Kioti CH20 Instruction manual

TO THE READER
1
S196-WOO Jul. 2003
TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism,
service and maintenance of KIOTI tractors CH20, CK20J, CK20H and CK20HJ. It is divided into two parts, “Mecha-
nism” and “Servicing” for each section.


MECHANISM
Information on the construction and functions are included. The part should be completely understood before
proceeding with troubleshooting, disassembling or servicing.


SERVICING
In this section you will find general precautions, maintenance and special tools. The are other sections which
include troubleshooting, servicing, specifications lists, disassembling, assembling and servicing that explains in
detail procedures, precautions, factory specifications and acceptable limits.
This manual contains the latest production information on illustrations and specifications based on the most up to
date production information available at the time of publication.
We reserve the right to make changes throughout the entire manual at any time without notice.

CK20(H)
2S196-WOO Jul. 2003
SAFETY STARTING
1. Always use the safety start switch to start the en-
gine and never by any other means.
2. Do not alter or remove any part of machine safety
system.
3. Before starting the engine, make sure that all shift
levers are in neutral positions or in disengaged
positions.
4. Never start the engine unless you are in the
operator’s seat.
196W002A
This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and the decals on the machine
itself to warn of the possibility of personal injury. It is essential that you read the instructions and safety regulations
before you attempt to repair or operate this unit. Read these instructions carefully.
SAFETY FIRST
SIGNS
DANGER
WARNING
CAUTION
IMPORTANT
DESCRIPTION
This mark indicates hazardous situation which, if not observed, may
result in death or fatal injury.
This mark should be indicated for most dangerous situations only.
This mark indicates potentially hazardous situation which, if not
observed, may result in death or moderate injury.
This mark indicates potentially hazardous situation which, if not
observed, may result in minor or moderate injury. And this mark can be
used as a warning against unsafe activities.
This mark indicates emphasis on notable characteristics in working
procedures or information on working procedures and technology for
convenient use.
NOTE Gives helpful information.
BEFORE SERVICINGAND REPAIRING
1. Read all safety instructions in this manual and be
aware of the safety decals on your machine itself.
2. Thoroughly clean your work area and the machine.
3. Make sure the machine is on firm and level ground
and that the parking brake is set.
4. Lower the implement to the ground.
5. Stop the engine and remove the key.
6. Disconnect the negative battery cable.
7. Place a “DO NOT OPERATE” tag in operator station.
196W001A

TO THE READER
3
S196-WOO Jul. 2003
SAFETY WORKING
1. Do not operate or service the machine while under
the influence of alcohol, medication, or other
substances.
2. Never wear loose fit clothing and always use safety
equipment appropriate to the job.
3. Never use improvised tools, parts or procedures.
Use only recommended tools appropriate to the
work.
4. Be careful to perform all work safely when servicing
is done by two or more people.
5. Always support the machine by safety stands. Never
work under the machine that is supported solely by
a jack.
6. Do not touch any rotating or hot parts while the en-
gine is running.
7. Never remove the radiator cap while the engine is
running, or immediately after stopping. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to relieve pressure
before removing completely.
8. Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury.
Relieve pressure before disconnecting hydraulic or
fuel lines. Tighten all connections before applying
pressure.
196W003A
196W004A
AVOID FIRES
1. Never smoke or allow flames or sparks in your work-
ing area, as fuel is extremely flammable and explo-
sive under certain conditions.
2. Always disconnect the negative battery cable first
and reconnect it last to avoid sparks from an acci-
dental short circuit.
3. Battery gas will ignite. Keep sparks and open flame
away from the top of battery, especially while
charging.
4. Be careful not to spill fuel on the engine.
196W005A

CK20(H)
4S196-WOO Jul. 2003
DISPOSE OF FLUIDS PROPERLY
1. Observe relevant environmental protection regula-
tions when disposing of oil, fuel, coolant, electro-
lyte and other harmful waste. Never pour fluids into
the ground, down a drain, or into a stream, pond, or
lake.
196W008A
VENTILATE WORKAREA
1. Exhaust contains poisonous carbon monoxide so
you should never run the engine in a closed area. If
the engine must be running while performing
maintenance, make sure the area is well ventilated.
PREVENTACID BURNS
1. Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill elec-
trolyte on yourself, flush with water, and get medi-
cal attention immediately.
196W006A
196W007A

TO THE READER
5
S196-WOO Jul. 2003
PREPARE FOR EMERGENCIES
1. Be sure to keep a first aid kit and fire extinguisher
handy at all times.
2. Keep emergency numbers for the nearest fire
department, hospital, doctor and ambulance
service, near your telephone in case of emergency.
196W009A

CK20(H)
6S196-WOO Jul. 2003
(1) Parts No. : T2350-54122 (Optional)
SAFETY DECALS
zThe 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.
(3) Parts No. : T4625-52361(2) Parts No. : T4625-52351

TO THE READER
7
S196-WOO Jul. 2003
CARE OF DANGER, WARNINGAND CAUTION LABELS
1. Keep danger, warning and caution labels clean and free from obstructing material.
2. Clean danger, warning and caution labels with soap and water, dry with a soft cloth.
3. Replace damaged or missing danger, warning and caution labels with new labels.
4. If a component with danger, warning or caution label(s) is replaced, make sure new label(s) is (are) attached
in the same locations(s) as the replaced component.
5. Mount new labels by applying on a clean dry surface and pressing any bubbles to outside edge.
(6) Parts No. : T2445-50724
(5) Parts No. : T2325-50512(4) Parts No. : T2325-50743
(9) Parts No. : T2615-54112
(7) Parts No. : T2615-53561
(8) Parts No. : T2350-54141

CHAPTER 1
GENERAL

GENERAL
1-3
S196-WOO Jul. 2003
196W101A
1. TRACTOR IDENTIFICATION
When contacting your local KIOTI distributor, always specify engine serial number, tractor serial number and hour
meter reading.
196W100A
(1) Statutory Plate (2) Identification Plate
(4) Transmission Serial Number
(3) Engine Serial Number
(5) Hour Meter
196W103A
196W102A

CHAPTER 1 CK20(H)
1-4 S196-WOO Jul. 2003
196W167A
2. DIMENSIONS
mm (in.)

GENERAL
1-5
S196-WOO Jul. 2003
3. GENERAL PRECAUTIONS
196W104A
(1) Grease
(2) Snap Ring for Shaft
(3) Snap Ring for Hole
(4) Assemble Towards to be Forced
(5) Reciprocating
(6) Rotating
1. Place the tractor on the flat surface for adjustment
or service.
2. Please work with the engine stop except for the case
that must be worked with the engine running.
3. Arrange each part properly on the clean space for
disassembly. For bolts and nuts, tighten manually
by hand to its original position.
4. Use only the approved special tool. For the tool that
is not used often, use the tool made by each ser-
vice workshop.
5. Use only part cleaning agent for manufacturing
when any part needs to be clean. Do not use the
diesel oil for cleaning to prevent any pollution. Use
only approved fluid oil for cleaning any hydraulic part.
6. Be careful not to attach any dust or metal chip etc.
for disassembly and assembly of any hydraulic part.
7. For measuring any part, remove any oil or polluted
material before performing the measurement.
8. Disconnet the battery negative (-) cable before re-
moving or installing the live components.
9. Use only the DAEDONG genuine part for replace-
ment to maintain the performance and safety.
10.Replace the packing bearing and O-ring as new
part. Apply the grease properly for O-rings and oil
seals before assembly.
•Use the packing bond as three bond 1208D or
LOCTITE product.
•For using any packing bond, remove any re-
mained bond in the part before apply.
•Apply the bond in center of the flange between
bolt holes of the contact surface and apply the
inner surface for bolt hole portion.
•Perform the assembly within 10 minutes after
apply and inject oil after passing 30 minutes
above.
IMPORTANT
11.For assembling any snap ring for shaft or snap ring
for hole, assemble the head by the direction to be
forced, like above figure.
12.Insert the split portion of any spring pin by the direc-
tion to be forced, like above figure.
13.Replace any split pin as a new one.
3.1 ASSEMBLY AND DISASSEMBLY

CHAPTER 1 CK20(H)
1-6 S196-WOO Jul. 2003
6. When replacing a broken fuse with a new one, be
sure to use the fuse of capacity as specified.
7. Be sure not to drop sensors and relays which are
fragile.
196W109A
3.2 ELECTRICAL SYSTEM
1. Check electrical wiring daily every year for any dam-
age or short circuit at junction. In addition, undergo
onerous inspection via the agency regularly.
2. Do not modify or reorganize the wiring of the elec-
tric field parts.
3. When disconnecting battery cable disconnect nega-
tive cable first, reinstall the positive cable first when
reinstalling.
Disconnect battery negative terminal
NOTE:
•Be sure to turn the starting key OFF when connect-
ing or disconnecting the cable.
4. Remove the connector by pulling the plastic sec-
tion not the wiring.
196W108A
196W107A
5. When reconnecting the connector, Insert it until it
snaps.

GENERAL
1-7
S196-WOO Jul. 2003
3.3 TUBES AND RUBBERS
Be cautious of oil or the like on the tubes and rubber
parts, which may cause change in quality.
3.4 LUBRICANT
When assembling and fixing, apply designated lubri-
cant where specified in accordance with this repair
manual.
196W110A
196W111A

CHAPTER 1 CK20(H)
1-8 S196-WOO Jul. 2003
To ensure safety and prevent damage to the machine
and surrounding equipment, heed the following pre-
cautions in handling electrical parts and wiring.
4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING
196W112A
•Check electrical wiring for damage and loosened
connection every year. To this end, educate the
customer to do his or her own check and at the
same time recommend the dealer to perform pe-
riodic check for a fee.
•Do not attempt to modify or remodel any electri-
cal parts and wiring.
•When removing the battery cables, disconnect the
negative cable first. When installing the battery
cables, connect the positive cable first.
IMPORTANT

GENERAL
1-9
S196-WOO Jul. 2003
CK20
3C093
Liquid-cooled, 3-cylinder diesel
21 (15.7)
927 (56.6)
2,800
20 (5.28)
Dry type single stage
Standard
Wet disc type
1 speed (540 rpm at 2,646 engine rpm)
1 speed (2,000 rpm at 2,706 engine rpm)
29 (7.66)
Cat.I
503 (1,109)
Position control
Hydrostatic
6 ~- 12 (23 x 8.50 ~ 12, 23 x 8.50 ~ 12)
9.5 ~ 16 (33 x 12.5 x 16.5, 12 ~ 16.5)
2,684 (105.7)
1,121 (44.1)
1,970 (77.5)
1,470 (57.9)
310 (12.2)
910 (35.8)
890 ~ 935 (35.0 ~ 36.8)
2.3 (7.5)
HST
15.5 (11.6)
Hydrostatic
INF.2
Live continuous
0 ~ 14.97 (0 ~ 9.30)
0 ~ 9.37 (0 ~ 5.82)
904 (1,993)
MECHANICAL
16.5 (12.3)
Synchro/constant
6F 2R
Trans
1.10 ~ 16.24 (0.68 ~ 10.09)
1.36 ~ 6.31 (0.85 ~ 3.92)
890 (1,962)
Model
Type
Engine gross HP (kW)
P.T.O HP (kW)
Displacement cc (cu.in)
Rated revolution r.p.m min-1
Fuel tank capacity (gal.)
Clutch
Transmission
Speeds
Differential lock
Brake
P.T.O
Rear (rpm)
Mid (rpm)
Pump capacity (Max. flow rate) /min (gpm)
3-point hitch
Maximum lifting capacity (24in. aft of hitch)
kgf (lbs.)
Hydraulic lift control system
Steering
Front (AG, TURF, INDUSTRIAL)
Rear (AG, TURF, INDUSTRIAL)
Forward (At rated engine rpm) km/h (mph)
Reverse (At rated engine rpm) km/h (mph)
Overall length (with 3p) mm (in.)
Overall width (minimum tread) mm (in.)
Overall height (Top of ROPS) mm (in.)
Wheel base mm (in.)
Min. ground clearance mm (in.)
Tread Front mm (in.)
Rear mm (in.)
Min. turning radius (with brake) m (Ft.)
Weight (with ROPS) kgf (lbs.)
Engine
Drive train
Hydraulic
system
Standard
tire size
Traveling
speeds
Dimen-
sions
5. SPECIFICATIONS
Model
NOTE: The specifications are subject to change for the purpose of improvement without any notice.

CHAPTER 1 CK20(H)
1-10 S196-WOO Jul. 2003
Fuel
Coolant
Engine crankcase
Transmission case
Front axle case
(4WD only)
Greasing
Battery terminal
20 (5.28 U.S.gal.)
5.7 (1.50 U.S.gal.)
2.6 (0.69 U.S.gal.)
3.1 (0.82 U.S.gal.)
No. of greasing points
2
6. LUBRICANTS, FUELAND COOLANT
Capacity
Moderate amount
Type of grease
Multipurpose type grease
SAE 90 gear oil
No. Locations Capacities Lubricants
No.2-D diesel fuel
No.1-D diesel fuel if temperature is below
-10°C (14°F)
Fresh clean water with anti-freeze
Engine oil: API Service Classification CC or CD
CK20H CK20
1
2
3
4
5
6
Multi-gradetransmission fluid the fluid listed below or
equivalent are recommended.
Above 25°C (77°F)
0 to 25°C (32 to 77°F)
Below 0°C (32°F)
SAE30, SAE10W-30 or 10W-40
SAE20, SAE10W-30 or 10W-40
SAE10W, SAE10W-30 or 10W-40
Maker
Shell
Mobil
Exxon
Brand(Standard)
DONAX-TD,DONAX-TM
Mobile Fluid 350
Torque Fluid 56
18.5
(4.89 U.S.gal.)
21.6
(5.71 U.S.gal.)

GENERAL
1-11
S196-WOO Jul. 2003
Diameter
7. TIGHTENING TORQUES
M6
(6 mm, 0.24 in.)
M8
(8 mm, 0.31 in.)
M10
(10 mm, 0.39 in.)
M12
(12 mm, 0.47 in.)
M14
(14 mm, 0.55 in.)
M16
(16 mm, 0.63 in.)
M18
(18 mm, 0.71 in.)
M20
(20 mm, 0.79 in.)
Material of
bolt
Indication on
top of bolt 7T 9T
7.1 GENERAL USE SCREWS, BOLTS AND NUTS
Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be tightened
according to the table below.
7 9
N·m
7.85
~
9.31
17.7
~
20.5
39.3
~
45.1
62.8
~
72.5
108
~
125
167
~
191
246
~
284
334
~
392
kgf·m
0.80
~
0.95
1.8
~
2.1
4.0
~
4.6
6.4
~
7.4
11.0
~
12.8
17.0
~
19.5
25.0
~
29.0
34.0
~
40.0
lbf·ft
5.79
~
6.87
13.1
~
15.1
29.0
~
33.2
46.3
~
53.5
79.6
~
92.5
123
~
141
181
~
209
246
~
289
N·m
7.85
~
8.82
16.7
~
19.6
31.4
~
34.3
kgf·m
0.80
~
0.90
1.7
~
2.0
3.2
~
3.5
lbf·ft
5.79
~
6.50
12.3
~
14.4
23.2
~
25.3
N·m
9.81
~
11.2
23.6
~
27.4
48.1
~
55.8
77.5
~
90.2
124
~
147
197
~
225
275
~
318
368
~
431
kgf·m
1.00
~
1.15
2.4
~
2.8
4.9
~
5.7
7.9
~
9.2
12.6
~
15.0
20.0
~
23.0
28.0
~
32.5
37.5
~
44.0
lbf·ft
7.24
~
8.31
17.4
~
20.2
35.5
~
41.2
57.2
~
66.5
91.2
~
108
145
~
166
203
~
235
272
~
318
Material of
opponent part
No-grade or 4T
SS400, S20C
Ordinariness Aluminum
S43C, S48C
Ordinariness Aluminum
N·m
7.85
~
8.82
17.7
~
20.5
39.3
~
44.1
62.8
~
72.5
kgf·m
0.80
~
0.90
1.8
~
2.1
4.0
~
4.5
6.4
~
7.4
lbf·ft
5.79
~
6.50
13.1
~
15.1
29.0
~
32.5
46.3
~
53.5
N·m
12.3
~
14.2
29.5
~
34.3
60.9
~
70.6
103
~
117
167
~
196
260
~
304
344
~
402
491
~
568
kgf·m
1.25
~
1.45
3.0
~
3.5
6.2
~
7.2
10.5
~
12.0
17.0
~
20.0
26.5
~
31.0
35.0
~
41.0
50.0
~
58.0
SCr435,
SCM435
Ordinariness
lbf·ft
9.05
~
10.4
21.7
~
25.3
44.9
~
52.0
76.0
~
86.7
123
~
144
192
~
224
254
~
296
362
~
419
7.2 STUD BOLTS
Unit
Material of opponent part
Diameter Unit
M8 (8 mm, 0.31 in.)
M10 (10 mm, 0.39 in.)
M12 (12 mm, 0.47 in.)
Ordinariness Aluminum
N·m
11.8 ~ 15.6
24.6 ~ 31.3
29.5 ~ 49.0
lbf·ft
8.68 ~ 11.5
18.1 ~ 23.1
21.7 ~ 36.1
N·m
8.82 ~ 11.8
19.7 ~ 25.4
31.4
kgf·m
0.90 ~ 1.2
2.0 ~ 2.6
3.2
lbf·ft
6.51 ~ 8.67
14.5 ~ 18.8
23.1
kgf·m
1.2 ~ 1.6
2.5 ~ 3.2
3.0 ~ 5.0
4

CHAPTER 1 CK20(H)
1-12 S196-WOO Jul. 2003
Grade
Unit
Nominal
diameter
5/16
3/8
1/2
9/16
5/8
N·m
23.1 ~ 27.8
47.5 ~ 57.0
108.5 ~ 130.2
149.2 ~ 179.0
203.4 ~ 244.1
kgf·m
2.35 ~ 2.84
4.84 ~ 5.82
11.07 ~ 13.29
15.22 ~ 18.27
20.75 ~ 24.91
lbf·ft
17.0 ~ 20.5
35.0 ~ 42.0
80.0 ~ 96.0
110.0 ~ 132.0
150.0 ~ 180.0
kgf·m
3.31 ~ 4.01
6.22 ~ 7.47
15.22 ~ 18.27
22.14 ~ 26.57
30.44 ~ 36.53
N·m
32.5 ~ 39.3
61.0 ~ 73.2
149.2 ~ 179.0
217.0 ~ 260.4
298.3 ~ 358.0
lbf·ft
24.0 ~ 29.0
45.0 ~ 54.0
110.0 ~ 132.0
160.0 ~192.0
220.0 ~ 264.0
7.3 AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF
THREADS
SAE GR.5 SAE GR.8