Table of Contents
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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.
S196-WOO
Jul. 2003
TO THE READER
TO THE READER
1
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Table of Contents
Related Manuals for Kioti CH20
Summary of Contents for Kioti CH20
- Page 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 CH20, CK20J, CK20H and CK20HJ. It is divided into two parts, “Mecha- nism” and “Servicing” for each section.
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Page 2: Safety First
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. - Page 3 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.
- Page 4 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.
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Page 5: Prepare For Emergencies
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 S196-WOO Jul. -
Page 6: Safety Decals
CK20(H) 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. (1) Parts No. : T2350-54122 (Optional) (2) Parts No. - Page 7 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.
- Page 9 CHAPTER 1 GENERAL...
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Page 11: Tractor Identification
GENERAL 1. TRACTOR IDENTIFICATION When contacting your local KIOTI distributor, always specify engine serial number, tractor serial number and hour meter reading. 196W102A 196W101A (1) Statutory Plate (2) Identification Plate (3) Engine Serial Number 196W100A 196W103A (4) Transmission Serial Number... - Page 12 CHAPTER 1 CK20(H) 2. DIMENSIONS mm (in.) 196W167A S196-WOO Jul. 2003...
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Page 13: General Precautions
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 11. For assembling any snap ring for shaft or snap ring 1. -
Page 14: Electrical System
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. -
Page 15: Tubes And Rubbers
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. -
Page 16: Handling Precautions For Electrical Parts And Wiring
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. -
Page 17: Specifications
GENERAL 5. SPECIFICATIONS CK20 Model MECHANICAL Model 3C093 Type Liquid-cooled, 3-cylinder diesel Engine gross HP (kW) 21 (15.7) Engine P.T.O HP (kW) 16.5 (12.3) 15.5 (11.6) Displacement cc (cu.in) 927 (56.6) Rated revolution r.p.m min-1 2,800 Fuel tank capacity (gal.) 20 (5.28) Clutch Dry type single stage... -
Page 18: Lubricants, Fuel And Coolant
CHAPTER 1 CK20(H) 6. LUBRICANTS, FUEL AND COOLANT Capacities Locations Lubricants CK20H CK20 No.2-D diesel fuel Fuel (5.28 U.S.gal.) No.1-D diesel fuel if temperature is below -10°C (14°F) Coolant (1.50 U.S.gal.) Fresh clean water with anti-freeze Engine oil: API Service Classification CC or CD Above 25°C (77°F) SAE30, SAE10W-30 or 10W-40 Engine crankcase... -
Page 19: Tightening Torques
GENERAL 7. TIGHTENING TORQUES 7.1 GENERAL USE SCREWS, BOLTS AND NUTS Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be tightened according to the table below. Indication on No-grade or 4T top of bolt Material of SCr435, SS400, S20C... -
Page 20: American Standard Screws, Bolts And Nuts With Unc Or Unf Threads
CHAPTER 1 CK20(H) 7.3 AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS Grade SAE GR.5 SAE GR.8 Unit Nominal N·m kgf·m lbf·ft N·m kgf·m lbf·ft diameter 23.1 ~ 27.8 2.35 ~ 2.84 17.0 ~ 20.5 32.5 ~ 39.3 3.31 ~ 4.01 24.0 ~ 29.0 5/16... -
Page 21: Maintenance Checklist
GENERAL 8. MAINTENANCE CHECK LIST After Period Indication On Hour Meter Purchase Important 50 100 150 200 250 1500 3000 year years Item Change Engine oil Engine oil filter Replace Replace Transmission oil filter Replace Hydraulic oil filter Transmission fluid Change Change Front axle case oil... - Page 22 *4 When the battery is used for less than 100 hours per year, check the fluid level annually. • The items listed above (@ marked) are registered as emission related critical parts by KIOTI in the U.S.EPA non-road emission regulation. As the engine owner, you are responsible for the performance of the re- quired maintenance on the engine according to the above instruction.
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Page 23: Daily Check
GENERAL 9. CHECK AND MAINIENANCE 9.1 DAILY CHECK For your own safety and maximum service life of the Walk Around Inspection machine, make a thorough daily inspection before op- Look around and under the tractor for such items as erating the machine to start the engine. loose bolts, trash build-up, oil or coolant leaks, broken or worn parts. -
Page 24: Checking Engine Oil Level
If the radiator cap has to be removed, follow the caution above and securely retighten the cap. • Use clean, fresh water and anti-freeze to fill the recovery tank. • If water should leak, consult your local KIOTI Dealer. 1-16 S196-WOO Jul. 2003... -
Page 25: Checking Head Light, Hazard Light Etc
GENERAL D. CHECKING HEAD LIGHT, HAZARD LIGHT ETC. 1. Inspect the lights for broken bulbs and lenses. 2. Replace if broken. E. CHECKING SEAT BELT AND ROPS 1. Always check condition of seat belt and ROPS at- taching hardware before operating tractor. 2. -
Page 26: Checking Brake Pedals And Clutch Pedal
CHAPTER 1 CK20(H) G. CHECKING BRAKE PEDALS AND CLUTCH PEDAL 1. Examine the brake and clutch pedals for free travel, and smooth operation. 2. Adjust if incorrect quantity is found: (See “Adjusting Clutch and Brake Pedal” in every 100 hours maintenance.) NOTE: Brake pedals should be equal when depressed. - Page 27 GENERAL 9.2 EVERY 50 HOURS A. LUBRICATING GREASE FITTINGS Apply a small amount of multipurpose grease to the following points every 50 hours: If you operated the machine in extremely wet and muddy conditions, lubricate grease fittings more often. 196W120A 196W118A (1) Grease Fitting (Power Steering Cylinder) (RH, LH) (1) Grease Fitting (Power Steering Cylinder) (RH, LH)
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Page 28: Checking Wheel Bolt Torque
CHAPTER 1 CK20(H) B. CHECKING WHEEL BOLT TORQUE CAUTION To avoid personal injury: • Never operate tractor with a loose rim, wheel, or axle. • Any time bolts and nuts are loosened, retighten to specified torque. • Check all bolts and nuts frequently and keep them tight. -
Page 29: Checking Fuel Line
GENERAL 9.3 EVERY 100 HOURS A. CHANGING ENGINE OIL CAUTION To avoid personal injury: • Be sure to stop the engine before changing the oil. • Allow engine to cool down sufficiently, oil can be hot and can burn. 1. To drain the used oil, remove the drain plug at the bottom of the engine and drain the oil completely into the oil pan. -
Page 30: Cleaning Air Cleaner Primary Ele- Ment
CHAPTER 1 CK20(H) C. CLEANING AIR CLEANER PRIMARY ELE- MENT 1. Remove the air cleaner cover and element. 2. Clean the element: 1) When dry dust adheres to the element, blow com pressed air from the inside, turning the element. Pressure of compressed air must be under 686 kPa (7 kgf/cm , 99 psi). -
Page 31: Evacuator Valve
GENERAL D. EVACUATOR VALVE Open the evacuator valve once a week under ordinary conditions - or daily when used in a dusty place - to get rid of large particles of dust and dirt. E. ADJUSTING CLUTCH PEDAL 1. Stop the engine and remove the key. 2. -
Page 32: Cleaning Fuel Filter
CHAPTER 1 CK20(H) G. CLEANING FUEL FILTER IMPORTANT • If dust and dirt enters the fuel system, the fuel pump and injection nozzles are subject to prema- ture wear. To prevent this, be sure to clean the fuel filter bowl and element periodically. This job should not be done in the field, but in a clean place. - Page 33 GENERAL H. BATTERY CAUTION To avoid personal injury: • Never remove the vent caps while the engine is running. • Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely with water immediately and get medi- cal attention.
- Page 34 CHAPTER 1 CK20(H) a . Battery Charging b. Table 1 Tractor Battery Capacity at CAUTION Volts (v) model TYPE 20HR (A.H) To avoid personal injury: CK20H 70D23L • When the battery is being activated, hydrogen and CK20 DF65D oxygen gases in the battery are extremely explosive.
- Page 35 9.4 EVERY 200 HOURS A. REPLACING ENGINE OIL FILTER IMPORTANT • To prevent serious damage to the engine, use only a KIOTI genuine filter. CAUTION To avoid personal injury: • Be sure to sop the engine before changing oil fil- ter cartridge.
- Page 36 8. Make sure that the transmission fluid doesn’t leak through the seal. 196W140A CK20H IMPORTANT • To prevent serious damage to the hydraulic system, use only a KIOTI genuine filter. 196W141A (1) Oil Inlet (2) Gauge (A) Oil Level is Acceptable Within this Range 1-28 S196-WOO...
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Page 37: Checking Radiator Hose And Clamp
GENERAL C. CHECKING RADIATOR HOSE AND CLAMP Check to see if radiator hoses are properly fixed every 200 hours of operation or six months, whichever comes first. 1. If hose clamps are loose or water leaks, tighten bands securely. 2. Replace hoses and tighten hose clamps securely, if radiator hoses are swollen, hardened or cracked. -
Page 38: Adjusting Toe-In
CHAPTER 1 CK20(H) E. ADJUSTING TOE-IN 1. Park tractor on a flat place. 2. Turn steering wheel so front wheels are in the straight ahead position. 3. Lower the implement, lock the park brake and stop the engine. 4. Measure distance between tire beads at front of tire, hub height. - Page 39 2. After draining reinstall the drain plug. 3. Fill with the new KIOTI TF65 fluid up to the upper line of the gauge. (See “LUBRICANTS” in Maintenance Section) 196W146A 4.
- Page 40 1/6 turn. Retighten the lock nut. 196W150A (1) Adjusting Screw (2) Lock Nut 9.7 EVERY 800 HOURS A. ADJUSTING ENGINE VALVE CLEARANCE Consult your local KIOTI Dealer for this service. 1-32 S196-WOO Jul. 2003...
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Page 41: Flush Cooling System And Changing Coolant
GENERAL 9.8 EVERY 1 YEAR A. REPLACING AIR CLEANER ELEMENT (See “Cleaning Air Cleaner Element” in every 100 hours maintenance.) 9.9 EVERY 2 YEAR A. FLUSH COOLING SYSTEM AND CHANGING COOLANT IMPORTANT • Do not start engine without coolant. • Use clean, fresh water and anti-freeze to fill the radiator and recovery tank. -
Page 42: Replacing Power Steering Hose
CHAPTER 1 CK20(H) B. ANTI-FREEZE C. REPLACING RADIATOR HOSE (WATER PIPES) If cooling water freezes, it can damage the cylinders and radiator. It is necessary, if the ambient tempera- Replace the hoses and clamps. ture falls below 0°C (32°F), to remove cooling water (See “Checking Radiator Hose and Clamp”... -
Page 43: Service As Required
GENERAL 9.10 SERVICE AS REQUIRED A. BLEEDING FUEL SYSTEM Air must be removed: 1. When the fuel filter or lines are removed. 2. When tank is completely empty. 3. After the tractor has not been used for a long period of time. -
Page 44: Replacing Fuse
Fail- ure to follow this procedure may result in serious damage to the tractor electrical system. Refer to the troubleshooting section of this manual or your local KIOTI Dealer for specific information deal- ing with electrical problems. 196W157A Protected circuit... -
Page 45: Inflation Pressure
GENERAL 10. TIRES CAUTION To avoid personal injury: • Do not attempt to mount a tire. This should be done by a qualified person with the proper equipment. • Always maintain the correct tire pressure. Do not inflate tires above the recommended pres- sure shown in the operator’s manual. -
Page 46: Front Wheels
CHAPTER 1 CK20(H) 10.2 TREAD A. FRONT WHEELS Front tread can not be adjusted. IMPORTANT • Do not turn front discs to obtain wider tread. NOTE: • IND… for Industrial Models CK20, CK20H 6 - 12 23 X 8.50 - 12 23 X 8.50 - 12 Tires 196W159A... -
Page 47: Front Ballast
. Front End Weights The front end weights can be attached to the bumper. 196W163A See your implement operator’s manual for required number of weights or consult your local KIOTI Dealer (1) Front End Weights to use. (2) Rear Wheel Weights IMPORTANT •... -
Page 48: Traveling Speed
CHAPTER 1 CK20(H) 10.4 TRAVELING SPEED At rated engine rpm with standard tires. CK20 km/h (mile/h) HI - LOW Speed Main Forward 1.10 (0.680) 1.70 (1.056) 3.50 (2.170) Reverse 1.36 (0.845) 5.11 (3.175) Forward 7.88 (4.896) 16.24 (10.091) 6.31 (3.920) Reverse CK20H km/h (mile/h) -
Page 49: Implement Limitations
Use with implements which are not sold or approved by KIOTI and which exceed the maximum specifications listed below, or which are otherwise unfit for use with the KIOTI tractor may result in malfunctions or failures of the tractor, damage to other property and injury to the operator or others. [Any malfunctions or failures of the tractor resulting from use with improper implements are not covered by the warranty.]... - Page 50 CHAPTER 1 CK20(H) Implement Remarks CK20 CK20H Remarks Loader Max. Bucket width mm (in.) 1219.2 (48), 1371.6 (54) Operating Capa. 300 kg (660 lbs) and below Backhoe with sub Max. Digging depth mm (ft.in.) 1955.8 (6.5) and below Do not use 3 point hitch fame backhoe Mid mower...