free service manual download

1. TO THE READER
1C34-WOO May. 2005
1. TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism,
service and maintenance of KIOTI tractors DK651/751/801/901. It is divided into two parts, “Mechanism” and
“Servicing”.
MECHANISM
Information on the construction and functions are included. The part should be completely understood before
proceeding with troubleshooting, disassembling or servicing.
SERVICING
In this section you will find general precautions, maintenance and special tools. The are other sections which
include troubleshooting, servicing, specifications lists, disassembling, assembling and servicing that explains in
detail procedures, precautions, factory specifications and acceptable limits.
This manual contains the latest production information on illustrations and specifications based on the most up to
date production information available at the time of publication.
We reserve the right to make changes throughout the entire manual at any time without notice.

2. DK651/751/801/901
2 C34-WOO May. 2005
SAFETY STARTING
1. Always use the safety start switch to start the en-
gine and never by any other means.
2. Do not alter or remove any part of machine safety
system.
3. Before starting the engine, make sure that all shift
levers are in neutral positions or in the disengaged
positions.
4. Never start the engine unless you are in the
operator’s seat.
C34W002A
This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and the decals on the machine
itself to warn of the possibility of personal injury. It is essential that you read the instructions and safety regula-
tions before you attempt to repair or operate this unit. Read these instructions carefully.
2. SAFETY FIRST
SIGNS
DANGER
WARNING
CAUTION
IMPORTANT
DESCRIPTION
This mark indicates hazardous situation which, if not observed, may
result in death or fatal injury.
This mark should be indicated for most dangerous situations only.
This mark indicates potentially hazardous situation which, if not
observed, may result in death or moderate injury.
This mark indicates potentially hazardous situation which, if not
observed, may result in minor or moderate injury. And this mark can be
used as a warning against unsafe activities.
This mark indicates emphasis on notable characteristics in working
procedures or information on working procedures and technology for
convenient use.
NOTE Gives helpful information.
BEFORE SERVICING AND REPAIRING
1. Read all safety instructions in this manual and be
aware of the safety decals on your machine itself.
2. Thoroughly clean your work area and the machine.
3. Make sure the machine is on firm and level ground
and that the parking brake is set.
4. Lower the implement to the ground.
5. Stop the engine and remove the key.
6. Disconnect the negative battery cable.
7. Place a “DO NOT OPERATE” tag in operator station.
C34W001A

3. TO THE READER
3C34-WOO May. 2005
SAFETY WORKING
1. Do not operate or service the machine while under
the influence of alcohol, medication, or other
substances.
2. Never wear loose fitting clothing and always use
safety equipment appropriate to the job.
3. Never use improvised tools, parts or procedures.
Use only recommended tools appropriate to the
work.
4. Be careful to perform all work safely when servic-
ing is done by two or more people.
5. Always support the machine by safety stands. Never
work under the machine that is supported solely
by a jack.
6. Do not touch any rotating or hot parts while the
engine is running.
7. Never remove the radiator cap while the engine is
running, or immediately after stopping. Only remove
radiator cap when it is cool enough to touch with
bare hands. Slowly loosen the cap to relieve pres-
sure before removing completely.
8. Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury.
Relieve pressure before disconnecting hydraulic or
fuel lines. Tighten all connections before applying
pressure.
C34W003A
C34W004A
AVOID FIRES
1. Never smoke or allow flames or sparks in your work
area, as fuel is extremely flammable and explosive
under certain conditions.
2. Always disconnect the negative battery cable first
and reconnect it last to avoid sparks from an acci-
dental short circuit.
3. Battery gas will ignite. Keep sparks and open flame
away from the top of battery, especially while
charging.
4. Be careful not to spill fuel on the engine.
C34W005A

4. DK651/751/801/901
4 C34-WOO May. 2005
DISPOSE OF FLUIDS PROPERLY
Observe relevant environmental protection regulations
when disposing of oil, fuel, coolant, electrolyte and
other harmful waste. Never pour fluids into the ground,
down a drain, or into a stream, pond, or lake.
C34W008A
VENTILATE WORK AREA
Exhaust contains poisonous carbon monoxide, so you
should never run the engine in a closed area. If the
engine must be running while performing maintenance,
make sure the area is well ventilated.
PREVENT ACID BURNS
Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause blind-
ness if splashed into eyes. Keep electrolyte away from
eyes, hands and clothing. If you spill electrolyte on
yourself, flush with water, and get medical attention
immediately.
C34W006A
C34W007A

5. TO THE READER
5C34-WOO May. 2005
PREPARE FOR EMERGENCIES
1. Be sure to keep a first aid kit and fire extinguisher
handy at all times.
2. Keep emergency numbers for the nearest fire
department, hospital, doctor and ambulance
service, near your telephone in case of emergency.
C34W009A

6. DK651/751/801/901
6 C34-WOO May. 2005
3. SAFETY DECALS
The following safety decals are installed on the machine.
If a decal becomes damaged, illegible or is not on the machine, replace it. The decal part number is listed in the
parts list.
C34W010A
C34W011A
ROPS
CABIN

7. TO THE READER
7C34-WOO May. 2005
(2) Parts No. : T4837-51181(1) Parts No. : E6500-51101
(4) Parts No. : T4817-52201(3) Parts No. : T4628-52201
(5) Parts No. : T2325-50743

8. DK651/751/801/901
8 C34-WOO May. 2005
(6) Parts No. : T4818-52142 (7) Parts No. : T4625-52351
(8) Parts No. : T2615-53561 (9) Parts No. : T2615-55112
(10) Parts No. : T4837-51191 (11) Parts No. : T2615-54112

9. TO THE READER
9C34-WOO May. 2005
(12) Parts No. : T4837-51093 (13) Parts No. : T4837-52121
MAINTAINING THE SAFETY SIGNS FOR DANGER, WARNING AND CAUTION
1. Make sure that these safety signs are clean and have no foreign and obstacle objects on them.
2. When cleaning, wash them with soup and water and clean using a soft cloth.
3. Immediately replace missing or damaged safety signs.
4. Make sure that new equipment components and repair parts include a new safety sign in its place.
5. Attach a new safety sign on dry surface and rub it outwards to remove bubbles

10. DK651/751/801/901
10 C34-WOO May. 2005
4. CONTENTS
CHAPTER 1. GENERAL ....................................................................................................... 1-1
1. TRACTOR IDENTIFICATION ............................................................................................................ 1-3
2. DIMENSIONS .................................................................................................................................. 1-5
3. GENERAL PRECAUTIONS ............................................................................................................. 1-5
3.1 ASSEMBLY AND DISASSEMBLY ....................................................................................... 1-5
3.2 ELECTRICAL SYSTEM ........................................................................................................ 1-7
3.3 TUBES AND RUBBERS ....................................................................................................... 1-7
3.4 LUBRICANT .......................................................................................................................... 1-7
4. SPECIFICATIONS ............................................................................................................................ 1-9
5. LUBRICANTS, FUELAND COOLANT ............................................................................................. 1-9
6. TIGHTENING TORQUES ................................................................................................................1-11
6.1 GENERAL USE SCREWS, BOLTS AND NUTS .................................................................1-11
6.2 STUD BOLTS .......................................................................................................................1-11
7. MAINTENANCE CHECK LIST ....................................................................................................... 1-13
8. CHECK AND MAINIENANCE ........................................................................................................ 1-15
8.1 DAILY CHECK .................................................................................................................... 1-15
8.2 INITIAL 50 HOURS ............................................................................................................. 1-17
8.3 EVERY 50 HOURS............................................................................................................. 1-21
8.4 EVERY 100 HOURS .......................................................................................................... 1-23
8.5 EVERY 200 HOURS .......................................................................................................... 1-27
8.6 EVERY 250 HOURS .......................................................................................................... 1-30
8.7 EVERY 400 HOURS .......................................................................................................... 1-30
8.8 EVERY 600 HOURS .......................................................................................................... 1-30
8.9 EVERY 800 HOURS .......................................................................................................... 1-31
8.10 EVERY 1 YEAR ................................................................................................................. 1-31
8.11 EVERY 2 YEAR ................................................................................................................. 1-32
8.12 SERVICE AS REQUIRED .................................................................................................. 1-34
9. TIRES ............................................................................................................................................. 1-37
9.1 INFLATION PRESSURE ..................................................................................................... 1-37
9.2 TREAD ................................................................................................................................ 1-38
9.3 BALLAST ............................................................................................................................ 1-40
9.4 TRAVELING SPEED .......................................................................................................... 1-41

11. TO THE READER
11C34-WOO May. 2005
CHAPTER 2. ENGINE ........................................................................................................... 2-1
1. SYSTEMS OPERATION SECTION .................................................................................................2-3
1.1 ENGINE MODEL VIEWS ......................................................................................................2-3
1.2 FUEL SYSTEM .....................................................................................................................2-4
1.3 AIR INLETAND EXHAUST SYSTEM ...................................................................................2-5
1.4 LABRICATION SYSTEM ......................................................................................................2-7
1.5 COOLING SYSTEM .............................................................................................................2-9
2. SPECIFICATIONS .........................................................................................................................2-10
2.1 ENGINE DESIGN ................................................................................................................2-10
2.2 FUEL INJECTION LINES .................................................................................................... 2-11
2.3 FUEL INJECTION PUMP .................................................................................................... 2-11
2.4 FUEL INJECTORS..............................................................................................................2-13
2.5 FUEL TRANSFER PUMP ...................................................................................................2-14
2.6 LIFTER GROUP .................................................................................................................2-14
2.7 ROCKER SHAFT ...............................................................................................................2-15
2.8 VALVE MECHANISM COVER ............................................................................................2-16
2.9 CYLINDER HEAD VALVES ................................................................................................2-17
2.10 CYLINDER HEAD ...............................................................................................................2-20
2.11 TURBOCHARGER .............................................................................................................2-22
2.12 EXHAUST MANIFOLD ........................................................................................................2-23
2.13 CAMSHAFT ........................................................................................................................2-24
2.14 CAMSHAFT BEARINGS.....................................................................................................2-26
2.15 ENGINE OIL FILTER ..........................................................................................................2-27
2.16 ENGINE OIL PUMP .............................................................................................................2-28
2.17 ENGINE OIL PRESSURE ...................................................................................................2-31
2.18 ENGINE OIL BYPASS VALVE ............................................................................................2-31
2.19 ENGINE OIL PAN................................................................................................................2-33
2.20 CRANKCASE BREATHER .................................................................................................2-35
2.22 WATER PUMP ....................................................................................................................2-36
2.21 WATER TEMPERATURE REGULATOR AND HOUSING ..................................................2-36
2.23 CYLINDER BLOCK ............................................................................................................2-37
2.24 CRANKSHAFT....................................................................................................................2-41
2.25 CRANKSHAFT SEALS .......................................................................................................2-44
2.26 CONNECTING ROD BEARING JOURNAL ........................................................................2-45
2.27 MAIN BEARING JOURNAL .................................................................................................2-45
2.28 CONNECTING ROD ...........................................................................................................2-46
2.29 PISTON AND RINGS ..........................................................................................................2-48

12. DK651/751/801/901
12 C34-WOO May. 2005
2.30 PISTON COOLING JET .....................................................................................................2-50
2.31 FRONT HOUSING AND COVERS .....................................................................................2-51
2.32 GEAR GROUP (FRONT) ...................................................................................................2-52
2.33 FLYWHEEL .........................................................................................................................2-54
2.34 FLYWHEEL HOUSING ........................................................................................................2-55
2.35 CRANKSHAFT PULLEY.....................................................................................................2-55
2.36 FAN DRIVE .........................................................................................................................2-56
2.37 ENGINE LIFTING BRACKET..............................................................................................2-57
2.38 GLOW PLUGS ...................................................................................................................2-57
3. SEPARATE THE ENGINE ..............................................................................................................2-58
4. DISASSEMBLYAND ASSEMBLY ..................................................................................................2-66
4.1 FUEL PRIMING PUMP ........................................................................................................2-66
4.2 FUEL FILTER BASE ...........................................................................................................2-67
4.3 FUEL INJECTION LINES ....................................................................................................2-68
4.4 FUEL INJECTOR COVER ..................................................................................................2-69
4.5 FUEL INJECTION PUMP / DELPHI DP210........................................................................2-70
4.6 FUEL INJECTION PUMP / BOSCH EPVE..........................................................................2-74
4.7 FUEL INJECTOR ................................................................................................................2-78
4.8 TURBOCHARGER .............................................................................................................2-79
4.9 EXHAUST MANIFOLD ........................................................................................................2-82
4.10 EXHAUST ELBOW (OPTION FOR FOUR CYLINDER ENGINES ONLY) .........................2-84
4.11 INLET AND EXHAUST VALVE SPRINGS ..........................................................................2-85
4.12 INLET AND EXHAUST VALVES .........................................................................................2-88
4.13 INLET AND EXHAUST VALVE GUIDES .............................................................................2-91
4.14 INLET AND EXHAUST VALVE SEAT INSERTS .................................................................2-93
4.15 ENGINE OIL FILTER BASE ................................................................................................2-96
4.16 ENGINE OIL COOLER .......................................................................................................2-98
4.17 ENGINE OIL RELIEF VALVE (ENGINE OIL PUMP).........................................................2-102
4.18 ENGINE OIL RELIEF VALVE (BALANCER UNIT FOR THE 1104 ENGINES ONLY) .....2-103
4.19 ENGINE OIL PUMP (ENGINES WITHOUT A BALANCER) ..............................................2-104
4.20 WATER PUMP ..................................................................................................................2-106
4.21 WATER TEMPERATURE REGULATOR ......................................................................... 2-111
4.22 FLYWHEEL ....................................................................................................................... 2-113
4.23 CRANKSHAFT REAR SEAL ............................................................................................ 2-115
4.24 CRANKSHAFT WEAR SLEEVE (REAR) ......................................................................... 2-118
4.25 FLYWHEEL HOUSING ...................................................................................................... 2-119

13. TO THE READER
13C34-WOO May. 2005
4.26 CRANKSHAFT PULLEY...................................................................................................2-121
4.27 CRANKSHAFT FRONT SEAL .........................................................................................2-122
4.28 CRANKSHAFT WEAR SLEEVE (FRONT) ......................................................................2-124
4.29 FRONT COVER ...............................................................................................................2-125
4.30 GEAR GROUP (FRONT) .................................................................................................2-127
4.31 IDLER GEAR ....................................................................................................................2-130
4.32 HOUSING (FRONT) .........................................................................................................2-134
4.33 ACCESSORY DRIVE .......................................................................................................2-137
4.34 CRANKCASE BREATHER ...............................................................................................2-139
4.35 VALVE MECHANISM COVER ..........................................................................................2-141
4.36 ROCKER SHAFT AND PUSHROD ..................................................................................2-143
4.37 CYLINDER HEAD .............................................................................................................2-147
4.38 LIFTER GROUP - INSTALL .............................................................................................2-153
4.39 CAMSHAFT ......................................................................................................................2-154
4.40 CAMSHAFT GEAR ...........................................................................................................2-155
4.41 CAMSHAFT BEARINGS...................................................................................................2-156
4.42 ENGINE OIL PAN..............................................................................................................2-157
4.43 BALANCER (4 CYLINDER ENGINS ONLY).....................................................................2-160
4.44 PISTON COOLING JETS .................................................................................................2-161
4.45 PISTONS AND CONNECTING RODS..............................................................................2-164
4.46 CONNECTING ROD BEARINGS .....................................................................................2-169
4.47 CRANKSHAFT MAIN BEARINGS.....................................................................................2-171
4.48 CRANKSHAFT..................................................................................................................2-176
4.49 CRANKSHAFT GEAR ......................................................................................................2-183
4.50 BEARING CLEARANCE ...................................................................................................2-184
4.51 GLOW PLUGS .................................................................................................................2-186
3.52 V-BELTS ...........................................................................................................................2-187
4.53 FAN ...................................................................................................................................2-188
4.54 FAN DRIVE .......................................................................................................................2-188
5. TESTING AND ADJUSTING SECTION .......................................................................................2-189
5.1 FUEL SYSTEM .................................................................................................................2-189
5.2 AIR INLETAND EXHAUST SYSTEM ...............................................................................2-198
5.3 LUBRICATION SYSTEM ..................................................................................................2-206
5.4. COOLING SYSTEM .........................................................................................................2-209
5.5 BASIC ENGINE .................................................................................................................2-215
6. LIST OF SPECIAL TOOLS .........................................................................................................2-221

14. DK651/751/801/901
14 C34-WOO May. 2005
CHAPTER 3. CLUTCH.......................................................................................................... 3-1
1. STRUCTURE ...................................................................................................................................3-3
2. TROUBLESHOOTING .....................................................................................................................3-4
3. SPECIFICATIONS ...........................................................................................................................3-5
4. INSPECTION, DISASSEMBLYAND REPAIR ..................................................................................3-6
4.1 INSPECTION ........................................................................................................................3-6
4.2 DISASSEMBLING AND ASSEMBLING .................................................................................3-8
4.3 INSPECTION AND REPAIR ................................................................................................3-16
CHAPTER 4. TRANSMISSION ............................................................................................. 3-1
1. STRUCTURE ...................................................................................................................................4-3
1.1 POWER TRAIN DIAGRAM ...................................................................................................4-3
1.2 POWER TRAIN ....................................................................................................................4-4
2. TROUBLESHOOTING ...................................................................................................................4-10
3. DISASSEMBLYAND SERVICE .....................................................................................................4-13
3.1 REMOVING TRANSMISSION .............................................................................................4-13
3.2 REMOVING CLUTCH HOUSING........................................................................................4-27
3.3 REMOVING TRANSMISSION .............................................................................................4-32
3.4 MAINTENANCE ..................................................................................................................4-40
CHAPTER 5. REAR AXLE .................................................................................................... 5-1
1. STRUCTURE ...................................................................................................................................5-3
2. TROUBLESHOOTING .....................................................................................................................5-4
3. TIGHTENING TORQUES ................................................................................................................5-5
4. DISASSEMBLYAND REPAIR ..........................................................................................................5-6
4.1 REMOVING REAR AXLE......................................................................................................5-6
4.2 MAINTENANCE ..................................................................................................................5-10
CHAPTER 6. BRAKE ............................................................................................................ 6-1
1. STRUCTURE ...................................................................................................................................6-3
1.1 OPERATIONAL PRINCIPLE .................................................................................................6-3
2. TROUBLESHOOTING .....................................................................................................................6-4
3. SPECIFICATIONS ...........................................................................................................................6-5
4. TIGHTENING TORQUE...................................................................................................................6-6

15. TO THE READER
15C34-WOO May. 2005
5. CHECK AND ADJUSTMENT ............................................................................................................6-7
5.1 BRAKE PEDAL FREE PLAY ................................................................................................6-7
5.2 DIFFERENCE BETWEEN RIGHT AND LEFT BRAKE PEDAL ...........................................6-7
5.3 ADJUSTING PARKING BRAKE WIRE..................................................................................6-8
5.4 AIR BLEEDING FROM BRAKE SYSTEM ............................................................................6-9
6. DISASSEMBLINGAND SERVICING .............................................................................................6-10
6.1 REMOVING REAR AXLE....................................................................................................6-10
CHAPTER 7. FRONT AXLE.................................................................................................. 7-1
1. STRUCTURE ...................................................................................................................................7-3
2. TROUBLESHOOTING .....................................................................................................................7-4
2.1 TROUBLESHOOTING FOR FRONT DIFFERENTIAL CLUTCH .........................................7-4
2.2 TROUBLESHOOTING FOR OIL LEAKAGE AT FRONT AXLE ...........................................7-4
3. INSPECTION, DIASSEMBLYAND REPAIR.....................................................................................7-5
3.1 TOE-IN..................................................................................................................................7-5
3.2 FRONT WHEEL STEERING ANGLE ...................................................................................7-6
3.3 ROCKING FORCE OF FRONT AXLE .................................................................................7-7
3.4 AXLE SWAY OF FRONT WHEEL ........................................................................................7-7
4. DISASSEMBLY AND SERVICE .......................................................................................................7-8
4.1 REMOVING FRONTAXLE ...................................................................................................7-8
4.2 SERVICING ........................................................................................................................7-17
CHAPTER 8. HYDRAULIC SYSTEM ................................................................................... 8-1
1. STRUCTURE ...................................................................................................................................8-3
1.1 HYDRAULIC SYSTEM DIAGRAM ........................................................................................8-3
1.2 HYDRAULIC CIRCUIT ..........................................................................................................8-4
1.3 OIL FILTER ...........................................................................................................................8-5
1.4 HYDRAULIC PUMP ..............................................................................................................8-6
1.5 POWER STEERING SYSTEM .............................................................................................8-7
1.6 PTO CLUTCH SYSTEM.......................................................................................................8-9
1.7 JOYSTICK VALVE ..............................................................................................................8-10
1.8 HORIZONTAL CONTROL SYSTEM ...................................................................................8-10
1.9 HYDRAULIC POWER ELEVATION SYSTEM ....................................................................8-12
2. TROUBLESHOOTING ...................................................................................................................8-14
2.1 POWER STEERING SYSTEM ...........................................................................................8-14
2.2 HYDRAULIC LIFT SYLINDER SYSTEM ............................................................................8-15

16. DK651/751/801/901
16 C34-WOO May. 2005
3. INSPECTION, DIASSEMBLYAND REPAIR...................................................................................8-16
3.1 HYDRAULIC FILTER ..........................................................................................................8-16
3.2 HYDRAULIC PUMP ............................................................................................................8-16
3.3 STEERING SYSTEM ..........................................................................................................8-18
3.4 PTO CLUTCH .....................................................................................................................8-21
CHAPTER 9. CABIN SYSTEM ............................................................................................. 8-1
1. AIR CONDITIONER/HEATER STRUCTURE ..................................................................................9-3
1.1 AIR CONDITIONER SYSTEM LAYOUT ...............................................................................9-3
1.2 CIRCUIT DIAGRAM ..............................................................................................................9-4
1.3 AIR CONDITIONER/HEATER SPECIFICATIONS ................................................................9-5
2. TROUBLE SHOOTING ....................................................................................................................9-6
2.1 VISUALANDAUDIO CHECK ................................................................................................9-6
2.2 TROUBLE DIAGNOSIS ........................................................................................................9-7
2.3 ADVANCED TROUBLESHOOTING .....................................................................................9-8
3. CHECKING AND CHARGING GAS ............................................................................................... 9-11
3.1 TROUBLESHOOTING BY MANIFOLD GAUGE ................................................................ 9-11
4. INSPECTION ANDADJUSTMENTS ..............................................................................................9-15
4.1 CHARGING REFRIGERANT ..............................................................................................9-16
5. INSPECTION, DISASSEMBLYAND REPAIR ................................................................................9-19
5.1 REMOVING CABIN .............................................................................................................9-19
5.2 REMOVING AIR CONDITIONER UNIT ...............................................................................9-25
5.3 REMOVING COMPRESSOR..............................................................................................9-26
CHAPTER 10. ELECTRIC SYSTEM .................................................................................. 10-1
1. WIRING DIAGRAM ........................................................................................................................10-3
1.1 GENERAL ...........................................................................................................................10-3
1.2 FITTING SPECIFICATIONS OF TRANSVERSE CONTOL CYLINDER ............................10-4
2. BATTERY ......................................................................................................................................10-5
3. STARTING SYSTEM .....................................................................................................................10-6
4. CHARGING SYSTEM ....................................................................................................................10-7
5. LIGHTING SYSTEM ......................................................................................................................10-8
5.1 LIGHT SWITCH ..................................................................................................................10-9
5.2 HAZARD WARNING SWITCH ............................................................................................10-9
5.3 FLASHER UNIT ..................................................................................................................10-9
5.4 LAMPS ..............................................................................................................................10-10
5.5 HEAD LIGHTS .................................................................................................................. 10-11

17. TO THE READER
17C34-WOO May. 2005
6. COMBINATION METER...............................................................................................................10-12
6.1 TACHOMETER AND HOURMETER (1) ..........................................................................10-13
6.2 ENGINE COOLANT TEMP. GAUGE (2), FUEL GAUGE (3) ..........................................10-13
6.3 GAUGES AND INDICATORS (BULB STANDARD: 14V, 1.4W) ......................................10-14
6.4 SENSORS.........................................................................................................................10-15
7. TROUBLESHOOTING10-16
8. INSPECTION, DISASSEMBLYAND REPAIR ..............................................................................10-18
8.1 BATTERY .........................................................................................................................10-18
8.2 STARTING SYSTEM ........................................................................................................10-20
8-3 LOGHT SYSTEM .............................................................................................................10-25

18. MEMO
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19. CHAPTER 1
GENERAL

21. GENERAL
1-3C34-WOO May. 2005
1. TRACTOR IDENTIFICATION
When contacting your local KIOTI distributor, always specify engine serial number, tractor serial number and hour
meter reading.
(1) Hour Meter
C34W103A
2
1
(1) Identification Number
(2) Transmission Serial Number
(1) Engine Serial Number
C34W101A C34W102A

22. CHAPTER 1 DK651/751/801/901
1-4 C34-WOO May. 2005
2. DIMENSIONS
C34W104A
F
423 (16.6)
443 (17.4)
443 (17.4)
470 (18.5)
E
1,406 (55.3)
1,504 (59.2)
1,504 (59.2)
1,534 (60.3)
D
1,477 (57.9)
1,534 (60.3)
1,534 (60.3)
1,576 (62.0)
C
2,048 (80.6)
2,142 (84.3)
2,142 (84.3)
2,142 (84.3)
B
2,650 (104.3)
2,710 (106.6)
2,710 (106.6)
2,754 (108.4)
A
3,943 (155.2)
4,142 (163.0)
4,269 (167.9)
4,269 (167.9)
DK651
DK751
DK801
DK901
mm (in.)

23. GENERAL
1-5C34-WOO May. 2005
3. GENERAL PRECAUTIONS
C34W105A
(1) Grease
(2) Snap Ring for Shaft
(3) Snap Ring for Hole
(4) Assemble Towards to be Forced
(5) Reciprocating
(6) Rotating
1. Place the tractor on firm and level ground prior to
any service or adjustment.
2. Work with the engine stopped whenever possible.
Be careful when doing any testing that requires the
engine to be running.
3. Use only DAEDONG (KIOTI) approved special
tools. Servicing dealers may machine tools to
DAEDONG (KIOTI) specifications, if the tool will not
be used often.
4. Keep your work area and the tractor clean during
all phases of the disassembly and reassembly
process.
5. After removal, keep parts clean and organized.
Tighten nuts to mating bolts by hand to keep
matched sets together.
6. Be careful during disassembly, assembly, and stor-
age of hydraulic parts. Dust and metal chips can
contaminate the whole hydraulic system. Keep
parts covered whenever possible.
7. Use only approved manufactures cleaning agents
for parts cleaning. Hydraulic parts should be
cleaned with an approved cleaning oil. Diesel fuel
should never be used for cleaning.
8. Remove all oil and contaminates before perform-
ing any measurement of parts.
9. Disconnect the battery negative (-) cable before re-
moving or installing any live electrical components.
10. Use only DAEDONG (KIOTI) genuine parts to main-
tain the performance and safety of your KIOTI
tractor.
• Use packing bond, gasket sealer, equivalent to
Three Bond 1208D.
• Remove all existing sealer before applying new
sealer to the part.
• Apply the bond, sealer, in a bead centered on the
sealing flange area. If a bolt hole is encountered,
continue bead to the center of the inner sealing
surface.
• Assemble the parts within 10 minutes of bond,
sealer, application. Wait 30 minutes before add-
ing oil to the sealed parts, if applicable.
IMPORTANT
3.1 ASSEMBLY AND DISASSEMBLY
11. When assembling an outside snap ring, on a shaft,
or an inside snap ring, in a hole, assemble with the
head in the direction of force. Reference the above
figure.
12. When replacing a new part also replace the asso-
ciated packing (gasket), bearing(s), and o-ring(s).
Apply grease properly for O-rings and oil seals be-
fore assembly.
13. Locate the split portion of any spring pin by refer-
encing the direction of force, like the above figure.
14. Replace any split pin with a new one.

24. CHAPTER 1 DK651/751/801/901
1-6 C34-WOO May. 2005
C34W108A
3.2 ELECTRICAL SYSTEM
1. Check all electrical connectors daily for any dam-
age or short circuit at their junctions. In addition,
annually schedule a complete electrical system in-
spection with your local KIOTI dealer.
2. Do not modify or reorganize the wiring harness or
the electric field parts.
3. When disconnecting battery cables, disconnect the
negative cable first. Reinstall the positive cable first
when reinstalling.
DISCONNECTING BATTERY NEGATIVE CABLE
NOTE:
• Be sure to turn the starting key OFF when connect-
ing or disconnecting the cable.
4. When disconnecting a connector, grasp the plastic
section, not the wiring.
5. When reconnecting the connector, insert it until it
snaps.
To ensure safety and prevent damage to the machine
and surrounding equipment, heed the following precau-
tions in handling electrical parts and wiring.
C34W106A
• Check electrical wiring for damage and loosened
connection every year. To this end, educate the
customer to do his or her own check. At the same
time recommend the dealer to performs a peri-
odic check during regular maintenance.
• Do not attempt to modify or remodel any electri-
cal parts and/or wiring.
• When removing the battery cables, disconnect
the negative cable first. When installing the bat-
tery cables, connect the positive cable first.
IMPORTANT
6. When replacing a broken fuse with a new on, be sure
to use the fuse with the correct amperage capacity.
Use your owner’s manual to establish the correct
capacity.
7. Be sure not to drop sensors and relays. They are
fragile.
C34W107A

25. GENERAL
1-7C34-WOO May. 2005
3.3 TUBES AND RUBBERS
Keep the tubes (hoses) and rubber parts free from oil
and other petroleum products. This may cause a change
in quality in these parts, and may shorten product life.
3.4 LUBRICANT
During assembly and repair, apply designated lubricant
where specified in accordance with this repair manual.
C34W109A
C34W110A

26. CHAPTER 1 DK651/751/801/901
1-8 C34-WOO May. 2005
2,200
100 (26.4)
Dry single
Synchro shuttle
12F 12R
Standard
Wet disc type
Independent
540/750 (Option 540/1,000)
Max. 2,400 (5,291)
Position, draft and mixed control
Hydrostatic power steering
Drawdar
1,990 (78.3)
2,754 (108.4)
470 (18.5)
1,576 (62.0)
1,534 (60.3)
3,557 (7,842)
4. SPECIFICATIONS
NOTE:
The specifications are subject to change for the purpose of improvement without any notice.
DK651
1103C-33T
3-cylinder, water-
cooled, tubo diesel
Max. 64 (48)/2,200
52 (39)/2,200
3,300 (201)
1st: 41.2 (14.4)
2nd: 31.7 (11.1)
Cat.1 & 2
DK751
1104C-44
4-cylinder, water-
cooled, diesel
Max. 72.4 (54)/2,200
57 (43)/2,200
DK801
1104C-44T (80HP)
Max. 80 (60)/2,200
67 (50)/2,200
DK901
1104C-44T (90HP)
Max. 90 (67)/2,200
83 (62)/2,200
Engine
Model
Model
Type
Engine gross HP (kW)/rpm
P.T.O HP (kW)/rpm
Displacement cc (cu.in)
Rated revolution rpm (min-1)
Fuel tank capacity (gal.)
Clutch
Transmission
Speeds
Differential lock
Brake
P.T.O
Rear rpm
Pump capacity (Max. flow rate)
/min (cc)
3-point hitch
Maximum lifting capacity
(24in. aft of hitch) kg (lbs.)
Hydraulic lift control system
Steering
Drawbar type
DrivetrainHydraulicsystem
4-cylinder, water-cooled, Tubo diesel
1st: 0.43 (0.26)
12th: 29.55 (18.36)
1st: 0.42 (0.26)
12th: 28.93 (17.97)
14.9 - 30
1st: 0.45 (0.27)
12th: 31.34 (19.47)
1st: 0.44 (0.27)
12th: 30.68 (19.06)
11.2 - 20
Standardtiresize
Front
Rear
Forward (At rated engine rpm)
km/h (mph)
Reverse (At rated engine rpm)
km/h (mph)
Overall length (with 3p) mm (in.)
Overall width (minimum tread)
mm (in.)
Overall height (Cabin)
mm (in.)
Wheel base mm (in.)
Min. ground clearance mm (in.)
Tread Front mm (in.)
Rear mm (in.)
Weight (cabin) kg (lbs.)
TravelingspeedsDimensions
4,267 (167.9)
4,400 (269)
1st: 45.3 (20.6)
2nd: 31.7 (14.4)
Cat.2
11.2 - 24
16.9 - 3416.9 - 30
1st: 0.42 (0.26)
12th: 28.71 (17.83)
1st: 0.41 (0.25)
12th: 28.11 (17.46)
4,062 (159.9)
1,790 (70.4)
2,650 (104.3)
2,048 (80.6)
4,23 (16.6)
1,473 (57.9)
1,406 (55.3)
3,093 (6,819)
4,234 (166.6)
3,331 (7,341)
1,940 (76.3)
2,710 (106.6)
443 (17.4)
1,534 (60.3)
1,504 (59.2)
2,142 (84.3)
3,421 (7,542)

27. GENERAL
1-9C34-WOO May. 2005
Fuel
Coolant
Engine crankcase
Transmission case
Front axle case
Front axle
Greasing
1
2
3
4
5
6
7
100 (26.4 U.S.gal.)
60 (15.85 U.S.gal.)
Each 3.5 (0.9 U.S.gal.)
4.5 (1.2 U.S.gal.)
As necessary
DK651 DK751/801/901
5. LUBRICANTS, FUEL AND COOLANT
No. Locations
Capacities
Lubricants
No.2-D diesel fuel
No.1-D diesel fuel if temperature is below -10°C (14°F)
Fresh clean water with anti-freeze (50:50)
Engine oil: API Service Classification CC or CD
Multi-gradetransmission fuid the fuid listed below or
equivalent are recommended.
SAE 90 gear oil or transmission case oil
Standad type grease
Above 25°C (77°F)
0 to 25°C (32 to 77°F)
Below 0°C (32°F)
SAE30, SAE10W-30 or 10W-40
SAE20, SAE10W-30 or 10W-40
SAE10W, SAE10W-30 or 10W-40
9.1
(2.4 U.S.gal.)
6.9
(1.82 U.S.gal.)
18.5
(4.9 U.S.gal.)
10.5
(2.77 U.S.gal.)
To prevent serious equipment damage, use only genuine KIOTI fluids, oils and greases, or equivalents.
Exxonmobil
shell
BP
Mobilfluid 423 or 424
Exxon hydraul 560
DONAX-TD/TD Plus
Tractran UTH

28. CHAPTER 1 DK651/751/801/901
1-10 C34-WOO May. 2005
Diameter
6. TIGHTENING TORQUES
M6
(6 mm, 0.24 in.)
M8
(8 mm, 0.31 in.)
M10
(10 mm, 0.39 in.)
M12
(12 mm, 0.47 in.)
M14
(14 mm, 0.55 in.)
M16
(16 mm, 0.63 in.)
M18
(18 mm, 0.71 in.)
M20
(20 mm, 0.79 in.)
Material of
bolt
Indication on
top of bolt 7T 9T
6.1 GENERAL USE SCREWS, BOLTS AND NUTS
Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be tightened
according to the table below.
7 9
N·m
7.85
~
9.31
17.7
~
20.5
39.3
~
45.1
62.8
~
72.5
108
~
125
167
~
191
246
~
284
334
~
392
kgf·m
0.80
~
0.95
1.8
~
2.1
4.0
~
4.6
6.4
~
7.4
11.0
~
12.8
17.0
~
19.5
25.0
~
29.0
34.0
~
40.0
lbf·ft
5.79
~
6.87
13.1
~
15.1
29.0
~
33.2
46.3
~
53.5
79.6
~
92.5
123
~
141
181
~
209
246
~
289
N·m
7.85
~
8.82
16.7
~
19.6
31.4
~
34.3
kgf·m
0.80
~
0.90
1.7
~
2.0
3.2
~
3.5
lbf·ft
5.79
~
6.50
12.3
~
14.4
23.2
~
25.3
N·m
9.81
~
11.2
23.6
~
27.4
48.1
~
55.8
77.5
~
90.2
124
~
147
197
~
225
275
~
318
368
~
431
kgf·m
1.00
~
1.15
2.4
~
2.8
4.9
~
5.7
7.9
~
9.2
12.6
~
15.0
20.0
~
23.0
28.0
~
32.5
37.5
~
44.0
lbf·ft
7.24
~
8.31
17.4
~
20.2
35.5
~
41.2
57.2
~
66.5
91.2
~
108
145
~
166
203
~
235
272
~
318
Material of
opponent part
No-grade or 4T
SS400, S20C
Ordinariness Aluminum
S43C, S48C
Ordinariness Aluminum
N·m
7.85
~
8.82
17.7
~
20.5
39.3
~
44.1
62.8
~
72.5
kgf·m
0.80
~
0.90
1.8
~
2.1
4.0
~
4.5
6.4
~
7.4
lbf·ft
5.79
~
6.50
13.1
~
15.1
29.0
~
32.5
46.3
~
53.5
N·m
12.3
~
14.2
29.5
~
34.3
60.9
~
70.6
103
~
117
167
~
704
260
~
304
344
~
402
491
~
568
kgf·m
1.25
~
1.45
3.0
~
3.5
6.2
~
7.2
10.5
~
12.0
17.0
~
20.0
26.5
~
31.0
35.0
~
41.0
50.0
~
58.0
SCr435,
SCM435
Ordinariness
lbf·ft
9.05
~
10.4
21.7
~
25.3
44.9
~
52.0
76.0
~
86.7
123
~
144
192
~
224
254
~
296
362
~
419
6.2 STUD BOLTS
Unit
Material of opponent part
Diameter
Unit
M8 (8 mm, 0.31 in.)
M10 (10 mm, 0.39 in.)
M12 (12 mm, 0.47 in.)
Ordinariness Aluminum
N·m
11.8 ~ 15.6
24.6 ~ 31.3
29.5 ~ 49.0
lbf·ft
8.68 ~ 11.5
18.1 ~ 23.1
21.7 ~ 36.1
N·m
8.82 ~ 11.8
19.7 ~ 25.4
31.4
kgf·m
0.90 ~ 1.2
2.0 ~ 2.6
3.2
lbf·ft
6.51 ~ 8.67
14.5 ~ 18.8
23.1
kgf·m
1.2 ~ 1.6
2.5 ~ 3.2
3.0 ~ 5.0
4

29. GENERAL
1-11C34-WOO May. 2005
Grade
Unit
Nominal
diameter
5/16
3/8
1/2
9/16
5/8
N·m
23.1 ~ 27.8
47.5 ~ 57.0
108.5 ~ 130.2
149.2 ~ 179.0
203.4 ~ 244.1
kgf·m
2.35 ~ 2.84
4.84 ~ 5.82
11.07 ~ 13.29
15.22 ~ 18.27
20.75 ~ 24.91
lbf·ft
17.0 ~ 20.5
35.0 ~ 42.0
80.0 ~ 96.0
110.0 ~ 132.0
150.0 ~ 180.0
kgf·m
3.31 ~ 4.01
6.22 ~ 7.47
15.22 ~ 18.27
22.14 ~ 26.57
30.44 ~ 36.53
N·m
32.5 ~ 39.3
61.0 ~ 73.2
149.2 ~ 179.0
217.0 ~ 260.4
298.3 ~ 358.0
lbf·ft
24.0 ~ 29.0
45.0 ~ 54.0
110.0 ~ 132.0
160.0 ~192.0
220.0 ~ 264.0
6.3 AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF
THREADS
SAE GR.5 SAE GR.8

30. CHAPTER 1 DK651/751/801/901
1-12 C34-WOO May. 2005
1
year
2
years
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Change
Change
Change
Change
Change
Change
Adjust
Check
-
Check
Check
Clean
Change
Check
Change
Adjust
Adjust
Adjust
Check
Change
Check
Change
Check
Change
Check
Change
Adjust
Adjust
Check
Check
Clean
Change
Check
Change
Change
Drain
Item
Engine oil
Engine oil filter
Transmission oil filter
Hydraulic oil filter
Transmission fluid
Front axle case oil
Front axle pivot
Engine start system
Greasing
Wheel bolt torque
Battery condition
Air cleaner element
Fuel filter element
Fan belt
Clutch
Brake
Radiator hose and
clamp
Power steering oil
line
Fuel line
Intake air line
Toe-in
Engine valve
clearance
Fuel injection
nozzle injection
pressure
Injection pump
Cooling system
Coolant
Fuel system
Fuse
Light bulb
Drain moisture from
clutch housing
Period Indication on Hour Meter
After
Purchase
Important
50 100 150 200 250 800750700650600500450400350300 15003000
*4
*1
*2
*3
7. MAINTENANCE CHECK LIST
550
Service
as
required
Everyday

31. GENERAL
1-13C34-WOO May. 2005
No.
31
32
33
34
35
36
37
38
1
year
2
years
Clean
Check
Clean
Clean
Check
Check
Check
Supple-
ment
Item
Air conditioner
condenser net
Air conditioner belt
tension
Intake air filter
Ambient air filter
Air conditioner hose
Heater hose
Refrigerant
Washer liquid
Period Indication On Hour Meter
After
Purchase
Important
50 100 150 200 250 800750700650600500450400350300 15003000550
As
necessary
Everyday
• The jobs indicated by must be done after the first 50 hours of operation.
*1 Air cleaner should be cleaned more often in dusty conditions than in normal conditions.
*2 Every year or every 6 times of cleaning.
*3 Replace only if necessary.
*4 When the battery is used for less than 100 hours per year, check the fluid level annually.
IMPORTANT

32. CHAPTER 1 DK651/751/801/901
1-14 C34-WOO May. 2005
1. Turn the key switch to “ON”, check the amount of
fuel showing on the fuel gauge.
2. Fill fuel tank when the fuel gauge shows 1/4 or less
fuel in the tank.
3. Use No.2-Diesel fuel at all temperatures above -10°C
(14°F).
8.1 DAILY CHECK
For your own safety and maximum service life of the
machine, make a thorough daily inspection before op-
erating the machine to start the engine.
A. CHECKING AND REFUELING
(1) Fuel Tank Cap
Fuel tank capacity
100
(26.4 U.S.gal.)
8. CHECK AND MAINIENANCE
To avoid personal injury:
• Be sure to check and service the tractor on a flat
place with the engine shut off and the parking
brake “ON”.
CAUTION
Walk Around Inspection
Look around and under the tractor for such items as
loose bolts, trash build-up, oil or coolant leaks, broken
or worn parts.
C34W111A
NOTE:
• No.2-D is a distillate fuel of lower volatility for en-
gines in industrial and heavy mobile service. (SAE
J313 JUN 87)
• Grade of Diesel Fuel Oil According to ASTM D975
Flash Point °C (°F)
Min
52 (125)
Water and Sediment,
Volume %
Max
0.05
Carbon Residue On,
10 Percent Residuum, %
Max
0.35
Ash, Weight %
Max
0.01
Distillation
Temperatures,
°C (°F) 90% Point
Viscosity Kinematic cSt
or mm²/s at 40°C
Min
282 (540)
Max
338 (640)
Min
1.9
Viscosity Saybolt,
SUS at 100°F
Min
32.6
Max
40.1
Sulfur,
Weight %
Copper
Strip
Corrosion
Cetane
Number
Max
4.1
Max
0.50
Max
No.3
Min
40
• Do not permit dirt or trash to get into the fuel
system.
• Be careful not to let the fuel tank become empty,
otherwise air will enter the fuel system, requiring
the fuel system to be bled before next engine start.
• Be careful not to spill during refueling. If a spill
should occur, wipe it off at once. Fuel on the trac-
tor may cause a fire.
• To prevent condensation( water) accumulation in
the fuel tank, fill the tank before parking the trac-
tor overnight.
IMPORTANT
To avoid personal injury:
• Do not smoke while refueling.
• Be sure to stop the engine before refueling.
CAUTION

33. GENERAL
1-15C34-WOO May. 2005
1. Make sure to see that the coolant level is between
the “FULL” and “LOW” marks of recovery tank.
2. When the coolant level drops due to evaporation,
add water only up to the full level.
In case of leakage, add anti-freeze and water in the
specified mixing ration up to the full level.
(See “Flush Cooling System and Changing Coolant”
in every 2 yours maintenance.)
B. CHECKING ENGINE OIL LEVEL
(1) Oil Inlet
(2) Dipstick
(A) Oil Level is Acceptable Within this Range
C. CHECKING COOLANT LEVEL
(1) Recovery Tank (A) FULL
(B) LOW
C34W112A
C34W113A
To avoid personal injury:
• Do not remove the radiator cap while coolant is
hot. When cool, slowly rotate cap to the first stop
and allow ample time for excess pressure to es-
cape before removing the cap completely.
CAUTION
• When using an oil of different maker or viscosity
from the previous one, remove all of the old oil.
Never mix two different types of oil.
• Never run engine is the oil level is low.
IMPORTANT
To avoid personal injury:
• Be sure to stop the engine before checking the
oil level.
CAUTION
1. Park the machine on a flat surface.
2. Check the engine oil before starting the engine or
5 minutes or more after the engine has stopped.
3. To check the oil level, draw out the dipstick, wipe it
clean, replace it, and draw it out again. Check to
see that the oil level is between the two notches. If
the level is too low, add new oil to the prescribed
level at the oil inlet.
(See “LUBRICANTS” in page 1-9)
• If the radiator cap has to be removed, follow the
caution above and securely retighten the cap.
• Use clean, fresh water and anti-freeze to fill the
recovery tank.
• If water should leak, consult your local KIOTI Dealer.
IMPORTANT

34. CHAPTER 1 DK651/751/801/901
1-16 C34-WOO May. 2005
F. CLEANING GRILL, RADIATOR SCREEN
AND OIL COOLER SCREEN
(1) Radiator Screen
1. Check the front grill and the side screens to be sure
they are clean of any debris.
2. Detach the screen and eliminate all the foreign
material.
C34W114A
E. CHECKING SEAT BELT AND ROPS
1. Always check condition of seat belt and ROPS at-
taching hardware before operating tractor.
2. Replace if damaged.
To avoid personal injury:
• Besuretostoptheenginebeforeremovingthescreen.
CAUTION
• Grill and screen must be clean from debris to
keep the engine from overheating and to allow
good air intake to the air cleaner.
IMPORTANT
D. CHECKING HEAD LIGHT, HAZARD LIGHT
ETC.
1. Inspect the lights for broken bulbs and lenses.
2. Replace if broken.
G. CHECKING BRAKE PEDALS AND CLUTCH
PEDAL
1. Examine the brake and clutch pedals for free travel,
and smooth operation.
2. Adjust if free travel is not within specifications:
(See “Adjusting Clutch and Brake Pedal” in every
100 hours maintenance.)
NOTE:
Brake pedals should be equal when depressed.
H. CHECKING GAUGES, METER AND EASY
CHECKER
1. Examine the instrument panel for broken gauge(s),
meter(s) and Easy Checker lamps.
2. Replace if broken.
I. DRAINING WATER FROM FUEL PRE-FILTER
Water and dirts in fuel are deposited at fuel filter. Re-
move the drain plug (1) to remove the deposited water
and dirts when necessary.
Water infuel results in breakage of injection pump
shaft or malfunction of injection nozzle. Drain the
water from the fuel pre-filter frequently.
CAUTION
(1) Drain Plug
C34W115A

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