DK 802
DK 802
DK 802
Congratulations on your purchase of a versatile KIOTI DK 802/902. This tractor has been designed and manufac-
tured with the finest materials and under rigid quality control standards set forth by the DAEDONG engineering
department. Reading and understanding this manual is the first step toward many years of safe, dependable and
reliable service. This manual covers models DK 802/902 tractors; and it provides important information about
tractor safety, operation and maintenance.
It is the policy of DAEDONG to provide a detailed owner’s manual with every tractor. Please read, understand and
follow the instructions in this manual before operating your new tractor. After reading and understanding this
manual, please contact your KIOTI dealer if you have additional questions.
SAFETY ALERT SYMBOL
The industry standard “SAFETY ALERT SYMBOL” is used throughout this manual to call your attention to items or
operations that could be dangerous to you or bystanders. Wherever this symbol appears, important information will
be provided for your safety. Please read, understand and heed these instructions.
Throughout this manual, the safety alert symbol will be followed by the words DANGER, WARNING, CAUTION or
IMPORTANT. These indicate the hazard level and are defined below.
SIGNS DESCRIPTION
This mark indicates a significant hazard. Failure to observe this warning may result in
DANGER
death.
WARNING This mark indicates a potential hazard which may result in serious injury or death.
This mark indicates a potential hazard which may result in minor injury or significant
CAUTION
equipment damage.
IMPORTANT This mark indicates important information regarding proper operating procedures.
ABBREVIATIONS LIST
ABBREVIATION DEFINITION
4WD Four-Wheel Drive
API American Petroleum Institute
ASAE American Society of Agricultural Engineers
SAE Society of Automotive Engineers
ISO International Organization for Standardization
PTO Power Take Off
ROPS Roll-Over Protective Structure
RPM Revolution Per Minute
Control-On Position
Engine Coolant-Temperature Audible Warning Device
Differential Lock
Diesel Preheat/Glow Plugs Four-Wheel Drive-ON
(Low Temperature Start Aid) Position Control-Raised
Position
Four-Wheel Drive-OFF
Parking Brake Position Control-Lowered
Position Creep
Battery Charging Condition
Hazard Warning Lights Slow
Engine Oil-Pressure
Master Lighting Switch Fast
Turn Signal
Position Lamps Coolant Level
PRE-DELIVERY SERVICE
CHECK AND ADJUST AS REQUIRED
PRE-OPERATIONAL SERVICE 11. Upper link, draw-bar and pin 21.Seat mounting and adjust-
CHECKS in position ............................. ment .......................................
4. V-belt tension and condition ..... 15. Front axle support bolts for 2. Neutral start switches opera-
tightness ............................... tive ..........................................
5. Engine oil level .......................
16. Fuel level ............................... 3. Parking brake operation .....
6. Transmission / rear axle oil
level ......................................... 17. Sheet metal and paint 4. Flashing lights/tail lights
condition ................................ operation ...............................
7. Front axle differential oil level ...
18. Drain diesel fuel filter and 5. Owner’s manual supplied .
8. Front axle oil level ..................
water separator .................... 6. PTO guard installed ............
9. Brake adjustment and pedal
19. Lubricate all grease fittings ... 7. SMV emblem installed
equalization .............................
20. Air cleaner element and air (where applicable) ..............
10. Parking brake adjustment
intake connections .................
OPERATIONAL SERVICE CHECKS • Draft control for tension RECORD MODEL AND SERIAL
and compression loads ... NUMBERS:
All operational checks are to be
• Auxiliary equipment control Tractor Model No.
performed with the tractor at nor-
and remote control valves
Tractor Serial No.
mal operating temperature.
(If installed) ........................
1. Lights and instruments for
proper operation ..................
PERFORMANCE SERVICE CHECKS:
2. Fluid and oil leaks ...............
3. SPECIFICATIONS ................................................................
5. OPERATING .........................................................................
6. MAINTENANCE ....................................................................
8. TROUBLESHOOTING ........................................................
9. INDEX ....................................................................................
BEFORE OPERATING THE TRACTOR
OPERATING THE TRACTOR
1
SAFETY PRECAUTIONS
DRIVING THE TRACTOR
PARKING THE TRACTOR
OPERATING THE P.T.O
USING 3-POINT HITCH
SERVICING THE TRACTOR
TRACTOR SAFETY LABELS
1-2 DK802/902
T30O101A T30O102A
1. It is recommended that you read and 6. When getting on and off the tractor,
understand this entire manual before handholds and step plates should al-
operation of your new tractor. Failure ways be used. This will help to pre-
to do so could result in accidents or vent accidental slips trips and falls.
injury. 7. Be sure to scrape off mud or soil from
2. Only persons who are properly trained your shoes before mounting the tractor.
should be allowed to operate the 8. Watch where you are going at all times
tractor. so that you are able to avoid obstacles
3. Read and follow all warning labels and that can cause injury or damage to
decals affixed to the tractor. your tractor.
4. Replace any missing or damaged de- 9. When starting the tractor make sure
cals as soon as it is practical. A list of your path is clear of people to avoid ac-
decals is shown on page1-14~16. cidents caused by sudden movements.
5. Keep safety decals clean from dirt and 10. Before making reverse movements
debris. with your tractor, you should always
check to see that the path is clear.
SAFETY PRECAUTIONS 1-3
11. Never operate this tractor or any other 14. Never start the engine while standing 16. All persons using the tractor should
agricultural equipment while under the on the ground. have knowledge of its proper opera-
influence of alcohol, drugs or while 15. Only the operator should ride on the tion and should read this manual
fatigued. tractor unless a passenger seat is carefully.
12. While working in cooperation with installed. Keep bystanders away from 17.Never get off the tractor without set-
other tractors always communicate the tractor while in operation. ting the parking brake, lowering the
your intentions. implement to the ground and shutting
13. Do not start your tractor by shorting of the tractor.
across the starter. 18.No alterations should be made to your
KIOTI tractor without first consulting
your KIOTI dealer.
1-4 DK802/902
NOTE
Always use seat belt when the tractor
is equipped with a ROPS. Never use
the seat belt when tractor is not
equipped with a ROPS.
(ROPS: Roll-Over Protective Structures)
19. Before starting your tractor you If the ROPS unit is removed or loosened 21. Extra caution should be taken when
should depress the clutch, and make for any reason, the parts should be fitted driving tractors with narrow tread
sure that all shift levers are in the back to their original positions and all bolts widths. For added stability you should
neutral position. should be properly torqued. adjust your rear wheel tread width, see
page 5-23.
SAFETY PRECAUTIONS 1-5
1. Avoid accidental contact with gear shift 2. Do not park your tractor on a steep 3. Do not operate your tractor in an en-
levers while the engine is running. Un- incline, and remember to shut off the closed building without the proper
expected tractor movements can result engine and P.T.O before dismounting ventilation. Exhaust fumes can cause
in bodily injury. the tractor. serious injury or death.
1-6 DK802/902
(1) Drawbar
4. Make sure that all pressure lines are 6. If The front of the tractor tends to rise 7. Do not leave equipment in the raised
tight before starting the tractor. up when heavy implements are at- position when the vehicle is stopped
5. Pull only from the drawbar. Never hitch tached to the three point hitch, the or unattended.
anything to the axle housing or any weights should be installed on the 8. When using implements or attach-
other point except the drawbar. pull- tractor. Do not operate the tractor with ments with your tractor you should first
ing from any other location only in- a light front end. read their respective owner’s manual.
crease the risk of serious personal You should always keep their safe op-
injury or death. eration procedures in mind.
9. You should be familiar with your equip-
ment and its limitations.
10. Always use the proper ballast weight
on your tractor when using rear
implements.
SAFETY PRECAUTIONS 1-7
13. If abused or used incorrectly your trac- 14. Never try to get on or off a moving
tor can become dangerous to you and tractor.
bystanders. Overloading your tractor 15. When working in groups, always let
or using unsafe equipment can also the others know what you are going
be dangerous and should be avoided. to do before you do it.
Refer to the “Specifications of Imple-
16. Never “freewheel”. Disengaging the
ment Limitation”, which outlines the
clutch or shifting into neutral while
maximum load for safe tractor
descending a slope as this could lead
operation.
to a loss of control.
17. Do not operate near ditches, holes,
embankments, or other terrain fea-
tures which may collapse under the
tractor’s weight. The risk of tractor
upset is even higher when the ground
is loose or wet.
1-8 DK802/902
4. Before jump starting a dead battery, 6. Do not remove the radiator cap while 7. When working with your tractors elec-
read and follow all of the instructions. the coolant is hot. When cool, slowly trical components you must first dis-
5. Keep a first aid kit and fire extinguisher rotate the cap to the first stop and al- connect the battery cables.
handy at all times. low sufficient time for excess pressure 8. To ensure that there are no accidents
to escape. After all the pressure is re- from sparks you must first disconnect
leased remove the cap completely. If the negative battery cable.
your tractor is equipped with a coolant
recovery tank, add coolant there in-
stead of to the radiator.
1-12 DK802/902
9. Tire mounting should be done by quali- 11. Securely support the tractor when 14. Fluid escaping from pinholes may be
fied professionals, with the proper changing wheels or the wheel tread invisible. Do not use hands to search
equipment. width. for suspected leaks;
12. Make sure that wheel bolts have been
10. Maintaining correct tire pressure is im- Use a piece of cardboard or wood,
tightened to the specified torque.
portant for the life of your tires. You instead. Use of safety goggles or
13. Escaping hydraulic fluid under pres-
should not inflate the tires above the sure has sufficient force to penetrate other eye protection is also highly
recommended pressure specified in skin, causing serious personal injury. recommended. If injured by escaping
the owner’s manual. Before disconnecting hydraulic lines, fluid, see a medical doctor at once.
be sure to release all residual pressure. This fluid can produce gangrene or
Before adding pressure to the hydrau- severe allergic reaction.
lic system, make sure that all connec-
tions are tight and that all line, pipes
and hoses are free of damage.
SAFETY PRECAUTIONS 1-13
T30O130A
T30O131A
SAFETY PRECAUTIONS 1-15
2. T4837-51181 5. T2325-50743
1-16 DK802/902
7. T4625-52351
12. T4837-51093
13. T4837-52121
2
SERVICING THE TRACTOR
2-2 DK802/902
Date of Purchase
(To be filled in by purchaser)
3
SPECIFICATIONS
SPECIFICATIONS
TRAVELING SPEED
3-2 DK802/902
SPECIFICATIONS
Model 1104C-44T
Type 4 cyl., Water Cooled, 4 Cycle,
Turbo Diesel
Engine gross HP(kw) 80 (59.7) 90 (67.1)
Displacement cc(cu.in) 4400 (268.5)
Bore and stroke mm(in) 105 x 127 (4.1 x 5)
Engine
Forward
Travel speeds 16th 34.01 (21.13)
km/h(mile/h) 1st 0.23 (0.14)
Reverse
16th 34.01 (21.13)
Differential lock (Rear, Front) Standard
Type Independent
P.T.O
Type Category
Lift Capacity at lift point kg(lbs) max 2400 (5291)
Drawbar type Drawbar
Pump Capacity 1st 45.3 (1.599)
Weight
3,421 (7,542) 3,557 (7,842)
Cabin (without front weight) kg(lbs)
SPECIFICATIONS 3-5
TRAVELING SPEED
* At rated engine speed(2200rpm)
km/h (mile/h)
LEVER SELECTIONS MODEL
km/h (mile/h)
(1) Headlight
(2) Front Grill
(3) Bonnet, Hood
(4) Side Cover, Hood
(5) Turn Signal (LH)
(6) Rear view Mirror
(7) Door Handle
(8) Muffler
(9) Step (LH)
(10) Fuel Filler Plug
(11) Work Lamp
(12) Wiper
T30O401A
DESCRIPTION OF OPERATING SYSTEM 4-3
T30O402A
4-4 DK802/902
T30O403A
(1) Steering Wheel (6) 4WD/QT Switch (11) Battery Charge Warning Lamp (16) Hydraulic System Warning Lamp
(2) Start Switch (7) Hour Meter (12) High Beam Indicator (17) Engine Oil Pressure Warning Lamp
(3) Headlight Switch (8) Tachometer (13) Preheater Indicator (18) 4WD Operation Indicator
(4) Turn Signal Switch (9) Fuel Gauge (14) PTO ON Indicator (19) Horn
(5) Hazard Lamp Switch (10) Temperature Gauge (15) Parking Brake Indicator (20) Turning Signal Indicator
DESCRIPTION OF OPERATING SYSTEM 4-5
ACC
Depress the clutch pedal to disengage
OFF
the clutch. Next, turning the key to the
next position activates the glow plugs
which preheat the combustion chamber
when the engine is cold. After the glow
plug lamp has turned red and the engine
T30O404A has been preheated, turn the key switch T30O405A
to the right again to activate the starter (1) Turn Signal Light Switch
(1) Key Switch (A) Start (B) Heat
which will start the engine. Release the (2) Head light Switch (3) Horn
(C) On (D) Acc (E) Off
key switch and it will return to the ON (A) Right (B) N (C) Left
position. Glow plugs will turn off
OFF Turning the headlight switch one click
automatically. The preheat step is not
Key position to shut down all systems. clockwise illuminates the low beam head-
necessary for a warm engine.
Position for key removal. lights and taillights. Turning it one more
click illuminates the high beam headlights.
ACC NOTE
Key position for operating accessory OFF
As a safety feature, the engine will
functions with engine off. not start unless the clutch pedal is Headlight is turned OFF
ON / HEAT depressed.
Key position for engine operation. Posi- Low beam headlight is turned ON
tion also used for preheat when starting
a cold engine.
High beam headlight is turned ON
ST
Key position for operating the starter
Turn signal lamp is turned ON.
motor.
4-6 DK802/902
T30O406A T30O408A
Front wheel is driven by 4WD,QT switch When the hazard lamp switch is pushed
in the illustration above. to the ON position, the hazard lamps blink.
• 2WD : normal 2WD.
CAUTION
• 4WD : normal 4WD.
Prolonged use of the hazard
• Q.T (Quick Turn): with 4WD driving,
lamps without the engine running
front wheel revolves approx. double
will drain the battery. Use only in
speed when steering angle is over 35
case of emergency.
degree.
DESCRIPTION OF OPERATING SYSTEM 4-7
The hour meter shows the number of Always check the engine coolant level Fuel gauge indicates the amount of fuel.
hours the tractor has been operated at before starting the tractor.
rated engine rpm. The last digit (white
Be careful to refill the fuel tank before it
background) indicates 1/10 of an hour.
The temperature gauge indicates the en- becomes empty. Once the fuel tank be-
gine coolant temperature. Always allow comes empty, it will be necessary to
The tachometer indicates engine speed the tractor to reach its normal operating bleed the fuel system before the engine
in revolutions per minute (RPM). temperature before doing work. will restart.
If the alternator is not charging the battery, This indicator lights up blue when the This lamp indicates preheat of the
the warning lamp in the Easy Checker headlamp switch is in the high-beam thermostat. When the starting switch is
will come on. position. turned On, this lamp lights On/Off accord-
If this should happen during operation, ing to the temperature of the engine
check the electrical charging system or coolant. After heating the thermostat coil
consult your local KIOTI dealer. about 8 sec., the lamp lights Off. Start the
engine as this lamp is Off.
DESCRIPTION OF OPERATING SYSTEM 4-9
This lamp lights up red when the PTO is This lamp lights up red when the parking A yellow light indicates possible prob-
on. brake is on. Do not drive the tractor with lems with the hydraulic system. The light
the parking brake on. comes on when hydraulic pressure
CAUTION drops below a specified level. Possible
As a safety feature, the engine causes are overheating, clogged filter,
will not start when the PTO light low oil level, fluid leak or improperly at-
is on. tached equipment.
4-10 DK802/902
T30O418A T30O419A
The oil pressure lamp glows red when This lamp lights up yellow when the 4WD
the key switch is turned on; indicating switch is “4WD” position, indicating the
that the system is functioning properly. tractor is in the 4WD mode.
The light should go out after engine
starts. If the light remains on, stop the
engine and determine the cause.
DESCRIPTION OF OPERATING SYSTEM 4-11
T30O420A
4-12 DK802/902
CAUTION
Depress the clutch pedal com-
pletely before making speed
changes.
DESCRIPTION OF OPERATING SYSTEM 4-13
(1) PTO switch (1) PTO Change Lever (1) PTO Selection Lever
ON
- ON OFF
- OFF (A) Independent PTO
(B) Ground Speed PTO
Two PTO speeds can be obtained by You can select independent PTO opera-
NOTE shifting the PTO speed lever from the tion or ground speed (by transmission
As a safety feature, the engine will operator’s seat. speed ratio) PTO.
not start unless the PTO switch is To select an operating mode; stop the
turned “OFF”. CAUTION
tractor completely, reduce the engine
To avoid personal injury: speed to idle, turn PTO clutch switch to
IMPORTANT Disengage the PTO, stop engine, neutral position, depress the clutch pedal
and allow all rotating compo- and now select the PTO operating mode.
Always turn the key switch to the nents to come to a complete stop
“OFF” position when the tractor before connecting, disconnec-
is shut down to avoid damage to ting, adjusting, or cleaning any
the electrical system. PTO driven equipment.
4-14 DK802/902
INDEPENDENT PTO
The independent PTO mode is used for
normal PTO operations. It operates con-
tinuously at a constant speed, indepen-
dent of the transmission speed
selections. The PTO shaft turns in a
clockwise direction (as viewed from the
rear of the tractor).
T30O427A T30O428A
(1) Tilting Pedal (A) Push (1) Brake Pedal (L) (3) Brake Lock
(2) Brake Pedal (R)
The steering wheel can be adjusted to 1. Before operating the tractor on the
WARNING
maximize operator comfort. Depress the road or before applying the parking
tilt pedal and move the steering wheel to brake, be sure to interlock the right Using only one brake or braking
the desired position. and left pedals as illustrated. unevenly at high speeds may
cause loss of control resulting in
WARNING 2. Use individual brakes to assist in mak-
an accident.
ing sharp turns at slow speeds (Field
DO NOT adjust the steering wheel Operation Only).
while driving.
Disengage the brake pedal lock and
depress only one brake pedal.
3. Be sure brake pedals have equal ad-
justment when using locked together.
4-16 DK802/902
WARNING
To avoid personal injury due to loss
of steering control.
Do not operate the tractor at high
speeds with the differential lock
engaged.
Do not attempt to turn with the
differential lock engaged.
(1) Seat (2) Seat Reclining Lever 2. Position the lap belt portion as low as (1) Drawbar Hitch
(3) Seat Adjusting Lever(Front & Rear) possible across your hips, not across
(4) Seat Control Handle(Cushion Load) your abdomen. Pull the loose end of
the belt until the seat belt is snug, but The drawbar should be used only for
SEAT SLIDING ADJUSTMENT comfortable. implements suitable for this tractor.
Pull the lever located under the front of 3. Press the button on the buckle to re-
lease the seat belt.
WARNING
the seat and slide the seat to the desire
position. After adjustment, gently rock in When towing, always connect the
the seat to make sure it is securely load to the drawbar hitch. Tow-
locked. ing or pulling from any other
point on the tractor may cause the
tractor to overturn.
4-18 DK802/902
T30O433A
WARNING
To avoid injury, always keep the
PTO shaft covered when not in T30O434A
use.
Apply a light coating of grease to (1) Cassette Tape Recorder (10) Interior Cab Light
the shaft before installing the (2) Air Intake Control Switch (11) Speaker
cover. (3) Fan Speed Control Switch (12) Inlet Air Circulation Device
(4) Air Conditioning Switch (13) Air Conditioner Ventilation Device
(5) Temperature Control Switch (14) Cigarette Lighter
(6) Work Light Switch (Front) (15) Ashtray
(7) Work Light Switch (Rear) (16) Sunroof Latch
(8) Front Wiper Switch (17) Wiper
(9) Rear Wiper Switch
DESCRIPTION OF OPERATING SYSTEM 4-19
(1) Work Lamp(Front) (3) Rear View Mirror (1) Rear Window Latch (1) Door Handle
(2) Work Lamp(Rear) (4) Wiper (2) Button (2) Button
1. The cab is constructed using a steel If you lightly push the rear window while Pressing the button on the handle will
frame, and it is designed for operator depressing the button on the handle, the open the door. The door can be latched
comfort and convenience. rear window will automatically open. in the open position. The cab doors can
2. The field of vision is maximized using be locked and unlocked by inserting the
a wide-angle window with external WARNING key into the lock and turning.
rear view mirrors on both sides; and Tractor attachments may some-
front and rear wipers. times interfere with windows. Al-
3. Air conditioning and heating systems ways check for clearance before
provide maximum comfort and reduce opening windows.
operator fatigue. Driving at full speed or making
4. With doors on both sides, the cab can sudden turns with the windows
be entered from either side. open may damage the windows.
4-20 DK802/902
(1) Door Prop(LH,RH) (1) Work Light (Front) Switch (1) Wiper Switch (Front)
(2) Work Light (Rear) Switch (2) Wiper Switch (Rear)
(3) Work Lamp (3) Wiper, Front
When operating the tractor with the doors To turn on, choose the switch marked 1. To turn on, position the switch marked
open, use the door prop to secure the “front” or “rear” and move to the “ON” (wiper) to the “ON” position.
door. Do not leave the doors fully open position. 2. Pressing the “ON” switch further will
while driving the tractor. momentarily activate the windshield
WARNING
washer.
Do not drive on the road with the
3. The tank for the washer fluid is lo-
rear work lights turned on. It cre-
cated on the left side behind the seat.
ates a hazard for other drivers
and may be illegal in some areas.
Use the hazard lights for road
travel.
DESCRIPTION OF OPERATING SYSTEM 4-21
HEATER/AIRCONDITIONER
WARNING
An automotive washer fluid is
highly recommended. Plain wa-
ter will freeze and damage the
system.
To avoid damage, do not operate
the windshield washer without
fluid.
Do not operate the washer if there
is mud or significant debris on the
windshield. Do not operate the
washer if the windshield is in-
T30O441A T30O442A
clined to freeze. Either will ob-
scure vision causing a hazard. (1) Air Intake Control Switch
Do not operate the wiper if it is (2) Fan Speed Control Switch
(3) Air Conditioning Switch
frozen to the windshield. System (4) Temperature Control Switch
damage may result.
AIR INTAKE CONTROL SWITCH WARNING
Recirculation mode Be careful not to keep this mode
for a long time. It may cause frost
The outside air intake can be shut off by
selecting the recirculation mode. This will in the glasses and passenger’s
recirculates the air that is already inside breathing may cause headache or
doze.
the vehicle. So set this mode so as to
prevent the polluted air from outside or
to actuate the maximum heat/ cool Air intake
function. Be careful not to keep this mode To get the outside air, turn this switch to
with heat function for a long time. It may air intake mode to receive the outside air.
cause frost in the front glass. Use it to ventilate the indoor.
4-22 DK802/902
AIR CONDITIONING SWITCH FAN SPEED CONTROL SWITCH TEMPERATURE CONTROL SWITCH
Turn the A/C switch on to run the A/C Choose number to select the blower fan Adjust the switch to control the
system. If return this switch, the A/C sys- speed. The higher number, the higher the temperature. The temperature varies with
tem will stop. blower fan speed. The ignition switch colors, red for hot, blue for cool.
needs to be ON.
DESCRIPTION OF OPERATING SYSTEM 4-23
HEATER OPERATION
If the air flow control knob 2 is turned on
with the temperature control knob 3 in
the red area, the heater will be on.
CAUTION
If the vehicle is excessively ex-
posed to a direct lay of light while
parking, open the windows to
ventilate its indoor with fresh air,
and then start the engine.
Close all the windows while acti-
T30O446A
vating A/C system.
(1) Fan Speed Control Switch Turn off the A/C not to overheat
(2) Air Conditioning Switch the engine while driving on a
(3) Temperature Control Switch steep hill.
AIR CONDITIONER OPERATION Do not activate A/C for a long time
while the vehicle is parking. Engine
1. Turn ON the A/C switch (2).
overheat may be over heated.
2. Turn the temperature control switch If non-cool air comes out from the
(3) to the left for cold mode. A/C system, stop it, turn the air
3. Turn the fan speed control switch (1) flow control knob in 4 mode, driv-
to the desired fan speed. ing the vehicle for 5-10 minutes,
and then reactivate the A/C.
CAUTION In winter season, it is recom-
Provide occasional ventilation at mended to activate the A/C sys-
the air intake mode to prevent the tem once or twice a month so as
indoor air from drying while a long to prevent the refrigerant from
driving with the air intake control leaking and to make a normal oil
switch in the recirculation mode recycle in the compressor of it.
and A/C activated.
4-24 DK802/902
POWER SUPPLY INSERTING A CASSETTE TAPE Use the switch in the light assembly to
Turn the knob clockwise to turn the Turn the power ON and insert the cas- turn the light ON and OFF.
power ON and to increase volume. sette tape with the tape side to the right.
Turning the switch counterclockwise re- It will play automatically. For more
duces the volume and turns the power information, please see the manual for
OFF. the cassette tape deck.
WARNING
RADIO ANTENNA
Adjust the volume so that you can You can adjust the antenna about 100° in
still hear the sounds from outside the forward and backward direction of
while driving. the tractor.
DESCRIPTION OF OPERATING SYSTEM 4-25
T30O453A
T30O504A T30O505A
4. Lower the implement if attached by 5. Set the hand throttle at about half
pushing the position control lever throttle.
forward.
T30O503A
7. Turn the switch key to “Start” position. 1. Turn the start switch to the “ON”
position. Wait until the preheat (glow
WARNING plug) indicator light goes off (about 20
Do not operate the starter motor seconds).
continuously for more than 10 2. Depress the clutch and continue the
seconds. normal starting procedure.
If the engine does not start; turn 3. If the engine does not run smoothly,
the switch to “OFF”, wait 30 shut down the engine and repeat the
seconds, and repeat the starting preheat procedure.
procedure.
4. Allow the engine to reach its normal
Never engage the starter motor be-
operating temperature before starting
fore the engine stops turning.
work.
T30O506A
8. Release the key as soon as the en-
(1) Clutch Pedal gine starts. It will return to the ON
position.
9. It is normal for the preheat (glow plug)
6. Fully depress the clutch pedal.
indicator to come on after operating
WARNING the starter motor for more than 8
seconds.
As a safety feature, the engine will
not start unless the clutch pedal WARNING
is fully depressed.
Do not turn the key switch to the
START position while the engine
is running.
1. Reduce the engine speed, depress the WARM-UP AND TRANSMISSION OIL IN TRANSMISSION OILWARM UP
clutch pedal and apply even pressure THE LOW TEMPERATURE RANGE
to both brake pedals. The hydraulic oil also serves as the
z Hydraulic oil serves as transmission transmission fluid. In cold weather,
2. Shift the transmission into neutral and
fluid. In cold weather, the oil may be high oil viscosity may cause low oil pres-
turn off the PTO.
cold with increased viscosity. This can sure and poor circulation until the sys-
3. Lower any attached implements. cause delayed oil circulation or abnor- tem warms up. To prevent damage or
4. Allow the engine to idle for a short mally low hydraulic pressure for some
time before turning it off. Stopping a malfunction, allow the system to warm
time after engine start-up. This in turn up at 50% of rated engine speed accord-
hot engine under load or at high speed can result in trouble in the hydraulic
may damage the engine. ing to the following table.
system. To prevent the above, observe
5. Set parking brake. the following instructions: AMBIENT REQUIRED
6. Turn the key switch to the OFF posi- z Warm up the engine at about 50 % of TEMPERATURE WARM UP TIME
tion and remove the key.
rated rpm according to the table
below: Above 0 °C
IMPORTANT At least 5 minutes
(32 °F)
Always remove the key when Ambient Warm-up time -10 °C ~ 0 °C
leaving tractor. It prevents unau- temperature requirement 5 ~ 10 minutes
(14 ~ 32 °F)
thorized use and ensures that all
Above 0 °C -20 ~ -10 °C
electrical systems are turned off. At least 5 minutes 10 ~ 15 minutes
(32 °F) (-4 ~ 14 °F)
0 ~ -10 °C Below -20 °C
WARNING 5 ~ 10 minutes 15 minutes +
(32 ~ 14 °F) (-4 °F)
Touching the muffler, heat shield
-10 ~ -20 °C
or exhaust after running the en- 10 ~ 20 minutes
(14 ~ -4 °F) IMPORTANT
gine will cause serious burns.
Below -20 °C More than 20 Do not operate the tractor under
CAUTION (-4 °F) minutes load until it is sufficiently warmed
up.
To avoid turbo charger damage:
IMPORTANT
Do not accelerate quickly right
after engine start. Do not operate the tractor under
Allow engine to idle before start- full load condition until it is suffi-
ing work and before shutdown. ciently warmed up.
OPERATION 5-7
JUMP STARTING
WARNING
1. Use a battery of the same voltage as
Keep sparks, open flames and
the disabled tractor to jump start the
smoking materials away from bat-
tractor. Locate the good battery in a
teries at all times. Gases emitted
safe place where the jumper cables
from batteries are explosive.
will reach.
2. Set the parking brake and turn the key
switch to OFF.
3. Put on safety goggles and rubber
gloves.
5-8 DK802/902
WARNING
Always wear the seatbelt when a
cab or ROPS is installed.
Do not use the seatbelt when there
is no cab or ROPS installed, or
when the ROPS is folded.
The seatbelt should always be
worn as low as possible, across the
T30O508A pelvis, to avoid abdominal injury. T30O509A
(1) Seat (2) Seat Reclining Lever (1) Brake Pedal (LH)
(3) Seat Adjusting Lever(Front & Rear) (2) Brake Pedal (RH)
(4) Seat Control Handle(Cushion Load) (A) Lock
1. Adjust the seat and fasten the seat 2. Adjust the steering wheel for operator 3. Make sure both the left and right brake
belt. comfort. pedals are engaged before preparing
to move.
SEAT ADJUSTMENT WARNING
Adjust the seat for easy access to the
Do not adjust the steering wheel
pedals and steering wheel.
while driving. You could lose the
WARNING control of your tractor, causing
an accident.
Ensure that the seat is securely
locked after any seat adjustment.
Do not adjust the seat while
driving. The seat may move sud-
denly causing loss of control of
the tractor.
OPERATION 5-9
(1) Position Control Lever (1) Hand Accelerator Lever (1) Parking Brake Lever
4. Pull the position control lever backward 5. Increase the engine speed slowly from 7. Release the parking brake.
to raise the implement, if attached. idle speed to about half throttle. 8. Using the main shift lever, the Hi-Lo
6. Fully depress the clutch shifter, and the forward/reverse
shuttle lever; select the desired direc-
tion of travel and the speed range.
9. Release the clutch slowly until the trac-
tor begins to move.
CAUTION
Interlock the right and left brake
pedals before starting. Uneven
braking may result in loss of con-
trol or rollover.
Do not allow any person other
than the driver to ride on the
tractor.
5-10 DK802/902
CAUTION CAUTION
Do not drive the tractor close to Always select a low speed set-
the edges of ditches or banks ting before driving in potentially
which may break under the hazardous conditions, such as:
weight of the tractor; especially - Steep slopes
when the ground is loose or wet. - Loading and unloading
Slow down to a safe speed be- - Entering or exiting a field
fore turning. - Uneven terrain
Turn off and secure any imple- Changing gears after entering a
ments or attachments before situation where there is poten-
driving on the road. tial instability can be dangerous.
Always release the differential
T30O513A
lock as soon as it is no longer
IMPORTANT
needed.
Always attach the SMV emblem Do not move the tractor with the 1. Slow the engine speed to the idle
for road travel. parking brake on. speed.
Do not rest your foot on the clutch To avoid premature wear, do not 2. Fully depress the clutch and brake
while driving. Doing so causes use the clutch pedal as a foot pedals.
premature clutch wear. rest.
3. After coming to a complete stop, put
Always depress the clutch Hi-Lo shift levers cannot be
the shift lever in the neutral position.
quickly and release it slowly. shifted while the tractor is
Avoid sudden speed changes for moving. The main gear shift le- 4. Turn off the PTO clutch switch and
safety. ver can be shifted by depressing put the PTO shift lever in the neutral
Look in all directions before mov- the clutch and selecting speed. position.
ing the tractor. Carelessness When descending a steep slope, 5. Slowly pull the position lever forward
causes accidents and injuries. engage a low gear and descend to lower the attachment.
with the clutch fully engaged. 6. Set the parking brake.
Always be sure to interlock the
brake pedals when operating the 7. Turn the start switch to the “OFF” po-
tractor on roads. sition to stop the engine.
OPERATION 5-11
PARKING
PARKING BRAKE LEVER
IMPORTANT WARNING
Always set the parking brake Driving without releasing the
when stopping the tractor. DO not parking brake will cause the
depend on the engine to keep the brake disc to wear out quickly.
tractor from moving. Apply the parking brake and
NOTE: If the Hi-Lo shifter is left in place the chocks at the rear
the “LOW” position, it is possible wheels when parking.
and normal that the tractor might When parking the vehicle on a hill,
still roll without the brake applied. position the shift lever at low for-
Do not leave the tractor until it has ward (1st gear) for uphill and low
come to a complete stop and the reverse (1st gear) for downhill. Set
parking brake has been set. the parking brake and chock the
T30O514A
If parking on a slope is necessary, wh e e l s .
always set the brake and chock (1) Parking Brake Lever Do not park on steep hills. The
the wheels. (2) Chocks vehicle may roll down and cause
To avoid fire, do not park a hot an accident.
tractor on or near combustible When parking or stopping the tractor,
materials such as straw or dry secure it by applying the brake pedal.
grass. With the brake pedals depressed, pull the
parking brake lever up to apply the park-
ing brake. In order to release the parking
brake, push in the button and release the
lever.
5-12 DK802/902
1. Power steering functions only when 1. Do not allow anyone to stand near the
the engine is running. Steering may be tractor, or between the tractor and
slightly harder at low engine speed. implement, when attaching or remov-
ing implements.
2. Turning the steering wheel will be 2. Remove and attach implements on a
more difficult when the tractor is not firm, level surface. Use proper light-
moving; and it will increase tire wear. ing at night.
3. The use of front mounted equipment 3. Use appropriate balance weights
such as a loader will affect steering when mounting heavy implements.
effort. When using front mounted 4. Before making any adjustments to an T30O516A
equipment, adjust the front tire pres- implement; turn off the PTO, stop the
engine, and apply the parking brake.
sure and install the appropriate coun- Ensure that all moving parts have
terweight per instructions in this
CAUTION
stopped.
manual. Steering while the tractor is 5. Always use the drawbar for pulling A label with attachment instruc-
in motion is recommended. and towing. Attaching a load or imple- tions can be found on imple-
4. Avoid turning the steering wheel to its ment to any other part of the tractor ments manufactured by DAE-
extreme position. The noise that oc- may cause damage or upset.
DONG.
curs is the relief valve which is de- 6. When working on slopes, increase the When attaching an implement that
signed to prevent damage to the hy- tread width (open wheels) to improve
stability. does not require high traction
draulic system. Other hydraulic func- (such as a mower), connect the
tions can be adversely affected by 7. The tractor is longer with implements
attached. Use extra care when turn- top link to position A.
continuously holding the steering ing and be alert for bystanders and When attaching an implement that
wheel in the extreme position. obstacles.
requires high traction (such as a
5. In cold weather, allow the system to 8. Use only approved counterweights to plow), connect the top link to po-
warm up so that the steering func- achieve a safe balance. Never use
people or other objects. sition B or C. Position C is used
tions properly.
9. When using a front loader, maintain for implements where greater
6. When servicing or repairing the steer- stability by adding a rear counter- sensitivity and response are re-
ing system, take precautions to avoid weight or a rear-mounted implement. quired (plow, box blade).
oil contamination.
Always use position A when
7. Power steering makes the steering WARNING
transporting any implement. Fail-
wheel very easy to turn. Be careful at Read and understand both the ure to do so may result in unex-
all times, especially at higher speeds. tractor and implement manuals
before using. Use implements only pected movement of the
8. When adding or changing the oil, use implement.
for their intended purpose to
only the prescribed oil. avoid equipment damage and
personal injury.
OPERATION 5-15
WARNING
The implement can be lowered
even with the engine off. Take spe-
cial care not to do this inadver-
tently. Never leave an implement
in the raised position.
T30O517A T30O518A
Operating the position control lever ac- This will control the pull of the 3-point
tuates the hydraulic lift arm. This con- implement. As the load on the 3-point hitch
trols the elevation of the 3-point hitch changes due to various soil conditions,
mounted implement. the draft control system automatically re-
Place the position control lever in a suit- sponds to these changes by either rais-
able position and set the implement pull ing or lowering the implement slightly to
with the draft control. maintain a constant pull.
Place the position control lever in the low-
est position and set the implement pull
with the draft control lever.
5-16 DK802/902
(1) Ground Surface (2) Soft Soil (1) 3-point hitch lowering speed knob
(3) Implement Penetration Limit (A) Lock ( ) Fast ( ) Slow
In the draft control mode; when draft The lowering speed of the 3-point hitch
CAUTION
decreases, the implement automatically can be controlled by adjusting the 3-point
lowers to increase draft. To avoid hav- lowering speed knob. To avoid personal injury:
ing the implement lowered too far, set Stop the engine and relieve pres-
the position control lever at the lowest sure before connecting or dis-
CAUTION connecting lines.
working depth desired. Move the draft
To avoid personal injury: Do not use your hand to check
control lever to the point where the imple-
Fast lowering speed may cause for leaks.
ment is at the desired depth. This pre-
vents the implement from going too deep damage or injury. Lowering speed
and causing loss of traction and ground of implement should be adjusted
speed. to two or more seconds.
OPERATION 5-17
HORIZENTAL CONTROL
HOW TO USE AN IMPLEMENT WITH A
DOUBLE ACTING CYLINDER
1. Connect the two hoses from the cyl-
inder by inserting the male couplers
into the ports marked A and B.
2. Start the tractor and operate the
implement.
CAUTION
Moving the control lever to the A
position will pressurize the A
port. Moving the control lever to
the B position will pressurize the
B port.
Connect the couplers to achieve
the desired operating direction
when the A and B ports are
pressurized. T30O523A
Use the horizontal controller after fully 2. PTO Stop Location Set Volume: Use
knowing following usages of each part; the volume after putting PTO auto
1. Horizontal Controller Switch: The switch on. The volume is designed to
switch manually regulates the height regulate the height of a machine.
of operating machine. (Same function (Generally, The volume is used after
with horizontal manual control outside) setting at medium range)
OPERATION 5-19
WARNING
For your safety and best perfor-
mance, use only implements and
attachments approved for use
with your tractor.
Always be sure that hydraulic
couplers are clean. Contamina-
T30O526A tion of the hydraulic system can
cause malfunctions, accelerated
wear and equipment damage.
Do not adjust hydraulic system
Attachments with a single acting cylin- pressure settings. Never change
der (such as a dump trailer) can be at- relief valve settings. Improper set-
tached and used as follows. tings can cause serious equip-
ment damage and personal injury.
1. Lock the changeover handle for single/
double acting valve to the right T30O527A
completely.
(1) Lower Link
2. Insert the male coupler of the dump
(2) Drawbar Hitch
trailer into the female coupler C.
(3) Top Link
3. When you move the control lever of (4) Lift Linkage
the single/double acting valve to the C (5) Stabilizer
position, hydraulic pressure is applied
so that the cylinder is extended.
4. When you let go of the control lever, it
automatically returns to the neutral
position.
OPERATION 5-21
1. Level or tilt the implement from the Adjust the stabilizers to control horizon-
operator’s station. Setting depends on tal sway of the implement.
the type of implement.
Type of implement Stabilizer adjust-
2. Activate the rocker switch to make the
ment
leveling adjustment.
Plow, furrow, Loosen until the
subsoiler, implement can be
cultivator, ditcher moved 50 ~ 60 mm
(1.97 ~ 2.36 in.)
horizontally.
Rotary mower, Tighten securely
hay rake, tender,
ridger
5-22 DK802/902
WARNING
Do not use tires larger than
specified. T30O530A
OPERATION 5-23
6 MAINTENANCE
EVERY 50 HOURS
EVERY 100 HOURS
EVERY 200 HOURS
EVERY 250 HOURS
EVERY 300 HOURS
EVERY 400 HOURS
EVERY 600 HOURS
EVERY 800 HOURS
EVERY 1 YEAR
EVERY 2 YEARS
SERVICE AS REQUIRED
6-2 DK802/902
SERVICE INTERVALS
Period After
Indication on Hour Meter Purchase
No. Remark
1 2
50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1500 3000
Item y e a r years
Period After
Indication on Hour Meter Purchase
No. Remark
1 2
50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1500 3000
Item y e a r years
Period After
Indication On Hour Meter Purchase
No. Remark
1 2
50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1500 3000
Item y e a r years
NOTE : The jobs indicated by must be done after the first 50 hours of operation.
MAINTENANCE 6-5
LUBRICANTS
To prevent serious equipment damage, use only genuine DAEDONG fluids, oils and greases, or equivalents.
Capacities
No. Locations Lubricants
DK802/902
No.2-D diesel fuel
1 Fuel 100 (26.4 U.S.gal.)
No.1-D diesel fuel if temperature is below -10°C (14°F)
18.5
2 Coolant Fresh clean water with anti-freeze (50:50)
(4.9 U.S.gal.)
Engine oil: API Service Classification CC or CD
10.5 Above 25°C (77°F) SAE30, SAE10W-30 or 10W-40
3 Engine crankcase (2.77 U.S.gal.) 0 to 25°C (32 to 77°F) SAE20, SAE10W-30 or 10W-40
Below 0°C (32°F) SAE10W, SAE10W-30 or 10W-40
DAILY CHECK
HOW TO DISCONNECT THE SIDE WALK AROUND INSPECTION
COVER AND HOOD
When the under side of the side cover is For your own safety and maximum ser-
pulled to outward, rocker "A" fixed at the vice life of the machine, make a thorough
under side is lifted. daily inspection before operating the
After pull, lift it upward slightly (rocker machine to start the engine.
"B" unlocked), then the side cover could
be removed. CAUTION
To avoid personal injury:
CAUTION Be sure to check and service the
Be careful not to trap your fingers tractor on a flat place with the en-
when closing the side cover. gine shut off and the parking
brake “ON”.
CAUTION
The wiring connection for the
headlights must be disconnected
before the front grille is removed
completely.
MAINTENANCE 6-7
IMPORTANT
If oil level is low, do not run en-
gine.
MAINTENANCE 6-9
IMPORTANT
Grill and screen must be clean
from debris to prevent engine
from overheating and to allow
good air intake for the air cleaner.
6-10 DK802/902
CHECKING SEAT BELT AND ROPS CHECKING GAUGES, METER AND DRAINING WATER FROM FUEL PRE-
1. Always check condition of seat belt EASY CHECKER FILTER
and ROPS attaching hardware before 1. Inspect the instrument panel for bro-
operating tractor. ken gauge(s), meter(s) and Easy
2. Replace if damaged. Checker lamps.
2. Replace if broken.
INITIAL 50 HOURS
CHANGING ENGINE OIL REPLACING ENGINE OIL FILTER
CAUTION
To avoid personal injury:
Be sure to stop the engine be-
fore changing the oil.
Allow engine to cool down suffici-
ently, oil can be hot and can burn.
(1) Oil Inlet (2) Dipstick 2. After draining reinstall the drain plug. (1) Engine Oil Filter
(A) Oil level is acceptable within this range 3. Fill with the new oil up to the upper
notch on the dipstick.
IMPORTANT
Model Oil capacity with filter
To prevent serious damage to the
DK802/902 10.5 (2.77 U.S.gal.) engine, use only a KIOTI genuine
filter.
T30O609A
CAUTION
To avoid personal injury:
Allow engine to cool down
sufficiently, oil can be not and can
burn.
EVERY 50 HOURS
ADJUSTING CLUTCH PEDAL LUBRICATING GREASE FITTINGS
You should apply a small amount of multi- If your tractor is operated in extremely
purpose grease to the following points wet, muddy, or dusty conditions you
every 50 hours or as needed. should lubricate the fittings more often.
T30O616A
(1) Grease Nipple (Front Axle Bracket) (Front) (1) Grease Nipple (Top Link)
0 ~ 10 mm (2) Grease Nipple ( Axle Case Bracket) (Front) (2) Grease Nipple (Lift Rod)
Proper clutch
(0 ~ 0.39 in.)
pedal free travel(A)
on the pedal
(1) Grease Nipple (Front Axle Bracket) (Rear) (1) Grease Nipple (Top Link Bracket)
MAINTENANCE 6-15
(1) Nut: 166.7 ~ 186.3 N·m (1) Fuel Lines (2) Clamp Bands (1) Element (2) Cover
(17 ~ 19 kgf·m, 122.9 ~ 137.4 lb·ft) (3) Evacuator Valve
Bolt:196 ~ 226 N·m
(20 ~ 23 kgf·m, 144.7 ~ 166.3 lbf·ft)
(2) Nut: 274.6 ~ 318.7 N·m 1. Check to see that all lines and hose 1. Remove the air cleaner cover and
(28 ~ 32.5 kgf·m, 202.6 ~ 235.0 lbf·ft) clamps are tight and not damaged. element.
CAUTION 2. If hoses and clamps are found worn 2. Clean the element:
or damaged, replace or repair them at 1) When dry dust adheres to the element,
To avoid personal injury: once. blow compressed air from the inside,
Never operate tractor with a
turning the element. The compressed
loose rim, wheel, or axle. NOTE air pressure must be below 686 kPa
Any time bolts and nuts are
If the fuel line is removed, be sure to (7 kgf/cm3, 99 psi).
loosened, retighten to specified
properly bleed the fuel system. (See
torque.
“Bleeding Fuel System” in as required
Check all bolts and nuts fre-
maintenance)
quently and keep them tight.
Check wheel bolts and nuts regularly
especially when new. If they are loose,
tighten them as above.
6-16 DK802/902
T30O645A
(1) Brake Fluid Reservoir (6) Brake Tube 2 (R) (10) 13 Gear Shaft (R)
(2) Brake Pedal (7) Brake Piston (11) Brake Plate
(3) Master Cylinder Assembly (8) Brake Plate (12) Brake Case
(4) Balance Valve (9) 13 Gear Shaft (L) (13) Breather
(5) Brake Tube 2 (L)
6-18 DK802/902
1. Fill the brake fluid reservoir (1) to its 9. Repeat 2 through 8 for the opposite Brake fluid
maximum line. brake. 0.47 (0.12 U.S.gal.)
capacity
2. Lower the brake hose line as low as 10.After completely bleeding both brakes,
possible and below the master cylin- ensure that brake fluid is filled up to Shell Korea:
Brake fluid type
der assembly (3). its maximum line. (Tellus) 32
(Daedong
3. If brake fluid does not get into the mas- genuine brake SK Oil: ZIC SW
ter cylinder (3), disconnect the hose fluid) AW 32
line from the balance valve (4). De-
CAUTION
press the brake pedal (2) slowly and • Because some of brake fluid will
consistently and release it. Repeat the be lost in the bleeding procedure, WARNING
procedure until the brake fluid comes frequently re-supply brake fluid • DAEDONG (KOITI) genuine brake
out the end of the hose. Reconnect and slowly press and release the fluids are petroleum-based. Do
the hose to the balance valve. Make brake pedal. not use vegetable-based fluids.
sure oil comes out of the cylinder. • When breather valves are
4. Unscrew halfway the brake breather fastened, the brake pedal should
valve (13) of the brake case (12) to be half-depressed.
the unfasten direction. • Breather valves should be fas-
tened after completely removing
5. Connect a transparent plastic hose to
all air inside of the brake line. En-
the bleeder.
sure that brake fluid is filled up
6. Slowly depress the brake pedal (2) to its maximum line.
and release it. Repeat this procedure • Before opening the brake fluid
as necessary. Frequently supply brake cap, clean up its surroundings and
fluid to make sure that there is enough carefully place it to a clean loca-
fluid in the reservoir. tion so that no foreign objects
7. Repeat 6 until there is no air trapped such as water and dusts will be
inside of the transparent hose. added to the brake fluid.
8. After completing the bleeding • Always use the brake reservoir
filter to re-supply the brake fluid.
procedure, fasten the bleeder valve.
When fastening the valve, depress the
brake pedal (2) halfway.
MAINTENANCE 6-19
T30O625A T30O626A
CAUTION CAUTION
To avoid personal injury: To avoid personal injury:
Be sure to stop the engine be- Never remove the vent caps
fore checking belt tension. while the engine is running.
Keep electrolyte away from eyes,
Proper A deflection of between hands and clothes. If you are spat-
fan belt 7 ~ 9 mm (0.28 ~ 0.34 in.) tered with it, wash it away com-
pletely with water immediately
tension when the belt is pressed
and get medical attention.
(A) in the middle of the span. Wear eye protection and rubber
gloves when working around the
battery.
6-20 DK802/902
Mishandling the battery shortens the ser- When using a boost-charged battery,
CAUTION
vice life and adds to maintenance costs. it is necessary to recharge the bat-
The original battery is maintenance free, tery as early as possible. To avoid personal injury:
but needs some servicing. Failure to do this will shorten the When the battery is being
battery’s service life. activated, hydrogen and oxygen
If the battery is weak, the engine will be
gases in the battery are ex-
difficult to start and the lights will be dim. 5. When the specific gravity of electro-
tremely explosive. Keep open
It is important to check the battery lyte is between 1.27 and 1.29 the
sparks and flames away from the
periodically. charging is completed.
battery at all times, especially
6. When exchanging an old battery for a when charging the battery.
BATTERY CHARGING new one, use battery of equal speci- When charging the battery, en-
fication shown in table 1. sure the vent caps are securely
1. Make sure each electrolyte level is
Table 1 in place. (If equipped)
somewhere between the markings (A)
When disconnecting the cable
and (B). Add a proper amount of dis-
Battery TYPE Volts (v) from the battery, start with the
tilled water up to the highest level as
negative terminal first.
required. 100 AH 12
When connecting the cable to the
2. The water in the electrolyte evapo- battery, start with the positive
rates during recharging. Liquid short- terminal first.
age damages the battery. Excessive • Never check battery change by
liquid spills over and damages the trac- DIRECTION FOR STORAGE
placing a metal object across the
tor body. 1. When storing the tractor for a long posts. Use a voltmeter or
3. To slow charge the battery, connect period, remove the battery from hydrometer.
the battery positive terminal to the tractor, adjust the electrolyte to the
charger positive terminal and the nega- proper level and store in a dry place
tive to the negative, then recharge in out of direct sunlight.
the standard fashion. 2. The battery self-discharges while it is
4. A boost charge is only for stored.
emergencies. It will partially charge the Recharge it once every three months
battery at a high rate and in a short in hot seasons and once every six
time. months in cold seasons.
MAINTENANCE 6-21
T30O627A
3. Keep yourself well away from the
machine for another 10 minutes or until
(1) Radiator Hoses (2) Clamp the steam has stopped blowing out of
the engine.
4. Allow the engine to cool sufficiently,
Check to see if radiator hoses are prop- before servicing the engine. Then fol-
erly fixed every 200 hours of operation low the manual’s “ Troubleshooting”
or six months, whichever comes first. section to find and repair the cause of
1. If hose clamps are loose, or water the overheating. Do not start the en-
leaks, tighten the clamps securely. gine again until all repairs are made.
2. Check radiator hoses. If hoses are
swollen, hardened, or cracked, re- Belt deflection should be
place both the hose and the related 10 to 12 mm (0.394 to 0.
clamps, and tighten securely. A/C belt 472 in.) when pressing the
Replace hoses and hose clamps every 2 tension center point of belt with
years or earlier if checked and found that the force of 10 kgf.
hoses are swollen, hard ended or
cracked.
6-22 DK802/902
(1) Power Steering Line (A) Wheel - to - wheel distance at front (1) Lock Nut (2) Ball Joint
(B) Wheel - to - wheel distance at rear
1. Check to see that all hydraulic lines 1. Park tractor on a flat surface. ADJUSTING PROCEDURE
and hose clamps are tight and 2. Turn the steering wheel so front 1. Loosen the lock nut and turn the ball
undamaged. wheels are in the straight ahead joint to adjust the rod length until the
2. If damage is found you should replace position. proper toe-in measurement is obtained.
the hose or clamp at once. 3. Lower the implement, lock the park (Same as rod length of left and right
brake and stop the engine. cylinder)
4. Measure the distance between tire 2. Retighten the lock nut.
beads at front of tire, hub height.
5. Measure the distance between tire
beads at rear of tire, hub height.
6. The front distance should be 2 to 8
mm less than rear distance. If not, ad-
just the tie rod length.
MAINTENANCE 6-23
T30O633A T30O634A
1. Clean the screen with a vacuum 1. Unscrew the bolts and remove the
cleaner. cover, element and filter.
2. Clean the filter and element with a
compressed air.
MAINTENANCE 6-25
T30O635A
ADJUSTING PROCEDURE
Loosen the lock nut,tighten the adjusting
screw all the way, and then loosen the
screw by 1/6 turn. Retighten the lock nut.
6-26 DK802/902
T30O636A T30O637A
1. Clean the outer surface of fuel filter 1. Check the hoses and clamps.
completely. 2. Replace the damaged parts.
2. Remove the drain plug from the bot-
tom of fuel filter to drain water and
fuel.
3. Remove the filter case with a filter
wrench.
4. Replace the element with new one.
CAUTION
Be sure not to contact any dirts
and foreign objects when replac-
ing the element.
MAINTENANCE 6-27
EVERY 2 YEARS
FLUSH COOLING SYSTEM AND
CHANGING COOLANT
1. Stop the engine and let it cool.
2. To drain the coolant, open the radia-
tor drain plug and remove radiator
cap. The radiator cap must be re-
moved to completely drain the coolant.
3. After all coolant is drained, close the
drain plug.
4. Fill with clean water and cooling sys-
tem cleaner.
5. Follow the cleaner manufacture’s
instruction.
T30O638A T30O639A 6. After flushing, fill with clean water
and anti-freeze until the coolant level
(1) Drain Cock (1) Radiator Cap (2) Recovery Tank is just below the port.
(A) Full (B) Low
7. Fill with coolant up to the “FULL” mark
on the recovery tank.
IMPORTANT CAUTION 8. Start and operate the engine for few
Do not start engine without cool- To avoid personal injury: minutes.
ant. Do not remove the radiator cap 9. Stop the engine and let cool.
Use clean, fresh water and anti- when the engine is hot. Then
10.Check coolant level of recovery tank
freeze to fill the radiator and re- loosen cap slightly to the stop the and add coolant if necessary.
covery tank. relieve any excess pressure be-
When the anti-freeze is mixed fore removing cap completely. Model Coolant capacity
with water, the anti-freeze mix-
ing ratio must be less than 50%. DK651 9.1 (2.4 U.S.gal.)
Securely tighten radiator cap. If DK751/801/
the cap is loose or improperly 18.5 (4.9 U.S.gal.)
901
fitted, water may leak out and the
engine could overheat.
6-28 DK802/902
SERVICE AS REQUIRED
BLEEDING FUEL SYSTEM DRAINING CLUTCH HOUSING REPLACING LIGHT BULB
WATER
AIR MUST BE REMOVED 1. Head lights and rear combination lights:
1. When the fuel filter or lines are Take the bulb out of the light body and
removed. replace with a new one.
2. When tank is completely empty. 2. Other lights:
3. After the tractor has not been used Detach the lens and replace the bulb.
for a long period of time.
Bulb name Standard
Reserve lamp 12V 10W
AIR BLEEDING
Head light 12V 55W/60W
For Delphi fuel injection pump, the air in Direction indicator (front) 12V 21W
fuel system is automatically removed
Direction indicator (rear) 12V 21W
when running the engine for 3 minutes. T30O640A
Work light 12V 35W
(1) Plug Taillight 12V 21W/5W
Lighting on instrument,
illumination lamp 12V 3.4W
Your tractor is equipped with a plug un-
der the clutch housing. Bulbs except the above
14V 1.4W
After you operate your tractor in the rain, bulbs on the instrument
snow, or after washing the tractor, wa- Cab interior lamp 12V 10W
ter may get into the clutch housing. If this
happens, remove the plug in the clutch
housing and drain water. Remember to
reinstall the plug to avoid serious dam-
age to clutch.
6-30 DK802/902
IMPORTANT
Before replacing a blown fuse, de-
T30O641A
termine why the fuse blew and
make any necessary repairs. Fail-
CAUTION ure to follow this procedure may
• Park tractor on a flat place and put result in serious damage to the
the block on the wheel. tractor electrical system. Refer to
• Put forward/backward lever, Main the troubleshooting section of
shift lever and PTO lever in neutral. this manual or your local KIOTI
Dealer for specific information
1. Operate air conditioner with the fol- dealing with electrical problems.
lowing status.
- Engine rpm : approx 1500 rpm
- Temperature control lever : at the point
of maximum cooling temperature
T30O642A
- Blower control switch : high
- Air conditioner switch : ON (1) Fuse Box
T30O644A
T30O643A
In case of engine problems, use the following charts to determine possible causes.
POSSIBLE CAUSES
PROBLEMS
CHECKS BY THE USER CHECKS BY THE WORK PERSONNEL
The starter motor turns the engine too slowly 1,2,3,4
The engine does not start. 5,6,7,8,9,10,12,13,14 34,35,36,37,38,42,43,44
The engine is difficult to start. 5,6,7,8,9,10,12,13,14,15,16,17,19 34,36,37,38,40,42,43,44
Insufficient engine power output 8,9,10,12,13,16,17,18,19, 20,21 34,36,37,38,40,42,43,44
Engine misfire 8,9,10,12,13,15,20,22,62 34,36,37,38,39,40,41,43
High fuel consumption 11,13,15,17,18,19,21,22 34,36,37,38,39,40,42,43,44
Black exhaust smoke 11,13,15,17,19,21,22 34,36,37,38,39,40,42,43,44
Blue or white exhaust smoke 4,15,21,23,62 36,37,38,39,42,44,45,52,58
Low oil pressure. 4,24,25,26 46,47,48,50,51,59
Engine knocking. 9,13,15,17,20,22,23,62 36,37,40,42,42,44,46,52,53,60
Engine runs erratically 7,8,9,10,11,12,13,15,16,18,20,22,23 34,38,39,40,41,44,52,60
Vibration 13,18,20,27,28 34,38,39,40,41,44,52,54
High oil pressure 4,25 49
Engine overheating 11,13,15,19,27,29,30,32,61 34,36,37,39,52,5556,57
Crankcase pressure 31,33 39,42,44,45,52
Bad compression 11,22 37,39,40,42,43,44,45,53,60
Engine stops right after starting 10,11,12
NOTE
If you do not find the cause of trouble, consult your dealer for assistance.
TROUBLESHOOTING 8-3
1. Battery capacity low. 24. Low oil level. 44. Piston rings are stuck, worn or
2. Bad or corroded electrical connections. 25. Defective gauge. broken.
3. Faulty starter motor. 26. Dirty lubricating oil filter element. 45. Valve stems and/or guides are worn.
4. Wrong grade of lubricating oil. 27. Cooling fan damaged. 46. Crankshaft bearings are worn or
5. Starter motor turns engine too slowly. 28. Fault in engine mounting or flywheel damaged.
6. Fuel tank empty. housing. 47. Lubricating oil pump is worn.
7. Fault in fuel shutoff. 29. Engine oil overfilled. 48. Relief valve does not close.
8. Restriction in a fuel line. 30. Restriction in air or water passages 49. Relief valve does not open.
of radiator. 50. Relief valve spring is broken.
9. Faulty fuel pump.
31. Restriction in breather pipe. 51. Oil pump suction blocked or damaged.
10. Dirty fuel filter element.
32. Insufficient coolant in system. 52. Piston is damaged.
11. Dirty or damaged air filter.
33. Vacuum line leaks or fault in crank- 53. Piston height is incorrect.
12. Air in fuel system.
case vent.
13. Faulty fuel injectors or incorrect type. 54. Flywheel housing or flywheel is not
34. Fault in fuel injection pump. aligned correctly.
14. Cold start system used incorrectly.
35. Broken drive on fuel injection pump. 55. Sticking or incorrect type of ther-
15. Fault in cold start system.
36. Timing of fuel injection pump is mostat.
16. Restriction in fuel tank vent. incorrect. 56. Restriction in coolant passages.
17. Wrong type or grade of fuel used. 37. Valve timing is incorrect. 57. Water pump failure.
18. Restricted movement of engine speed 38. Bad compression. 58. Valve stem seal is damaged
control.
39. Cylinder head gasket leaks. (If equipped).
19. Restriction in exhaust pipe.
40. Valve damaged or sticking. 59. Oil sump strainer clogged.
20. Engine temperature is too high.
41. Fuel injector sticking, or clogged in- 60. Valve spring is broken.
21. Engine temperature is too low. jector nozzle. 61. Drive belt for water pump is loose.
22. Incorrect valve tappet clearances. 42. Worn or damaged cylinder bores. 62. Faulty cold start switch/faulty wiring.
23. Air filter incorrectly installed or wrong 43. Leakage between valve and seats.
type; or air intake blockage.
9
INDEX
9-2 DK802/902
CHECKING TRANSMISSION FLUID LEVEL ....................... 6-8 EVERY 200 HOURS .......................................................... 6-21
CHECKING WHEEL BOLT TORQUE .................................. 6-15 EVERY 250 HOURS .......................................................... 6-24
CLEANING AIR CLEANER PRIMARY ELEMENT .............. 6-15 EVERY 300 HOURS .......................................................... 6-25
CLEANING AMBIENT AIR FILTER ..................................... 6-24 EVERY 400 HOURS .......................................................... 6-25
CLEANING GRILL, RADIATOR NETAND OIL COOLER SCREEN 6-9 EVERY 50 HOURS ............................................................ 6-14
CLEANING INTAKE AIR FILTER ......................................... 6-24 EVERY 600 HOURS .......................................................... 6-25
CLUTCH PEDAL ................................................................. 4-14 EVERY 800 HOURS .......................................................... 6-26
CONNECTING HYDRAULIC ACCESSORIES - DOUBLE ACTING EXTERIOR VIEW AND APPELLATION ................................ 4-2
VALVE (IF EQUIPPED) ....................................................... 5-16
F
D FLUSH COOLING SYSTEM AND CHANGING COOLANT .. 6-27
DAILY CHECK ...................................................................... 6-6 FOOT THROTTLE .............................................................. 4-16
DESCRIPTION OF CAB OPERATING SYSTEM ................ 4-18 FUEL GAUGE ....................................................................... 4-7
DIFFERENTIAL LOCK PEDAL ........................................... 4-16
DRAINING CLUTCH HOUSING WATER ............................ 6-29 H
DRAINING WATER FROM FUEL PRE-FILTER .................. 6-10 HAZARD LAMP SWITCH .................................................... 4-6
DRAWBAR HITCH ............................................................. 4-17 HEATER/AIRCONDITIONER ............................................... 4-21
DRIVING THE TRACTOR ..................................................... 1-8 HIGH-BEAM INDICATOR ..................................................... 4-8
HORIZENTAL CONTROL ................................................... 5-18
E HOW TO DISCONNECT THE SIDE COVER AND HOOD .... 6-6
ENGINE OIL PRESSURE WARNING LAMP ...................... 4-10 HOW TO DRIVE ON A SLOPE ........................................... 5-12
ENTRANCE ON EITHER SIDE ............................................ 4-19 HOW TO START IN WINTER ............................................... 5-5
EVERY 1 YEAR ................................................................. 6-26 HOW TO TURN .................................................................. 5-12
EVERY 100 HOURS .......................................................... 6-15 HYDRAULIC SYSTEM WARNING LAMP ........................... 4-9
EVERY 2 YEARS .............................................................. 6-27
9-4 DK802/902
J P
JUMP STARTING .................................................................. 5-7 P.T.O SHAFT COVER ........................................................ 4-18
PARKING ............................................................................ 5-11
K PARKING BRAKE INDICATOR ............................................. 4-9
KEY SWITCH ........................................................................ 4-5 PARKING BRAKE LEVER ................................................. 4-14
PARKING THE TRACTOR .................................................... 1-9
L POWER STEERING PRECAUTIONS .................................. 5-14
LIFTING DEVICES FOR AN ATTACHMENT ...................... 5-15 PRECAUTIONS WHEN ENTERING OR LEAVING A PAVED ROAD
LIST OF POSSIBLE CAUSES .............................................. 8-3 ............................................................................................ 5-12
LOADING AND UNLOADING THE TRACTOR .................. 5-13 PRECAUTIONS WHILE DRIVING ON THE ROAD ............ 5-13
LUBRICANTS ....................................................................... 6-5 PREHEATER INDICATOR ..................................................... 4-8
LUBRICATING GREASE FITTINGS ................................... 6-14 PRE-OPERATION CHECK .................................................... 5-3
PTO LAMP ............................................................................ 4-9
M PTO SELECTION LEVER ................................................... 4-13
MAIN SHIFT LEVER &HI-LO SHIFT LEVER ..................... 4-12 PTO SPEED CHANGE LEVER ........................................... 4-13
MAJOR PROBLEMS AND POSSIBLE CAUSES ................. 8-2 PTO SWITCH(ON/OFF) ..................................................... 4-13
O R
OPERATING NEW TRACTOR .............................................. 5-2 REAR WINDOW ................................................................. 4-19
OPERATING THE CONTROLS ........................................... 4-11 REMOVING THE TRACTOR FROM STORAGE .................. 7-2
INDEX 9-5