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Warranty repairs or replacements and the Purchaser shall deliver the KIOTI loader to the Dealer's place of business for repair. The obligation of KIOTI to the Purchaser under this Warranty is limited to the repair or replacement of defective parts by an authorized KIOTI dealer.
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KIOTI's liability under this warranty is subject to the observance by the Purchaser of the following provisions: 1. The purchaser shall at all times in the operation of any KIOTI Product, use those brands and grades of lubricating oils, lubricants or fuel and spare parts officially approved by KIOTI.
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PLEASE NOTE Make sure all potential operators of this equipment review this manual and all safety messages con- tained within. Signs Description This safety symbol indicates important safety messages in this manual. When you see this symbol, carefully read the message that follows and be alert to the possibility of personal injury CAUTION or death.
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1-2 KL120 SAFETY SAFETY PRECAUTIONS Understand that your safety and the safety of other persons is Before starting the engine of your tractor, make sure all operation measured by how you service and operate this loader. Know the controls are in park lock or neutral position.
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SAFETY PRECAUTIONS 1-3 Travel speed should be such that complete control and machine A loader attachment should be transported in a low position at slow stability is maintained at all times. Where possible, avoid operation ground speeds. Make turns slowly and use the tractor brakes near ditches, embankments and holes.
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2. Clean safety decals with soap and water and dry with a soft cloth. 3. Replace damaged or missing safety decals with new decals from your Kioti Dealer. 4. If a component with a safety decal(s) affixed is replaced with a new part, make sure new safety decal(s) are attached in the same location(s) as the replaced components.
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SAFETY DECALS 2-3 (5) Part No : CK12-3002 (4) Part No : CK12-3003 (6) Part No : CK12-5001 Daedong-USA INC, KIOTI 6300 Kioti Drive Pure Animal wendell, NC USA Model No. Serial No. www. kiotitractor.com...
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3-2 KL120 LOADER SPECIFICATIONS Specifications and design are subject to change without prior notice. 120O301A Loader Model KL120 CK20 Tractor Model...
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LOADER SPECIFICATIONS 3-3 88.0 in. Maximum Lift Height 2,236 mm Clearance with Attachment Level 2,063 mm 81.0 in. Clearance with Attachment Dumped 1,756 mm 69.13 in. 19.25 in. Reach at Maximum Height 489 mm Maximum Dump Angle 45 degree Reach with Attachment on Ground 1,381 mm 54.37 in.
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The purpose of this manual is to assist you in maintaining and Warranty Registration operating your KIOTI loader. Read it carefully, it furnishes informa- The Delivery and Warranty Registration forms must be filled out tion and instructions that will help you achieve years of dependable and signed to validate your warranty protection.
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5-2 KL120 TRACTOR PREPARATION Rear Counterweight ROPS System CAUTION The tractor must be equipped with an approved ROPS System to Add recommended rear tire liquid weight, rear wheel ensure adequate operator's protection. or rear ballast for increased stability. Do not exceed the manufacturer's rating for maximum Tractor Hydraulic System gross vehicle weight.
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TRACTOR PREPARATION 5-3 TRACTOR TIRES Selection of tires(size, profile, tread type) should be restricted to tire recommendations as specified by KIOTI. Tire Inflation Front tires must be maintained at the maximum recommended inflation to maintain normal tire profile with the added weight of loader/material.
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6-2 KL120 LOADER OPERATION We urge you to follow this advice: CAUTION 1. Read and understand this manual as well as the Tractor Operator's The tractor/loader should only be operated with all Manual. safety equipment properly installed. 2. Remember and observe the Safety Precautions brought to your...
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LOADER OPERATION 6-3 Cold Weather Operation CAUTION For smooth operation in cold weather, let the tractor warm up. Before disconnecting hydraulic lines, relieve all hy- Slowly cycle the lift and bucket cylinders several times to warm the draulic pressure. Escaping hydraulic oil under pres- oil in the hydraulic system.
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6-4 KL120 Transporting a Loaded Bucket WARNING Transport material with the bucket as low as possible to prevent Contact with overhead power lines can cause severe spilling and keep maximum stability. The loader must be in a posi- electrical burns or death from electrocution. make sure tion that will not block the operators' vision.
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LOADER OPERATION 6-5 Loader Hydraulic Controls The Single lever joystick control lever is mounts on the CK25/30 From the factory. The control lever has the safety lock function. Lock the control lever when leaving the tractor while the Bucket is in the air.
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7-2 KL120 LOADER REMOVAL CAUTION Never park loader without bucket attached to the loader. Never allow weight of tractor to be put on parking leg when removing loader. 120O701A (1) Long Pivot Pin (2) Short Pivot Pin (3) Packing Leg Park the tractor and loader on hard level surface.
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LOADER REMOVAL 7-3 120O702A 120O703A (1) Latch Pin Remove the latch pin while move the control lever back Pull the control lever to raise the loader until the inner and forth slightly to make the latch pin easy. bearing box. Adjust the bucket until the bottom surface of bucket touch the ground.
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8-2 KL120 LOADER MOUNTING CAUTION Never allow weight of tractor to be put on parking leg when mounting loader. 120O801A STEP 1. Carefully drive the tractor into the loader to a position where the hydraulic hoses(Quick coupler) can be con- nected to the control valve block.
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LOADER MOUNTING 8-3 120O802A STEP 4. Move the tractor forward to put the inner bearing box into the outer bearing box. Stop the tractor when the hook is right over the pin. Lower the inner bearing box with moving the boom and bucket until it hooked securely each other.
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9-2 KL120 LUBRICATION AND MAINTENANCE CAUTION WARNING Do not operate the loader if the fittings are leaking or Do not perform and service or maintenance Opera- if the hoses are damaged. A sudden line burst could tions with loader raised off the ground. For additional cause the mainframe to drop suddenly, causing dam- access to tractor components remove loader.
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LUBRICATION AND MAINTENANCE 9-3 GREASE GREASE GREASE 120O901B ITEM SERVICE SERVICE INTERVAL Hydraulic System Oil Level Check Daily/10 hours Hydraulic System Oil/Filter Replace As specified in Tractor Operator's Manual Tire Inflation Check Weekly/50 hours Loader Pivot Points Lubricate Daily/10 hours Loader Hydraulic Lines, Hoses, Connections Check for leaks, wear Daily/10 hours...
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10-2 KL120 TROUBLESHOOTING This Troubleshooting Chart is provided for reference to possible loader operational problems. Determine the problem that best describes the operational problem being experienced and eliminate the possible causes as listed by following the correction procedures. Problem Possible Cause...
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TROUBLESHOOTING 10-3 Problem Possible Cause Correction Lift and/or Bucket Cylin- Hydraulic hoses connected incorrectly. Correct hydraulic hose connections. ders operate in wrong direction relative to control lever position. Slow or erratic lift Low hydraulic fluid level. Check and replenish hydraulic fluid. Cold hydraulic fluid.
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10-4 KL120 Problem Possible Cause Correction Slow or erratic lift Relief valve erratic or set below Check and reset relief valve. Setting as needed. specifications. Control valve leaking internally. Replace control valve and recheck operation. (hypassing fluid within valve). Inadequate hydraulic pump capacity.
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TROUBLESHOOTING 10-5 Problem Possible Cause Correction System relief valve Cold Hydraulic Fluid. A low hydraulic fluid to warm up to operating squeals. temperature. Excessive load in bucket. Weight Reduce load. exceeds specified loader capacity. Relief valve setting below specifications. Check and reset valve setting as needed. Hydraulic hose, tubeline or quick Check for evidence of restriction in hydraulic oil disconnect coupler restriction.
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10-6 KL120 Problem Possible Cause Correction External hydraulic fluid Loose hydraulic connection. Tighten loose connections. leakage. Defective hydraulic hose, tubeline, Check for origin of oil leak and replace defective adapter fitting or adapter fitting o-ring. part. Control valve o-rings defective.
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TROUBLESHOOTING 10-7 Problem Possible Cause Correction Bucket cutting edge wear Bucket is not level to ground. Check rear tire inflation and adjust to level bucket is uneven side to side to ground. Bucket cutting edge wear Incorrect operational practices. Exces- Refer to operation-scraping section for correct rate is excessive.
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12-2 KL120 TORQUE TIGHTENING CHART 1 SAE FASTENER TORQUE CHART Note : Use these torques, unless special torques are specified. Values are for UNC and UNF thread fasteners, plated or unplated as received from supplier. Fasteners can be dry or lubricated with normal engine oil. Values do not apply if graphite, moly- disulphide or other extreme pressure lubricant is used.
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TORQUE TIGHTENING CHART 12-3 TORQUE TIGHTENING CHART 2 METRIC FASTENER (ISO) TORQUE CHART Note : Use these torques, unless special torques are specified. Values are for course thread fasteners, plated or unplated as received from supplier. Fasteners can be dry or lubricated with normal engine oil. Values do not apply if graphite, moly-disulphide or other extreme pressure lubricant is used.
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13-2 KL 120 GENERAL INFORMATION Illustrations All parts are illustrated in "exploded views" which show the individual parts in their normal reationship to eash other. Reference numbers are used in the illustrations. These numbers correspond to those in the "Reference Number". column and are followed by the quantity required and description.
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PART ILLUSTRATIONS 13-3 Interchangeability : Indicates the interchangeabillty of parts due to design change. Indicates that a new part can be used instead of an old part when you order this part, plese order new part. Indicates that either parts can be used. Indicates that a part has a serial number break.
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PART ILLUSTRATIONS 13-11 REF. NO PART. NO DESCRIPTION REMARK 1002-1452 Hex Head Nut, M14-1.5P CK02-0116 Over Cross Bar 1001-1458 Hex Head Bolt, M14-1.5P-40L 1003-0014 Spring Washer, ø14 1002-1452 Hex Head Nut, M14-1.5P...
13-28 KL 120 13.10 DECALS CAUTION Read and refer to the Tractor Operation Manual or De- cals on the Tractor. and Loader Decals on as shown. 120OD09A (1) CK12-3001 (2) CK12-3002...
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PART ILLUSTRATIONS 13-29 120OD10A 120OD10B (1) CK12-3003 (1) CK12-3004 Refer to category "Safety decals"...
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14-2 KL120 LOADER INSTALLATION CAUTION Release loader, bucket and mount kit box from pallet. See your Loader Operator's manual for Safety Pre- cautions and Tractor Preparations. Install Bearing Box LH and Bearing Box RH. 1 Bearing Box LH - 1EA 2 Bearing Box RH - 1EA 3 Hex Head Bolt M14X1.5PX40L - 8EA...
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LOADER INSTALLATION 14-3 120OE02A 120OE03A (1) Bearing Box (2) Bearing Inner Box Install Boom Ass'y Install Front Grille Hang the groove on the pin located on outer bearing box. 1 Front Grill - 1EA 2 Hex Head Bolt M12X1.75Px40L - 4EA Spring Washer ø...
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14-4 KL120 120OE04A 120OE05A Install Attach Fitting Flange. Install the hydraulic hose matching color code rings as shown on the diagram below. W/Quick Coupler (Male) 1 Attach Fitting Flange W/Quick Coupler(Male) -1SET 2 Hex Head Bolt M10X1.5PX25L -2EA Spring washer ø 10 - 2EA...
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LOADER INSTALLATION 14-5 120OE06A 120OE07A (1) Valve Block (2) Hydraulic Hose Fit the hydraulic hoses as shown in the diagram below. 3 Adapter w/o - Ring - 4Sets...
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14-6 KL120 Install Latch pin 4 Latch pin W/Linch Pin - 2Sets Install the Bucket Ass'y 1 Bucket Ass'y - 1Sets 2 Pivot Pin (Hole) - 4EA 3 Linch Pin - 4EA Grease every fitting. See page 9-3 for the grease chart.