASSIS NUMBER OF THE MACHINE) ..................... 1-8
5. CAUTION BEFORE REPAIR .......................................................................................................................... 1-9
5.1 BEFORE REPAIR OR INSPECTION ................................................................................................... 1-9
5.2 ASSEMBLY AND DISASSEMBLY ......................................................................................................... 1-9
5.3 PARTS TO BE REPLACED ................................................................................................................... 1-9
5.4 PARTS ..................................................................................................................................................... 1-9
5.5 ASBESTOS PARTS .............................................................................................................................. 1-10
5.6 ELECTRICAL SYSTEM ........................................................................................................................ 1-10
5.7 TUBES AND RUBBERS ...................................................................................................................... 1-11
5.8 LUBRICANT .......................................................................................................................................... 1-11
6. REGULAR CHECK LIST ............................................................................................................................... 1-12
7. OIL & WATER SUPPLY LIST ........................................................................................................................ 1-13
CHAPTER 2. ENGINE SYSTEM ..................................................................................................... 2-1
1. BASIC ENGINE DATA ...................................................................................................................................... 2-3
2. STANDARD TORQUE TENSIONS ................................................................................................................ 2-4
3. COMPRESSION TEST DATA .......................................................................................................................... 2-7
3.1 COMPRESSION TEST DATA ................................................................................................................ 2-7
3.2 HOW TO DO A COMPRESSION TEST ................................................................................................ 2-7
4. CYLINDER HEAD ASSEMBLY ....................................................................................................................... 2-8
4.1 GENERAL DESCRIPTION .................................................................................................................... 2-8
4.2 ROCKER COVER ................................................................................................................................... 2-9
4.3 ROCKER ASSEMBLY .......................................................................................................................... 2-10
4.4 VALVE TIP CLEARANCES .................................................................................................................. 2-14
4.5 VALVE SPRINGS .................................................................................................................................. 2-15
4.6 CYLINDER HEAD ASSEMBLY ............................................................................................................ 2-17
4.7 VALVES AND VALVE SPRINGS .......................................................................................................... 2-23
4.8 VALVE GUIDES ..................................................................................................................................... 2-25
4.9 CYLINDER HEAD ................................................................................................................................ 2-27
4.10 DATA AND DIMENSIONS .................................................................................................................... 2-30
5. PISTON AND CONNECTING ROD ASSEMBLY ........................................................................................ 2-33
5.1 GENERAL DESCRIPTION .................................................................................................................. 2-33
5.2 BIG END BEARING .............................................................................................................................. 2-34
5.3 PISTON AND CONNECTING ROD ASSEMBLY ............................................................................... 2-36
5.4 PISTON RINGS .................................................................................................................................... 2-42
5.5 CONNECTING ROD ............................................................................................................................ 2-44
5.6 SMALL END BUSH .............................................................................................................................. 2-44
5.7 DATA AND DIMENSIONS .................................................................................................................... 2-45
6. CRANKSHAFT ASSEMBLY ........................................................................................................................... 2-47
6.1 GENERAL DESCRIPTION .................................................................................................................. 2-47
6.2 CRANKSHAFT PULLEY ...................................................................................................................... 2-48
6.3 REAR OIL SEAL ASSEMBLY .............................................................................................................. 2-49
6.4 THRUST WASHERS ............................................................................................................................ 2-51
6.5 MAIN BEARINGS .................................................................................................................................. 2-54
6.6 CRANKSHAFT ...................................................................................................................................... 2-56
6.7 DATA AND DIMENSIONS .................................................................................................................... 2-59
7. TIMING CASE AND DRIVE ASSEMBLY ...................................................................................................... 2-61
7.1 GENERAL DESCRIPTION .................................................................................................................. 2-61
7.2 TIMING CASE COVER ......................................................................................................................... 2-62
7.3 FRONT OIL SEAL ................................................................................................................................. 2-63
7.4 IDLE GEAR AND HUB ......................................................................................................................... 2-64
7.5 FUEL PUMP GEAR .............................................................................................................................. 2-66
7.6 CAMSHAFT GEAR ................................................................................................................................ 2-69
7.7 CRANKSHAFT GEAR .......................................................................................................................... 2-70
7.8 TIMING CASE ........................................................................................................................................ 2-71
7.9 CAMSHAFT ............................................................................................................................................ 2-73
7.10 DATA AND DIMENSIONS .................................................................................................................... 2-74
8. CYLINDER BLOCK ASSEMBLY ................................................................................................................... 2-75
8.1 GENERAL DESCRIPTION .................................................................................................................. 2-75
8.2 CYLINDER BLOCK .............................................................................................................................. 2-75
8.3 CYLINDER LINER ............................................................................................................................... 2-78
8.4 DATA AND DIMENSIONS .................................................................................................................... 2-81
9. ENGINE TIMING ............................................................................................................................................ 2-83
9.1 GENERAL DESCRIPTION .................................................................................................................. 2-83
9.2 DATA AND DIMENSIONS .................................................................................................................... 2-88
10. ASPIRATION SYSTEM ................................................................................................................................... 2-89
10.1 GENERAL DESCRIPTION .................................................................................................................. 2-89
10.2 TURBO CHARGER .............................................................................................................................. 2-90
11. LUBRICATION SYSTEM ............................................................................................................................... 2-93
11.1 GENERAL DESCRIPTION .................................................................................................................. 2-93
11.2 FILTER CANISTER .............................................................................................................................. 2-95
11.3 FILTER HEAD ....................................................................................................................................... 2-96
11.4 OIL PAN ................................................................................................................................................. 2-97
11.5 OIL STRAINER AND SUCTION PIPE ASSEMBLY ....................................................................... 2-103
11.6 LUBRICATING OIL PUMP ................................................................................................................ 2-104
11.7 RELIEF VALVE ................................................................................................................................... 2-107
11.8 DATA AND DIMENSIONS ................................................................................................................. 2-108
12. FUEL SYSTEM ........................................................................................................................................... 2-109
12.1 GENERAL DESCRIPTION ............................................................................................................... 2-109
12.2 FUEL FILTER ELEMENT ................................................................................................................... 2-111
12.3 ATOMIZERS ........................................................................................................................................ 2-112
12.4 FUEL LIFT PUMP ............................................................................................................................... 2-116
12.5 FUEL INJECTION PUMPS ................................................................................................................ 2-119
12.6 DATA AND DIMENSIONS ................................................................................................................. 2-126
13. COOLING SYSTEM ................................................................................................................................... 2-127
13.1 GENERAL DESCRIPTION ............................................................................................................... 2-127
13.2 THERMOSTAT .................................................................................................................................... 2-129
13.3 COOLANT PUMP ............................................................................................................................... 2-130
13.4 FAN ...................................................................................................................................................... 2-134
13.5 DATA AND DIMENSIONS ................................................................................................................. 2-134
14. FLYWHEEL AND FLYWHEEL HOUSING ............................................................................................... 2-135
14.1 GENERAL DESCRIPTION ............................................................................................................... 2-135
14.2 FLYWHEEL ......................................................................................................................................... 2-135
14.3 RING GEAR ........................................................................................................................................ 2-136
14.4 FLYWHEEL HOUSING ..................................................................................................................... 2-136
15. ELECTRICAL EQUIPMENT ...................................................................................................................... 2-137
15.1 DRIVE BELTS .................................................................................................................................... 2-137
15.2 STARTING AID ................................................................................................................................... 2-138
16. LIST OF SPECIAL TOOLS ........................................................................................................................ 2-140
CHAPTER 3. CLUTCH ..................................................................................................................... 3-1
1. SPECIFICATION .............................................................................................................................................. 3-3
2. DISASSEMBLING AND ASSEMBLING ......................................................................................................... 3-3
2.1 CLUTCH .................................................................................................................................................. 3-3
3. ADJUSTMENT OF PEDAL .............................................................................................................................. 3-4
3.1 CLUTCH PEDAL CLEARANCE ............................................................................................................ 3-4
3.2 GAP BETWEEN SAFETY SWITCH AND LINK ................................................................................... 3-4
4. CHECKING AND ADJUSTING ....................................................................................................................... 3-5
4.1 WEARING AND DAMAGE OF CLUTCH DISC .................................................................................... 3-5
4.2 CLEARANCE BETWEEN SPLINE BOSS OF CLUTCH DISC AND SHUTTLE AXLE SPLINE ... 3-5
4.3 DAMAGE OF THE SURFACE OF CLUTCH PRESSURE PLATE ..................................................... 3-6
4.4 DAMAGE OF FLY WHEEL AND CHECKING OF RELEASE BEARING ........................................... 3-6
4.5 WEARING AND DAMAGE OF RELEASE BEARING, RELEASE FORK AND RELEASE HUB ..... 3-6
4.6 HOLDING LOAD OF CLUTCH PRESSURE PLATE .......................................................................... 3-7
5. TROUBLE-SHOOTING AND ACTION ........................................................................................................... 3-8
5.1 CLUTCH .................................................................................................................................................. 3-8
CHAPTER 4. TRANSMISSION ....................................................................................................... 4-1
1. SPECIFICATION .............................................................................................................................................. 4-4
2. DISASSEMBLING AND ASSEMBLING ......................................................................................................... 4-4
2.1 CLUTCH HOUSING ............................................................................................................................... 4-4
2.2 CLUTCH HOUSING AND TRANSMISSION CASE ............................................................................ 4-6
2.3 20 GEAR SHAFT RELATION ................................................................................................................ 4-7
2.4 REVERSE IDLE GEAR SECTION ........................................................................................................ 4-9
2.5 17 GEAR SHAFT SECTION ................................................................................................................ 4-10
2.6 SHUTTLE SHAFT SECTION .............................................................................................................. 4-11
2.7 FRONT WHEEL DRIVE SHAFT SECTION ....................................................................................... 4-13
2.8 PTO DRIVE SHAFT SECTION ............................................................................................................ 4-14
2.9 42 GEAR, AUXILIARY SHIFT SYNCHRONIZER RELATION .......................................................... 4-15
2.10 MAIN SHIFT FORK RELATION ........................................................................................................... 4-16
2.11 PTO CLUTCH RELATION ................................................................................................................... 4-17
2.12 CREEP SPEED GEAR, FRONT WHEEL DRIVE GEAR, SPIRAL BEVEL PINION ...................... 4-20
2.13 AUXILIARY SHIFT GEAR RELATION ................................................................................................. 4-22
2.14 FRONT WHEEL IDLE GEAR .............................................................................................................. 4-23
2.15 FRONT WHEEL DRIVE SHAFT .......................................................................................................... 4-24
2.16 FRONT WHEEL DRIVE FORK ........................................................................................................... 4-25
2.17 AUXILIARY SHIFT AND CREEP SPEED FORK ............................................................................... 4-26
2.18 AUXILIARY SHIFT COVER SECTION ............................................................................................... 4-28
2.19 GROUND PTO ...................................................................................................................................... 4-29
2.20 PTO SHAFT ........................................................................................................................................... 4-30
2.21 TRANSMISSION CASE AND PTO COVER ....................................................................................... 4-32
2.22 PARKING BRAKE ................................................................................................................................. 4-33
2.23 DIFFERENTIAL GEAR ASSEMBLY .................................................................................................... 4-34
2.24 REAR DIFFERENTIAL GEAR GROUP .............................................................................................. 4-36
2.25 BRAKE CASE ........................................................................................................................................ 4-39
2.26 REAR AXLE ASSEMBLY RELATION .................................................................................................. 4-40
2.27 PLANETARY GEAR ASSEMBLY ......................................................................................................... 4-42
3. OPERATION PRINCIPLE .............................................................................................................................. 4-43
3.1 POWER TRANSMISSION OF TRANSMISSION GEAR ................................................................... 4-43
3.2 PTO OPERATION ................................................................................................................................. 4-44
3.3 POWER TRANSMISSION OF REAR DIFFERENTIAL GEAR ......................................................... 4-45
3.4 LOCKING OPERATION OF DIFFERENTIAL GEAR ......................................................................... 4-46
3.5 REAR AXLE OPERATION .................................................................................................................... 4-47
3.6 FRONT WHEEL DRIVE OPERATION ................................................................................................ 4-48
4. TROUBLE-SHOOTING ................................................................................................................................. 4-49
4.1 CLUTCH NOISE, CLUTCH OPERATION PROBLEM ..................................................................... 4-49
4.2 SHUTTLE SHIFT TROUBLES ............................................................................................................ 4-49
4.3 MAIN SHIFT SECTION OPERATION TROUBLES ........................................................................... 4-50
4.4 AUXILIARY SHIFT, CREEP SPEED SECTION OPERATION TROUBLES ................................... 4-50
4.5 FRONT WHEEL DRIVE OPERATION TROUBLES .......................................................................... 4-51
4.6 PTO CLUTCH OPERATION TROUBLES .......................................................................................... 4-51
4.7 PTO OPERATION TROUBLES ........................................................................................................... 4-51
4.8 REAR DIFFERENTIAL GEAR OPERATION TROUBLES ................................................................ 4-52
4.9 REAR AXLE OPERATION TROUBLES .............................................................................................. 4-52
4.10 PARKING BRAKE OPERATING TROUBLES .................................................................................... 4-52
CHAPTER 5. FRONT AXLE ASSEMBLY ...................................................................................... 5-1
1. FRONT AXLE ASSEMBLY ............................................................................................................................... 5-4
1.1 TOE-IN ..................................................................................................................................................... 5-4
1.2 FRONT WHEEL STEERING ANGLE ................................................................................................... 5-4
1.3 ROLLING OF THE FRONT AXLE AND THE CLEARANCE OF FRONT
AND REAR DIRECTION ........................................................................................................................ 5-5
1.4 LATERAL VIBRATION AND LONGITUDINAL VIBRATION OF THE FRONT WHEEL .................... 5-6
1.5 CAMBER, CAST, KINGPIN (REFERENCE) ....................................................................................... 5-6
2. DISASSEMBLING & ASSEMBLING ............................................................................................................... 5-7
2.1 FRONT AXLE CASE AND FRONT AXLE ............................................................................................. 5-7
2.2 FRONT AXLE PLANETARY GEAR SUPPORT .................................................................................... 5-9
2.3 BEVEL GEAR CASE AND FRONT AXLE CASE ............................................................................... 5-10
2.4 BEVEL GEAR CASE AND FRONT AXLE SUPPORT ...................................................................... 5-13
2.5 FRONT AXLE SUPPORT AND DIFFERENTIAL GEAR CASE ....................................................... 5-14
2.6 FRONT DIFFERENTIAL GEAR .......................................................................................................... 5-15
2.7 FRONT BRACKET ASSEMBLY ........................................................................................................... 5-18
2.8 REAR BRACKET .................................................................................................................................. 5-19
2.9 PROPELLER SHAFT ........................................................................................................................... 5-20
2.10 FRONT WHEEL .................................................................................................................................... 5-21
3. TROUBLE SHOOTING .................................................................................................................................. 5-22
3.1 FRONT DIFFERENTIAL FIXING CLUTCH OPERATION TROUBLES .......................................... 5-22
3.2 FRONT AXLE LEAKAGE TROUBLES ............................................................................................... 5-22
CHAPTER 6. HYDRAULIC SYSTEM ............................................................................................... 6-1
1. HYDRAULIC SYSTEM ..................................................................................................................................... 6-3
1.1 CIRCUIT .................................................................................................................................................. 6-5
1.2 STRUCTURE AND MECHANISM OF HYDRAULIC CYLINDER ...................................................... 6-7
1.3 DISASSEMBLY AND ASSEMBLY ....................................................................................................... 6-18
1.4 CHECK UP AND ADJUSTMENT ........................................................................................................ 6-21
1.5 TROUBLESHOOTER ........................................................................................................................... 6-23
2. PTO CLUTCH SYSTEM ................................................................................................................................ 6-24
2.1 SPECIFICATIONS ................................................................................................................................ 6-24
2.2 PTO CLUTCH SYSTEM STRUCTURE ............................................................................................. 6-24
2.3 STRUCTURE AND MECHANISM ....................................................................................................... 6-25
2.4 DISASSEMBLY AND ASSEMBLY ....................................................................................................... 6-32
2.5 MAINTAINANCE AND CHECK UP ..................................................................................................... 6-34
3. POWER STEERING SYSTEM ...................................................................................................................... 6-35
3.1 SPECIFICATIONS ................................................................................................................................ 6-37
3.2 STEERING SYSTEM PARTS .............................................................................................................. 6-37
3.3 STRUCTURE AND MECHANISM ....................................................................................................... 6-38
4. HYDRAULIC PUMP ....................................................................................................................................... 6-61
4.1 SPECIFICATIONS ................................................................................................................................ 6-61
4.2 COMPONENTS OF HYDRAULIC PUMP ........................................................................................... 6-62
4.3 STRUCTURE AND MECHANISM ....................................................................................................... 6-63
4.4 DISASSEMBLY AND ASSEMBLY ....................................................................................................... 6-64
5. HYDRAULIC FILTER ..................................................................................................................................... 6-65
5.1 STRUCTURE ........................................................................................................................................ 6-65
5.2 FUNCTION AND MECHANISM ........................................................................................................... 6-65
5.3 CHECK UP ............................................................................................................................................ 6-65
6. JOYSTICK VALVE ........................................................................................................................................... 6-66
6.1 JOYSTICK VALVE ................................................................................................................................. 6-66
CHAPTER 7. BRAKE SYSTEM ..................................................................................................... 7-1
1. SPECIFICATIONS ............................................................................................................................................ 7-3
2. STRUCTURE AND OPERATION ................................................................................................................... 7-4
3. DISASSEMBLY AND ASSEMBLY ................................................................................................................. 7-10
3.1 MASTER CYLINDER AND EQUALIZE VALVE .................................................................................. 7-10
4. CHECK UP AND ADJUSTMENT ................................................................................................................. 7-11
4.1 CLEARANCE OF BRAKE PEDAL ...................................................................................................... 7-11
4.2 DIFFERENCE OF BRAKE PEDAL DEPTH ....................................................................................... 7-11
4.3 BRAKE TEST ........................................................................................................................................ 7-11
CHAPTER 8. ELECTRIC SYSTEM ................................................................................................... 8-1
1. CONTROL PANEL ........................................................................................................................................... 8-3
1.1 TECHNICAL TERMS .............................................................................................................................. 8-3
1.2 TO REPLACE CONTROL PANEL AND LIGHT BULBS .................................................................... 8-5
2. ENGINE STARTING SYSTEM ........................................................................................................................ 8-6
2.1 ENGINE STARTING CIRCUIT .............................................................................................................. 8-6
2.2 STARTING MOTOR SPECIFICATIONS ............................................................................................... 8-7
2.3 MECHANISM ........................................................................................................................................... 8-7
2.4 DISASSEMBLING AND ASSEMBLING ................................................................................................ 8-7
3. CHARGING SYSTEM ....................................................................................................................................... 8-8
3.1 CIRCUIT .................................................................................................................................................. 8-8
3.2 GENERATOR SPECIFICATIONS ......................................................................................................... 8-9
3.3 DISASSEMBLING AND ASSEMBLING .............................................................................................. 8-10
4. PREHEATING SYSTEM ................................................................................................................................. 8-11
4.1 CIRCUIT ................................................................................................................................................ 8-11
4.2 PARTS SPECIFICATIONS ................................................................................................................... 8-12
4.3 MECHANISM ......................................................................................................................................... 8-12
4.4 TEST FOR PARTS ................................................................................................................................ 8-12
5. SWITCH SYSTEM .......................................................................................................................................... 8-13
6. FUSE SYSTEM ............................................................................................................................................... 8-18
6.1 FUSE WIRING ARRANGEMENT ........................................................................................................ 8-18
6.2 FUSE DIAGRAM CIRCUIT .................................................................................................................. 8-21
CHAPTER 9. CABIN ........................................................................................................................... 9-1
1. DISASSEMBLING AND ASSEMBLING ......................................................................................................... 9-3
CHAPTER 10. AIR CONDITIONER, HEATER .............................................................................. 10-1
1. HEATER .......................................................................................................................................................... 10-3
1.1 SPECIFICATIONS ................................................................................................................................ 10-3
1.2 DISASSEMBLY AND ASSEMBLY ....................................................................................................... 10-4
1.3 HEATER CONTROL PANEL ............................................................................................................... 10-4
2. AIR-CONDITIONER ....................................................................................................................................... 10-5
2.1 STRUCTURE ........................................................................................................................................ 10-5
2.2 PRINCIPLE OF AIR-CONDITIONING ............................................................................................... 10-6
2.3 OPERATION PRINCIPLES OF SYSTEM COMPONENTS .............................................................. 10-8
2.4 AIR-CONDITIONING COMPONENTS ............................................................................................... 10-9
2.5 SAFETY PREVENTION MEASURES .............................................................................................. 10-10
2.6 OIL ........................................................................................................................................................ 10-11
2.7 CHECKING OF REFRIGERANT LEAKAGE .................................................................................... 10-11
2.8 DISASSEMBLING AND ASSEMBLING ............................................................................................ 10-11
2.9 AIR-CONDITIONER CONTROL ...................................................................................................... 10-13
2.10 CHECKING OF THE AIR-CONDITIONING SYSTEM ................................................................... 10-13
3. TROUBLE SHOOTING ............................................................................................................................... 10-14
3.1 TROUBLE SHOOTING BY AUDIO/VISUAL ................................................................................... 10-14
3.2 EARLY FINDING OF TROUBLE SHOOTING ................................................................................. 10-15
3.3 TROUBLE SHOOTING BY GAUGE PRESSURE .......................................................................... 10-18
CHAPTER 1
GENERAL INFORMATION
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Thank you for considering this comprehensive Workshop Service Repair Manual for the Kioti Daedong DK65 Tractor.
This manual is an invaluable resource covering every service and repair procedure necessary for professional mechanics and DIY enthusiasts alike.
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