Kioti Daedong CS2410 CS2610 Tractor Service & Repair Manual

CS2410(US) CS2610(EU/AU) WORKSHOP MANUAL

We reserve the right to make changes throughout the entire manual at any time without notice. • Using unspecified parts, fuel and lubricants other than KIOTI's genuine parts can damage the tractor and such damage will not be covered by warranty. • IMPORTANT REMARK PREFACE This manual is to provide servicing personnel with information on the general speci- ﬁcations, service, operating principle, troubleshooting, exploded view including part name, removing and installing procedures for CS2410(US) and CS2610(EU/AU) trac- tors with high-end technology. All information in this manual is based on the latest product information available at the time of publication. Therefore, some of the information in this manual may differ from the machine you have. KIOTI has a principle to apply update to the next edition of the manual if there is any. However, KIOTI has no obligation to modify the contents in this manual, especially the contents in the manual which is already distributed or published. The modified information is available in KIOTI's online electronic manual system (DEMSS). This manual is ultimately to satisfy customers with best performance of tractor. If there is any typo, wrong information or question for this manual, feel free to contact KIOTI. Mar. 2012 service division DAEDONG INDUSTRIAL Co., Ltd.

TABLE OF CONTENTS CHAPTER 1 SAFETY FIRST CHAPTER 2 GENERAL CHAPTER 3 ENGINE CHAPTER 4 TRANSMISSION CHAPTER 5 HST CHAPTER 6 REAR AXLE CHAPTER 7 BRAKE CHAPTER 8 FRONT AXLE CHAPTER 10 HYDRAULIC SYSTEM CHAPTER 11 ELECTRIC SYSTEM CHAPTER 9 STEERING CHAPTER 12 INDEX

TABLE OF CONTENTS SAFETY FIRST CS2410(US) CS2610(EU/AU) CHAPTER 1 1. FOR SAFETY .......................................... 1-2 1.1 Alert symbols.......................................... 1-2 2. SAFETY TIPS .......................................... 1-3 2.1 Safety gear ............................................. 1-3 2.2 Work place ............................................ 1-3 2.3 Safety instructions when preparing tractor ..................................................... 1-4 2.4 Avoid ﬁres............................................... 1-4 2.5 Cautions when handling the battery ....... 1-5 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 Prevention of scald................................. 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 Location of decals .................................. 1-9

1 -2 DY51-W00 CS2410(US) CS2610(EU/AU) SAFETY FIRST GENERAL ENGINE CLUTCH TRANSMI SSION HST REAR AXLE BRAKE FRONT AXLE STEERING SYSTEM HYDRAULIC SYSTEM ELECTRIC SYSTEM SAFETY FIRST GENERAL ENGINE TRANSMISSION HST REAR AXLE BRAKE FRONT AXLE STEERING SYSTEM HYDRAULIC SYSTEM ELECTRIC SYSTEM INDEX 1. FOR SAFETY 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 service manual carefully before starting servicing and follow the instructions for servicing, maintenance and inspection to prevent any injury. • • T46W001A 1.1 ALERT SYMBOLS In this manual, the following safety-alert symbols are used. Their meanings are as follows: REMARK ▶ Broaden your knowledge with additionally supplied service information for optimal service. • T46W002A REMARK CAUTION ▶ This mark indicates potentially hazardous situation which, if not observed, may result in serious injury. • T46W004A CAUTION IMPORTANT ▶ This mark indicates emphasis on information which can be confused when servicing. If this information is not carefully read and observed, the tractor can- not fully function or may be damaged. • T46W003A WARNING ▶ This mark indicates hazardous situation which, if not observed, may result in death or injury. • T46W005A WARNING READ MANUAL! SAFETY FIRST - FOR SAFETY

1 -3 DY51-W00 CS2410(US) CS2610(EU/AU) SAFETY FIRST GENERAL ENGINE CLUTCH TRANSMI SSION HST REAR AXLE BRAKE FRONT AXLE STEERING SYSTEM HYDRAULIC SYSTEM ELECTRIC SYSTEM SAFETY FIRST GENERAL ENGINE TRANSMISSION HST REAR AXLE BRAKE FRONT AXLE STEERING SYSTEM HYDRAULIC SYSTEM ELECTRIC SYSTEM INDEX 2. SAFETY TIPS 2.1 SAFETY GEAR A. VENTILATING SYSTEM The service should be performed in well-ventilated area. If the engine should be started in an enclosed place, the exhaust gas pipe should be installed. T46W006A California Proposition 65 Warning Inhaling exhaust gas can cause cancer or damage the generative function leading to infertility. • WARNING When working on the tractor, wear safety gloves, safety shoes, ear plugs, safety goggles, safety helmet, working clothes, etc. appropriate for your working environ- ment. Never wear loose fitting clothing or a tie which can be caught to the rotating part. According to the statistics, most accidents that occurred with rotating parts are due to this inappropriate manner of wearing clothes. 2.2 WORK PLACE T46W007A B. SAFE WORKING PLACE T46W008A The work should be done in a wide, level and safe place to prevent slip and fall accident. C. ILLUMINATION The work place should be well illuminated. If working in a dark place or under the tractor, use the work lamp. The work lamp should be covered by the safety cover. The bulb can cause fire due to leaked fuel if it is broken. D. SAFETY EQUIPMENT Be sure to keep a first aid kit and fire extinguisher han- dy at all times. E. CLEAN WORKING AREA Keep the working area clean before and during work. If any oil or fuel is spilled, it should be cleaned up immedi- ately. SAFETY FIRST - SAFETY TIPS

1 - DY51-W00 CS2410(US) CS2610(EU/AU) SAFETY FIRST GENERAL ENGINE CLUTCH TRANSMI SSION HST REAR AXLE BRAKE FRONT AXLE STEERING SYSTEM HYDRAULIC SYSTEM ELECTRIC SYSTEM SAFETY FIRST GENERAL ENGINE TRANSMISSION HST REAR AXLE BRAKE FRONT AXLE STEERING SYSTEM HYDRAULIC SYSTEM ELECTRIC SYSTEM INDEX Lower the implement on to the ground. • T46W009A 2.3 SAFETY INSTRUCTIONS WHEN PREPARING TRACTOR T46W010A Stop the engine and remove the key. Put "Do not operate" label on the tractor if necessary. • • 2. AVOID FIRES Never smoke or allow flames in your work area when servicing the fuel system. • T46W011A T46W012A Keep flames or sparks away from the spray paint or fuel containers and be careful of leak. • T46W013A Always disconnect the battery cable before servicing. Be extra cautious of fire when welding. • • T46W014A Always keep a fire extinguisher in workshop. • SAFETY FIRST - SAFETY TIPS

1 -5 DY51-W00 CS2410(US) CS2610(EU/AU) SAFETY FIRST GENERAL ENGINE CLUTCH TRANSMI SSION HST REAR AXLE BRAKE FRONT AXLE STEERING SYSTEM HYDRAULIC SYSTEM ELECTRIC SYSTEM SAFETY FIRST GENERAL ENGINE TRANSMISSION HST REAR AXLE BRAKE FRONT AXLE STEERING SYSTEM HYDRAULIC SYSTEM ELECTRIC SYSTEM INDEX 2.5 CAUTIONS WHEN HANDLING THE BATTERY Always disconnect the negative battery cable first and reconnect it last to avoid sparks from an accidental short circuit. You can get injured or fire may break out. • Keep sparks and flames (match, lighter) away from the battery. The battery can explode due to the battery fluid. Never connect the battery's negative and positive cables with metal for test. Use only tester when checking the battery voltage. • • Do not charge the frozen battery. Charging the frozen battery can cause explosion. Let the battery warmed up to ambient temperature (16°C, 60°F) before charging. • The battery contains the acid that can burn you. When it contacts with your eyes, you may lose your sight. • T46W015A T46W016A T46W017A T46W018A T46W019A 2.6 CAUTIONS FOR HIGH PRESSURE HOSES The hydraulic fluid leaked from high pressure hoses or pipes can penetrate your skin. • T46W020A Before connecting a high pressure hose or pipe, stop the engine and depressurize it by valve. Check the bolts for tightness before starting the engine after servicing the hydraulic system. Use a cardboard or plank when checking leakage. • • • T46W021A Never weld the high pressure pipe or the surround- ing area. The pipe or hose can be heated and explode which can lead to fire or burn. • SAFETY FIRST - SAFETY TIPS

1 -6 DY51-W00 CS2410(US) CS2610(EU/AU) SAFETY FIRST GENERAL ENGINE CLUTCH TRANSMI SSION HST REAR AXLE BRAKE FRONT AXLE STEERING SYSTEM HYDRAULIC SYSTEM ELECTRIC SYSTEM SAFETY FIRST GENERAL ENGINE TRANSMISSION HST REAR AXLE BRAKE FRONT AXLE STEERING SYSTEM HYDRAULIC SYSTEM ELECTRIC SYSTEM INDEX 2.7 USE OF APPROPRIATE TOOLS AND EQUIPMENT Use the appropriate tools in proper size. If an inappropriate tool is used, it can be slipped which can damage parts or injure you. Do not confuse units (mm, inch, etc.). Use the air impact wrench only when unscrewing the bolts or nuts. Such wrench should not be used when assembly precisely machined parts which its tightening torque should be strictly observed. It can cause malfunction. Be careful of a socket popped out due to the turning force when using the air impact wrench. Especially, be extra cautious when working on connection or socket with joint. • • • • 2.8 HANDLING OF HAZARDOUS MATERIALS Do not use pressurized air to blow out hazardous materials, such as clutch dust, with compressed air. Inhaling such hazardous materials can damage your health. • When lifting the tractor with a hydraulic jack or a hoist, fix it firmly 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 use it over the limit of the equipment and the conveying belt. Make sure that the hydraulic lock operates properly before using the hydraulic jack. 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 continuous- ly applied to them, they can be broken or collapsed. • • • • • T46W022A All KIOTI's genuine parts contain no asbetos. • REMARK These materials should be rinsed or wiped away after spraying oil. • SAFETY FIRST - SAFETY TIPS

1 -7 DY51-W00 CS2410(US) CS2610(EU/AU) SAFETY FIRST GENERAL ENGINE CLUTCH TRANSMI SSION HST REAR AXLE BRAKE FRONT AXLE STEERING SYSTEM HYDRAULIC SYSTEM ELECTRIC SYSTEM SAFETY FIRST GENERAL ENGINE TRANSMISSION HST REAR AXLE BRAKE FRONT AXLE STEERING SYSTEM HYDRAULIC SYSTEM ELECTRIC SYSTEM INDEX Do not open the radiator cap when the radiator is hot. Hot coolant or steam can be surged leading to a serious scald. • T46W027A 2.9 HANDLING OF ROTATING BLADE, SHAFT AND DRIVING BELT Do not set a hand or a foot into the tractor's rotating blade or PTO shaft. Be extra careful when you are in loose clothes. • Be careful not to get caught by the rotating engine cooling fan. • T46W025A You can be seriously injured if your hand or clothes is caught by the rotating fan belt or A/C belt. • T46W026A 2.10 PREVENTION OF SCALD Check the surface temperature of the container before draining the engine oil, transmission ﬂuid, coolant, etc. If it is hot, let it cool down before draining it. There is danger of burning. Perform any service on the engine parts (muffler, exhaust manifold, turbocharger, etc.) only when they are not hot. • • T46W028A T46W023A T46W024A SAFETY FIRST - SAFETY TIPS

Kioti Daedong CS2410 CS2610 Tractor Service & Repair Manual

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