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 MAINIENANCE ....................................................................................................................... 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 ............................................................................................................................................... 1-39
11. IMPLEMENT LIMITATIONS ........................................................................................................................... 1-41

CHAPTER 2. ENGINE ........................................................................................................................ 2-1

1. GENERAL ......................................................................................................................................................... 2-3
1.1 ENGINE IDENTIFICATION ................................................................................................................... 2-3
1.2 SPECIFICATIONS .................................................................................................................................. 2-4
 1.3 PERFORMANCE CURVE ..................................................................................................................... 2-5
1.4 DIMENSIONS ......................................................................................................................................... 2-6
2. CONSTRUCTION AND FUNCTION .............................................................................................................. 2-7
2.1 ENGINE ................................................................................................................................................... 2-7
2.2 LUBRICATION SYSTEM ..................................................................................................................... 2-12
2.3 COOLING SYSTEM ............................................................................................................................. 2-15
2.4 FUEL SYSTEM ..................................................................................................................................... 2-17
2.5 INLET AND EXHAUST SYSTEM ........................................................................................................ 2-24
3. DISASSEMBLY AND SERVICING OF ENGINE ......................................................................................... 2-25
3.1 TROUBLESHOOTING ......................................................................................................................... 2-25
3.2 SERVICE DIRECTIONS ..................................................................................................................... 2-28
3.3 CHECKING, DISASSEMBLING AND SERVICING .......................................................................... 2-33
3.4 DISASSEMBLY AND REASSEMBLY .................................................................................................. 2-39
3.5 SERVCING ........................................................................................................................................... 2-55

CHAPTER 3. CLUTCH ....................................................................................................................... 3-1

1. STRUCTURE ................................................................................................................................................... 3-3
2. SERVICING ...................................................................................................................................................... 3-4
2.1 TROUBLESHOOTING ........................................................................................................................... 3-4
2.2 SPECIFICATIONS .................................................................................................................................. 3-5
2.3 CHECKING AND ADJUSTMENT ......................................................................................................... 3-6
2.4 DISASSEMBLING AND ASSEMBLING ................................................................................................ 3-7
2.5 INSPECTION AND REPAIR ................................................................................................................ 3-12

CHAPTER 4. TRANSMISSION ......................................................................................................... 4-1

1. STRUCTURE ................................................................................................................................................... 4-3
1.1 POWER TRAIN DIAGRAM .................................................................................................................... 4-3
1.2 POWER TRAIN ....................................................................................................................................... 4-5
1.3 TRANSMISSION SHIFT LINKAGE STRUCTURE ........................................................................... 4-12
1.4 DIFFERENTIAL GEAR ........................................................................................................................ 4-17
1.5 HST CONTROL LINKAGE .................................................................................................................. 4-20
2. SERVICING .................................................................................................................................................... 4-21
2.1 TORUBLESHOOTING ......................................................................................................................... 4-21
2.2 SPECIFICATIONS ................................................................................................................................ 4-25
2.3 DISASSEMBLING AND ASSEMBLING .............................................................................................. 4-26
2.4 HYDROSTATIC TRANSMISSION(CK20H) ....................................................................................... 4-48

CHAPTER 5. REAR AXLE .................................................................................................................. 5-1

1. STRUCTURE ................................................................................................................................................... 5-3
2. SERVICING ...................................................................................................................................................... 5-4
2.1 TROUBLESHOOTING ........................................................................................................................... 5-4
2.2 SPECIFICATIONS .................................................................................................................................. 5-4
2.3 DISASSEMBLING AND ASSEMBLING ................................................................................................ 5-5
CHAPTER 6. BRAKE .......................................................................................................................... 6-1
1. STRUCTURE ................................................................................................................................................... 6-3
1.1 FEATURES OF WET DISC BRAKES .................................................................................................. 6-3
2. SERVICING ...................................................................................................................................................... 6-5
2.1 TROUBLESHOOTING ........................................................................................................................... 6-5
2.2 SPECIFICATIONS .................................................................................................................................. 6-5
2.3 DISASSEMBLING AND ASSEMBLING ................................................................................................ 6-6
2.4 SERVICING .......................................................................................................................................... 6-10

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 SYSYTEM ............................................................................................... 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. SERVICING .................................................................................................................................................... 8-11
2.1 TROUBLESHOOTING ......................................................................................................................... 8-11
2.2 SPECIFICATION .................................................................................................................................. 8-12
2.3 DISASSEMBLY AND ASSEMBLY ....................................................................................................... 8-13

CHAPTER 9. HYDRAULIC SYSTEM ............................................................................................... 9-1

1. STRUCTURE ................................................................................................................................................... 9-3
1.1 HYDRAULIC CIRCUIT DIAGRAM ........................................................................................................ 9-3
1.2 OIL FILTER ............................................................................................................................................. 9-5
1.3 STRUCTURE ......................................................................................................................................... 9-6
1.4 HYDRAULIC CIRCUIT DIAGRAM OF 3-POINT HUDRAULIC SYSTEM ........................................ 9-7
1.5 PRIORITY FLOW CONTROL [HYDRAULIC BLOCK TYPE OUTLET] ............................................ 9-8
1.6 JOYSTICK VALVE ................................................................................................................................ 9-11
1.7 AUXILIARY CONTROL VALVE (IF EQUIPPED) ............................................................................... 9-18
1.8 CONTROL (MLS) VALVE .................................................................................................................... 9-20
1.9 OPERATION OF INTERNAL LEVERS IN CONTROLLED POSITION .......................................... 9-24
1.10 ASSEMBLY MEASUREMENT OF PUSH ROD ................................................................................. 9-26
 2. SERVICING .................................................................................................................................................... 9-27
2.1 TROUBLECHOOTING ........................................................................................................................ 9-27
2.2 SPECIFICATION .................................................................................................................................. 9-29
2.3 DISASSEMBLING AND ASSEMPLING .............................................................................................. 9-31

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. SERVICING ................................................................................................................................................. 10-14
2.1 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
 TO THE READER

TO THE READER

This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism,
service and maintenance of KIOTI tractors CH20, CK20J, CK20H and CK20HJ. It is divided into two parts, “Mecha-
nism” and “Servicing” for each section.

„ 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.

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CK20(H)

SAFETY FIRST

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.

SIGNS DESCRIPTION

This mark indicates hazardous situation which, if not observed, may

DANGER 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

WARNING
observed, may result in death or moderate injury.

This mark indicates potentially hazardous situation which, if not

CAUTION 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

IMPORTANT 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.

196W001A

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 disengaged
positions.
4. Never start the engine unless you are in the
operator’s seat.

196W002A

2 S196-WOO Jul. 2003

 TO THE READER

SAFETY WORKING
1. Do not operate or service the machine while under
the influence of alcohol, medication, or other
substances.
2. Never wear loose fit 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 196W003A
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 cool enough to touch with bare
hands. Slowly loosen the cap to relieve pressure
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.

196W004A

AVOID FIRES
1. Never smoke or allow flames or sparks in your work-
ing area, as fuel is extremely flammable and explo-
sive 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.

196W005A

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CK20(H)

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.

196W006A

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.

196W007A

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.

196W008A

4 S196-WOO Jul. 2003

 TO THE READER

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.

196W009A

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CK20(H)

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.

(1) Parts No. : T2350-54122 (Optional) (2) Parts No. : T4625-52351 (3) Parts No. : T4625-52361

6 S196-WOO Jul. 2003

 TO THE READER

(4) Parts No. : T2325-50743 (5) Parts No. : T2325-50512

(6) Parts No. : T2445-50724 (7) Parts No. : T2615-53561

(8) Parts No. : T2350-54141 (9) Parts No. : T2615-54112

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.

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CHAPTER 1

GENERAL
 GENERAL

1. TRACTOR IDENTIFICATION

When contacting your local KIOTI distributor, always specify engine serial number, tractor serial number and hour
meter reading.

196W101A 196W102A

(1) Statutory Plate (2) Identification Plate (3) Engine Serial Number

196W100A 196W103A

(4) Transmission Serial Number (5) Hour Meter

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CHAPTER 1 CK20(H)

2. DIMENSIONS

mm (in.)

196W167A

1-4 S196-WOO Jul. 2003

 GENERAL

3. GENERAL PRECAUTIONS

3.1 ASSEMBLY AND DISASSEMBLY

196W104A

(1) Grease (4) Assemble Towards to be Forced

(2) Snap Ring for Shaft (5) Reciprocating
(3) Snap Ring for Hole (6) Rotating

1. Place the tractor on the flat surface for adjustment 11. For assembling any snap ring for shaft or snap ring
or service. for hole, assemble the head by the direction to be
2. Please work with the engine stop except for the case forced, like above figure.
that must be worked with the engine running. 12.Insert the split portion of any spring pin by the direc-
3. Arrange each part properly on the clean space for tion to be forced, like above figure.
disassembly. For bolts and nuts, tighten manually 13.Replace any split pin as a new one.
by hand to its original position.
4. Use only the approved special tool. For the tool that
is not used often, use the tool made by each ser-
vice workshop.
5. Use only part cleaning agent for manufacturing
when any part needs to be clean. Do not use the IMPORTANT
diesel oil for cleaning to prevent any pollution. Use
• Use the packing bond as three bond 1208D or
only approved fluid oil for cleaning any hydraulic part.
LOCTITE product.
6. Be careful not to attach any dust or metal chip etc.
for disassembly and assembly of any hydraulic part. • For using any packing bond, remove any re-
mained bond in the part before apply.
7. For measuring any part, remove any oil or polluted
material before performing the measurement. • Apply the bond in center of the flange between
bolt holes of the contact surface and apply the
8. Disconnet the battery negative (-) cable before re-
inner surface for bolt hole portion.
moving or installing the live components.
9. Use only the DAEDONG genuine part for replace- • Perform the assembly within 10 minutes after
ment to maintain the performance and safety. apply and inject oil after passing 30 minutes
above.
10.Replace the packing bearing and O-ring as new
part. Apply the grease properly for O-rings and oil
seals before assembly.

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CHAPTER 1 CK20(H)

3.2 ELECTRICAL SYSTEM

1. Check electrical wiring daily every year for any dam-

age or short circuit at junction. In addition, undergo
onerous inspection via the agency regularly.
2. Do not modify or reorganize the wiring of the elec-
tric field parts.
3. When disconnecting battery cable disconnect nega-
tive cable first, reinstall the positive cable first when
reinstalling.

Disconnect battery negative terminal

NOTE:
• Be sure to turn the starting key OFF when connect-
ing or disconnecting the cable. 196W107A

4. Remove the connector by pulling the plastic sec-

tion not the wiring.

5. When reconnecting the connector, Insert it until it

snaps.

196W108A

6. When replacing a broken fuse with a new one, be

sure to use the fuse of capacity as specified.
7. Be sure not to drop sensors and relays which are
fragile.

196W109A

1-6 S196-WOO Jul. 2003

 GENERAL

3.3 TUBES AND RUBBERS

Be cautious of oil or the like on the tubes and rubber

parts, which may cause change in quality.

196W110A

3.4 LUBRICANT

When assembling and fixing, apply designated lubri-

cant where specified in accordance with this repair
manual.

196W111A

S196-WOO Jul. 2003 1-7

CHAPTER 1 CK20(H)

4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING

To ensure safety and prevent damage to the machine

and surrounding equipment, heed the following pre-
cautions in handling electrical parts and wiring.

IMPORTANT
• Check electrical wiring for damage and loosened
connection every year. To this end, educate the
customer to do his or her own check and at the
same time recommend the dealer to perform pe-
riodic check for a fee.
• Do not attempt to modify or remodel any electri-
cal parts and wiring.
• When removing the battery cables, disconnect the 196W112A
negative cable first. When installing the battery
cables, connect the positive cable first.

1-8 S196-WOO Jul. 2003

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