Page 1 LK30 TRACTOR WORKSHOP MANUAL...
Page 3 This manual is ultimately to satisfy customers with best performance of tractor. If there is any typo, wrong information or question for this manual, feel free to contact KIOTI. 2007. 05 Overseas service team DAEDONG INDUSTRIAL Co., Ltd. IMPORTANT REMARK • Using unspecified parts, fuel and lubricants •...
Page 5 TABLE OF CONTENTS CHAPTER 0 SAFETY FIRST CHAPTER 1 GENERAL CHAPTER 2 ENGINE CHAPTER 3 CLUTCH CHAPTER 4 TRANSMISSION CHAPTER 5 REAR AXLE CHAPTER 6 BRAKE CHAPTER 7 FRONT AXLE CHAPTER 8 STEERING SYSTEM CHAPTER 9 HYDRAULIC SYSTEM CHAPTER 10 ELECTRIC SYSTEM CHAPTER 11 INDEX...
Page 7: Table Of Contents
LK30 SAFETY FIRST TABLE OF CONTENTS 1. FOR SAFETY ................0-2 1.1 Alert symbols ..............0-2 2. SAFETY TIPS ................. 0-3 2.1 Safety gear ..............0-3 2.2 Work place ............... 0-3 2.2.1 Ventilating system ..........0-3 2.2.2 Safe working place ..........0-3 2.2.3 Illumination ............
Page 8: For Safety
SAFETY FIRST - FOR SAFETY LK30 1. FOR SAFETY • Most accidents can be avoided if basic safety in- structions and regulations are followed. Always fol- low the safety regulations and avoid any dangerous situation to prevent an accident. • You can be unexpectedly injured if inspecting or servicing the tractor without full knowledge of it.
Page 9: Safety Tips
SAFETY FIRST - SAFETY TIPS LK30 2. SAFETY TIPS 2.1 SAFETY GEAR When working on the tractor, wear safety gloves, safety shoes, ear plugs, safety goggles, safety helmet, work- ing clothes, etc. appropriate for your working environment. Never wear loose fitting clothing or a tie which can be caught to the rotating part.
Page 10: Safety Instructions When Preparing Tractor
SAFETY FIRST - SAFETY TIPS LK30 2.3 SAFETY INSTRUCTIONS WHEN PREPARING TRACTOR T46W009A T46W012A • Lower the implement on to the ground. • Keep flames or sparks away from the spray paint or fuel containers and be careful of leak. T46W010A T46W013A •...
Page 11: Cautions When Handling The Battery
SAFETY FIRST - SAFETY TIPS LK30 2.5 CAUTIONS WHEN HANDLING THE BATTERY T46W015A T46W018A • Always disconnect the negative battery cable first • The battery contains the acid that can burn you. and reconnect it last to avoid sparks from an acci- When it contacts with your eyes, you may lose your dental short circuit.
Page 12: Cautions For High Pressure Hoses
SAFETY FIRST - SAFETY TIPS LK30 2.6 CAUTIONS FOR HIGH PRESSURE 2.7 USE OF APPROPRIATE TOOLS HOSES AND EQUIPMENT T46W022A T46W019A • The hydraulic fluid leaked from high pressure hoses • Use the appropriate tools in proper size. If an inap- or pipes can penetrate your skin.
Page 13: Handling Of Rotating Blade, Shaft And Driving Belt
SAFETY FIRST - SAFETY TIPS LK30 2.9 HANDLING OF ROTATING BLADE, 2.10 PREVENTION OF SCALD SHAFT AND DRIVING BELT T46W023A T46W027A • Do not open the radiator cap when the radiator is hot. Hot coolant or steam can be surged leading to a serious scald.
Page 14: Disposal Of Environmental Waste
SAFETY FIRST - SAFETY TIPS LK30 2.11 DISPOSAL OF ENVIRONMENTAL 2.12 CAUTIONS WHEN HANDLING WASTE TIRES T46W029A T46W030A • Observe all relevant environmental protection regu- • The tire rims can fall out of the tires. Therefore, stay lations when disposing used oil, transmission fluid, out of its way when checking or inflating tires.
Page 15: Safety Decals
SAFETY FIRST - SAFETY DECALS LK30 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.
Page 16 SAFETY FIRST - SAFETY DECALS LK30 (3) Parts No. : T2445-50724 (4) Parts No. : T2615-55111 (5) Parts No. : T2241-50702 (7) Parts No. : T2615-53561 TO AVOID POSSIBLE INJURY OR DEATH Do not start engine by shorting across starter terminals. Machine may start in gear and move if normal starting circuitry is bypassed.
Page 17 LK30 GENERAL TABLE OF CONTENTS 1. TRACTOR IDENTIFICATION ...... 1-3 8.2.3 Changing engine oil ....1-15 8.2.4 Replacing engine oil filter ..1-16 2. DIMENSIONS ..........1-4 8.2.5 Replacing transmission fluid filter 3. SPECIFICATIONS ........1-5 ..........1-16 4. LUBRICANTS, FUEL AND COOLANT ..1-6 8.2.6 Changing transmission fluid ...
Page 18 TABLE OF CONTENTS 8.4.5 Checking power steering line .. 1-25 8.9.4 Replacing power steering hose ..........1-29 8.4.6 Adjusting toe-in ......1-25 8.9.5 Replacing fuel hose ....1-29 8.4.7 Checking intake air hose ..1-26 8.9.6 Replacing intake air hose ..1-29 8.5 Every 400 hours ........
Page 19: Tractor Identification
GENERAL - TRACTOR IDENTIFICATION LK30 1. TRACTOR IDENTIFICATION When contacting your local KIOTI distributor, always specify engine serial number, tractor serial number and hour meter reading. 265W101B (1) Serial number plate (3) Transmission serial number (2) Engine serial number 265W102B (4) Hour meter SS41-W00 May.
Page 20: Dimensions
GENERAL - DIMENSIONS LK30 2. DIMENSIONS mm (in.) 1,020 (40.157) 1,640 (64.567) 2,830 (111.4) 265W103B SS41-W00 May. 2007...
Page 21: Specifications
GENERAL - SPECIFICATIONS LK30 3. SPECIFICATIONS Model LK30 Model 3A150 L X B Type Vertical, water-cooled, 3-cylinder diesel Engine gross HP (kW) 30 (22.3) P.T.O HP (kW)/rpm 23 (17.2) / 2,600 Displacement cc (cu.in) 1,500 (91.5) Rated revolution r.p.m min-1 2,600 Fuel tank capacity (gal.)
Page 22: Lubricants, Fuel And Coolant
GENERAL - LUBRICANTS, FUEL AND COOLANT LK30 4. LUBRICANTS, FUEL AND COOLANT To prevent serious equipment damage, use only genuine KIOTI fluids, oils and greases, or equivalents. Locations Capacities Lubricants No.2-D diesel fuel Fuel (7.4 U.S.gal.) No.1-D diesel fuel if temperature is below -10°C (14°F) Coolant (2.0 U.S.gal.) Fresh clean water with anti-freeze (Ethylene glycol 50%)
Page 23: Tightening Torques
GENERAL - TIGHTENING TORQUES LK30 5. TIGHTENING TORQUES 5.1 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,...
Page 24: American Standard Screws, Bolts And Nuts With Unc Or Unf Threads
GENERAL - TIGHTENING TORQUES LK30 5.3 AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS Grade SAE GR.5 SAE GR.8 Unit Nominal kgf-m lb-ft kgf-m lb-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 25: Unit Conversion Table
GENERAL - UNIT CONVERSION TABLE LK30 6. UNIT CONVERSION TABLE Torque Length Volume Pressure Temperature Kgf-m lb-ft Inch U.S.gal kgf/cm °C °F 25.4 0.26418 14.22 19.6 14.5 50.8 142.2 29.4 21.7 76.2 1960 284.4 39.2 28.9 101.6 2940 426.6 36.2 3920 568.8 58.8...
Page 26: Maintenance Check List
GENERAL - MAINTENANCE CHECK LIST LK30 7. MAINTENANCE CHECK LIST Maintenance interval Run hour Run age Remarks Item 1500 3000 1 year 2 year Engine oil Change Engine oil filter Replace Transmission oil filter Replace HST oil filter Replace Transmission fluid Change Front axle oil Change...
Page 27: Check And Maintenance
GENERAL - CHECK AND MAINTENANCE LK30 8. CHECK AND MAINTENANCE 8.1 DAILY CHECK Walk around inspection For your own safety and maximum service life of the 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.
Page 28: Checking Engine Oil Level
GENERAL - CHECK AND MAINTENANCE LK30 8.1.2 CHECKING ENGINE OIL LEVEL IMPORTANT • When using an oil of different maker or viscosity from the previous one, remove all of the old oil. Never mix two different types of oil. • Never run engine if the oil level is low.
Page 29: Checking Head Light, Hazard Light Etc
GENERAL - CHECK AND MAINTENANCE LK30 8.1.4 CHECKING HEAD LIGHT, HAZARD LIGHT ETC. 1. Inspect the lights for broken bulbs and lenses. 2. Replace if broken. 8.1.5 CHECKING SEAT BELT AND ROPS 1. Always check condition of seat belt and ROPS at- taching hardware before operating tractor.
Page 30: Every 50 Hours
GENERAL - CHECK AND MAINTENANCE LK30 8.2 EVERY 50 HOURS 8.2.1 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. 265W115B 265W118B (1) Grease fitting (Power steering cylinder - RH, LH)
Page 31: Checking Wheel Bolt Torque
GENERAL - CHECK AND MAINTENANCE LK30 8.2.2 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 32: Replacing Engine Oil Filter
GENERAL - CHECK AND MAINTENANCE LK30 8.2.4 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 stop the engine before changing oil •...
Page 33: Changing Transmission Fluid
GENERAL - CHECK AND MAINTENANCE LK30 8.2.6 CHANGING TRANSMISSION FLUID CAUTION To avoid personal injury: • 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 transmission case and drain the oil completely into the oil pan.
Page 34: Adjusting Clutch Pedal
GENERAL - CHECK AND MAINTENANCE LK30 8.2.8 ADJUSTING CLUTCH PEDAL 1. Stop the engine and remove the key. 2. Slightly depress the clutch pedal and measure free travel at top of pedal stroke. 3. If adjustment is needed, loosen the lock nut, re- move the clevis pin and adjust the rod length within acceptable limits.
Page 35: Replacing Hydraulic Oil Filter
GENERAL - CHECK AND MAINTENANCE LK30 8.2.9 REPLACING HYDRAULIC OIL FILTER CAUTION To avoid personal injury: • Be sure to stop the engine before changing the oil filter. • Allow engine to cool down sufficiently, oil can be hot and can burn. 1.
Page 36: Every 100 Hours
GENERAL - CHECK AND MAINTENANCE LK30 8.3 EVERY 100 HOURS 8.3.1 CHANGING ENGINE OIL (REFER TO “EVERY 50 HOURS”) 8.3.2 CHECKING FUEL LINE 1. Check to see that all lines and hose clamps are tight and not damaged. 2. If hoses and clamps are found worn or damaged, replace or repair them at once.
Page 37: Adjusting Clutch Pedal (Refer To "Every 50 Hours")
GENERAL - CHECK AND MAINTENANCE LK30 8.3.4 ADJUSTING CLUTCH PEDAL (REFER TO “EVERY 50 HOURS”) 8.3.5 ADJUSTING BRAKE PEDAL CAUTION To avoid personal injury: • Stop the engine and chock the wheels before checking brake pedal. 1. Release the parking brake. 2.
Page 38: Adjusting Fan Belt Tension
GENERAL - CHECK AND MAINTENANCE LK30 8.3.7 ADJUSTING FAN BELT TENSION CAUTION To avoid personal injury: • Be sure to stop the engine before checking belt tension. Item Specified Proper fan belt tension A deflection of between 8 mm (0.32 in.) when the belt is pressed in the middle of the span.
Page 39: Battery
GENERAL - CHECK AND MAINTENANCE LK30 8.3.8 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 40: Every 200 Hours
GENERAL - CHECK AND MAINTENANCE LK30 8.4 EVERY 200 HOURS 8.4.1 REPLACING ENGINE OIL FILTER (REFER TO “EVERY 50 HOURS”) 8.4.2 REPLACING HYDRAULIC OIL FILTER (REFER TO “EVERY 50 HOURS”) 8.4.3 REPLACING FUEL FILTER (REFER TO “8.3.6 REPLACING FUEL FILTER”) 8.4.4 CHECKING RADIATOR HOSE AND CLAMP Check to see if radiator hoses are properly fixed every...
Page 41: Checking Power Steering Line
GENERAL - CHECK AND MAINTENANCE LK30 8.4.5 CHECKING POWER STEERING LINE 1. Check to see that all hydraulic lines and hose clamps are tight and undamaged. 2. If damage is found you should replace the hose or clamp at once. 265W137B (1) Power steering line 8.4.6 ADJUSTING TOE-IN...
Page 42: Checking Intake Air Hose
GENERAL - CHECK AND MAINTENANCE LK30 8.4.7 CHECKING INTAKE AIR HOSE Check if the intake air hose is properly fixed every hour of operation. If not, replace it with a new one. Also, it should be replaced every 2 years of operation and whenever it is found to be swollen, hardened or cracked.
Page 43: Every 400 Hours
GENERAL - CHECK AND MAINTENANCE LK30 8.5 EVERY 400 HOURS 8.5.1 CHANGING TRANSMISSION FLUID (REFER TO “EVERY 50 HOURS”) 8.5.2 CHANGING FRONT AXLE CASE OIL (REFER TO “EVERY 50 HOURS”) 8.6 EVERY 600 HOURS 8.6.1 ADJUSTING FRONT AXLE PIVOT If the front axle pivot pin adjustment is not correct, front wheel vibration can occur causing vibration in the steer- ing wheel.
Page 44: Every 2 Years
GENERAL - CHECK AND MAINTENANCE LK30 8.9 EVERY 2 YEARS 8.9.1 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. • When the anti-freeze is mixed with water, the anti- freeze mixing ratio must be less than 50 %.
Page 45: Anti-Freeze
GENERAL - CHECK AND MAINTENANCE LK30 8.9.2 ANTI-FREEZE 8.9.3 REPLACING RADIATOR HOSE (WATER PIPES) Should never run water only; water has no rust prevention. Always run proper water/antifreeze mix. Replace the hoses and clamps. 1. There are two types of anti-freeze available; use the (See “Checking Radiator Hose and Clamp”...
Page 46: Service As Required
GENERAL - CHECK AND MAINTENANCE LK30 8.10 SERVICE AS REQUIRED 8.10.1 BLEEDING FUEL SYSTEM A. 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 47: Replacing Fuse
GENERAL - CHECK AND MAINTENANCE LK30 8.10.4 REPLACING FUSE The tractor electrical system is protected from poten- tial damage by fuses. A blown fuse indicates that there is an overload or short somewhere in the electrical system. If any of the fuses should blow, replace with a new one of the same capacity.
Page 48: Tires
GENERAL - TIRES LK30 9. 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 49: Tread
GENERAL - TIRES LK30 9.2 TREAD 9.2.1 FRONT WHEELS Front tread can not be adjusted. IMPORTANT • Do not turn front discs to obtain wider tread. Tire Tread 7 - 14 1,115 mm Farm (43.9 in.) 27 x 8.50 - 15 1,161 mm Turf (45.7 in.)
Page 50: Ballast
GENERAL - TIRES LK30 9.3 BALLAST 9.3.1 FRONT BALLAST CAUTION To avoid personal injury: • Additional ballast will be needed for transporting heavy implements. When the implement is raised, drive slowly over rough ground, regardless of how much ballast is used. •...
Page 51: Traveling Speed
GENERAL - TIRES LK30 9.4 TRAVELING SPEED At rated engine rpm with standard tires. km/h (mile/h) km/h (mile/h) Shuttle Hi-Lo Main LK30 Shuttle Hi-Lo Main LK30 1.36 (0.84) 1.24 (0.77) 1.89 (1.17) 1.72 (1.06) 2.68 (1.66) 2.44 (1.51) 4.34 (2.69) 3.96 (2.46) 6.34 (3.93) 5.78 (3.59)
Page 52 MEMO ...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 53 LK30 ENGINE TABLE OF CONTENTS 1. ENGINE IDENTIFICATION ......2-3 3. OPERATING PRINCIPLE ......2-11 1.1 General features ........2-3 3.1 Body and power train ......2-11 3.1.1 Cylinder head ......2-11 2. SPECIFICATIONS ........2-4 3.1.2 Cylinder block ......2-11 2.1 Engine body ...........
Page 54 TABLE OF CONTENTS 3.4.4 Fuel feed pump ......2-21 7.1.5 Propeller shaft ......2-44 3.4.5 Fuel injection pump ....2-21 7.1.6 Separating engine & clutch housing ........2-44 3.5 Governor system ........ 2-25 7.1.7 Removing clutch ....2-45 3.5.1 Disassembled view ....2-25 7.1.8 Removing the fuel tank ..
Page 55: Engine Identification
704W201B The 3A150LXB engines are vertical, water-cooled, 4-cycle, three or four cylinders diesel engines. They concentrate DAEDONG’s foremost technologies. With swirl combustion chamber, bosch K type fuel injection pump, well-balanced designs, they feature greater power, low fuel consumption, less vibration and noise, and low emissions.
Page 56: Specifications
ENGINE - SPECIFICATIONS LK30 2. SPECIFICATIONS 2.1 ENGINE BODY 2.1.1 CYLINDER HEAD Item Factory Specification Allowable Limit Cylinder head surface flatness 0.05 mm / 100 mm 0.002 in. / 3.94 in. Top clearance 0.75 ~ 0.9 mm 0.0294 ~ 0.0354 in. Thickness of gasket free When tightened 1.17 ~ 1.26 mm...
Page 57: Cylinder Bore
ENGINE - SPECIFICATIONS LK30 2.1.4 CYLINDER BORE Item Factory Specification Allowable Limit Cylinder bore inner diameter (3A150) 83.000 ~ 83.022 mm 0.15 mm 3.2677 ~ 3.2690 in. 0.0059 in. 2.1.5 VALVE SPRING Item Factory Specification Allowable Limit Free length 41.7 ~ 42.2 mm 41.2 mm 1.6417 ~ 1.6614 in.
Page 58: Timing Gear
ENGINE - SPECIFICATIONS LK30 2.1.9 TIMING GEAR Item Factory Specification Allowable Limit Timing gear backlash 0.04 ~ 0.11 mm 0.15 mm 0.0016 ~ 0.0043 in. 0.0059 in. Idle gear side clearance 0.20 ~ 0.51 mm 0.9 mm 0.0079 ~ 0.0201 in. 0.035 in.
Page 59: Crankshaft
ENGINE - SPECIFICATIONS LK30 2.1.12 CRANKSHAFT Item Factory Specification Allowable Limit Crankshaft alignment 0.08 mm 0.0031 in. Clearance between Crankshaft and crankshaft 0.040 ~ 0.118 mm 0.20 mm bearing 1 0.00157 ~ 0.00465 in. 0.0079 in. 51.921 ~ 51.940 mm Crankshaft O.D 2.04414 ~ 2.04488 in.
Page 60: Cooling System
ENGINE - SPECIFICATIONS LK30 2.3 COOLING SYSTEM 2.3.1 THERMOSTAT Valve opening temperature at beginning 69.5 ~ 72.5°C (157.1 ~ 162.5°F) Opened completely (height 8 mm 0.315 in.) 85°C (185°F) 2.3.2 RADIATOR Radiator tightness No leak at 137 kPa, 1.4 kgf/cm , 20 psi Radiator cap tightness 10 seconds or more for pressure...
Page 61: Tightening Torques
ENGINE - SPECIFICATIONS LK30 2.5 TIGHTENING TORQUES Item Size x Pitch kgf-m lb-ft Cylinder head screws M11 x 1.25 103.0 ~ 107.9 10.5 ~ 11.0 75.9 ~ 79.6 M6 x 1.0 Head cover bolts 8.8 ~ 11.8 0.9 ~ 1.2 6.5 ~ 8.7 * Bearing case screw 1 M9 x 1.25...
Page 62: Performance Curve
ENGINE - SPECIFICATIONS LK30 2.6 PERFORMANCE CURVE 1400 1600 1800 2000 2200 2400 2600 2800 Eng.Speed, rpm 265W200B NOTE: • Performance curve, obtained in accordance with SAE J 1995. 2-10 SS41-W00 May. 2007...
Page 63: Operating Principle
ENGINE - OPERATING PRINCIPLE LK30 3. OPERATING PRINCIPLE 3.1 BODY AND POWER TRAIN 3.1.1 CYLINDER HEAD The cylinder head is made of special alloy cast iron which can resist high temperature and pressure caused by combustion. The intake and exhaust ports are arranged cross-flow type to get high combustion efficiency by protecting the suction air from being heated and expanded by heated exhaust air.
Page 64: Crankshaft
ENGINE - OPERATING PRINCIPLE LK30 3.1.3 CRANKSHAFT The crankshaft drives the pistons and connecting rods, and translates its reciprocating movement into a circu- lar camshaft. Six counterweights are integrated into one unit to minimize bearing wear and lubricating oil temperature rise. Seal sliding sections are induction-hardened to raise wear resistance quality.
Page 65: Camshaft And Fuel Camshaft
ENGINE - OPERATING PRINCIPLE LK30 3.1.6 CAMSHAFT AND FUEL CAMSHAFT The camshaft is made of special cast iron; the journal and cam sections are chilled to resist wear. The jour- nal sections are force-lubricated. The fuel camshaft controls the reciprocating movement of the injection pump, and is also equipped with a ball to control the governor.
Page 66: Inlet And Exhaust Valves
ENGINE - OPERATING PRINCIPLE LK30 3.1.8 INLET AND EXHAUST VALVES The inlet and exhaust valves and their guides are dif- ferent from each other. Other parts, such as valve springs, spring retainers, valve spring collets, valve stem seals, valves and all contact or sliding parts are covered and tempered to resist, wear.
Page 67: Lubricating System
ENGINE - OPERATING PRINCIPLE LK30 3.2 LUBRICATING SYSTEM 196W200B A. Oil filter 1 C. Oil filter cartridge and relief D. Camshaft valve B. Oil pump E. Rocker arm rocker arm shaft 3. To rocker arm shaft and 1. Inlet hole F.
Page 68: Engine Oil Flow
ENGINE - OPERATING PRINCIPLE LK30 3.2.1 ENGINE OIL FLOW Rocker arm shaft Rocker arm Rocker arm Rocker arm Engine oil pressure sensor Valve Valve cam shaft Valve cam shaft Valve cam shaft Valve cam shaft shaft Valve cam shaft Valve cam shaft Valve cam shaft journal journal...
Page 69: Relief Valve
ENGINE - OPERATING PRINCIPLE LK30 3.2.2 RELIEF VALVE High oil and the oil push when oil pressure exceeds the limit the ball back escapes preventing damage to the lubrication system due to high oil pressure. Con- trol range of the relief valve is 196 to 441 Kpa (2.0 to 4.5 kgh/cm², 28 to 64 psi).
Page 70: Cooling System
ENGINE - OPERATING PRINCIPLE LK30 3.3 COOLING SYSTEM The cooling system consists of a radiator (not included in the basic engine), centrifugal water pump, suction fan and thermostat. The water is cooled through the radiator core, and the fan set behind the radiator pulls cooling air through the core to improve cooling.
Page 71: Thermostat
ENGINE - OPERATING PRINCIPLE LK30 3.3.2 THERMOSTAT The thermostat is wax pellet type, which controls the flow of the cooling water to the radiator to keep the proper temperature. The case has a seat (1) and the pellet has a valve (2). The spindle attached to the case is inserted into the synthetic rubber in the pellet.
Page 72: Fuel System
ENGINE - OPERATING PRINCIPLE LK30 3.4 FUEL SYSTEM 3.4.1 FLOW OF FUEL The fuel is feed from the fuel tank (1) through the fuel filter (2) to the injection pump (4) by the fuel feed pump (3). The injection pump force-feeds the fuel through the injection nozzles (6), which inject the fuel into the cylinders for combustion.
Page 73: Fuel Feed Pump
ENGINE - OPERATING PRINCIPLE LK30 3.4.4 FUEL FEED PUMP To fuel injec- The diaphragm (6) is linked to the tappet (3) with the From fuel filter tion nozzle push rod (2). The tappet is reciprocated by the eccen- tric cam on the fuel camshaft (7). A.
Page 74 ENGINE - FUEL SYSTEM LK30 A. PUMP ELEMENT The pump element (1) consists of a plunger (3) and cylinder (2) which their sliding surfaces are finely ma- chined to maintain the fuel tightness. The plunger (3) is installed in the control sleeve (5) and the sleeve is engaged with the control rack that rotates the plunger in the cylinder to control the amount of fuel delivered.
Page 75 ENGINE - FUEL SYSTEM LK30 C. AMOUNT OF FUEL DELIVERY No fuel delivery When the control rack (3) is at the engine stop position, the lengthwise slot (1) on the plunger (2) aligns with the feed hole (5). The pressure in the delivery chamber does not build up and no fuel is forced to the injection nozzle since the delivery chamber (4) is opened to the feed hole during the entire stroke of the plunger.
Page 76 (6) Nozzle body (9) Packing This injection nozzle is a throttle type nozzle. It features low fuel consumption and works well with DAEDONG’s combustion chamber. The nozzle valve opening pres- sure is about 14.7 MPa (150 kgf/cm², 2134 psi). When...
Page 77: Governor System
ENGINE - FUEL SYSTEM LK30 3.5 GOVERNOR SYSTEM 3.5.1 DISASSEMBLED VIEW 196W239B (1) Start spring (6) Fork lever shaft (11) Steel ball (2) Governor spring 1 (7) Fork lever holder (12) Governor sleeve (3) Governor spring 2 (8) Governor lever (13) Steel ball (4) Fork lever 1 (9) Fuel injection camshaft...
Page 78: Basic Principle Of Governor System
ENGINE - FUEL SYSTEM LK30 3.5.2 BASIC PRINCIPLE OF GOVERNOR SYSTEM 15 14 Torque Spring Torque control screw T46W246C (1) Governor spring 1, 2 (6) Steel ball (11) Governor sleeve (2) Solenoid guide (7) Governor lever (12) Fork lever 2 (3) Stop solenoid (8) Idle spring (13) Fork lever 1...
Page 79: Operation Of Governor
Therefore, never adjust them without permission from DAEDONG. Such action violates the EPA regula- tion and also can void the warranty. F. WHEN STOPPED When the key switch is moved to the “OFF” position, the stop solenoid power is cut off to release the electromagnet.
Page 80: Intake And Exhaust System
ENGINE - FUEL SYSTEM LK30 3.6 INTAKE AND EXHAUST SYSTEM 3.6.1 FLOW OF INTAKE AIR AND EXHAUST 196W244C (A) Inlet air (3) Cylinder head (B) Exhaust gas (4) Muffler (1) Inlet manifold (5) Exhaust manifold (2) Air cleaner 3.6.2 AIR CLEANER The air cleaner is dry-cyclone type and easy to maintain.
Page 81: Pcv Valve
ENGINE - FUEL SYSTEM LK30 3.7 PCV VALVE 3.7.1 PCV (POSITIVE CRANKCASES VENTILATION) The PCV system prevents air pollution by returning the unburned gases to the intake manifold through the bleeding pipe of the cylinder head cover for recircula- tion of the gas. (However, turbo charged engines have the open crankcase type that discharges the blow-by gas to the air.) T46W248A...
Page 82: Troubleshooting
ENGINE - TROUBLESHOOTING LK30 4. TROUBLESHOOTING ENGINE DOES NOT START. Crankshaft and camshaft have seized up. Crankshaft Frictional resis- does not turn tance of moving Piston and cylinder liner have seized up. parts is too much Bearings are oil-stuck. Lubrication system not working property. Starter faulty.
Page 83 ENGINE - TROUBLESHOOTING LK30 Engine does not turn normally. Fuel filter clogged. Fuel pipes broken or loose. Air in pump. Revolution is Injection not smooth at pump fault Pump capacity not constant. high speeds. Tappet roller and pin worn. Delivery valve not completely oil-tight. Fuel leaks from nozzle tip.
Page 84 ENGINE - TROUBLESHOOTING LK30 Color of exhaust fumes not normal. Piston ring stuck. Piston ring worn. Excessive gap between cylinder liner and White or blue Lubricant piston. exhaust rises through fumes. piston gap. Too much oil. Injection delayed. Compression pressure insufficient. Injection too early.
Page 85: Measurement And Adjustment
ENGINE - MEASUREMENT AND ADJUSTMENT LK30 5. MEASUREMENT AND ADJUSTMENT 5.1 FAN BELT 1. Measure the deflection, depressing the belt half- way between the fan drive pulley and the alternator pulley at 78 N (8 kgf, 18 lbs) of force. 2.
Page 86: Compression Pressure
ENGINE - MEASUREMENT AND ADJUSTMENT LK30 5.4 COMPRESSION PRESSURE 1. Run the engine until warmed up. 2. Stop the engine and remove the air cleaner, the muffler and all nozzle holders. 3. Connect a compression tester to the nozzle holder hole.
Page 87: Valve Clearance
ENGINE - MEASUREMENT AND ADJUSTMENT LK30 5.5 VALVE CLEARANCE 1. The valve clearance should be measured only when the engine temperature is equal to the ambi- ent temperature. 2. Disconnect the negative battery cable. 3. Remove the cylinder head cover. 4.
Page 88: Injection Timing Measurement And Adjust- Ment
NOTE: • How to make the crankshaft turning socket T46W258A T46W259A a. Cut the coupler (DAEDONG part No.: 37805-4452-1) in half. b. Weld the 1/2” socket to the coupler. c. You can use DAEDONG special tool kit (part No.: G0611-B0010).
Page 89 ENGINE - MEASUREMENT AND ADJUSTMENT LK30 5. Remove the No. 1 high pressure pipe. 6. Unscrew the nozzle holder (1) slightly and tighten it when it is filled with fuel. T46W260B 7. Remove the fuel in the nozzle holder with clean cloth and leave only small amount of fuel.
Page 90: Engine Oil Pressure
ENGINE - MEASUREMENT AND ADJUSTMENT LK30 5.7 ENGINE OIL PRESSURE 1. Remove the oil pressure switch. Install the adapter and pressure tester in its place. 2. Start the engine and run it until it is warmed up. Measure the oil pressure at both idling and rated speed.
Page 91: Exploded View (Lk30)
ENGINE - EXPLODED WIEW (LK30) LK30 6. EXPLODED VIEW (LK30) 704W243B (1) Cylinder block (12) Bearing case bolt 1 (23) Piston (33) Fuel feed pump (43) Cooling fan (2) Oil pressure switch (13) Main bearing case (24) Connecting rod (34) Fuel camshaft (44) Radiator (3) Oil pump (14) Bearing case bolt 2...
Page 93: Servicing
ENGINE - SERVICING LK30 7. SERVICING 7.1 DISASSEMBLING AND MAINTENANCE 7.1.1 DRAINING THE 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.
Page 94: Draining The Coolant
ENGINE - SERVICING LK30 7.1.2 DRAINING THE COOLANT CAUTION • Never open radiator cap when the coolant’s temprature reaches boiling point. • Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop. Re- lieve any excess pressure before removing cap completely.
Page 95: Hydraulic Pipe And Electric Wiring
ENGINE - SERVICING LK30 7.1.4 HYDRAULIC PIPE AND ELECTRIC WIRING 1. Remove the throttle rod. 2. Disconnect the engine accelerator wire (1). 3. Disconnect the tachometer cable (2). 4. Disconnect the fuel hose (3). 5. Remove the inlet pipe1 (4). 6.
Page 96: Propeller Shaft
ENGINE - SERVICING LK30 7.1.5 PROPELLER SHAFT 1. Remove the bolts and slide the propeller shaft cover . 2. Tap out the spring pin (8), and then slide the cou- pling (2) to the rear. 3. Romove the propeller shaft and cover. (When reassembling) •...
Page 97: Removing Clutch
ENGINE - SERVICING LK30 7.1.7 REMOVING CLUTCH 1. Put alignment marks on the clutch cover and fly wheel. 2. Insert the clutch center tool. 3. Remove the clutch assembly. 30 12 704W313C 704W313A This would be good place to include the part or may notes for this tool.
Page 98: Disassembling Front Axle Frame
ENGINE - SERVICING LK30 7.1.9 DISASSEMBLING FRONT AXLE FRAME 1. Lift engine with chain hook and support it. 2. Loosen bolts and remove the engine from the front axle frame. Item Tightening torque M10 Bolt 60.9 ~ 70.6 Nm 6.2 ~ 7.2 kgf-m 44.9 ~ 52.0 lb-ft 103 ~ 117 Nm M12 Bolts...
Page 99: Removal And Reassemble
ENGINE - SERVICING LK30 7.2 REMOVAL AND REASSEMBLE 7.2.1 ENGINE STOP SOLENOID 1. Disconnect the wire connector of solenoid (1). 2. Remove the two nuts (2). 3. Remove the stop solenoid (1). 196W250B (1) Engine stop solenoid (2) Nut 7.2.2 INTAKE MANIFOLD AND FUEL HOSES 1.
Page 100 ENGINE - SERVICING LK30 B. REMOVING INJECTION PIPES 1, 2 AND 3 1. Loosen the screws on the pipe clamps. 2. Detach the injection pipes in the order of 1, 2 and 3. (Note for reassembling) • Send compressed air, into the pipes to blow out dust.
Page 101 ENGINE - SERVICING LK30 E. NOZZLE HOLDER Disassembling Nozzle Holder 1. Secure the retaining nut with a vise. 2. Remove the nut, the over flow pipe Assembly and the plain washer. 3. Remove the nozzle holder body and take out parts inside. (Note for reassembling) •...
Page 102: Rocker Arm Assembly
ENGINE - SERVICING LK30 7.2.4 ROCKER ARM ASSEMBLY 1. Loosen the bolts in several steps and the specified sequence shown in the figure and remove them. • To loosen (3) to (1) • To tighten (1) to (3) 2. Remove the rocker arm assembly and the push rod. 265W224A (A) Gear case (When reassembling)
Page 103 ENGINE - SERVICING LK30 (Note for reassembling) • Tighten the bolts and nuts after applying sufficient oil to the bolts and nuts. • Tighten the bolts and nuts in diagonal sequence starting from the center. Tighten them uniformly, or the head may deform in the long run. •...
Page 104: Fuel Feed Pump And Injection Pump
ENGINE - SERVICING LK30 7.2.6 FUEL FEED PUMP AND INJECTION PUMP A. FUEL FEED PUMP Removing Fuel Feed Pump 1. Remove the two fuel feed pump mounting nuts. 2. Detach the fuel feed pump. 3. Remove the injection pump cover(2). (Note for assembling) •...
Page 105 ENGINE - SERVICING LK30 4. Remove the idle limit system (3). 5. Remove the injection pump mounting bolts and nuts (A). 6. Align the control rack pin (4) with the slot (5) on the cylinder and remove the injection pump. 7.
Page 106 ENGINE - SERVICING LK30 D. INJECTION PUMP INSTALLATION 1. Apply the liquid gasket (Three bond 1215, 1104 or equivalent) on the pump installation surface of the Injection pump cylinder block. control rack lever 2. Install the shims as they were. Fork lever 1 3.
Page 107: Crank Case
ENGINE - SERVICING LK30 7.2.7 CRANK CASE A. DETACH THE GOVERNOR SPRING 1. Detach the governor spring 1, 2 and speed control plate from governor lever. 2. Remove the manual stop lever plate (4). (Note for reassembling) • Be careful not to drop the governor spring 1, 2 in the gear case.
Page 108 ENGINE - SERVICING LK30 B. REMOVAL 1. Flatten the locking washer (1) and remove the crank- shaft nut (2). 2. Remove the fan drive pulley (3). Tightening Crankshaft 137.3 ~ 156.9 Nm torque 14.0 ~ 16.0 kgf-m 101.3 ~ 115.7 lb-ft 3.
Page 109 ENGINE - SERVICING LK30 6. When installing the governor spring, make sure that the governor spring 2 is installed on the inside of governor spring 1. CAUTION • Be careful of the direction of the governor spring 1. The longer side should face the governor fork. •...
Page 110: Timing Gears, Cam Shafts And Oil Pump
ENGINE - SERVICING LK30 7.2.8 TIMING GEARS, CAM SHAFTS AND OIL PUMP A. REMOVING CRANKSHAFT OIL SLINGER 1. Remove the crankshaft collar. 2. Remove the O-ring. 3. Detach the crankshaft oil slinger. 196W280A (1) Crankshaft oil slinger (2) O-ring (3) Crankshaft collar B.
Page 111 ENGINE - SERVICING LK30 C. REMOVING CAMSHAFT STOPPER 1. Align the round hole on the cam gear with the cam- shaft stopper mounting bolt position. 2. Remove the camshaft stopper mounting bolt. 3. Detach the camshaft stopper. 196W283A (1) Camshaft stopper D.
Page 112 ENGINE - SERVICING LK30 F. REMOVING OIL PUMP DRIVE GEAR 1. Remove the nut from oil pump. 2. Draw out the oil pump drive gear with gear puller. (Note for reassembling) • Check to see if there is a feather key. 196W287A (1) Crank gear (2) Oil pump drive gear...
Page 113: Piston
ENGINE - SERVICING LK30 7.2.9 PISTON A. REMOVING OIL PAN 1. Lay the engine on the engine cradle on its side. 2. Remove the eighteen oil pan mounting bolts. 3. Detach the oil pan by lightly tapping the groove of the pan with a dead blow hammer.
Page 114 ENGINE - SERVICING LK30 D. REMOVING PISTONS 1. Turn the crankshaft and bring the piston to top dead center. 2. Draw out the piston upward by lightly tapping it from the bottom of the crankcase with the grip of a hammer.
Page 115 ENGINE - SERVICING LK30 E. PISTON RING AND PISTON PIN 1. Remove the piston rings with a piston ring replac- ing tool. 2. Remove the piston pin. 704W271A (1) Piston pin (5) Second ring (2) Piston (6) Oil ring (3) Piston pin snap ring (7) Connecting rod (4) Top ring (When reassembling)
Page 116: Flywheel And Main Bearing Case
ENGINE - SERVICING LK30 7.2.10 FLYWHEEL AND MAIN BEARING CASE A. FLYWHEEL 1. Install the stopper to the flywheel and loosen the screw. 2. Remove the flywheel stopper and the flywheel. (When reassembling) • Clean the end of the crankshaft and the mating sur- face of the flywheel.
Page 117: Crankshaft And Journal Bearing
ENGINE - SERVICING LK30 7.2.11 CRANKSHAFT AND JOURNAL BEARING 1. Remove the bearing case screw 2. 2. Pull out the crankshaft, taking care not to damage the crankshaft bearing 1. (When reassembling) • Apply oil to the bearing case screw 2. •...
Page 118: Inspection For Overhaul
ENGINE - SERVICING LK30 7.3 INSPECTION FOR OVERHAUL 7.3.1 CYLINDER HEAD A. CYLINDER HEAD SURFACE FLATNESS 1. Thoroughly clean the cylinder head surface. 2. Place a straightedge on the cylinder head and mea- sure the clearance with a feeler gage as shown in the figure.
Page 119 ENGINE - SERVICING LK30 C. VALVE STEM CLEARANCE 1. Remove the carbon from the valve guide. 2. Measure the valve stem O.D. with an outside micrometer. 3. Measure the valve guide I.D. of cylinder head, and calculate the clearance. 4. If the measurement exceeds the allowable limit, replace the valve guide or the valve.
Page 120 ENGINE - SERVICING LK30 E. VALVE SEAT 1. Coat the valve face lightly with red lead and put the valve on its seat to check the contact. 2. If the valve does not seat all the way around the valve seat or the valve contact is less than 70%, correct the valve seating as follows.
Page 121: Rocker Arm Bushing And Shaft Clearance
ENGINE - SERVICING LK30 7.3.2 ROCKER ARM BUSHING AND SHAFT CLEARANCE 1. Measure the rocker arm I.D. with an inside micrometer. 2. Measure the rocker arm shaft O.D. with an outside micrometer. 3. If the clearance exceeds the allowable limit, replace the rocker arm.
Page 122 ENGINE - SERVICING LK30 B. IDLE GEAR SIDE CLEARANCE 1. Pull the idle gear collar 2 (1) and push the idle gear (2) to each end. 2. Measure the clearance A between the idle gear and the idle gear collar 2 with a feeler gauge. 3.
Page 123 ENGINE - SERVICING LK30 E. IDLE GEAR OIL CLEARANCE 1. Measure the idle gear shaft O.D. with an outside micrometer. 2. Measure the idle gear bushings I.D. with an inside micrometer. 3. If the clearance exceeds the allowable limit, replace the bushing.
Page 124 ENGINE - SERVICING LK30 H. CAMSHAFT ALIGNMENT 1. Support the camshaft with V blocks on the surface plate at both end journals and set a dial indicator with its tip on the intermediate journal. 2. Rotate the camshaft in the V block and get the ec- centricity (half of the measurement).
Page 125: Connecting Rod And Piston
ENGINE - SERVICING LK30 7.3.4 CONNECTING ROD AND PISTON A. PISTON PIN BORE 1. Measure the I.D. of piston pin bore in piston (length- wise and widthwise of the piston) with a cylinder gauge. 2. If the measurement exceeds the allowable limit, re- place the piston.
Page 126 ENGINE - SERVICING LK30 D. PISTON RING END GAP 1. Push down the ring into the cylinder to the lower limit of ring travel in the assembled engine with a piston. 2. Measure the ring gap with a feeler gauge. 3.
Page 127: Crankshaft
ENGINE - SERVICING LK30 7.3.5 CRANKSHAFT A. FLYWHEEL DEFLECTION AND CRANK- SHAFT END PLAY 1. Set a dial indicator with its tip on the rear friction face of the flywheel near the edge. 2. Turn the flywheel and measure the deflection or the uneven wear.
Page 128 ENGINE - SERVICING LK30 D. REPLACING CRANKSHAFT BEARING 1 1. Press out the crankshaft bearing 1 using replacing tool. 2. Clean a new crankshaft bearing 1 and bore, and apply engine oil to them. 3. Press fit a new bearing 1 using a inserting tool, taking due care to see that the seam of bearing 1 faces the exhaust manifold side.
Page 129: Cylinder Bore
ENGINE - SERVICING LK30 7.3.6 CYLINDER BORE A. CYLINDER BORE DIAMETER 1. Measure the cylinder liner I.D. at sit positions shown in the figure to find the maximum wear. Item Specified Cylinder liner I.D. 85.000 ~ 85.022 mm 3.3465 ~ 3.3473 in. 265W279A 265W280A (A) Axial direction...
Page 130: Lubricating System
ENGINE - SERVICING LK30 7.3.7 LUBRICATING SYSTEM A. ROTOR AND LOBE CLEARANCE OF OIL PUMP 1. Measure the clearance between the outer and in- ner rotor with a feeler gauge. 2. Measure the clearance between the outer and the housing with a feeler gauge. 3.
Page 131: Cooling System
ENGINE - SERVICING LK30 7.3.8 COOLING SYSTEM A. THERMOSTAT 1. Remove the thermostat cover (2). 2. Take out the thermostat (1). (When reassembling) • Apply liquid gasket (Three Bond 1215 or equivalent) to the gasket. 265W289A (1) Thermostat (2) Thermostat cover B.
Page 132 ENGINE - SERVICING LK30 C. SERVICING THERMOSTAT VALVE OPENING TEMPERATURE 1. Suspend the thermostat in the water by a string with its end inserted between the valve and seat. 2. Heating the water gradually, read the temperature when the valve opens and then when the valve opens to approx.
Page 133: Injection Nozzle
ENGINE - SERVICING LK30 7.3.9 INJECTION NOZZLE CAUTION • Prevent contact with spraying diesel fuel under pressure, pressure, which can have sufficient force to penetrate the skin, causing serious per- sonal injury. • Be sure no one is in direction of the spray. A.
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Page 135 LK30 CLUTCH TABLE OF CONTENTS 1. SPECIFICATIONS ........3-2 5.1.8 Disassembling clutch assembly ........... 3-11 2. OPERATION PRINCIPLE ......3-3 5.1.9 Clutch release hub and clutch 3. TROUBLESHOOTING ........3-5 lever ..........3-11 5.2 Inspection for overhaul ....... 3-12 4. CHECKING AND ADJUSTMENT ....3-6 5.2.1 Release lever height ....
Page 136: Specifications
CLUTCH - SPECIFICATIONS LK30 1. SPECIFICATIONS Item Reference Value Allowable Limit Clutch pedal free play 20 ~ 30 mm 0.79 ~ 1.18 in. 3.0 ~ 4.0 mm Safety switch pedal movement (When depressing clutch pedal to the stroke end) 0.0118 ~ 0.0157 in. Clutch disc O.D 225 mm 8.86 in.
Page 137: Operation Principle
CLUTCH - OPERATION PRINCIPLE LK30 2. OPERATION PRINCIPLE 265W301B (1) Flywheel (7) Release fork (13) Joint pin (2) Pressure plate (PTO) (8) Clutch disc (PTO) (14) Release lever (3) Adjusting bolt (9) Clutch spring (15) Adjusting bolt (4) Clutch cover 1 (10) Clutch disc (Traveling) (16) Release bearing (5) Pressure plate (traveling)
Page 138 CLUTCH - OPERATION PRINCIPLE LK30 A. TRAVELING CLUTCH “ENGAGED” / PTO C. TRAVELING CLUTCH “DISENGAGED” / PTO CLUTCH “ENGAGED” CLUTCH “DISENGAGED” When the clutch pedal is not depressed, there is a When the clutch pedal is depressed to the full stroke, certain amount of clearance between the release bear- the pressure plate (2) moves together with the pres- ing (16) and the adjusting bolt (15) mounted on the...
Page 139: Troubleshooting
CLUTCH - TROUBLESHOOTING LK30 3. TROUBLESHOOTING Symptom Probable Cause Solution Clutch drags • Clutch pedal free play excessive Adjust • Clutch release lever improperly adjusted Adjust • Clutch disc boss spline sticking or rusted Replace or remove rust • Dust on clutch disc generated from clutch disc facing Remove rust •...
Page 140: Checking And Adjustment
CLUTCH - CHECKING AND ADJUSTMENT LK30 4. CHECKING AND ADJUSTMENT 4.1 CLUTCH PEDAL PLAY ADJUST- MENT 1. Press clutch pedal (1) by hand and measure (A) at the end of pedal. 2. If the measurement is not within the factory specifications, loosen lock nut (3), of clutch rod (2), adjust the clutch rod (2) length.
Page 141: Servicing
CLUTCH - SERVICING LK30 5. SERVICING 5.1 DISASSEMBLING AND ASSEMBLING 5.1.1 CHANGING TRANSMISSION FLUID CAUTION To avoid personal injury: • 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 transmission case and drain the oil completely into the oil pan.
Page 142: Hydraulic Pipe And Electric Wiring
CLUTCH - SERVICING LK30 5.1.3 HYDRAULIC PIPE AND ELECTRIC WIRING 1. Remove the throttle rod. 2. Disconnect the engine accelerator wire (1). 3. Disconnect the tachometer cable (2). 4. Disconnect the fuel hose (3). 5. Remove the inlet pipe1 (4). 6.
Page 143: Propeller Shaft
CLUTCH - SERVICING LK30 5.1.4 PROPELLER SHAFT 1. Remove the bolts, which mount propeller shaft cover1 (4), 2 (5) and slide the covers toward the inside. (When reassembling) • Apply grease to the splines of the propeller shaft. 265W310B (1) Propeller shaft (6) O-ring (2) Coupling (7) O-ring...
Page 144: Disassembling The Clutch
CLUTCH - SERVICING LK30 5.1.6 DISASSEMBLING THE CLUTCH 1. Insert the clutch center tool. 2. Remove the clutch assembly. Daedong special tool kit: G0611-40271 30 12 704W313C This would be good place to include the part or 265W312A may notes for this tool.
Page 145: Disassembling Clutch Assembly
CLUTCH - SERVICING LK30 5.1.8 DISASSEMBLING CLUTCH ASSEMBLY 1. Draw out the split pins, plain washer, and joint pin from the release lever kits. 2. Loosen the tightened screws and the three adjust- ing screws. Remove the clutch covers. 3. Remove the clutch cover 2 (8), diaphragm spring (3), pressure plate 2 (6) and clutch disc assembly (driving) (5) in order.
Page 146: Inspection For Overhaul
CLUTCH - SERVICING LK30 5.2 INSPECTION FOR OVERHAUL 5.2.1 RELEASE LEVER HEIGHT 1. Measure the height from the clutch cover to the top of the adjusting screws with a scale or vernier calipers. 2. If the height exceeds the allowable limit; check the clutch disc, pressure plate and other parts.
Page 147: Clearance Between Traveling Pressure Plate And Adjusting Screw
CLUTCH - SERVICING LK30 5.2.3 CLEARANCE BETWEEN TRAVELING PRESSURE PLATE AND ADJUSTING SCREW 1. Measure the clearance between traveling pressure plate and the bottom of the head of adjusting screw with a feeler gauge. 2. If the clearance is not within the factory specifications, loosen the lock nut and rotate adjusting screw to adjust.
Page 148: Pressure Plate Flatness
CLUTCH - SERVICING LK30 5.2.6 PRESSURE PLATE FLATNESS 1. Place a straightedge (1) on the pressure plate and measure clearance with a feeler gauge (2) at sev- eral points. 2. If the clearance exceeds the allowable limit, replace it. 3. When the pressure plate is worn around its outside and its inside surface only is in contact with the straightedge, replace it even if the clearance is within the allowable limit.
Page 149: Thrust Ball Bearing
CLUTCH - SERVICING LK30 5.2.9 THRUST BALL BEARING 1. Check the contacted is worn excessive wear. 2. With inner wheel seized and outer wheel loaded, check for abnormal noise or operation. 3. If faulty, replace it. CAUTION • When assembling bearing, take care that the outer wheel is not shocked.
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Page 151 LK30 TRANSMISSION TABLE OF CONTENTS 1. SPECIFICATIONS ........4-2 4.1.11 Clutch release hub and release fork .......... 4-19 2. OPERATING PRINCIPLE ......4-3 4.1.12 Main shift cover assemble ..4-20 2.1 Power train diagram ......4-3 4.1.13 Main shift group ..... 4-21 2.2 Power train ..........
Page 152: Specifications
TRANSMISSION - SPECIFICATIONS LK30 1. SPECIFICATIONS Item Reference Value Allowable Limit Spiral bevel gear pinion turning torque 1.96 ~ 2.94 Nm 0.2 ~ 0.3 kgf-m 1.446 ~ 2.169 lb-ft PTO shaft lock nut tightening torque 147.0 ~ 196.1 Nm 15 ~ 20 kgf-m 108.49 ~ 144.65 lb-ft Differential pinion to Backlash between...
Page 153: Operating Principle
TRANSMISSION - OPERATING PRINCIPLE LK30 2. OPERATING PRINCIPLE 2.1 POWER TRAIN DIAGRAM Range Gear Shift Section PTO Shift Section Main Gear Shift Section Shuttle Shift Section Front Wheel Drive Section 265W401B SS41-W01 May. 2007...
Page 155: Power Train
TRANSMISSION - OPERATING PRINCIPLE LK30 2.2 POWER TRAIN The transmission consists of a series of gears and shaft as shown previously. It offers the most suitable speed for traveling and operation by combination of these gears. It transmits power to the front axle, rear axle and PTO shaft. LK30 is equipped a transmission with 8 forwards and 8 reverses.
Page 156 TRANSMISSION - MANUAL TRANSMISSION MODEL LK30 B. SYNCHRO OPERATION 1ST STAGE • When shifting the main transmission shift lever, the shifter (3) and key (2) are moved. The end of the key contacts the cone of the gear (6) and the synchro- nizer ring (5) is pushed.
Page 157: Shuttle Shift Section
TRANSMISSION - MANUAL TRANSMISSION MODEL LK30 2.2.2 SHUTTLE SHIFT SECTION The standard 8 x 8 gear transmission, consists of four forward speeds and four reverse in the main transmis- sion gearbox. A two speed range gearbox provides two speed ratios for each of the main transmission gears for a total of eight forward and eight reverse speeds.
Page 158: Range Gear Shift Section
TRANSMISSION - MANUAL TRANSMISSION MODEL LK30 2.2.3 RANGE GEAR SHIFT SECTION 265W407B (1) 15T gear shaft (4) 17T gear (7) 44T gear (2) 27T gear (5) Shifter (L) Low (3) Spiral bevel pinion shaft (6) Spline boss (H) High With high/low stage, employs constant-mesh type shift mechanism and when setting high-low shift lever to transmission position, the power will be transmitted.
Page 159: Front Wheel Drive Section
TRANSMISSION - MANUAL TRANSMISSION MODEL LK30 2.2.4 FRONT WHEEL DRIVE SECTION Either four wheel drive or two wheel drive is selected by operating the front wheel drive lever to shift the shift gear (3). When the front wheel drive lever is set to disengaged, the front wheel gear is in neutral and power is not trans- mitted to the front wheel drive shaft (4).
Page 160: Differential Gear
TRANSMISSION - OPERATING PRINCIPLE LK30 2.3 DIFFERENTIAL GEAR 2.3.1 STRUCTURE 14,15,16 22,23,24 2~18 27,18 22,23,24 14,15,16 22,23,24 22,23,24 265W473B (1) Assembly, diff rear (11) Washer (20) Case, bearing LH (2) Case, differential system (12) Gear, diff (RH) (21) Bolt (3) Cap, differential (13) Gear, diff (LH) (22) Shim 0.2 (4) Pin, straight...
Page 161 TRANSMISSION - OPERATING PRINCIPLE LK30 A. DURING STRAIGHT RUNNING Rotation of the spiral bevel pinion (2) is transmitted to the spiral bevel gear (1) and differential case (4). When road resistance to right and left wheels are equal, differential pinions (3) and differential side gears (5) are all rotates as a unit.
Page 162 TRANSMISSION - OPERATING PRINCIPLE LK30 C. DIFFERENTIAL LOCK When resistance to the right and left tires is different due to ground conditions or type of work, the wheel with less resistance slips and prevents the tractor moving ahead. To compensate for this, the differential lock restricts the differential action and causes both rear axles to rotate as a unit.
Page 163: Trouble Shooting
TRANSMISSION - TROUBLE SHOOTING LK30 3. TROUBLE SHOOTING Symptom Probable Cause Solution Noise from • Transmission fluid insufficient Replenish transmission • Gear worn or backlash improper Replace • Improper backlash between bevel pinion shaft and Adjust bevel gear • Improper backlash between differential pinion and Adjust side gear •...
Page 164: Servicing
TRANSMISSION - SERVICING LK30 4. SERVICING 4.1 DISASSEMBLING AND ASSEMBLING OF THE CLUTCH HOUSING 4.1.1 CHANGING TRANSMISSION FLUID CAUTION To avoid personal injury: • 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 transmission case and drain the oil completely into the oil pan.
Page 165: Bonnet
TRANSMISSION - SERVICING LK30 4.1.2 BONNET 1. Loosen the butterfly bolt and then remove the front grill. 2. Open the bonnet. 3. Remove the side cover. 4. Disconnect the light wire harness assembly. 5. Loosen the bolts and nuts, and bonnet assembly. 6.
Page 166: Propeller Shaft
TRANSMISSION - SERVICING LK30 4.1.4 PROPELLER SHAFT 1. Remover the bolts, which mount propeller shaft cover 1 (4), 2 (5) and slide the covers toward the inside. (When reassembling) • Apply grease to the splines of the propeller shaft. 265W415B (1) Propeller shaft (6) O-ring (2) Coupling...
Page 167: Fuel Tank
TRANSMISSION - SERVICING LK30 4.1.6 FUEL TANK 1. Remove the steering wheel cap. 2. Loosen the nut and tap out the steering wheel (1). 3. Loosen bolts and remove the instrument cover (rear) (2) and then disconnect the wire connector. 4.
Page 168: Disassemble The Steering Unit And Hydraulic Block
TRANSMISSION - SERVICING LK30 4.1.8 DISASSEMBLE THE STEERING UNIT AND HYDRAULIC BLOCK 1. Loosen the joint pipe and then steering hose (L, R) (1), delivery pipe (2) and return pipe (3). 2. Loosen the bolts and then remove the power-steering unit assembly (4).
Page 169: Disassemble The Clutch Housing
TRANSMISSION - SERVICING LK30 4.1.10 DISASSEMBLE THE CLUTCH HOUSING 1. Remove the split pin, plain washer and clutch rod assembly (1). 2. Disconnect the brake rod (2). 3. Loosen the bolts and remove the clutch hosing (3). (When reassembling) • Be sure to replace the gasket with a new one.
Page 170: Main Shift Cover Assemble
TRANSMISSION - SERVICING LK30 4.1.12 MAIN SHIFT COVER ASSEMBLE 1. Loosen the bolts (2) and remove the cover assemble (1). 2. Remove the bolt (3) and tongue washer (4). 3. Remove the shift lever (6), shift arm and etc.. (When reassembling) •...
Page 171: Main Shift Group
TRANSMISSION - SERVICING LK30 4.1.13 MAIN SHIFT GROUP 265W425A (1) Snap ring (10) Main shaft (19) Thrust collar (27) Synchro hub (2) Snap ring (11) 21 gear (20) Counter shaft (28) Inner ring (3) Ball bearing (12) Spacer (21) Inner ring (29) 46 gear (4) PTO driving shaft 1 (13) 27 gear...
Page 172: Disassemble The Middle Case
TRANSMISSION - SERVICING LK30 4.1.14 DISASSEMBLE THE MIDDLE CASE 265W427A 265W426A (1) Brake(LH) pedal (5) Spacer (9) Grease nipple (13) Stud bolt (2) Spring pin (6) Bushing (10) Stopper spring (14) Middle case (3) Brake (RH) pedal (7) Clutch pedal (11) Nut (15) Packing (4) Snap ring...
Page 173: Shuttle Shift Gear Group
TRANSMISSION - SERVICING LK30 4.1.15 SHUTTLE SHIFT GEAR GROUP 265W428A (1) Bolt (9) Thust collar (17) 38 gear (25) Needle bearing (2) Cover (10) Shuttle counter shaft (18) Ball bearing (26) Snap ring (3) Packing (11) Needle bearing (19) Bolt (27) Washer (4) Bolt (12) Snap ring...
Page 174: Shuttle Shift Fork
TRANSMISSION - SERVICING LK30 4.1.16 SHUTTLE SHIFT FORK 265W429A (1) Nut (5) Bolt (9) Spring (13) Stopper (2) Spring washer (6) Stopper (10) Ball (14) O-ring (3) Plain washer (7) Shuttle fork rod (11) Shuttle shfter arm (A) Alignment marks (4) Shuttle lever 1 (8) Shuttle fork (12) Bolt...
Page 175: Separate The Transmission Case
TRANSMISSION - SERVICING LK30 4.2 SEPARATE THE TRANSMISSION CASE 4.2.1 ROPS 1. Remove the snap pin, plain washer and check chain from the ROPS support. 2. Loosen the bolts and remove the ROPS support. 265W466B (1) Check chain (2) ROPS support 4.2.2 WHEEL 1.
Page 176: Point Link
TRANSMISSION - SERVICING LK30 4.2.4 3 POINT LINK 1. Remove the clip pin and disconnect the lift rod (1) from the hydraulic cylinder. 2. Loosen the bolt and remove the lower link pin. 3. Remove the lower link (2) and lift rod. 4.
Page 177 TRANSMISSION - SERVICING LK30 5. Loosen the pipe joint and remove the return tube (14). 6. Loosen the bolts and fender support (LH/RH). 7. Remove the split pin and plain washer from the feed back rod (9). 8. Loosen the bolts and remove the feed back rod (9) and control links (13).
Page 178: Rear Axle Case
TRANSMISSION - SERVICING LK30 4.2.6 REAR AXLE CASE 265W471B (1) Axle, rear (8) Gear,55 (15) Packing (22) O-ring (2) Bearing, ball (9) Spacer (16) Pin, straight (23) Bolt (3) Shaft, gear 10 RH (10) Spacer (17) Bolt (24) Plug (4) Shaft, gear 10 LH (11) Seal, oil (18) Stud (25) Bolt...
Page 179: Brake Case
TRANSMISSION - SERVICING LK30 4.2.7 BRAKE CASE 265W472B (1) Guide, ball (8) Plate (15) Case, brake RH (22) Stud (2) Pin, straight (9) Cam, brake (16) Packing (23) Stud (3) Ball, steel (10) O-ring (17) Packing (24) Bolt (4) Plate cam (RH) (11) Washer, plain (18) Pin, straight (25) Bolt, hex.
Page 180: Pto Shaft
TRANSMISSION - SERVICING LK30 4.2.8 PTO SHAFT 265W436A 265W437A (1) Bolt (9) Spring (17) Stud bolt (25) Shift (2) Stopper (10) Ball (18) 12-16 gear (26) Inner ring (3) PTO shift arm (11) Nut (19) Bolt bearing (27) 58 gear (4) O-ring (12) Spring washer (20) Ball bearing...
Page 181: Gear Shaft
TRANSMISSION - SERVICING LK30 4.2.9 15 GEAR SHAFT 1. Loosen the bolt and remove the bearing retainer. 2. Remove the snap ring and spacer. 3. Tap out the 15 gear shaft to the front. 4. Draw out the 27 gear and etc.. 265W438A (1) Bolt (6) 15 hear shaft...
Page 182: Differential System
TRANSMISSION - SERVICING LK30 4.2.11 DIFFERENTIAL SYSTEM 1. Remove the bearing case (LH), noting the number of left shims. 2. Take out the differential assembly, noting the num- ber of right shims. (When reassembling) • Check the 39 spiral bevel gear for wear or damage. If it is no longer serviceable, replace it.
Page 183: Front Drive Case
TRANSMISSION - SERVICING LK30 4.2.13 FRONT DRIVE CASE A. REMOVING FRONT DRIVE CASE 1. Remove the case (1). 2. Remove the snap ring (7). 3. Tap out the propeller shaft 1 (12) to the front. 4. Take out the 35 spur gear (17). (When reassembling) •...
Page 184 TRANSMISSION - SERVICING LK30 C. DIFFERENTIAL CASE COVER AND DIFFER- ENTIAL SIDE GEAR 1. Remove the differential case cover (3). 2. Remove the differential side gear (1) and differen- tial side gear washer (2). (When reassembling) • Apply liquid lock (Three bond 1372 or equivalent) to the differential case cover mounting screws.
Page 185 TRANSMISSION - SERVICING LK30 (When reassembling) • Check the differential pinion (2), (3) and pinion shaft (1), (5) or excessive wear. If these parts are dam- aged or excessively worn, replace the parts they are in mesh with, or they are sliding on. •...
Page 186: Servicing
TRANSMISSION - SERVICING LK30 4.3 SERVICING 4.3.1 BEARING, SHAFT AND GEAR A. CHECKING BEARING 1. Hold the inner race, and push and pull the outer race in all directions to check for wear and roughness. 2. Apply transmission fluid to the bearing, and hold the inner race.
Page 187 TRANSMISSION - SERVICING LK30 D. CLEARANCE BETWEEN GEAR AND SHAFT 1. Measure the shaft O.D. (rubbing surface). 2. Measure the gear I.D. (rubbing surface). 3. Measure the O.D. of the two needles installed di- agonally in the needle bearing. 4. Calculate the clearance. (Clearance = Gear I.D.
Page 188: Synchronized Gear
TRANSMISSION - SERVICING LK30 4.3.2 SYNCHRONIZED GEAR A. CHECKING CONTACT BETWEEN COU- PLING AND SHIFTER 1. Check to see if there is any flaw or wear on the spline of the coupling and shifter, and the key groove on the coupling. 2.
Page 189: Differential Gear
TRANSMISSION - SERVICING LK30 4.3.3 DIFFERENTIAL GEAR A. ADJUSTING TURNING TORQUE OF 9T BEVEL PINION SHAFT AND DIFFERENTIAL ASSEMBLY COMBINED 1. Install the differential assembly with left and right shims (4) same as before removing. Item Tightening torque Rearing case mounting 48.1 ~ 55.8 Nm screw and nut M10 (7T) 4.9 ~ 5.7 kgf-m...
Page 190 TRANSMISSION - SERVICING LK30 B. ADJUSTING BACKLASH AND TOOTH CON- TACT BETWEEN BEVEL GEAR AND 9T BEVEL PINION SHAFT 1. Set a dial indicator (lever type) with its finger on the tooth surface. 2. Measure the backlash by fixing the 9T bevel pinion shaft (2) and moving the bevel gear (5) by hand.
Page 191 TRANSMISSION - SERVICING LK30 The contact area should be over 35 % of the entire teeth area and the center of the contact mark should be close to the center of the pinion in height. Also, the center of the contact mark should be located on the 1/3 spot from the toe of the teeth to the center of the teeth in length.
Page 192 TRANSMISSION - SERVICING LK30 C. ADJUSTING TURNING TORQUE OF 9T BEVEL PINION SHAFT ONLY 1. Install the 9T bevel pinion shaft and tighten the stak- ing nut lightly. 2. After striking the shaft to the front and rear, adjust the turning torque of 9T bevel pinion shaft to the factory specifications by tightening the staking nut.
Page 193 TRANSMISSION - SERVICING LK30 E. CLEARANCE BETWEEN DIFFERENTIAL PINION SHAFT AND DIFFERENTIAL PINION 1. Measure the differential pinion shaft O.D 2. Measure the differential pinion I.D and calculate the clearance. 3. If the clearance exceeds the allowable limit, replace them. Factory spec.
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Page 195 LK30 REAR AXLE TABLE OF CONTENTS 1. SPECIFICAIONS ..............5-2 1.1 Differential gear ..............5-2 1.2 Tightening torques ............. 5-2 2. OPERATING PRINCIPLE ............5-3 2.1 Power train ................. 5-3 2.2 Principle of differential system ........5-4 2.3 Differential lock system ............ 5-6 3.
Page 196: Specificaions
REAR AXLE - SPECIFICAIONS LK30 1. SPECIFICAIONS 1.1 DIFFERENTIAL GEAR Item Factory specification Allowable Limit Differential case bore, differential case Clearance 0.050 ~ 0.151 mm 0.35 mm cover bore to differential case boss 0.0197 ~ 0.00594 in. 0.0138 in. Differential case bore I.D.
Page 197: Operating Principle
REAR AXLE - OPERATING PRINCIPLE LK30 2. OPERATING PRINCIPLE 2.1 POWER TRAIN 265W501A (1) Ball bearing (8) Spiral bevel gear (2) Rear axle (9) Differential pinion (3) Rear axle case (10) Final gear (4) Differential gear shaft (11) Differential lock shifter (5) Brake case (12) Differential case (6) Brake discs...
Page 198: Principle Of Differential System
REAR AXLE - OPERATING PRINCIPLE LK30 2.2 PRINCIPLE OF DIFFERENTIAL SYSTEM If two racks with same weight are set between the pin- ion as shown in the figure (A) and the pinion is lifted by pulling up the string attached to it as shown in the fig- ure (B), the pinion does not rotate and the pinion and both racks are lifted in the same height (H).
Page 199 REAR AXLE - OPERATING PRINCIPLE LK30 However, if the wheels on one side are on the slippery road, the load difference between both differential side gears remarkably increases and the self-rotating speed of differential pinion (3) considerably increases too. Therefore, the side gear (5) with very low load rotates at twice the speed and the side gear (6) with compara- tively high load does not rotate at all.
Page 200: Differential Lock System
REAR AXLE - OPERATING PRINCIPLE LK30 2.3 DIFFERENTIAL LOCK SYSTEM 265W501B The differential lock system is to solve such problems as described on the previous page. When the differen- tial lock lever is depressed, the differential fork shaft (1) rotates and the differential fork (2) moves to lock the differential system.
Page 201: Troubleshooting
REAR AXLE - TROUBLESHOOTING LK30 3. TROUBLESHOOTING Symptom Items Solution Excessive or unusual • Improper backlash between 9T spiral bevel pinion and Adjust noise at all times bevel gear. • Improper backlash between differential pinion and Adjust differential side gear. •...
Page 202: Servicing
REAR AXLE - SERVICING LK30 4. SERVICING 4.1 DRAINING TRANSMISSION OIL CAUTION To avoid personal injury: • 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 transmission case and drain the oil completely into the oil pan.
Page 203: Wheel
REAR AXLE - SERVICING LK30 4.1.2 WHEEL 1. Place disassembly stands under the transmission case and support each of them with jacks. 2. Loosen the bolts and nuts, and remove the rear wheels. Item Tightening torque Mounting nuts and bolts 196.13 ~ 225.55 Nm 20.0 ~ 23.0 kgf-m 144.66 ~ 166.36 lb-ft...
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Page 205 LK30 BRAKE TABLE OF CONTENTS 1. SPECIFICATIONS ..............6-2 1.1 Servicing specifications ............ 6-2 1.2 Tightening torque ............... 6-2 2. OPERATING PRINCIPLE ............6-3 2.1 Structure ................6-3 2.1.1 Operation ..............6-4 2.2 Features of wet disc brakes ..........6-5 3.
Page 206: Specifications
BRAKE - SPECIFICATIONS LK30 1. SPECIFICATIONS 1.1 SERVICING SPECIFICATIONS Item Factory Specifications Allowable Limit Brake pedal Free Play 20 ~ 25 mm 0.79 ~ 0.98 in. Right and left Difference Less than 5 mm 0.20 in. Brake pedal pedal shaft to bushing Clearance 0.010 ~ 0.15 mm 1.0 mm...
Page 207: Operating Principle
BRAKE - OPERATING PRINCIPLE LK30 2. OPERATING PRINCIPLE 2.1 STRUCTURE Independent mechanical wet disc brakes are used for the right and left traveling brakes. They are operated by the brake pedals through the mechanical linkages and provide stable braking and require little adjustment The parking brake is a mechanical type which is de- signed to actuate the traveling brakes through the linkage.
Page 208: Operation
BRAKE - OPERATING PRINCIPLE LK30 2.1.1 OPERATION 265W602B (1) Brake case (5) Cam plate (2) Brake cam lever (6) Brake disc (3) Brake cam (7) Plate (4) Brake shaft (8) Differential bearing case (Differential gear shaft) (9) Steel ball Power is transmitted through the brake shafts (4) to During Braking the final reduction system.
Page 209: Features Of Wet Disc Brakes
BRAKE - OPERATING PRINCIPLE LK30 2.2 FEATURES OF WET DISC BRAKES A. REDUCED DISC WEAR Although wet discs are worn by approximately several tens of microns depending on the initial contact in ini- tial period (50 hours or so) of use, almost no wear occurs afterwards.
Page 210: Troubleshooting
BRAKE - TROUBLESHOOTING LK30 3. TROUBLESHOOTING Solution Symptom Probable Cause Uneven braking force • Brake pedal play unevenly adjusted Adjust • Brake disc is worn Replace • Cam plate warped Replace Brake drags • Brake pedal play too small Adjust •...
Page 211: Servicing
BRAKE - SERVICING LK30 4. SERVICING 4.1 DISASSEMBLING AND ASSEMBLING 4.1.1 WHEEL 1. Place disassembly stands under the transmission case and support each of them with jacks. 2. Loosen the bolts and nuts, and remove the rear wheels. Item Tightening torque Mounting nuts and bolts 196.13 ~ 225.55 Nm 20.0 ~ 23.0 kgf-m...
Page 212: Disassemble The Brake Pedals
BRAKE - SERVICING LK30 4.1.4 DISASSEMBLE THE BRAKE PEDALS 1. Remove the split pin, plain washer, joint pin and, disconnect the brake rods and clutch rod. 2. Tap out the spring pin from the pedal shaft (LH). 3. Remove the snap ring, plain washer and draw out the brake pedal, pedal shaft and clutch pedal.
Page 213: Brake Disk Wear
BRAKE - SERVICING LK30 4.1.6 BRAKE DISK WEAR 1. Measure the brake disc thickness with venire calipers. 2. If the thickness is less than the allowable limit, re- place it. Item Factory spec. Allowable limit Brake disc 4.6 ~ 4.8 mm 4.2 mm thickness 0.181 ~ 0.189 in.
Page 214: Inspection For Overhaul
BRAKE - SERVICING LK30 4.2 INSPECTION FOR OVERHAUL 4.2.1 BRAKE CAM LEVER MOVEMENT 1. Move the brake cam lever by hand to check the movement. 2. If the movement is heavy, refine the brake cam with sandpaper. 265W610A (1) Brake case (2) Brake cam lever 4.2.2 CAM PLATE FLATNESS 1.
Page 215: Brake Disc Wear
BRAKE - SERVICING LK30 4.2.4 BRAKE DISC WEAR 1. Measure the brake disc thickness with vernier calipers. 2. If the thickness is less than the allowable limit, re- place it. Item Factory spec. Allowable limit 4.6 ~ 4.8 mm 4.2 mm Brake disc thickness 0.181 ~ 0.189 in.
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Page 217 LK30 FRONT AXLE TABLE OF CONTENTS 1. SPECIFICATIONS ......... 7-2 5.1.8 Disassembling bevel gear case gears ........7-13 2. OPERATING PRINCIPLE ......7-4 5.1.9 Disassembling axle ....7-13 2.1 Front axle structure ....... 7-4 5.1.10 Disassembling spiral bevel pinion 2.2 Wheel alignment ........7-5 shaft and differential gear assem- bly ..........
Page 218: Specifications
FRONT AXLE - SPECIFICATIONS LK30 1. SPECIFICATIONS Item Factory Specification Allowable Limit Front wheel alignment Toe-in 2 ~ 8 mm 0.08 ~ 0.31 in. Front wheel Axial sway Less than 5 mm 0.20 in. Front axle Rocking force 49.0 ~ 117.7 N 5.0 ~ 12.0 kgf 11.0 ~ 26.5 lbs Front axle case boss (front) to bracket...
Page 219 FRONT AXLE - SPECIFICATIONS LK30 Item Factory Specification Allowable Limit Spiral bevel pinion shaft (Pinion shaft only) Turning force 98.1 ~ 117.7 N 10 ~ 12 kgf 22.0 ~ 26.5 lbs Spiral bevel pinion shaft to spiral bevel gear Backlash 0.2 ~ 0.3 mm 0.0078 ~ 0.0118 in.
Page 220: Operating Principle
FRONT AXLE - OPERATING PRINCIPLE LK30 2. OPERATING PRINCIPLE 2.1 FRONT AXLE STRUCTURE 704W701A (1) Front bracket (7) Front axle cover (13) 11 bevel gear (2) Rear bracket (8) Front axle (14) 16 bevel gear (3) Center pin (9) Spiral bevel pinion shaft (15) Bevel gear shaft (4) Front axle support (10) Spiral bevel gear...
Page 221: Wheel Alignment
FRONT AXLE - OPERATING PRINCIPLE LK30 2.2 WHEEL ALIGNMENT To improve control and safety running, front wheel is applied with adequate inclination, called caster, camber, kingpin angle, and toe-in. 704W704A 704W702A 3. Kingpin angle reduces the rolling resistance of the 1.
Page 222: Troubleshooting
FRONT AXLE - TROUBLESHOOTING LK30 3. TROUBLESHOOTING Symptom Provable Causes Solution Front wheels wander to • Tire pressure uneven Adjust right or left • Improper toe-in adjustment (improper alignment) Adjust • Clearance between front axle case boss and front axle Replace bracket (front, rear) bushing excessive.
Page 223: Measurment And Adjusting
FRONT AXLE - MEASURMENT AND ADJUSTING LK30 4. MEASURMENT AND ADJUSTING 4.1 TOE-IN 1. Apply specified air pressure to the tires. 2. Measure the front width (A) and the rear width (B) between the front wheels while straightened to ob- tain the difference (toe-in).
Page 224: Axial Sway Of Front Wheel
FRONT AXLE - MEASURMENT AND ADJUSTING LK30 4.3 AXIAL SWAY OF FRONT WHEEL 1. Jack up the front side of tractor. 2. Set a dial gauge on the outside of the rim. 3. Turn the wheel slowly and read the runout of rim. 4.
Page 225: Servicing
FRONT AXLE - SERVICING LK30 5. SERVICING 5.1 DISASSEMBLING AND ASSEMBLING 5.1.1 DRAINING FRONT AXLE CASE OIL 1. Place oil pans underneath the front axle case. 2. Remove the drain plug (3) from both sides and fill- ing port plug (2) to drain the oil. 3.
Page 226: Disconnecting Propeller Shaft
FRONT AXLE - SERVICING LK30 5.1.3 DISCONNECTING PROPELLER SHAFT 1. Remove the bolts(10) from the propeller shaft cov- ers (5) & (4). Slide the covers to remove. 2. Tap out the spring pin (8), and then slide the cou- pling (2) to the rear. (When reassembling) •...
Page 227: Disassembling Front Axle
FRONT AXLE - SERVICING LK30 5.1.5 DISASSEMBLING FRONT AXLE 1. Place the jacks under the front axle, and hang up the bumper by a hoist to support it. 2. Remove the shaft bracket 1 mounting screws and shaft bracket 2 mounting screws. 3.
Page 228: Disassembling Bevel Gear Case, Front Differential Case And 42 Bevel Gear
FRONT AXLE - SERVICING LK30 5.1.7 DISASSEMBLING BEVEL GEAR CASE, FRONT DIFFERENTIAL CASE AND 42 BEVEL GEAR 704W717A (1) 42 bevel gear (7) 11 bevel gear (12) Snap ring (2) Shim (8) Bevel bearing (13) Bevel gear shaft (3) Snap ring (9) Floating seal (14) Bevel gear case (4) Plug...
Page 229: Disassembling Bevel Gear Case Gears
FRONT AXLE - SERVICING LK30 5.1.8 DISASSEMBLING BEVEL GEAR CASE GEARS 1. Remove the internal snap ring (1). 2. Take out the bevel gears (4), (7) with ball bearings (3), (6) and shims (2). (When reassembling) • Install the same shims (2) which you removed. 704W718A (1) Snap ring (5) Bevel gear case...
Page 230: Disassembling Spiral Bevel Pinion Shaft And Differential Gear Assembly
FRONT AXLE - SERVICING LK30 5.1.10 DISASSEMBLING SPIRAL BEVEL PINION SHAFT AND DIFFERENTIAL GEAR ASSEMBLY 1. Take out both sides of the differential gear shaft (12)& (13). 2. Remove the oil seal (7) and the internal snap ring (6). 3. Remove the plug (11), and then tap out the spiral bevel pinion shaft (3) using a brass rod and hammer.
Page 231: Pre-Load Of Taper Roller Bearing On Spiral Bevel Pinion Shaft
FRONT AXLE - SERVICING LK30 5.1.11 PRE-LOAD OF TAPER ROLLER BEAR- ING ON SPIRAL BEVEL PINION SHAFT IMPORTANT Cloth If measuring the pre-load of the bearing as- • sembled to the front axle as shown in the figure (A), measure it before inserting the oil seal and installing the 23 bevel gear.
Page 232: Disassembling Differential Gear
FRONT AXLE - SERVICING LK30 5.1.12 DISASSEMBLING DIFFERENTIAL GEAR 1. Put the shim (11) and the differential side gear (9) to the front differential case (1). 2. Install two differential pinions (7) and pinion wash- ers (8) while inserting the differential pinion shaft (5) to the differential case.
Page 233: Inspection For Overhaul
FRONT AXLE - SERVICING LK30 5.2 INSPECTION FOR OVERHAUL 5.2.1 CLEARANCE BETWEEN DIFFERENTIAL CASE AND DIFFERENTIAL SIDE GEAR 1. Measure the differential side gear boss O.D. 2. Measure the differential case bore I.D. and calcu- late the clearance. 3. Measure the differential case cover bore I.D. and calculate the clearance.
Page 234: Backlash Between Differential Pinion And Differential Side Gear
FRONT AXLE - SERVICING LK30 5.2.3 BACKLASH BETWEEN DIFFERENTIAL PINION AND DIFFERENTIAL SIDE GEAR 1. Set a dial gauge (lever type) on a tooth of the differ- ential pinion. 2. Fix the differential side gear and move the differen- tial pinion to measure the backlash. 3.
Page 235: Backlash Between Spiral Bevel Pinion Shaft And Spiral Bevel Gear
FRONT AXLE - SERVICING LK30 5.2.5 BACKLASH BETWEEN SPIRAL BEVEL PINION SHAFT AND SPIRAL BEVEL GEAR 1. Set a dial gauge (lever type) with its finger on the spline of spiral bevel pinion shaft. 2. Measure the backlash by moving the spiral bevel pinion shaft by hand lightly.
Page 236: Backlash Between 11 Bevel Gear And 16 Bevel Gear
FRONT AXLE - SERVICING LK30 5.2.6 BACKLASH BETWEEN 11 BEVEL GEAR AND 16 BEVEL GEAR 1. Stick a strip of plastic gauge to three spots on the 16 bevel gear (1) with grease. 2. Fix the front axle case, bevel gear case and front gear case.
Page 237: Clearance Between Front Axle Case Bosses And Bracket Bushings
FRONT AXLE - SERVICING LK30 5.2.8 CLEARANCE BETWEEN FRONT AXLE CASE BOSSES AND BRACKET BUSHINGS 1. Measure the front axle case bosses O.D. with an outside micrometer. 2. Measure the bracket bushing I.D. with an inside mi- crometer and calculate the clearance. 3.
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Page 239 LK30 STEERING SYSTEM TABLE OF CONTENTS 1. SPECIFICATIONS ........8-2 3. TROUBLESHOOTING ........ 8-11 2. OPERATING PRINCIPLE ......8-3 4. SERVICING ..........8-12 2.1 Hydraulic schematic ......8-3 4.1 Separating the steering unit ....8-12 2.2 Hydraulic circuit diagram ..... 8-4 4.2 Disassembling the steering unit ..
Page 240: Specifications
STEERING SYSTEM - SPECIFICATIONS LK30 1. SPECIFICATIONS Item Reference Value Hydraulic pump Type Gear Pump capacity 12.7 cc/rev Pump gear ratio Power steering unit Power steering unit volume 51 cc/rev Relief pressure 120 ~ 127 kgf/cm 11.8 ~ 12.54 MPa Steering cylinder Tube O.D.
Page 241: Operating Principle
STEERING SYSTEM - OPERATING PRINCIPLE LK30 2. OPERATING PRINCIPLE 2.1 HYDRAULIC SCHEMATIC In&out 265W801B (1) Hydraulic filter (4) Power steering unit (2) Hydraulic pump (5) Control valve (3) Hydraulic block The steering system is hydrostatic. It includes a power The power steering motor has a relief valve for protect- steering motor, hydraulic relief assembly, and a steer- ing the hydraulic circuit.
Page 242: Hydraulic Circuit Diagram
STEERING SYSTEM - OPERATING PRINCIPLE LK30 2.2 HYDRAULIC CIRCUIT DIAGRAM 2.2.1 HYDRAULIC OIL FLOW • The hydraulic pump, driven by the engine, will pass the transmission case oil through a valve to the power steering unit. • When the steering wheel control is activated, oil is passed through the Gerotor to steering cylinder.
Page 243: Operation
STEERING SYSTEM - OPERATING PRINCIPLE LK30 2.3 OPERATION 2.3.1 NEUTRAL POSITION If the steering wheel is not rotated, the valve plate (3) stays in neutral because of the centering spring (4). Oil flow is formed between port p (from pump) of the control valve and port T of the transmission case.
Page 244: Left Turn
STEERING SYSTEM - OPERATING PRINCIPLE LK30 2.3.3 LEFT TURN The steering system operates the same when rotating to the left as it does to the right, except for the flow in and out. 120Kg 265W809B P: Pump port R: Cylinder port R T: Tank port L: Cylinder port T (1) Steering controller...
Page 245: Operating Of Steering Unit
STEERING SYSTEM - OPERATING PRINCIPLE LK30 2.4 OPERATING OF STEERING UNIT T46W912A (1) Steering case assembly (9) Control valve assembly (16) Gerotor (2) Dust seal (9a) Relief valve (17) Star seal assembly (3) Retainer ring (10) Centering spring (18) Endcap (4) Seal gland bushing (11) Plain spring (19) Bolt...
Page 246: Power Steering Control Motor
STEERING SYSTEM - OPERATING PRINCIPLE LK30 2.4.1 POWER STEERING CONTROL MOTOR A. SPOOL AND SLEEVE D. CHECK VALVE The check valve normally remains closed, which pre- 1. The spool (22) and sleeve (23) consists of the ro- tary valve to selectively switch the fluid passage as vents the fluid from flowing from its inlet side to its well as the direction of the fluid flow.
Page 247: Steering Cylinder
STEERING SYSTEM - STRUCTURE LK30 2.5 STEERING CYLINDER 2.5.1 STRUCTURE 265W806A (1) Tube (6) Ring (A) Rod O.D. (2) Packing (7) Housing (B) Tube I.D. (3) Bush (8) Bearing (C) Tube O.D. (4) Dust seal (9) Snap ring (D) Stroke (5) Rod 2.5.2 MAJOR SPECIFICATION Stroke...
Page 248: Power Steering Unit
STEERING SYSTEM - STRUCTURE LK30 2.6 POWER STEERING UNIT 2.6.1 POWER STEERING UNIT SPEC. Item Factory spec. 12.7 cc/rev Power steering unit volume Relief pressure 11.8 Mpa 120 kgf/cm 1711.44 psi 265W805A 2.6.2 STRUCTURE AND OPERATION The power steering system described in this Section is standard equipment for all model tractors.
Page 249: Troubleshooting
STEERING SYSTEM - TROUBLESHOOTING LK30 3. TROUBLESHOOTING Provable Causes Symptom Solution Excessive • Backlash between sector gear shaft and ball nut too large Adjust steering wheel • Steering linkage worn Replace play • Sector gear shaft worn Replace • Centering spring weaken or broken Replace Tractor pulls to •...
Page 250: Servicing
STEERING SYSTEM - SERVICING LK30 4. SERVICING 4.1 SEPARATING THE STEERING UNIT 1. Remove the instrument cover support and then dis- connect the connectors. 2. Loosen the joint pipe and then steering hose (T, P, L, R) (1). 3. Loosen the bolts (2) and then remove the power- steering unit assembly (3).
Page 251: Disassembling The Steering Unit
STEERING SYSTEM - SERVICING LK30 4.2 DISASSEMBLING THE STEERING UNIT 265W818A (1) Screw (8) Spacer plate (15) Spool (22) Spring (2) End cap (9) O-ring (16) Stop ring (23) Poppet (3) O-ring (10) Rotor (17) Retainer ring (24) O-ring (4) Stator (11) Drive (18) Bearingless (25) Plug...
Page 252 STEERING SYSTEM - SERVICING LK30 3. Loosen 7 screws (1). 4. Remove end cap (2). 5. Remove O-ring (3) out of the end cap. 265W820A (1) Screw (3) O-ring (2) Endcap 6. Take out spacers (5), (7) and O-ring (6) located in- side the inner spline of the rotor (10) in gerotor (4).
Page 253 STEERING SYSTEM - SERVICING LK30 11. Take out the spool and sleeve assembly at the op- posite side to the flange of the housing while push- ing the inner spline of the spool with the thumb. Be careful not to allow the circumference of the sleeve to be stuck in the inner bore of the housing this time.
Page 254: To Disassemble The Relief Valve
STEERING SYSTEM - SERVICING LK30 4.2.2 TO DISASSEMBLE THE RELIEF VALVE 1. Loosen retainer screw (1) on plug (25) area of hous- ing (20) and take out retainer pin (2) and ball (3). 2. Loosen relief adjusting plug (25) with the flange face of housing (20) upward and remove O-ring (24).
Page 255 STEERING SYSTEM - SERVICING LK30 3. While turning around spool (11), insert it slowly into sleeve (10), Take up the spline area to the spool to check if the spool turns lightly inside the sleeve. 265W829A (10) Sleeve (A) Positioning marks (11) Spool (D) Spring slot 4.
Page 256 STEERING SYSTEM - SERVICING LK30 6. Insert pin (13) onto the sleeve groove and insert the spool and sleeve assembly from the gerotor side of the housing. CAUTION • Check if the spool and sleeve assembly turns lightly inside the housing. 7.
Page 257: To Assemble The Relief Valve
STEERING SYSTEM - SERVICING LK30 4.2.4 TO ASSEMBLE THE RELIEF VALVE 1. Pick up the spring guide part with a pin set to insert poppet (21) into the flange area of the housing. 2. Insert spring (22) and damper collar (23). 3.
Page 258: Disassembling The Steering Cylinder
STEERING SYSTEM - SERVICING LK30 4.3 DISASSEMBLING THE STEERING CYLINDER 1. Disconnect the steering hoses (1, 2) 2. Pull out the split pin (5) and remove the nut (6). 3. Tap the end of support pin using a plastic hammer. Pull out the support pin from the front axle case.
Page 259: Checking The Operating
STEERING SYSTEM - SERVICING LK30 4.4 CHECKING THE OPERATING 4.4.1 STEERING WHEEL CLEARANCE IMPORTANT • Before disassembling the power steering system, check the performance of hydraulic relief assem- bly and power steering motor using a hydraulic tester. • Do not disassemble the power steering motor needlessly.
Page 260 MEMO ...............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 261 LK30 HYDRAULIC SYSTEM TABLE OF CONTENTS 1. SPECIFICATIONS ........9-2 4. SERVICING ..........9-11 1.1 Oil pressure relief assembly ....9-2 4.1 Location of hydraulic system components .............. 9-11 1.2 Hydraulic cylinder ......... 9-2 4.2 Hydraulic pump ........9-12 1.3 Control linkage ........9-2 4.2.1 Disassembly of gear pump ..
Page 262: Specifications
HYDRAULIC SYSTEM - SPECIFICATIONS LK30 1. SPECIFICATIONS 1.1 OIL PRESSURE RELIEF ASSEMBLY Item Factory Specification Allowable Limit Setting pressure 15.2 ~ 15.7 MPa Relief valve Condition 155 ~ 160 kgf/cm Engine speed maximum 2,205 ~ 2,276 psi Oil temperature 40 ~ 60 °C 104 ~ 140 °F Auxiliary hydraulics Max.
Page 263: Operating Principle
HYDRAULIC SYSTEM - OPERATING PRINCIPLE LK30 2. OPERATING PRINCIPLE 2.1 HYDRAULIC CIRCUIT Steering Cylinder Steering Unit Gear Pump 265W901A SS41-W00 May. 2007...
Page 264: Hydraulic Circuit Diagram
HYDRAULIC SYSTEM - OPERATING PRINCIPLE LK30 2.2 HYDRAULIC CIRCUIT DIAGRAM Steering Cylinder Steering Unit Return Gear Pump 265W902A SS41-W00 May. 2007...
Page 265: Hydraulic Pump
HYDRAULIC SYSTEM - OPERATING PRINCIPLE LK30 2.3 HYDRAULIC PUMP 2.3.1 LOCATION AND STRUCTURE OF GEAR PUMP Location Gear pump 265W903A The hydraulic pump is driven by the fuel camshaft in 2.3.2 HYDRAULIC PUMP SPECIFICATIONS the engine. The fuel camshaft rotates at one half of the engine Specifications for hydraulic pump speed.
Page 266: Oil Filter
HYDRAULIC SYSTEM - OPERATING PRINCIPLE LK30 2.4 OIL FILTER 265W905A 2.4.1 STRUCTURE OF OIL FILTER The suction filter (1) is a canister-type filter and should be replace after 200 hour of use. There is a permanent magnet installed on the center of the element of the hydraulic filter on the inlet hydrau- lic pump and the filter mounted on the hydraulic lift is structured.
Page 267: Position Control
HYDRAULIC SYSTEM - OPERATING PRINCIPLE LK30 2.5 POSITION CONTROL Position control is a system to move the implement up and down using the position control valve and feed- back link mechanism. The position of implement is determined by the position of the control lever. With this system, an implement can be set to any de- sired point by changing the position of the lever, and fine adjustment is also easy.
Page 268: High Pressure Relief Valve
HYDRAULIC SYSTEM - OPERATING PRINCIPLE LK30 2.6 HIGH PRESSURE RELIEF VALVE The high pressure relief assembly enables the use of hydraulic implements. One circuit from pump activates hydraulic raising and lowering. The other controls the power steering. A high pressure relief assembly should be used when both the 3-point linkage and the auxiliary hydraulics are required.
Page 269: Hydraulic Cylinder
HYDRAULIC SYSTEM - OPERATING PRINCIPLE LK30 2.7 HYDRAULIC CYLINDER 265W909B (1) Down speed adjusting valve (7) Position control valve (3-point control valve) (2) Adjusting collar (8) Hydraulic arm (3) Hydraulic cylinder cover (9) Hydraulic arm shaft (rock shaft) (4) O-ring (10) Lift arm (5) Hydraulic piston (11) Breather...
Page 270: Troubleshooting
HYDRAULIC SYSTEM - TROUBLESHOOTING LK30 3. TROUBLESHOOTING Symptom Provable Causes Solution Adjust Implement dose not • Control linkage improperly adjusted rise Repair or replace • Control linkage improperly assembled or damaged (no sound emitted) Repair or replace • Control valve malfunctioning (Unload valve, spool, check valve, poppet valve) Replace •...
Page 271: Servicing
HYDRAULIC SYSTEM - SERVICING LK30 4. SERVICING 4.1 LOCATION OF HYDRAULIC SYSTEM COMPONENTS Hydraulic pump Hydraulic filter Hydraulic block 265W909A SS41-W00 May. 2007 9-11...
Page 272: Hydraulic Pump
HYDRAULIC SYSTEM - SERVICING LK30 4.2 HYDRAULIC PUMP 1. Disconnect the hoses (1, 2) from the suction tube (B). Then, disconnect the pipes (3, 4). Item Tightening torque Pipe mounting bolt 16 Nm (3, 4) 1.6 kgf-m 11.8 lb-ft 265W910A 2.
Page 273: Disassembly Of Gear Pump
HYDRAULIC SYSTEM - SERVICING LK30 4.2.1 DISASSEMBLY OF GEAR PUMP 265W912A (1) Gear pump assembly (7) Drive gear shaft (13) Seal (18) Flange (2) 1st pump body (8) Driven gear (14) Retainer (19) Connecting shaft (3) Front cover (nose) (9) Driven gear (15) Snap ring (20) Dowel pin (4) Rear cover...
Page 274 HYDRAULIC SYSTEM - SERVICING LK30 A. INSPECTION Gear traces 1. Check the gear trace in the housing. • It is normal if there is some gear tracing. The trace in the suction side is severer than that in the discharge side. •...
Page 275 HYDRAULIC SYSTEM - SERVICING LK30 B. REMOVAL AND INSTALLATION REMOVAL CAUTION • The hydraulic pump can be disassembled and reassembled. However, only qualified KIOTI tech- nicians should disassemble and assemble the hy- draulic pump with proper tools. Alignment • Before assembling the components, clean all the mark components and replace the seals with new ones if possible.
Page 276 HYDRAULIC SYSTEM - SERVICING LK30 4. Remove the thrust block (3) from the secondary pump. 265W920A 5. Remove the drivegear (4) and drivegear (5) from the secondary pump. 265W921A 6. Remove the thrust block (6) and connecting shaft (7) from the main pump body. 265W922A 9-16 SS41-W00 May.
Page 277 HYDRAULIC SYSTEM - SERVICING LK30 7. Remove the flange (8) between the primary pump body and the secondary pump body. 265W923A 8. Remove the primary pump body (9). 265W924A 9. Remove the thrust block (A), drive gear shaft (B) and driven gear (c) from the primary pump. 265W925A 10.Remove the snap ring (1) and retainer (2) from the front cover.
Page 278: Installation
HYDRAULIC SYSTEM - SERVICING LK30 4.2.2 INSTALLATION CAUTION • Make sure that the gears of the primary and sec- ondary pumps and the thrust block are installed in the correct direction. 265W927A 1. Install the retainer ring and the snap ring to the front cover.
Page 279 HYDRAULIC SYSTEM - SERVICING LK30 4. Install the thrust block with its seal toward the flange. 265W931A 5. Fit the flange aligning it to the dowel pin and install the connecting shaft. 265W932A 6. Install the secondary pump body and install the in- ternal components following the same procedures as primary pump.
Page 280 HYDRAULIC SYSTEM - SERVICING LK30 7. Install the rear cover aligning it to the dowel pin. 265W934A 8. Tighten the mounting bolt of the hydraulic pump to the specified torque. Item Tightening torque Mounting bolt 50 Nm 5.0 kgf-m 36.8 lb-ft 265W935A 9-20 SS41-W00 May.
Page 281: Hydraulic Block
HYDRAULIC SYSTEM - SERVICING LK30 4.3 HYDRAULIC BLOCK 1. Disconnect the delivery pipe 1 (1) and delivery pipe 2 (2). 2. Remove the return pipe (3). 3. Remove the hydraulic block mounting bolts (4), and remove the hydraulic block (5). (When reassembling) •...
Page 282: Directional Valve And Cap
HYDRAULIC SYSTEM - SERVICING LK30 4.3.1 DIRECTIONAL VALVE AND CAP 1. Remove the mounting snap ring (1) from the direc- tional valve spool shaft. 2. Remove the spool shaft (2) from the valve body. Cross flow Oil hole 265W937A CAUTION •...
Page 283: Relief Valve
HYDRAULIC SYSTEM - SERVICING LK30 4.3.2 RELIEF VALVE 1. Unscrew the relief valve and remove it from the hy- draulic valve body. Relief Valve 265W940A 2. Unscrew the relief valve cap (1) and remove the components in the relief valve in order. (When reassembling) •...
Page 284: Position Control Valve
HYDRAULIC SYSTEM - SERVICING LK30 4.4 POSITION CONTROL VALVE 4.4.1 REMOVING CONTROL VALVE (WITH HYDRAULIC CYLINDER BODY REMOVED FROM TRACTOR) 1. Remove the control valve assembly. NOTE: Do not loosen adjusting section at the end of the • spool unless necessary. (When reassembling) •...
Page 285: Hydraulic Cylinder
HYDRAULIC SYSTEM - SERVICING LK30 4.5 HYDRAULIC CYLINDER 4.5.1 DISASSEMBLING AND ASSEMBLING A. HYDRAULIC CYLINDER COVER AND PISTON 1. Remove the hydraulic cylinder cover. 2. Draw out the piston from the hydraulic cylinder. (When reassembling) • Install the piston, noting O-ring and backup ring. •...
Page 286: Servicing
HYDRAULIC SYSTEM - SERVICING LK30 4.6 SERVICING 4.6.1 HYDRAULIC CYLINDER BORE (WITH PISTON REMOVED) 1. Check the cylinder internal surface for scoring or Cylinder gauge damage. 1. Measure the cylinder I.D. with a cylinder gauge. 2. If the measurement exceeds the allowable limit, replace it.
Page 287 LK30 ELECTRIC SYSTEM TABLE OF CONTENTS 1. CIRCUIT AND COMPONENT LOCATION 10-3 3. TROUBLESHOOTING ......10-21 1.1 Circuit diagram ........10-3 4. SERVICING ..........10-23 1.2 Electric component location (LK30: 2007~) 4.1 Starting system ........ 10-23 ............. 10-4 4.1.1 Key switch ......10-23 1.3 Legend for circuit diagram ....
Page 289: Circuit And Component Location
ELECTRIC SYSTEM - CIRCUIT AND COMPONENT LOCATION LK30 1. CIRCUIT AND COMPONENT LOCATION 1.1 CIRCUIT DIAGRAM 5.0R 3.0RW OPTION 2.0Y TURN SIGNAL SWITCH 2.0Y 1.25Y 1.25Y 3.0R 5.0R 5.0R STARTER 3.0RW 0.85B WARNING LAMP SWITCH 3.0R STARTER SWITCH BRAKE RELAY SWICH HEAD LAMP SAFETY START SWITCH...
Page 290: Electric Component Location (Lk30: 2007~)
ELECTRIC SYSTEM - CIRCUIT AND COMPONENT LOCATION LK30 1.2 ELECTRIC COMPONENT LOCATION (LK30: 2007~) Engine (LH) Lamp Switch, Sensor, Sender Relay, Solenoid Other Components 2.Horn 1.Head Lamp 25.fuse box Engine (RH) 10.Engine temperature sensor 8.Preheat controller 18.Engine stop solenoid 25.fuse box 19.Diode 2.Horn 17.Battery...
Page 291: Legend For Circuit Diagram
ELECTRIC SYSTEM - CIRCUIT AND COMPONENT LOCATION LK30 1.3 LEGEND FOR CIRCUIT DIAGRAM 1.3.1 BATTERY A. DEFINITION B. CAUSE OF BATTERY EXPIRATION The causes for battery failure can be divided into the following three parts: 1. OVERLY DISCHARGED The specific gravity of electrolyte is too low and the terminal voltage is not measurable.
Page 292: Symbols For Electric Components
ELECTRIC SYSTEM - CIRCUIT AND COMPONENT LOCATION LK30 1.3.2 SYMBOLS FOR ELECTRIC COMPONENTS Symbol Description Symbol Description Single bulb Fuse Lamp Slow-blow fuse Double bulb Diode Motor Zener-diode Switch (Normally Open Type) (Light Emitting Diode) Switch (Normally Close Type) Compressor Photo Diode Ground (Wire) N.P.N Transistor...
Page 293: Checking Circuits
ELECTRIC SYSTEM - CIRCUIT AND COMPONENT LOCATION LK30 1.3.3 CHECKING CIRCUITS A. OVERVIEWS In general, it is not hard to inspect an electric circuit in a logical and organized way. It is very import to collect as much information as possible before starting an inspection.
Page 294 ELECTRIC SYSTEM - CIRCUIT AND COMPONENT LOCATION LK30 CONTINUITY TEST VOLTAGE TEST The continuity test is to find an open circuit. It is consid- Refer to the diagram on the previous page to analyze ered to be an open circuit if there is no ‘beep’ sound or an open circuit.
Page 295 ELECTRIC SYSTEM - CIRCUIT AND COMPONENT LOCATION LK30 C. SHORT CIRCUIT TEST Refer to the diagram below for better understanding of short circuit. Resistance test IGN "ON" Relay or "ST" Slow blow fuse Solenoid B+ power Short Short Short circuit (A) circuit (B) circuit (C) Voltage tester...
Page 296 ELECTRIC SYSTEM - CIRCUIT AND COMPONENT LOCATION LK30 D. GROUND TEST The ground connection is critical for the electric and electronic circuits’ operation. It is often exposed to sev- eral factors for corrosion such as humidity and dust. Corrosion produces unnecessary resistance and this resistance can affect the circuit operation.
Page 297 ELECTRIC SYSTEM - CIRCUIT AND COMPONENT LOCATION LK30 VOLTAGE DROP TEST VOLTAGE DROP MEASUREMENT - METHOD The voltage drop test is to find a part or circuit with 1. Connect the resistance tester to the connector or excessive resistance. circuit for inspection. Connect the tester’s positive (+) probe to the point close to power terminal and The voltage drop in a circuit occurs due to resistance negative (-) probe to the point close to ground.
Page 298: Operation Principle
ELECTRIC SYSTEM - OPERATION PRINCIPLE LK30 2. OPERATION PRINCIPLE 2.1 STARTING & PREHEATING 3.0RW 5.0R 5.0R 5.0R STARTER 0.85B 3.0RW SWITCH STARTER RELAY SAFETY START SWITCH 0.85BW 0.85LB GLOW RELAY GLOW PLUG 0.5R Preheat Controller Engine stop STARTER MOTOR solenoid relay ALTERNATOR 2.0L Glow Lamp(I/P)
Page 299: Charging System
ELECTRIC SYSTEM - OPERATION PRINCIPLE LK30 2.2 CHARGING SYSTEM 3.0RW 5.0R 5.0R 5.0R STARTER 0.85B 3.0RW SWITCH STARTER RELAY SAFETY START SWITCH 0.85BW 0.85LB 0.5R GLOW STARTER MOTOR RELAY ALTERNATOR 0.5BR 0.85RB 0.85RB GLOW IC REG PLUG Charge lamp 265WA06A The charging system supplies electric power to vari- ous electrical devices.
Page 300: Lighting System
ELECTRIC SYSTEM - OPERATION PRINCIPLE LK30 2.3 LIGHTING SYSTEM 265WA08A The lighting system consists of combination switch, hazard warning switch, flasher unit, stop lamp relay, stop switch, head lights, turn signal lamps, tail lamps and stop lamps. 10-14 SS41-W00 May. 2007...
Page 301 ELECTRIC SYSTEM - OPERATION PRINCIPLE LK30 A. HEAD LIGHT SWITCH & TURN SIGNAL LIGHT SWITCH • The light switch is located on the left-hand side of the dash. • The three position of the light switch are; - OFF - Taillight/Headlight (low-beam) - Taillight/Headlight (high-beam) 265WA09A B.
Page 302 ELECTRIC SYSTEM - OPERATION PRINCIPLE LK30 D. STOP AND TAIL LIGHTING COMPONENTS STOP SWITCH Depressing the brake pedals opens the stop switch and the signal will be sent to stop the relay. This switch is a normally closed type. 265WA12A STOP LIGHTS When the operator pushes the brake pedal, these lights (2) will be illuminated.
Page 303: Combination Meter
ELECTRIC SYSTEM - OPERATION PRINCIPLE LK30 2.4 COMBINATION METER 2.4.1 GAUGES AND INDICATORS 265WA15A This shows entire condition of the tractor. It consists of 3 gauges, a hour meter and 8 warning lamps. They are; 1. Tachometer 6. Turn signal indicator (RH) This shows the Engine RPM and PTO RPM.
Page 304: Wiring Diagram
ELECTRIC SYSTEM - OPERATION PRINCIPLE LK30 2.4.2 WIRING DIAGRAM 3.0RW 0.5YL 0.5B 265WA16A 10-18 SS41-W00 May. 2007...
Page 305: Engine Oil Pressure Switch
ELECTRIC SYSTEM - OPERATION PRINCIPLE LK30 2.5 ENGINE OIL PRESSURE SWITCH The oil pressure switch is located on the rear left side of the engine. The switch opens under normal oil pressure (above 0.5 ± 0.1 kgf/cm², 7.1 ± 1.4 psi). It closes when the oil pressure is low (0.5 ±...
Page 306: Fuse Box
ELECTRIC SYSTEM - OPERATION PRINCIPLE LK30 2.8 FUSE BOX It is installed on the firewall, under the hood. • Function: It protects devices from excessive elec- tric load. • Operating principle: If the current through the fuse is over the specified capacity, the conductor of the Spare Spare Back up Lamp...
Page 307: Troubleshooting
ELECTRIC SYSTEM - TROUBLESHOOTING LK30 3. TROUBLESHOOTING Symptom Provable Causes Solution All electrical • Battery discharged or defective Recharge or replace equipment does • Battery positive or negative cable disconnected or improp- Repair or replace not operate erly connected • Slowblow fuse blown Repair or replace Fuse blown •...
Page 308 ELECTRIC SYSTEM - TROUBLESHOOTING LK30 Symptom Provable Causes Solution Coolant level • Bulb blown Replace lamp does not • Water level switch defective Replace illuminate when • Fuse blown Replace cooling water is • Circuit in instrument panel defective Replace insufficient Coolant level •...
Page 309: Servicing
ELECTRIC SYSTEM - SERVICING LK30 4. SERVICING 4.1 STARTING SYSTEM 4.1.1 KEY SWITCH The key switch is located on the right side of the PREHEAT operator’s console. The 4 positions of the switch are: NOTE: START • The “START” position is spring loaded to return to “ON”...
Page 310: Start Relay
ELECTRIC SYSTEM - SERVICING LK30 4.1.2 START RELAY A. RELAY TESTING To test a relay, disconnect it from the circuit. Use an ohmmeter to verify non-energized conditions. Connect the ohmmeter leads to terminals 87 and 30. • There will be no continuity between terminals 87 and 30 if the relay is working properly.
Page 311: Glow Plugs
ELECTRIC SYSTEM - SERVICING LK30 4.1.3 GLOW PLUGS Glow plugs are heating elements used to warm the air in the combustion chambers before and during engine startup. The glow plugs are located on the right side of the engine cylinder lead. •...
Page 312: Starter Motor
ELECTRIC SYSTEM - SERVICING LK30 4.1.5 STARTER MOTOR Battery Body 265WA26A A. VOLTAGE TEST (B+ TERMINAL) 1. Measure the voltage with a voltmeter across the B terminal and chassis. 2. If the voltage differs from the battery voltage, the battery’s positive cable or the battery negative cable is faulty.
Page 313 ELECTRIC SYSTEM - SERVICING LK30 C. HOLD IN TEST OF SOLENOID SWITCH 1. Disconnect the M terminal of the starter. 2. Connect battery negative terminal to the M terminal of the starter motor. 3. Connect Battery positive terminal to the S terminal. (Use a switch) 4.
Page 314: Charging System
ELECTRIC SYSTEM - SERVICING LK30 4.2 CHARGING SYSTEM 4.2.1 CHARGING CURRENT CHECK 1. After engine starts, disconnect battery positive cable, then connect the ampere meter like figure. 2. Operate all electric loads (like lamps) and mea- sure the charging current. NOTES: Connect Ampere meter only with engine starts.
Page 315: Lighting System
ELECTRIC SYSTEM - SERVICING LK30 4.3 LIGHTING SYSTEM 4.3.1 HEAD LIGHT SWITCH TESTING A. USE AN OHMMETER TO TEST THE LIGHT SWITCH • With the switch in the “OFF” position, the continuity will not exist between any of the terminals. •...
Page 316: Turn Signal Switch Testing
ELECTRIC SYSTEM - SERVICING LK30 4.3.2 TURN SIGNAL SWITCH TESTING A. USE AN OHMMETER TO TEST THE LIGHT SWITCH • When the flasher switch knob is turned right, there will be continuity between terminals 1 and 3. • When the flasher switch knob is turned left, there will be continuity between terminals 1 and 2.
Page 317: Hazard Light Switch Test
ELECTRIC SYSTEM - SERVICING LK30 4.3.4 HAZARD LIGHT SWITCH TEST Use the ohmmeter to test the hazard light switch. • With the switch in the “OFF” position, there will be no continuity between terminals 1 and 2, 3. • With the switch in the “ON” position, there will be continuity between terminals 1 and 2, 3.
Page 318: Flasher Warning Light
ELECTRIC SYSTEM - SERVICING LK30 4.3.6 FLASHER WARNING LIGHT To replace a flasher warning light bulb: 1. Remove the three screws, then remove the lens. * Bulb (12V/21W) 2. Push in on the bulb and rotate counterclockwise in the socket to remove the old bulb. 3.
Page 319 LK30 INDEX...
Page 320 INDEX LK30 NUMBER 15 gear shaft ............4-31 Cam plate flatness ..........6-10 3 point link ..............4-26 Camshaft and fuel camshaft ........2-13 9 bevel pinion shaft ..........4-32 Camshaft ..............2-5 Caution for assembly of the power steering unit ... 8-19 Cautions for high pressure hoses ......
Page 321 INDEX LK30 Clearance between hydraulic arm shaft and Disassemble the step ..........4-18 bushing ............... 9-26 Disassembled view of governor system ....2-25 Clearance between pinion shaft and differential Disassembling and assembling of the clutch pinion ..............7-17 housing ............... 4-14 Clearance between traveling pressure plate Disassembling and assembling of clutch ....
Page 322 INDEX LK30 Height of cam plate and ball ........6-10 Every 100 hours ............1-20 High pressure relief valve ......... 9-8 Every 2 years ............1-28 Horn switch ............. 10-30 Every 200 hours ............1-24 Hydraulic block ............9-21 Every 400 hours ............1-27 Hydraulic circuit diagram of steering system ..
Page 323 INDEX LK30 Power train diagram of transmission ...... 4-3 Power train of transmission ........4-5 Main gear shift section ..........4-5 Power train of rear axle ..........5-3 Main shift cover assemble ........4-20 Pre-load of taper roller bearing on spiral bevel pinion Main shift group ............
Page 324 INDEX LK30 Starter motor ............10-26 Replacing radiator hose (water pipes) ....1-29 Starting & preheating ..........10-12 Replacing transmission fluid filter ......1-16 Starting system ............10-23 Right turn ..............8-5 Steering cylinder ............8-9 Rocker arm assembly overview ......2-13 Steering wheel clearance ........
Page 325 INDEX LK30 Unit conversion table ..........1-9 Use of appropriate tools and equipment ....0-6 valve clearance ............2-35 Valve spring ..............2-5 Valve timing ..............2-4 Valves ................2-4 Ventilating system ............0-3 Water pump .............. 2-18 Wheel alignment ............7-5 Wheel ............

Daedong Kioti LK30 Workshop Manual

Lk30 Safety First

1 For Safety

2 Safety Tips

3 Safety Decals

Lk30 General

1 Tractor Identification

2 Dimensions

3 Specifications

4 Lubricants, Fuel and Coolant

5 Tightening Torques

6 Unit Conversion Table

7 Maintenance Check List

8 Check and Maintenance

9 Tires

Lk30 Engine

1 Engine Identification

2 Specifications

3 Operating Principle

4 Troubleshooting

5 Measurement and Adjustment

6 Exploded View (Lk30)

7 Servicing

Lk30 Clutch

1 Specifications

2 Operation Principle

3 Troubleshooting

4 Checking and Adjustment

5 Servicing

Lk30 Transmission

1 Specifications

2 Operating Principle

3 Trouble Shooting

4 Servicing

Lk30 Rear Axle

1 Specificaions

2 Operating Principle

3 Troubleshooting

4 Servicing

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Chapters

Troubleshooting

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Summary of Contents for Daedong Kioti LK30