Kioti DK 802 Manual
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Kioti DK 802 Manual

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Table of Contents

FOREWORD
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.

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Summary of Contents for Kioti DK 802

  • Page 1 FOREWORD 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.
  • Page 2 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.
  • Page 3 ABBREVIATIONS LIST ABBREVIATION DEFINITION Four-Wheel Drive American Petroleum Institute ASAE American Society of Agricultural Engineers Society of Automotive Engineers International Organization for Standardization Power Take Off ROPS Roll-Over Protective Structure Revolution Per Minute Slow Moving Vehicle...
  • Page 4 UNIVERSAL SYMBOLS As a guide to the operation of your tractor, various universal symbols have been utilized on the instruments and controls. The symbols are shown below with an indication of their meaning. Headlight-Low Beam Safety Alert Symbol Power Take-Off Clutch Control-Off Position T/M Oil Filter Headlight-High Beam...
  • Page 5 PRE-DELIVERY SERVICE CHECK AND ADJUST AS REQUIRED PRE-OPERATIONAL SERVICE 21.Seat mounting and adjust- 11. Upper link, draw-bar and pin ment ........CHECKS in position ......22. All electrical cables, termi- 12. Wheel-to-rim clamp bolts 1. Tire pressure and condition ..nals and wires .....
  • Page 6 RECORD MODEL AND SERIAL OPERATIONAL SERVICE CHECKS • Draft control for tension NUMBERS: and compression loads ... All operational checks are to be • Auxiliary equipment control Tractor Model No. performed with the tractor at nor- and remote control valves Serial Tractor mal operating temperature.

  • Page 7: Table Of Contents

    CONTENTS 1. SAFETY PRECAUTIONS ............ 2. SERVICING THE TRACTOR ..........3. SPECIFICATIONS ..............4. DESCRIPTION OF OPERATING SYSTEM ....... 5. OPERATING ................. 6. MAINTENANCE ..............7. LONG-TERM STORAGE ............. 8. TROUBLESHOOTING ............9. INDEX ..................

  • Page 8: Safety Precautions

    BEFORE OPERATING THE TRACTOR OPERATING THE TRACTOR DRIVING THE TRACTOR PARKING THE TRACTOR OPERATING THE P.T.O SAFETY PRECAUTIONS USING 3-POINT HITCH SERVICING THE TRACTOR TRACTOR SAFETY LABELS...
  • Page 9 1-2 DK802/902 BEFORE OPERATING THE TRACTOR A careful operator is the best operator. Most accidents can be avoided by observ- ing certain precautions. To help prevent accidents, use these safety precautions and pay attention to the job at hand. If you can prevent an accident in advance, your time will have been well spent.
  • Page 10 13. Do not start your tractor by shorting across the starter. 18.No alterations should be made to your KIOTI tractor without first consulting your KIOTI dealer.
  • Page 11 1-4 DK802/902 20. For your safety ROPS with a seat belt is recommended for most applications. 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) A ROPS should never be modified by welding, grinding or cutting, as this can...
  • Page 12 SAFETY PRECAUTIONS 1-5 OPERATING THE TRACTOR T30O108A T30O109A T30O110A 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...
  • Page 13 1-6 DK802/902 T30O111A T30O112A T30O113A (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 tached to the three point hitch, the or unattended.
  • Page 14 SAFETY PRECAUTIONS 1-7 11. Driving forward out of a ditch or steep inclines can cause the tractor to tip over backwards. To avoid this you should back out of these positions. Four wheel drive tractors can give you a false sense of security in the trac- tors ability to maneuver out of these positions, so extra caution should be taken.
  • Page 15 1-8 DK802/902 DRIVING THE TRACTOR T30O116A T30O117A T30O118A (1) Brake Pedal(LH) (3) Brake Pedal Lock (1) SMV Emblem (2) Brake Pedal(RH) (A) Whenever traveling on the road 1. Lock the brake pedals together when 2. Always slow the tractor down before 3.
  • Page 16 SAFETY PRECAUTIONS 1-9 PARKING THE TRACTOR OPERATING THE P.T.O 4. Observe all local traffic and safety regulations. 5. Turn the headlights on. Dim them when meeting another vehicle. 6. Drive at speeds that allow you to main- tain control at all times. 7.
  • Page 17 1-10 DK802/902 USING 3-POINT HITCH SERVICING THE TRACTOR T30O121A T30O122A T30O123A (1) 3-point hitch lowering speed knob In order to service your tractor you must (A) Lock ) Fast ) Slow park it on a flat level surface, set the park- ing brake, place the gear shift lever in neutral and stop the engine.
  • Page 18 SAFETY PRECAUTIONS 1-11 T30O124A T30O125A T30O126A 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- rotate the cap to the first stop and al- connect the battery cables.
  • Page 19 1-12 DK802/902 T30O127A T30O128A T30O129A (1) Cardboard (3) Magnifying Glass (2) Hydraulic Line 9. Tire mounting should be done by quali- 11. Securely support the tractor when 14. Fluid escaping from pinholes may be changing wheels or the wheel tread fied professionals, with the proper invisible.
  • Page 20 SAFETY PRECAUTIONS 1-13 T30O130A 15. Keep the environmental pollution in mind. When replacing cooling water or oil, disuse it to the right way. Be sure to observe the relevant regu- lations when you dispose of the en- gine oil, transmission oil, fuel, coolant, filter and battery...
  • Page 21 1-14 DK802/902 TRACTOR SAFETY LABELS T30O131A...
  • Page 22 SAFETY PRECAUTIONS 1-15 1. E6500-51101 3. T4628-52201 4. T4817-52201 2. T4837-51181 5. T2325-50743...
  • Page 23 1-16 DK802/902 6. T4818-52142 8. T2615-53561 10. T4837-51191 7. T4625-52351 9. T2615-55112 11. T2615-54112...
  • Page 24 SAFETY PRECAUTIONS 1-17 12. T4837-51093 13. T4837-52121...

  • Page 25: Servicing The Tractor

    SERVICING THE TRACTOR...
  • Page 26 When parts or major service are required, please contact your authorized KIOTI dealer. When contacting your dealer, al- ways be prepared to provide the tractor model number, the tractor serial number, the engine serial number, and the trans- mission serial number.

  • Page 27: Specifications

    SPECIFICATIONS SPECIFICATIONS TRAVELING SPEED...
  • Page 28 3-2 DK802/902 SPECIFICATIONS MODEL DK802 DK902 Model 1104C-44T Type 4 cyl., Water Cooled, 4 Cycle, Turbo Diesel 90 (67.1) Engine gross 80 (59.7) HP(kw) Displacement cc(cu.in) 4400 (268.5) Bore and stroke mm(in) 105 x 127 (4.1 x 5) Rated revolution rpm min-1 2200 Injection timing...
  • Page 29 SPECIFICATIONS 3-3 DK802 DK902 MODEL Type Dry single plate-single stage type Clutch size mm(in) 325 (13) Type Full synchromesh 0.23 (0.14) F o r w a r d Travel speeds 16th 34.01 (21.13) km/h(mile/h) 0.23 (0.14) Reverse 16th 34.01 (21.13) Differential lock (Rear, Front) Standard Type...
  • Page 30 3-4 DK802/902 DK802 MODEL DK902 Brakes Wet Disc (Hydraulic) Standard Tires Front 9.5 - 24 Rear 12.4 - 38 Length(with 3point & front weight) 4,435 (174) mm(in) Width mm(in) 1,635 (64.3) Height(Cabin) mm(in) 2,720 (107.0) Wheelbase mm(in) 2,300 (90.5) Ground Clearance mm(in) 436 (17.1) Front Tread - Std.
  • Page 31 SPECIFICATIONS 3-5 TRAVELING SPEED * At rated engine speed(2200rpm) km/h (mile/h) LEVER SELECTIONS MODEL Shuttle Hi-Low Main DK802 DK902 Tire size (Rear wheel) 18.4-34 18.4-34 1635mm (64.37 in) 1635mm (64.37 in) 0.21 (0.13) 0.21 (0.13) 0.29 (0.18) 0.29 (0.18) Creep 0.39 (0.24) 0.39 (0.24) 0.54 (0.33)
  • Page 32 3-6 DK802/902 km/h (mile/h) LEVER SELECTIONS MODEL Shuttle Hi-Low Main DK802 DK902 Tire size (Rear wheel) 18.4-34 18.4-34 1635mm (64.37 in) 1635mm (64.37 in) 0.20 (0.12) 0.20 (0.12) 0.27 (0.16) 0.27 (0.16) Creep 0.36 (0.22) 0.36 (0.22) 0.50 (0.31) 0.50 (0.31) 1.57 (0.97) 1.57 (0.97) 2.13 (1.32)

  • Page 33: Description Of Operating System

    EXTERIOR VIEW AND APPELLATION DESCRIPTION OF INSTRUMENTS PANEL AND SWITCHES OPERATING SYSTEM OPERATING THE CONTROLS DESCRIPTION OF CAB OPERATING SYSTEM(OPTION)
  • Page 34 4-2 DK802/902 EXTERIOR VIEW AND APPELLATION (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...
  • Page 35 DESCRIPTION OF OPERATING SYSTEM 4-3 (1) Work Lamp (2) Drawbar Hitch (3) Lower Link (4) Lift Linkage (5) Top Link (6) Transmission Oil Filler Plug (7) PTO Cover (8) Wiper (9) Oil Gauge T30O402A...
  • Page 36 4-4 DK802/902 INSTRUMENTS PANEL AND SWITCHES T30O403A (1) Steering Wheel (16) Hydraulic System Warning Lamp (6) 4WD/QT Switch (11) Battery Charge Warning Lamp (2) Start Switch (17) Engine Oil Pressure Warning Lamp (7) Hour Meter (12) High Beam Indicator (3) Headlight Switch (18) 4WD Operation Indicator (8) Tachometer (13) Preheater Indicator...
  • Page 37 DESCRIPTION OF OPERATING SYSTEM 4-5 KEY SWITCH TURN SIGNAL/ HEADLIGHT/HORN SWITCH STARTING INSTRUCTIONS Inserting the key and turning it one click to the right energizes the electrical sys- tem and lights up the engine oil pressure lamp (RED). Electrical accessories can START be operated in this position.
  • Page 38 4-6 DK802/902 4WD/QT SWITCH HAZARD LAMP SWITCH T30O406A T30O408A (1) 4WD/QT Switch (1) Hazard Lamp Switch (A) Hazard Lights OFF (B) Hazard Lights ON 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.
  • Page 39 DESCRIPTION OF OPERATING SYSTEM 4-7 TACHOMETER/HOUR METER TEMPERATURE GAUGE FUEL GAUGE T30O409A T30O410A T30O411A (1) Hour Meter (1) Temperature Gauge (1) Fuel Gauge (2) Engine Revolution Meter The hour meter shows the number of Always check the engine coolant level Fuel gauge indicates the amount of fuel.
  • Page 40 If this should happen during operation, coolant. After heating the thermostat coil check the electrical charging system or about 8 sec., the lamp lights Off. Start the consult your local KIOTI dealer. engine as this lamp is Off.
  • Page 41 DESCRIPTION OF OPERATING SYSTEM 4-9 PTO LAMP PARKING BRAKE INDICATOR HYDRAULIC SYSTEM WARNING LAMP T30O415A T30O416A T30O417A This lamp lights up red when the PTO is This lamp lights up red when the parking A yellow light indicates possible prob- brake is on.
  • Page 42 4-10 DK802/902 ENGINE OIL PRESSURE WARNING 4WD OPERATION INDICATOR LAMP 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.
  • Page 43 DESCRIPTION OF OPERATING SYSTEM 4-11 OPERATING THE CONTROLS (1) Main Shift Lever (2) Hi-Lo Shift Lever (3) Shuttle Shift Lever (4) PTO Speed Change Lever (5) Parking Brake Lever (6) Clutch Pedal (7) Steering Wheel Tilt Lever (8) Brake Pedal(LH) (9) Brake Pedal(RH) (10) Foot Throttle (11)
  • Page 44 4-12 DK802/902 MAIN SHIFT LEVER &HI-LO SHIFT LEVER SHUTTLE SHIFT LEVER USING CREEP SPEED OPTION 1. RECOMMENDED USES • Rotary tilling • Transplanting • Loading, unloading • Trenching 2. NOT RECOMMENDED • Operation in mud • Pulling a trailer or other load •...
  • Page 45 DESCRIPTION OF OPERATING SYSTEM 4-13 PTO SWITCH(ON/OFF) PTO SPEED CHANGE LEVER PTO SELECTION LEVER T30O407A T30O423A T30O424A (1) PTO Selection Lever (1) PTO switch (1) PTO Change Lever (A) Independent PTO - ON - OFF (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...
  • Page 46 4-14 DK802/902 PARKING BRAKE LEVER CLUTCH PEDAL INDEPENDENT PTO The independent PTO mode is used for normal PTO operations. It operates con- tinuously at a constant speed, indepen- dent transmission speed selections. The PTO shaft turns in a clockwise direction (as viewed from the rear of the tractor).
  • Page 47 DESCRIPTION OF OPERATING SYSTEM 4-15 STEERING WHEEL ADJUSTMENT BRAKE PEDAL(RIGHT AND LEFT) (TILTING PEDAL) 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.
  • Page 48 4-16 DK802/902 FOOT THROTTLE DIFFERENTIAL LOCK PEDAL 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. If one of the rear wheels should slip, use the differential lock.
  • Page 49 DESCRIPTION OF OPERATING SYSTEM 4-17 SEAT DRAWBAR HITCH SEATBACK RECLINING ADJUSTMENT To adjust the seatback reclining angle, lean forward and pull the lever upwards. Adjust the seatback angle then release the lever. After adjustment, ensure that the seatback is locked firmly in position. SEAT BELT ADJUSTMENT 1.
  • Page 50 4-18 DK802/902 DESCRIPTION OF CAB OPERATING SYSTEM P.T.O SHAFT COVER T30O433A (1) P.T.O Shaft Cover 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...
  • Page 51 DESCRIPTION OF OPERATING SYSTEM 4-19 REAR WINDOW ENTRANCE ON EITHER SIDE CAB - EXTERNAL PARTS T30O435A T30O436A T30O437A (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.
  • Page 52 4-20 DK802/902 WORK LIGHT (FRONT/REAR) WIPER T30O439A T30O440A T30O438A (1) Work Light (Front) Switch (1) Wiper Switch (Front) (1) Door Prop(LH,RH) (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.
  • Page 53 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.
  • Page 54 4-22 DK802/902 T30O443A T30O444A T30O445A 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.
  • Page 55 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.
  • Page 56 4-24 DK802/902 CASSETTE TAPE RECORDER INTERIOR CAB LIGHT T30O448A T30O449A T30O450A (1) Cassette (1) Antenna (1) Interior Cab Light POWER SUPPLY INSERTING A CASSETTE TAPE Use the switch in the light assembly to turn the light ON and OFF. Turn the knob clockwise to turn the Turn the power ON and insert the cas- power ON and to increase volume.
  • Page 57 DESCRIPTION OF OPERATING SYSTEM 4-25 ROOF VENT ACCESSORIES T30O453A (1) Cigar lighter (2) Ashtray T30O451A T30O452A (1) Roof Vent (1) Roof Vent Latch 1. Use the roof vent to allow fresh air into the cab. 2. To open, press the button on the handle.
  • Page 58 OPERATING A NEW TRACTOR PRE-OPERATION CHECK OPERATION OPERATING THE ENGINE OPERATING THE TRACTOR...
  • Page 59 5-2 DK802/902 OPERATING NEW TRACTOR CHANGING LUBRICATING OIL FOR NEW TRACTOR In handling a new tractor, the following How a new tractor is handled and main- Special attention should be given to new precautions should be observed. tained determines the life of the tractor. tractors lubrication oil.
  • Page 60 OPERATION 5-3 PRE-OPERATION CHECK OPERATING THE ENGINE STARTING THE ENGINE It is a good practice to know the condition WARNING of your tractor before you start it. You Carefully read and understand should do routine check before each use. the instructions in this entire manual;...
  • Page 61 5-4 DK802/902 T30O504A T30O505A (1) Position Control Lever (1) Hand Accelerator Lever 4. Lower the implement if attached by 5. Set the hand throttle at about half pushing the position control lever throttle. forward. T30O503A (1) PTO Switch (2) Main Shift Lever (3) P.T.O Change Lever 2.
  • Page 62 OPERATION 5-5 HOW TO START IN WINTER 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 seconds). Do not operate the starter motor continuously for more than 10 2.
  • Page 63 5-6 DK802/902 STOPPING THE ENGINE WARMING UP 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 The hydraulic oil also serves as the to both brake pedals. Hydraulic oil serves as transmission transmission fluid.
  • Page 64 OPERATION 5-7 JUMP STARTING 4. Attach the red clamp to the positive terminal of the dead battery, and at- tach the other end to the positive ter- minal of the helper battery. 5. Clamp the black cable to the negative terminal of the Engine hooks, and at- tach the other end to the negative ter- minal of the helper battery.
  • Page 65 5-8 DK802/902 OPERATING THE TRACTOR STARTING THE TRACTOR WEARING THE SEATBELT For the safety reasons, always wear the seatbelt properly. 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.
  • Page 66 OPERATION 5-9 T30O512A T30O510A T30O511A (1) Position Control Lever (1) Hand Accelerator Lever (1) Parking Brake Lever 7. Release the parking brake. 4. Pull the position control lever backward 5. Increase the engine speed slowly from to raise the implement, if attached. idle speed to about half throttle.
  • Page 67 5-10 DK802/902 STOPPING THE TRACTOR 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;...
  • Page 68 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.
  • Page 69 5-12 DK802/902 HOW TO TURN HOW TO DRIVE ON A SLOPE PRECAUTIONS WHEN ENTERING OR LEAVING A PAVED ROAD Approach all turns slowly. Always re- 1. Always drive slowly on slopes. Do not 1. Make sure that the left and right brake duce speed before turning.
  • Page 70 OPERATION 5-13 PRECAUTIONS WHILE DRIVING ON LOADING AND UNLOADING THE THE ROAD TRACTOR 1. When loading the tractor on a truck or WARNING trailer, do it by driving backward. Always connect the left and right 2. If the engine stalls during loading, ap- brake pedals before driving on ply the brake and allow the tractor to the road.
  • Page 71 5-14 DK802/902 POWER STEERING PRECAUTIONS USING IMPLEMENTS SAFELY ATTACHING AN IMPLEMENT 1. Do not allow anyone to stand near the 1. Power steering functions only when tractor, or between the tractor and the engine is running. Steering may be implement, when attaching or remov- slightly harder at low engine speed.
  • Page 72 OPERATION 5-15 LIFTING DEVICES FOR AN ATTACH- POSITION CONTROL DRAFT CONTROL MENT The hydraulic lift will raise and lower implements attached to the 3-point hitch. It can be operated anytime that the en- gine is running; whether or not the clutch is engaged.
  • Page 73 5-16 DK802/902 CONNECTING HYDRAULIC ACCESSORIES MIXED CONTROL 3-POINT HITCH LOWERING SPEED - DOUBLE ACTING VALVE (IF EQUIPPED) T30O519A T30O521A T30O520A (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;...
  • Page 74 NOTE position. Continuous operation of the re- Your local KIOTI Dealer can supply lief valve serves no purpose and will parts to adapt couplers to hydraulic cause overheating.
  • Page 75 5-18 DK802/902 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.
  • Page 76 OPERATION 5-19 ATTACHING A LOADER 3. Horizontal Control Volume: Use the volume by putting horizontal auto switch. By regulating the height of lift cylinder, the volume enables operat- ing machine to keep horizontal..(Use after the volume is set at medium range) 4.
  • Page 77 5-20 DK802/902 ATTACHING DEVICES FOR GENERAL HOW TO USE ATTACHMENTS WITH A IMPLEMENTS SINGLE ACTING CYLINDER (IF EQUIPPED) 5. When you move the control lever of the single/double acting valve to the D position, the cylinder retracts as the load comes down by its own weight. WARNING For your safety and best perfor- mance, use only implements and...
  • Page 78 OPERATION 5-21 WHEN IMPLEMENT IS NOT ATTACHED LEVELING ADJUSTMENT ADJUSTMENT OF CHECK LINK 1. Fix lower link (LH & RH) so that the links do not come in contact with the wheels. 2. Use the bracket provided to secure the top link. ADJUSTMENT OF TOP LINK 1.
  • Page 79 5-22 DK802/902 WHEELS, TIRES AND TREAD WHEELS - FRONT WHEELS - REAR Front tread can not be adjusted. Rear tread width can be adjusted as shown with the standard equipped tires. Model Tread To change the tread width DK802/902 1,576 (62.0 in.) 1.
  • Page 80 Rear wheel weights are available, or liquid may be added to the Remove weight when it is no longer tires. Consult your KIOTI dealer for the needed. Front weights are available from correct ballasting necessary for your your dealer.

  • Page 81: Maintenance

    SERVICE INTERVALS LUBRICANTS DAILY CHECK INITAIL 50 HOURS EVERY 50 HOURS EVERY 100 HOURS EVERY 200 HOURS MAINTENANCE EVERY 250 HOURS EVERY 300 HOURS EVERY 400 HOURS EVERY 600 HOURS EVERY 800 HOURS EVERY 1 YEAR EVERY 2 YEARS SERVICE AS REQUIRED...
  • Page 82 6-2 DK802/902 SERVICE INTERVALS After Period Indication on Hour Meter Purchase Remark 50 100 150 200 250 1500 3000 y e a r years Item Change Engine oil Change Engine oil filter Change Transmission oil filter Change Hydraulic oil filter Transmission fluid Change Change...
  • Page 83 MAINTENANCE 6-3 After Period Indication on Hour Meter Purchase Remark 50 100 150 200 250 1500 3000 y e a r years Item Check Power steering oil line Change Check Fuel line Change Check Intake air line Change Adjust Toe-in Engine valve Adjust clearance...
  • Page 84 6-4 DK802/902 After Period Indication On Hour Meter Purchase Remark 50 100 150 200 250 1500 3000 y e a r years Item Clean Air conditioner Everyday condenser net Air conditioner belt Check tension Intake air filter Clean Clean Ambient air filter Check Air conditioner hose Heater hose...
  • Page 85 MAINTENANCE 6-5 LUBRICANTS To prevent serious equipment damage, use only genuine DAEDONG fluids, oils and greases, or equivalents. Capacities Locations Lubricants DK802/902 No.2-D diesel fuel Fuel 100 (26.4 U.S.gal.) No.1-D diesel fuel if temperature is below -10°C (14°F) 18.5 Coolant Fresh clean water with anti-freeze (50:50) (4.9 U.S.gal.) Engine oil: API Service Classification CC or CD...
  • Page 86 6-6 DK802/902 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.
  • Page 87 MAINTENANCE 6-7 CHECKING AND REFUELING Dirt may block the vent hole for the fuel NOTE tank, thus causing the engine to lose power, periodically clear the vent hole No.2-D is a distillate fuel of lower vola- and do not cover. tility for engines in industrial and heavy mobile service.
  • Page 88 6-8 DK802/902 CHECKING TRANSMISSION FLUID CHECKING ENGINE OIL LEVEL LEVEL CAUTION To avoid personal injury: Be sure to stop the engine be- fore checking the oil level. 1. Park the machine on a flat surface. 2. Check engine oil before starting the engine or 5 minutes or more after the engine has stopped.
  • Page 89 If water should leak, consult your rotate cap to the first stop and 1. Check front grill and side screens to local KIOTI Dealer. allow sufficient time for excess be sure they are clean of debris. pressure to escape before re- 2.
  • Page 90 6-10 DK802/902 CHECKING SEAT BELT AND ROPS CHECKING GAUGES, METER AND DRAINING WATER FROM FUEL PRE- EASY CHECKER FILTER 1. Always check condition of seat belt 1. Inspect the instrument panel for bro- and ROPS attaching hardware before ken gauge(s), meter(s) and Easy operating tractor.
  • Page 91 3. Fill with the new oil up to the upper (A) Oil level is acceptable within this range 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 (1) Drain Plug...
  • Page 92 2. Remove the oil filter. doesn’t leak through the seal. 3. Put a film of clean transmission oil on the rubber seal of the new filter. IMPORTANT To prevent serious damage to the hydraulic system, use only a KIOTI genuine filter.
  • Page 93 2. After draining reinstall the drain plug. 3. Fill with the new KIOTI TF65 fluid up to T30O613A T30O615A the upper line of the gauge.
  • Page 94 6-14 DK802/902 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.
  • Page 95 MAINTENANCE 6-15 EVERY 100 HOURS CHECKING WHEEL BOLT TORQUE CHECKING FUEL LINE CLEANING AIR CLEANER PRIMARY ELEMENT T30O621A T30O622A T30O623A (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)
  • Page 96 6-16 DK802/902 ADJUSTING BRAKE PEDAL 2) When carbon or oil adheres to the IMPORTANT element, soak the element in deter- The air cleaner uses a dry ele- gent for 15 minutes then wash it sev- ment, never apply oil. eral times in water, rinse with clean Do not run the engine with filter water and dry it naturally.
  • Page 97 MAINTENANCE 6-17 AIR BLEEDING FROM BRAKE SYSTEM 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...
  • Page 98 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:...
  • Page 99 MAINTENANCE 6-19 ADJUSTING FAN BELT TENSION BATTERY 1. Stop the engine and remove the key. 2. Apply moderate thumb pressure to belt between pulleys. 3. If tension is incorrect, loosen the al- ternator mounting bolts and, using a lever placed between the alternator and the engine block, pull the alterna- tor out until the deflection of the belts falls within acceptable limits.
  • Page 100 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- tery as early as possible. To avoid personal injury: The original battery is maintenance free, When battery being...
  • Page 101 MAINTENANCE 6-21 EVERY 200 HOURS REPLACING HYDRAULIC OIL & CHECKING RADIATOR HOSE AND TRANSMISSION OIL FILTER CLAMP PRECAUTION AT OVERHEATING Look at page 6-12. Take the following actions in the event of engine “overheating”, an event that oc- curs when the engine coolant tempera- ture is equal to or greater than it’s boiling point.
  • Page 102 6-22 DK802/902 CHECKING POWER STEERING LINE ADJUSTING TOE-IN T30O628A T30O629A T30O630A (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.
  • Page 103 MAINTENANCE 6-23 CHECKING AIR INTAKE LINE ADJUSTING AIR CONDITIONER BELT TENSION (CABIN MODEL) 1. Stop the engine and remove the igni- tion key. 2. Check the belt tension. 3. If the tension is out of the specified range, adjust it. 4.
  • Page 104 6-24 DK802/902 EVERY 250 HOURS CLEANING INTAKE AIR FILTER CLEANING AMBIENT AIR FILTER CHANGING ENGINE OIL Look at page 6-11. CHANGING ENGINE OIL FILTER Look at page 6-11. T30O633A T30O634A (1) Grille (1) Bolts (3) Element (2) Cover (4) Filter 1.
  • Page 105 MAINTENANCE 6-25 EVERY 300 HOURS EVERY 400 HOURS EVERY 600 HOURS CHANGING TRANSMISSION FLUID CHANGING FRONT AXLE CASE OIL ADJUSTING FRONT AXLE PIVOT Look at page 6-13. Look at page 6-13. T30O635A (1) Lock Nut (2) Adjusting Screw If the front axle pivot pin adjustment is not correct, front wheel vibration can occur causing vibration in the steering wheel.
  • Page 106 EVERY 800 HOURS EVERY 1 YEAR ADJUSTING ENGINE VALVE CLEAR- REPLACING FUEL FILTER ELEMENT CHECKING HEATER HOSES AND A/ ANCE C HOSES Consult your local KIOTI DEALER for this service. T30O636A T30O637A (1) Fuel Filter (1) Heater Hose (3) A/C Hose (2) Clamp 1.
  • Page 107 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.
  • Page 108 6-28 DK802/902 ANTI-FREEZE REPLACING RADIATOR HOSE (WATER PIPES) If cooling water freezes, it can damage * At 760 mmHg pressure (atmospheric). the cylinders and radiator. It is necessary, A higher boiling point is obtained by Replace the hoses and clamps. if the ambient temperature falls below 0°C using a radiator pressure cap which (See “Checking Radiator Hose and Clamp”...
  • Page 109 MAINTENANCE 6-29 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.
  • Page 110 Refer to the block on the wheel. the troubleshooting section of • Put forward/backward lever, Main this manual or your local KIOTI shift lever and PTO lever in neutral. Dealer for specific information 1. Operate air conditioner with the fol- dealing with electrical problems.
  • Page 111 MAINTENANCE 6-31 T30O644A (1) Slow Blow Fuse T30O643A Fuse Slow Blow Fuse Capacity (A) Protected circuit Capacity (A) Protected circuit Whole Turn signal lights Work light Head lights / Tail light Timer relay Stop lights Customer use...

  • Page 112: Long-Term Storage

    LONG-TERM STORAGE REMOVING THE TRACTOR FROM STORAGE...
  • Page 113 7-2 DK802/902 REMOVING THE TRACTOR FROM STORAGE INSTRUCTIONS FOR LONG-TERM STORAGE 1. Make any repairs and adjustments that 1. Check the tire air pressure and inflate are needed. the tires if they are low. 2. Change the engine oil, and then let 2.

  • Page 114: Troubleshooting

    TROUBLESHOOTING...
  • Page 115 8-2 DK802/902 MAJOR PROBLEM AND POSSIBLE CAUSES 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.
  • Page 116 TROUBLESHOOTING 8-3 LIST OF POSSIBLE CAUSES 1. Battery capacity low. 24. Low oil level. 44. Piston rings are stuck, worn or broken. 2. Bad or corroded electrical connections. 25. Defective gauge. 45. Valve stems and/or guides are worn. 3. Faulty starter motor. 26.

  • Page 117: Index

    INDEX...
  • Page 118 9-2 DK802/902 4WD OPERATION INDICATOR .......... 4-10 4WD/QT SWITCH ..............4-6 CAB - EXTERNAL PARTS ..........4-19 CASSETTE TAPE RECORDER .......... 4-24 CHANGING ENGINE OIL ............ 6-11 ACCESSORIES ..............4-25 CHANGING ENGINE OIL ............ 6-24 ADJUSTING AIR CONDITIONER BELT TENSION (CABIN CHANGING ENGINE OIL FILTER ........
  • Page 119 INDEX 9-3 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 ............
  • Page 120 9-4 DK802/902 OPERATING THE ENGINE ............ 5-3 INITIAL 50 HOURS ............. 6-11 OPERATING THE P.T.O ............1-9 INSTRUMENTS PANEL AND SWITCHES ......4-4 OPERATING THE TRACTOR ..........1-5 INTERIOR CAB LIGHT ............4-24 OPERATING THE TRACTOR ..........5-8 JUMP STARTING ..............5-7 P.T.O SHAFT COVER ............
  • Page 121 INDEX 9-5 REPLACING ENGINE OIL FILTER ........6-11 REPLACING FUEL FILTER ELEMENT ........ 6-26 TACHOMETER/HOUR METER ..........4-7 REPLACING FUEL HOSE ..........6-28 TEMPERATURE GAUGE ............4-7 REPLACING FUSE ............. 6-30 TRACTOR SAFETY LABELS ........... 1-14 REPLACING HYDRAULIC OIL & TRANSMISSION OIL FILTER TRAVELING SPEED .............

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