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.
매뉴얼 숙지 ! reaD manual!
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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MEMO
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