Kioti Daedong DS4110 Tractor Service Repair Manual

DS4110(HS)/4510(HS) workshop manual

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TABLE OF CONTENTS CHAPTER 1

SAFETY FIRST

CHAPTER 2

GENERAL

CHAPTER 3

ENGINE

CHAPTER 4

CLUTCH

CHAPTER 5

TRANSMISSION

CHAPTER 6

REAR AXLE

CHAPTER 7

BRAKE

CHAPTER 8

FRONT AXLE

CHAPTER 9

STEERING SYSTEM

CHAPTER 10

HYDRAULIC SYSTEM

CHAPTER 11

ELECTRIC SYSTEM

CHAPTER 12

INDEX

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DS4110(HS)/4510(HS)

Safety First

CHAPTER 1

TABLE OF CONTENTS 1. SAFETY DECALS.................................... 1-2

2.4 Fire.......................................................... 1-4

1.1 Alert symbols........................................... 1-2

2.5 Cautions when handling the battery........ 1-5

2. Safety tips........................................... 1-3 2.1 Safety gear.............................................. 1-3 2.2 Workplace .............................................. 1-3 2.2.1 Ventilating system.......................... 1-3 2.2.2 Safe workplace.............................. 1-3 2.2.3 Illumination.................................... 1-3 2.2.4 Safety equipment........................... 1-3 2.2.5 keeping your work area clean........ 1-3 2.3 Safety instructions when preparing tractor..... 1-4

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2.6 Cautions for high pressure hoses.................1-5 2.7 Use of appropriate tools and equipment......... 1-6 2.8 Handling of hazardous materials................ 1-6 2.9 Handling of rotating blade, shaft and driving belt.........1-7 2.10 Scald prevention..................................... 1-7 2.11 Disposal of environmental waste............ 1-8 2.12 Cautions when handling tires.................. 1-8

3. Safety decals.................................... 1-9 3.1 The location of safety decal.................... 1-9

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DS4110(HS)/4510(HS)

1. SAFETY DECALS •

Most accidents can be avoided if basic safety instructions and regulations are followed. Always follow the safety regulations and avoid any dangerous situation to prevent an accident.

•

You can be unexpectedly injured if inspecting or servicing the tractor without full knowledge of it.

Read the manual carefully before starting any type service, and follow the instructions on service, maintenance and inspection to prevent any injury.

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ENGINE

GENERAL

SAFETY FIRST

SAFETY FIRST - SAFETY DECALS

CLUTCH

S76W001A

1.1 Alert symbols The meanings of the safety-alert symbols used in this manual are as follows:

C. Caution

REAR AXLE

TRANSMISSION

A. Remark

주의

Remark

CAUTION

BRAKE

S76W002A

•

Broaden your knowledge with supplied service information for optimal performance.

•

This mark indicates potentially hazardous situations which, if not observed, may result in serious injury.

D. Warning

STEERING

FRONT AXLE

B. Important

S76W004A

WARNING •

This mark places emphasis on information which can be confusing when servicing. If this information is not carefully read and observed, the tractor may not function properly or may be damaged.

S76W005A

•

This mark indicates hazardous situations which, if not observed, may result in death or injury.

ELECTRIC

HYDRAULIC

S76W003A

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DS4110(HS)/4510(HS)

SAFETY FIRST - SAFETY TIPS SAFETY FIRST

2. Safety tips 2.2 Workplace

S76W007A

ENGINE

GENERAL

2.1 Safety gear

When working on the tractor, wear safety gloves, safety shoes, ear plugs, safety goggles, safety helmet, working clothes, etc. appropriate for your working environment.

Never wear loose fitting clothing or a tie which can be caught by rotating parts. According to the statistics, most accidents occurring with rotating parts are due to inappropriate or loose fitting clothing.

Any type of service should be performed in a well-ventilated area. If the engine should be started in an enclosed place, an exhaust vent pipe should be installed to the outside.

WARNING • California Proposition 65 Warning Inhaling exhaust gas can cause cancer or damage the generative function leading to infertility.

S76W008A

All work should be performed in a wide, level and safe place to prevent slips and fall accidents.

FRONT AXLE

BRAKE

REAR AXLE

2.2.2 SAFE WORKPLACE

TRANSMISSION

S76W006A

CLUTCH

2.2.1 Ventilating system

2.2.4 Safety equipment Be sure to keep a first aid kit and fire extinguisher handy at all times.

HYDRAULIC

The work place should be well illuminated. If working in a dark place or under the tractor, use an approved work lamp. The work lamp should be covered with a safety hot cover. Bulbs can catch on fire if they come in contact with fuel.

STEERING

2.2.3 Illumination

Keep the working area clean before and during work. If any oil or fuel is spilled, it should be cleaned up immediately to prevent falls.

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ELECTRIC

2.2.5 KEEPING YOUR WORK AREA CLEAN

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2.3 Safety instructions when preparing THE tractor

DS4110(HS)/4510(HS)

2.4 FIRE

GENERAL

SAFETY FIRST

SAFETY FIRST - SAFETY TIPS

ENGINE

S76W011A

• S76W009A

Always ensure all implements are lowered to the ground prior to working on the tractor.

S76W012A

•

Keep flames or sparks away from fuel containers, spray paint, etc. and be careful of leaks.

S76W010A

•

Stop the engine and remove the key.

•

Put "No Operation" label on the tractor if necessary.

BRAKE

REAR AXLE

TRANSMISSION

CLUTCH

•

Never smoke or allow flames or sparks in your work area when performing maintenance.

•

Disconnect the negative battery cable.

•

Always disconnect the battery cable for fire prevention before performing service.

•

Be extra cautious of fire when welding.

HYDRAULIC

STEERING

FRONT AXLE

S76W013A

S76W014A

Always keep a fire extinguisher in the workplace.

ELECTRIC

•

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SAFETY FIRST - Safety tips 2.6 Cautions for high pressure hoses

S76W015A

•

Hydraulic fluid leaking from high pressure hoses or pipes can penetrate your skin.

CLUTCH

Always disconnect the negative battery cable first and reconnect it last to avoid sparks from an accidental short circuit. Otherwise, it could result in fire or injury.

S76W017A

S76W020A

Do not charge a frozen battery. Charging a frozen battery can cause explosion. Let the battery warm up to ambient temperature (16°C, 60°F) before charging.

•

Before connecting a high pressure hose or pipe, stop the engine and depressurize it by. Check bolts for proper torque before starting the engine after hydraulic system service.

•

Keep sparks and flames (match, lighter) away from the battery to prevent an explosion. Never connect the battery's negative and positive cables together to test. Use only an approved tester when checking removed the battery voltage.

•

Use a cardboard or plank when checking for leaks.

•

Never use your hands !

HYDRAULIC

STEERING

FRONT AXLE

•

BRAKE

S76W016A

REAR AXLE

TRANSMISSION

•

S76W019A

ENGINE

GENERAL

2.5 Cautions when handling the battery

SAFETY FIRST

DS4110(HS)/4510(HS)

•

A battery can be very hazardous because it contains sulfuric acid. It can damage your clothes, and even burn your skin when directly contacted. If it contacts with your eyes, you could lose your sight.

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S76W021A

•

Never weld a high pressure pipe or the surrounding area. The pipe or hose can be heated and explode which can lead to fire or severe burns.

ELECTRIC

S76W018A

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DS4110(HS)/4510(HS)

2.7 Use of appropriate tools and equipment

2.8 Handling of hazardous materials

•

Use the correct tools in proper size. If an inappropriate tool is used, it can slip which can damage parts or injure you.

•

Do not use compressed air to remove hazardous materials, such as clutch dust. Inhaling such hazardous materials can damage your health.

•

Do not confuse units (mm, inch, etc.). Use air driven impact wrench only when loosening bolts or nuts.

Impact wrenches should not be used when assembling precisely machined parts requiring specific tightening torques. Failure to follow these suggestions could result in premature failure or improper operation of a specific part.

•

These materials should be rinsed or wiped away after sprayed with oil.

•

Remark All genuine KIOTI parts are asbestos free.

Make sure impact tools are securely fastened to hard ware. Impact tools can easily dislodge of injure the operator.

REAR AXLE

TRANSMISSION

CLUTCH

ENGINE

GENERAL

SAFETY FIRST

SAFETY FIRST - Safety tips

S76W022A

When lifting the tractor with a hydraulic jack or a hoist, connect the tool securely to the tractor before lifting, use auxiliary supports to suspend equipment in place and install the auxiliary support. Never work under the tractor if the support and the hydraulic jack (hoist) are not installed.

•

When using a hydraulic jack or a hoist, do not attempt to exceed the safe lifting capacity of the device.

•

Make sure that the hydraulic lock operates properly before used. Improper use of lock can cause a serious accident.

•

Check the buttons and operating direction of the hoist before using it. Improper operation can cause a serious accident.

•

Do not use wooden blocks or bricks as support under the tractor. As the tractor's weight is continuously applied to them, they can be broken or collapse.

•

Failure to follow these warnings could cause serious damage to equipment and lead to serious injury or death to the operator/technician.

ELECTRIC

HYDRAULIC

STEERING

FRONT AXLE

BRAKE

•

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SAFETY FIRST - Safety tips 2.10 SCALD PREVENTION

ENGINE

GENERAL

2.9 Handling of rotating blade, shaft and driving belt

SAFETY FIRST

DS4110(HS)/4510(HS)

S76W023A

•

Do not open the radiator cap when the radiator is hot. Hot coolant or fumes can escape leading to a serious burn.

CLUTCH

S76W027A

Do not place hands or feet near the tractor's PTO shaft or rotating blades.

•

Be extra careful when you are in loose clothes.

Loose clothing could create an entanglement hazard.

•

Check the surface temperature of the engine before draining the engine oil, transmission fluid, coolant, etc. If it is hot, let it cool down before draining it.

•

Only perform service on the engine or parts (muffler, exhaust manifold, turbocharger, etc.) when they are cool.

•

Hot fluids or engine parts can seriously injury or burn you.

S76W025A

Do not place hands near the engine cooling fan or drive belts when the engine is running.

HYDRAULIC

STEERING

•

FRONT AXLE

S76W028A

BRAKE

REAR AXLE

•

TRANSMISSION

S76W024A

S76W026A

You can be seriously injured if your hand or clothes is caught by a rotating fan belt or A/C belt.

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ELECTRIC

•

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2.11 Disposal of environmental waste

DS4110(HS)/4510(HS)

2.12 Cautions when handling tires

ENGINE

GENERAL

SAFETY FIRST

SAFETY FIRST - Safety tips

•

Observe relevant environmental protection regulations when disposing used oil, transmission fluid, coolant, oil filter, etc. Otherwise, they can pollute the environment seriously and you could be charged in violation of regulations.

S76W030A

•

The tire rims can fall out of the tires. Therefore, stay out of its way when checking or inflating tires.

Improper tire inflation can cause tires to slide off of rims. When checking tire pressure or inflating tires, do not stand directly in front of the rim/tire. Position yourself adjacent to the rim/tire, out of the way should a failure occur.

BRAKE

REAR AXLE

TRANSMISSION

CLUTCH

S76W029A

•

Do not weld or apply heat to the tire rim or disc. The tire can explode due to the rapidly increased pressure in the tire.

•

Check tires for proper inflation pressure, damage, deformation, extended wear on lug and damage of rim and disc. Also check for proper torque wheel bolts, rim bolts and nuts are loose.

ELECTRIC

HYDRAULIC

STEERING

FRONT AXLE

S76W031A

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SAFETY FIRST - SAFETY DECALs

3. Safety decals When replacing an existing part with a new one, attach the same safety decal to the new part. Otherwise,the customer's safety will be threatened.

•

If a decal is damaged or detached, attach a new decal to the part.

•

The decals and their attaching locations are as follows.

•

There are part numbers on the bottom of each decal.

GENERAL

•

SAFETY FIRST

DS4110(HS)/4510(HS)

ENGINE

3.1 THE LOCATION OF SAFETY DECAL

CLUTCH

6

HYDRAULIC

STEERING

FRONT AXLE

BRAKE

REAR AXLE

TRANSMISSION

7

ELECTRIC

8

H61W001A

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SAFETY FIRST

SAFETY FIRST - SAFETY DECALs (1) t2615-54112

DS4110(HS)/4510(HS)

(4) t4625-52351

WARNING ONLY use diesel.

T2615-54112

(2) t2615-53561

(5) t4625-52361

(3) t2325-50743

ELECTRIC

HYDRAULIC

STEERING

FRONT AXLE

BRAKE

REAR AXLE

TRANSMISSION

CLUTCH

ENGINE

GENERAL

Avoid flames and sparks.

STOP engine while refueling.

1-10

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SAFETY FIRST - SAFETY DECALs

(6) t4625-53191

(8) t2625-55111

SAFETY FIRST

DS4110(HS)/4510(HS)

ENGINE

GENERAL

1. Before leaving the tractor, park the tractor on level ground, apply the parking brake, disengage the P.T.O. and stop the engine.

2.Avoid accidental contact with the gear shift levers while the engine is running as unexpected tractor movement can result.

T4625-53191

CLUTCH

(7) t2241-50702

TO AVOID POSSIBLE INJURY OR DEATH

TRANSMISSION

1. Start engine only from operator’s seat with transmission and PTO in neutral.

Never start engine while standing on ground.

2. Do not start engine by shorting across starter terminals.

Machine may start in gear and move if normal starting circuitry is bypassed.

ELECTRIC

HYDRAULIC

STEERING

FRONT AXLE

BRAKE

REAR AXLE

T2241-50702

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