Mahindra 4010 HST Operator's Manual
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Mahindra 4010 HST Operator's Manual

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The Mahindra Group Mahindra USA, Inc. 9020 Jackrabbit Road Houston, Texas 77041 1-877-499-7771 www.mahindrausa.com

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  • Page 1 Operator's Manual Click here to go on '10' Series INDEX 4010 HST Main Menu The Mahindra Group Mahindra USA, Inc. 9020 Jackrabbit Road Houston, Texas 77041 1-877-499-7771 www.mahindrausa.com...
  • Page 2 Mahindra USA, Inc. 5203 Aeropark Drive Houston, TX 77032 (281) 449-7771 www.mahindrausa.com ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■...
  • Page 3 DAEDONG Off-Road compression-Ignition Engine Emission Control System Warranty statement EMISSION RELATED SYSTEM DEFECT WARRANTY The warranty period shall begin on the date the engine or equipment is delivered to an ultimate purchaser. Daedong-USA INC.warrants to the ultimate purchaser and each subsequent purchaser of certified off- road compression-ignition engine(powering off-road machines and equipment),that such engine is;...
  • Page 4 This warranty covers the following emission-related parts and components. -Fuel Injection pump -Nozzle Assembly -Injection pipe -Turbocharger (if equipped) -Intake,Exhaust manifold If failure of one of these components results in failure of another part,both will be covered by this warranty. Any replacement part may be used for maintenance or repairs,The owner should ensure that such parts are equivalent in design and durability to Daedong genuine parts.
  • Page 5 LIMITATION The emission control system defects warranty and the emission control system performance warranty shall not apply to: -malfunctions in any part directly caused by abuse,misuse,modification,improper adjustment except those done by a dealership during warranty service work,alterations,tempering connections,improper or inadequate maintenance,neglect or use of leaded diesel or other fuels not recommended in the owner’s Manual.
  • Page 6 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Daedong-USA, INC. are pleased to explain the emission control system warranty on your 2004 and later engine. In California, new off-road engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards.
  • Page 7 — Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with California’s emissions requirements. — You are responsible for initiating the warranty process. The CARB suggests that you present your off- road compression ignition engine to a Daedong-USA, INC.
  • Page 8 FUEL INJECTION PUMP OR NOZZLES – Fuel injection pumps or nozzles are subject to tip wear as a result to fuel contamination. This damage can cause an increase in fuel consumption,the engine to emit black smoke misfire or run rough. Inspect, test, and replace if necessary. Fuel injection pumps can be tested by an authorized Daedong engine dealer.
  • Page 9 FOREWARD Thank you very much for purchasing our tractor, which, we feel sure, will give you many years of troubling the service. The introduction in this manual set out the correct manner of operating, maintaining and checking the tractor to ensure long-term durability. Please ensure correct operation of the tractor as incorrect operation can cause substantial mechanical damage as well as cause accidents with the associated injuries.

  • Page 10: Table Of Contents

    CONTENTS Sr. No. Description Page No. 1. Tractor Identification --------------------------------------------------------------------------------- 2. About this manual ------------------------------------------------------------------------------------- 3. Introduction & Description --------------------------------------------------------------------------- 11~12 4. Owner assistance -------------------------------------------------------------------------------------- 5. ROPS (Roll over protection structures) ------------------------------------------------------------ 14~16 6. Safety instructions, Do’s & Don’ts ----------------------------------------------------------------- 17~29 7.

  • Page 11: Tractor Identification

    The manufacturer warrants this product and full details of the warranty are provided on a separate warranty schedule. SERVICE. Service is available from any Mahindra dealer in the country. PARTS. To obtain spare parts please contact your nearest dealer and give him the details listed below.

  • Page 12: About This Manual

    Your Tractor has been designed and built to give maximum performance, with good fuel economy and ease of operation under a wide variety of operating conditions. Prior to delivery, The tractor was carefully inspected, both at the factory and by your Mahindra Dealer/Distributor, to ensure that it reaches you in optimum conditions .

  • Page 13: Introduction & Description

    Power Take or PTO shaft. In this book the operating, maintenance and storage instructions for all models of Mahindra Diesel Tractors has been complied. This material has been prepared in detail to help you in the better understanding of maintenance and efficient operation of the machine.
  • Page 14 The rim & Disc fitted with Rear tires are bolted to the outer flange of Rear Axle. Hydraulic system & Linkages. ■ ■ ■ ■ Mahindra Tractors are fitted with Live (i.e. system is in operation) independent, very touch of hydraulic System. Three point Linkages can be used for category 1 type of implements. Steering ■...

  • Page 15: Owner Assistance

    • Nature of problem Before contacting Mahindra office, be aware that your problem will likely to be resolved in the Dealership using the Dealer’s/Distributor’s facilities, equipment and personnel. So it is important that your initial contact be with the Dealer/Distributor.
  • Page 16 The objective of the frame or cab structure is to protect the operator in the event of a roll over and they are designed to support the entire weight of the tractor in that event. Each Mahindra ROPS frame or cab structure is designed and has been tested to meet industry and or Government standards.
  • Page 17 DAMAGE OF THE ROPS ► ► ► ► If the tractor has rolled over or the ROPS has damaged (such as striking an overhead object during transport), It must be replaced to provide the original protection. After an accident, check for damages to the 1.ROPS.2.Seat 3.seat belt &...
  • Page 18 How to adjust the Seat * Sliding type NOTE: Do not use solvents to clean the seat. Use warm water with a little detergent added. Before operating a Tractor it is important to adjust the seat to the most comfortable position &...

  • Page 19: Safety Signs

    SAFETY INSTRUCTIONS RECOGNIZE SAFETY INFORMATION This symbol means ATTENTION! YOUR SAFETY IS INVOLVED. The message that follows the symbol contains important information about safety. Carefully read the message SIGNAL WORDS. DANGER A signal word D ANGER, WARNING OR CAUTION i s used ―...
  • Page 20 USE OF ROPS AND SEAT BELT The Roll Over Protective Structure(ROPS) has been certified to industry and/or government standards. Any damage or alternation to the ROPS, mounting hard-ware, or seat belt voids the certification and will reduce or eliminate protection for the operator in the event of a roll-over.
  • Page 21 HANDLE FUEL SAFELY-AVOID FIRES Handle fuel with care; it is highly flammable. Do not refuel the Tractor while smoking or near open flame or sparks. Always stop engine before refueling Tractors. Always keep your tractor clean of accumulated grease, and debris. Always clean up spilled fuel.
  • Page 22 AVOID HIGH-PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury. Keep hands and body away from pinholes and nozzles, which eject fluids under high pressure. If ANY fluid is injected into the skin. Consult your doctor immediately. PREVENT BATTERY EXPLOSIONS Keep sparks, lighted matches, and open flame away from the top of battery.
  • Page 23 WORK IN VENTILATED AREA Do not start the Tractor in an enclosed building unless the doors & windows are open for proper ventilation, as tractor fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area remove the exhaust fumes by connecting exhaust pipe extension.
  • Page 24 SAFE OPERATION OF YOUR TRACTOR The manufacturer of your tractor has made every effort to make it as safe as is humanly possible. Beyond this point it is the responsibility of the operator to avoid accidents and we ask that you read and implement our suggestions for your safety.
  • Page 25 SAFETY TIPS DURING MAINTENANCE 1. At least on a daily basis check all oil levels. Water level in the radiator and electrolyte level in the battery and perform services according to the service schedule. 2. Ensure tire pressure are even and the correct pressure for the job being done is maintained. 3.
  • Page 26 MOUNTING AND DEMOUNTING IMPLEMENTS ► ► ► ► (1)Ensure that all mounting and removal of implements is done on safe flat ground. Ensure no one is between the Tractor and implement and do not get under the implement to avoid accidental injuries.
  • Page 27 THE FOLLOWING PRECAUTIONS ARE SUGGESTED TO HELP PREVENT ACCIDENTS. ► ► ► ► A careful operator is the best operator. Most accidents can be avoided by observing certain precautions . Read and take the following precautions before operating the Tractor to prevent accidents. Tractor should be operated only by those who are responsible and properly trained to do so.
  • Page 28 Do not bypass the safety starter switch. Consult your Mahindra Tractor Dealer/Distributor if safety- starting switch malfunctions. 4. Avoid accidental contact with the gear shifter lever while the engine is running. Unexpected Tractor movement can result from such contact.
  • Page 29 Driving the tractor ■ 1. Watch where you are going especially at row ends, on roads, around trees and low hanging obstacles. 2. To avoid upsets, drive the tractor with care and at speeds compatible with safety, especially when operating over rough ground, crossing ditches or slopes, and when turning at corners. 3.
  • Page 30 DO’S AND DON’T’S DO’S-For Better performance ► ► ► ► DO-Ensure that safety shields are in place and in good condition. DO-Read all operating instructions before commencing to operate Tractor. DO-Carry out all maintenance tasks without fail. DO-Keep the air cleaner clean. DO -Ensure that the correct grade of lubricating oils is used and that they are replenished and changed at the recommended intervals.
  • Page 31 DON’T-Use the independent brakes for making turns on the highway or at high speeds. DON’T-Refuel the tractor with the engine running. DON’T-Mount or dismount from the right side of the tractor. DON’T-Temper the hydraulic control levers’ upper limit stops. DON’T-Use draft control lever for lifting of implements. DON’T-Start the engine with the PTO engaged.
  • Page 32 SAFETY SIGNS GENERAL SAFETY INFORMATION ► ► ► ► IMPORTANT: This “General safety Information” should be kept with the machine at all times as reference data. This symbol means ATTENTION! YOUR SAFETY IS INVOLVED. The message that follows the symbol contains important information about safety. Follow recommended precautions and safe operating practice.
  • Page 33 DECALS ON THE CHASSIS...
  • Page 34 DECALS AROUND THE SEAT...

  • Page 35: Universal Symbols

    UNIVERSAL SYMBOLS Some of the universal symbols have been shown below with an indication of their meaning Engine speed Pressured- Corrosive rev/minX100) open slowly substance ”Tortoise” Hours, Continuous Slow or recorded variable minimum Setting Engine ”Hare” fast or coolant Warning maximum temperature setting...

  • Page 36: Controls, Instruments & Operations

    It is too late to learn once the Tractor is moving. If in doubt about any aspect of the operation of the tractor consult your Mahindra Tractor Dealer/Distributor. Particular attention should be paid to the recommendations for running-in to ensure that your tractor...
  • Page 37 DESCRIPTION OF TRACTOR CONTROLS INSTRUMENT AND SWITCHES ► ► ► ► MAIN SWITCH (KEY SWITCH) ► [OFF] - The key can be inserted or removed [ON] - The electric circuit is on. [GLOW] - Glow plugs preheat the combustion chamber [START] - The starter motor is engaged.
  • Page 38 HOUR METER ► The hour meter consists of digits with the last digit indicating 1/10 of an hour. Symbol Illuminates when Hour meter is operated. TACHOMETER ► This meter shows the revolutions of the engine and the PTO shafts as well as the travel speed in top gear. FUEL GAUGE ►...
  • Page 39 W ARNING LIGHTS ► ► ► ► Charge lamp This light will go off as soon as the engine starts to run to indicate that the alternator is changing. (Please note, as broken fan belt can cause the light to come on, please stop the engine as overheating can occur if not rectified immediately) Oil pressure lamp Will go out as soon as the engine starts if the oil pressure is correct.
  • Page 40 CRUISE CONTROL LMAP ► ► ► ► Engaging Cruise Control ■ DO NOT engage cruise control when reversing. Engage the cruise control as follows: – Depress the forward speed control pedal until the required speed is achieved. – Press the cruise control switch to engage cruise control. –...
  • Page 41 HYDRAULIC PTO MONITOR POSITION ON/OFF CONTROL LAMP ON THE SHAFT CONTROL SWITCH SWITCH DASH PANEL LEVER. Manual Either raised Glows Rotates Mode or lowered Auto Either raised Blinks Stationary Mode or lowered Auto Raised Blinks Stationary Mode Auto Lowered Glows Rotates Mode From the table above we learn about the safety features of the PTO.
  • Page 42 TRACTOR CONTROLS ► ► ► ► THROTTLE LEVER (HAND THROTTLE) ► ► ► ► The hand operated throttle lever is located on the RHS of the Dash cover. To increase the engine speed, Pull the lever downward. To decrease the engine speed, Push the lever upward. The Lever can be left in any position between idle and maximum as required.
  • Page 43 Do not change from forward to backward or backward to forward suddenly in high range. Sudden change may result in damage of mechanism and place the operator at risk of injury. important MASTER BRAKE PEDAL (A) ► ► ► ► The master brake pedal is located on the RHS of the operator.
  • Page 44 Traveling with the parking brake on will damage the brakes. important SUB GEAR LEVER (RANGE SHIFT LEVER) ► ► ► ► The Sub Gear Lever is located on the LHS of the operator. Operate the sub gear lever during neutral position of the forward and reverse pedal to select the appropriate speed for different applications.
  • Page 45 FRONT WHEEL DRIVE LEVER (4WD) ► ► ► ► The Differential Lock Pedal is located below the LHS of the Operator. In the ON position the front wheels are engaged and in the OFF position they are disengaged. Engage & disengage the front wheel drive with the front wheels in the straight position and at low Engine RPM.
  • Page 46 TILT LEVER ► ► ► ► To adjust the inclination of the steering wheel with a 3 stages and set it to the desired position. Ensure that the tilt lever has locked before moving the tractor. Danger PTO SELECTION LEVER ►...
  • Page 47 OPERATING THE HYDRAULICS ► ► ► ► The hydraulics are powered with an engine driven hydraulic pump and controlled with a position control lever mounted beside the driver. HYDRAULIC POSITION CONTROL LEVER ► ► ► ► Hydraulic Position Control Lever is located on the RHS of operator. Implements can be raised and lowered with the hydraulic position control lever and can be stopped at any position by stopping the lever.
  • Page 48 Always set the knob to lock when 1.Traveling on the road 2.Replacing tires or blades on an implement. 3.Making adjustments to an implement. Sudden dropping of an implement due to Caution hydraulic problems can cause serious injury or death. HYDRAULIC REMOTE CONTROL VALVE LEVER (IF EQUIPED) ►...
  • Page 49 OPERATING THE 3 POINT LINKAGE (TPL) ► ► ► ►...
  • Page 50 ADJUSTMENT OF THE CHECK CHAIN ► ► ► ► To adjust the check chain turn the turnbuckle to lengthen or shorten the chain and tighten the lock nut when the correct adjustment is achieved. Turn buckle Fixing Nut Check chain ADJUSTMENT OF THE TOP LINK ►...
  • Page 51 ADJUSTMENT OF THE YOKE ROD ON THE LOWER LINK ► ► ► ► For different applications change the position of the Yoke rod on the lower link holes as shown and insert the pin in the direction of the arrow. Lift Rod Only use drawbar to tow and keep the 3 point linkage in raised position when toeing with the drawbar.
  • Page 52 DRIVING THE TRACTOR STARTING THE ENGINE ► ► ► ► Before starting the engine carry out the pre-operational checks as set out on page 26. (1) Sit on the driver seat (2) Apply the footbrake. (3) Put the hydraulic lever in the down position. (4) Press down the master brake pedal to activate the safety-starting switch.
  • Page 53 WARMING UP ► ► ► ► When starting the engine allow it to warm up to operating temperature by allowing it to idle 5-10 minutes to ensure full lubrication and operating temperature. Failure to do so can shorten engine life substantially. WARMING UP IN COLD WEATHER ►...
  • Page 54 Always connect the brake pedals when traveling on the road. Never tow anything except with the drawbar. Do not tow loads which are too large for the tractor’s capacity to brake effectively especially in hilly terrain. Take special care when towing large or wide implements. Danger Do not carry passengers.
  • Page 55 UPHILL STARTS ON A STEEP SLOPE ► ► ► ► With the pedals connected together press down the brake pedals. Set range gear levers to low and the throttle to medium engine speed. Release the brake pedals and press down the forward pedal.
  • Page 56 FUEL GAUGE ► ► ► ► To avoid excessive condensation in the fuel tank refill at the end of each day’s work and ensure during the day that it does not drop to a low level where the fuel system will require bleeding to expel air in the system after refilling the tank.
  • Page 57 TRACK ADJUSTMENT ► ► ► ► As 4010HST models of Mahindra are front wheel assist the front track can be set in 1 position. The rear track can be set in positions as illustrated. Tread Tread (*) Marking is STANDARD...

  • Page 58: Lubrication & Maintenance

    Section-B Lubrication & Maintenance This section gives full details of the service procedures necessary to maintain your Tractor at peak efficiency while the lubrication and maintenance chart provides a ready reference to these requirements.
  • Page 59 CHECKS AND SERVICE PRE-START CHECKS ► ► ► ► To avoid problems it is recommended that a range of checks be carried out daily before starting the tractor. For full details of the items and frequency please refer to the tables on page 60,61 and 62. ENGINE COOLANT ►...
  • Page 60 TRANSMISSION OIL ► ► ► ► Check the level with the dipstick on top of the transmission in rear of the seat. If the level is low add oil through the filler hole. Always ensure that you use the correct oil for topping up or oil changes Caution FUEL ►...
  • Page 61 STEERING ► ► ► ► Ensure that the steering wheel does not have excessive free play. BRAKE ► ► ► ► Ensure that the left and right brakes are adjusted correctly so they operate simultaneously. The correct free play on the brake is 1.18-1.57 in (30~40 mm). ELECTRICAL ►...
  • Page 62 MAINTENANCE AND ADJUSTMENT SCHEDULE Check, Top-up or adjust Replace ○ ● Periodical check and service table ► ► ► ► Clean or wash Consult the service Dealer △ ★ Service interval(hour meter,mark) Item Frequency Comment To correct Every 150 hours level on Engine oil or 12months after...
  • Page 63 Service interval(hour meter,mark) Item Frequency Comment 50 10 0 15 0 20 0 25 0 30 0 35 0 40 0 45 0 50 0 55 0 60 0 Every 500 hours or Trans 12months ○ ● ★ ● mission oil after first 50 hours Free play of...
  • Page 64 Service interval(hour meter,mark) Item Frequency Comment 50 100 Operation of Check ○ daily instrument Adjustment of the throttle ○ ○ pedal HST oil ● ● Filter Change every 500 hours Hydraulic oil ● ● filter Check after every 100hrs . 4WD front Replace Replace if...
  • Page 65 See next page * ( 9.25 US gal) ℓ FRONT AXLE (API GL-4 Grades)Gear oil #80 or #90 MAHINDRA EP GEAR OIL SAE 80W-90 ( 2.166US gal) ℓ FINAL DRIVE CASE(B) (API GL-4 Grades) Gear oil #80 or #90 MAHINDRA UNIVERSAL TRACTOR...
  • Page 66 RECOMMENDED TRANSMISSION OIL ► ► ► ► RPM Tractor Hydraulic Fluid or Textron TDH Premium (CALTEX) ① TDH Oil or TDH Oil special (TEXACO) ② Chevron 1000THF (CHEVRON) ③ OPENING METHOD OF EACH COVER ► ► ► ► OPENING METHOD OF FAN COVER ►...
  • Page 67 BLEEDING THE FUEL SYSTEM ( Fuel Filter)- ► ► ► ► ① ① ① ① 1. Raise the engine cover. ① ① ① ① 2. Make sure there is fuel in the fuel tank. 3. Make sure the fuel cock on the fuel filter is set to ON. 4.

  • Page 68: Specifications

    CHANGING THE OILS IN THE TRACTOR ► ► ► ► Always use quality oils as engine or transmission oil Refer to the table on page 60 and 61 for the change frequency. CHANGING ENGINE OIL ► ► ► ► Park tractor on level surface, shut-off engine. Remove sump plug &...
  • Page 69 CHANGING OIL IN THE FRONT AXLE ► ► ► ► 1. Drain the oil from the center diff plug and the drain plug in each drive. 2. Replace and tighten all drain plugs. 3. Remove the Fill/Lever Plugs from each final drive to vent air from final drives. 4.
  • Page 70 HYDRAULIC OIL FILTER AND ENGINE OIL FILTER CARTRIDGE ► ► ► ► Remove the filter with a filter wrench. To replace, apply oil or grease on the seal, fit by hand until seal contacts bare, then turn it 2/3 turn further to tighten it check for leaks.
  • Page 71 ANTI FREEZE ► ► ► ► Frozen cooling water can damage the engine. Before replacing the anti freeze solution flush the radiator. Mix the anti freeze solution in accordance with the instructions applicable to the brand of anti freeze and the locals climate. Replace the solution in the radiator.
  • Page 72 GAP ADJUSTMENT ► ► ► ► ADJUSTING THE BRAKES ► ► ► ► Use of the brakes will change the pedal free play and the balance between right and left pedal. The correct pedal free play is 1.18~ 1.57 in Adjusting Method ■...
  • Page 73 CHECKING THE BATTERY ► ► ► ► Indicator condition Check the Indicator condition Green color – Good condition Black color – Charging necessary White color – Replace battery Low electrolyte levels can cause premature battery failure and corrosion. important Electrolyte contains acid and can cause serious burns. Any spillage on skin should be washed off by running water immediately.
  • Page 74 Always disconnect the negative terminal first when removing the battery and always connect the positive terminal first when fitting the battery. When connecting the battery leads make sure not to reverse the polarity. Quick charging will reduce battery life. Caution Disconnect the terminals prior to charging the battery to avoid damage to the circuit and electrical instruments.
  • Page 75 CHECKING HOSES AND LINES ► ► ► ► The fuel lines, radiator hoses, hydraulic and rubber hoses are consumables, which deteriorate by age and use. Check them regularly and replace if faulty. Damaged fuel lines leak and cause fires. Damaged radiator hoses can cause hot water burns and in severe cases seize the engine. Caution CHECKING THE WIRING HARNESS AND FUSES ►...
  • Page 76 Always check the reason for a blown fuse otherwise the new fuse is also likely to blow. NEVER EVER USE WIRE in place of correct grade fuse. important SERVICE PRIOR TO DAILY AND SHORT TERMS STORAGE. ► ► ► ► Wash the tractor and keep it clean.
  • Page 77 MAINTENANCE For daily or short term storage Clean the tractor and remove all dirt from field work. Fill the fuel tank to avoid condensation and rust. Lower the implement to the ground.. Keep it in a machinery shed or, if not available cover the unit if left outside. In very cold conditions it is advisable to remove the battery and keep it inside in a warm environment.

  • Page 78: Specifications

    For further information concerning your Tractor and equipment, consult your Authorized Mahindra Dealer/Distributor. Mahindra policy is one of continuous improvement and the right to change prices, specifications or equipment at any time without notice is reserved. All date given in this book is subject to production variations. Dimensions and weights are approximate only and the illustrations do not necessary show Tractors in standard condition.
  • Page 79 SPECIFICATIONS Model: 4010 HST ENGINE CLUTCH Four strokes, Indirect injection, water-cooled Type : Damper Diesel Engine. Model : 3B183LW (DAEDONG) TRANSMISSION No. of cylinders Type : synchro mesh Displacement : 1,826cm No. of gears : 3 Speed forward, Bore : 87 mm (3.43 in)
  • Page 80 Water cooled 4 cycle 4 cylinder diesel 4010 HST – 38HP / 2600rpm Out put (HP/rpm) Number of Cylinder 1,826 cm Displacement (cm 4010 HST - 87 mm X 102.4 mm Bore and Stroke 4010 HST – 22:1 Compression ratio Firing order 1-2-3...
  • Page 81 MODEL 4010 HST Main Damper Clutch Multiple wet disk Overall length(mm) 3030 (119.3”) Overall width (mm) 1520 (59.8”) Overall Height (mm) 2400 (94.5”) Wheel base (mm) 1680 (66.1”) (Distance between shafts) Min. Ground Clearance (mm) 323 (12.8”) Dimensions Front 8.0-16 Rear 12.4-24...

  • Page 82: Fuel Saving Tips

    FUEL SAVING TIPS To save fuel & oil in your tractor, following things should always be kept in mind. A) Air cleaning system 1) Clean the air cleaner regularly so that dust does not settle down. 2) For every 50 hours & everyday in sandy/dusty conditions. (a) Clean the air cleaner filter element with compressed air.
  • Page 83 E) Engine system 1) Always use recommended grade of oil. 2) Everyday before starting the engine, check the oil level with a dipstick & refill between the minimum & maximum level. 3) Charge the engine oil, Replace filter & “O” ring, as & when required. F) Cooling system 1) Check the fan belt tension regularly.
  • Page 84 FAULT TRACKING SYMPTOM CAUSE REMEDY Turning the main switch Master brake pedal not Push the master brake pedal in will not operate the starter pushed in Battery flat Charge or replace the battery Dealer to repair or replace Switch faulty Contact dealer for repair or replace Starter operates but not...
  • Page 85 SYMPTOM CAUSE REMEDY White smoking from the Oil level too high Reduce to correct quantity exhaust Shortage of or faulty fuel Contact dealer for repair Reduced performance of The injectors are clogged, Contact dealer for repair the engine carbon coated and sticking Low compression Leaking valve seat Contact dealer for repair...
  • Page 86 SYMPTOM CAUSE REMEDY Brake not working Incorrect free play Worm Adjust to correct free play or burnt lining Left and Contact dealer for repair right gap different Equalize Brake pedal not returning Faulty return spring Lack Replace spring of grease on the joints Remove rust and lubricate with grease Hydraulics are not lifting...
  • Page 87 SYMPTOM CAUSE REMEDY Steering wheel shaking Wrong toe-in Adjust toe-in Unequal tire pressure Inflate both to correct pressure Loose component Tighten or replace if worn Excessive play in the Worn steering shaft Contact dealer for repair steering Worn components Contact dealer for repair Flat battery Faulty wiring Repair,reconnect or tighten as...

  • Page 88: Wiring Diagram

    Drawing for fixing position of the fuse ► ► ► ► Wiring diagram of the electric instrument ► ► ► ► * Main Fuse Light / Horn Panel Turn Signal Lamp Working Light 7.5A Hazard Coupler Head lamp 12V/55W/60W Controller Glow Timer PTO, Cruise, Meta panel Light 12V/3.4W...

  • Page 89: Power Train

    POWER TRAIN ◎ ◎ ◎ ◎...

  • Page 90: Tractor History Card

    TRACTOR HISTORY CARD NATURE OF JOB CARD W/CLAIM NO. DATE PARTS REPLACEMENT REMARKS AND DATE DEFECT...

  • Page 91: Service Record

    SERVICE RECORD DATE TRACTOR HOURS NATURE/TYPE OF REPAIR/SERVICE CARRIED OUT...
  • Page 92 DAILY OPERATION LOG MACHINE HOURS FUEL ENGINE OIL DATE REMARKS DONE CONSUMPTION TOPPED UP START...

  • Page 93: Part Replacement Record

    PART REPLACEMENT RECORD PART PART DATE Q’TY COST DATE Q’TY COST DESCRIPTION DESCRIPTION...
  • Page 94 4010 HST Operator’s Manual for Tractors Code No. 1265-940-001-0 Printed on December. 2011 1st Edition...
  • Page 95 Operator's Manual - Engine Click here to go on 4010 Gear / HST INDEX Main Menu The Mahindra Group Mahindra USA, Inc. 9020 Jackrabbit Road Houston, Texas 77041 1-877-499-7771 www.mahindrausa.com...
  • Page 96 FORWARD DAEDONG Corporation wishes to thank you for purchasing your new DAEDONG diesel engine. This Diesel engine is designed based on strict quality standards established by the unit assuring quality of DAEDONG genuine components. Its knowledge on the operation of the diesel engine is based on faithful services and reliability for years.
  • Page 97 SAFETY AND VEHICLE DAMAGE WARNING This manual includes information titled as WARNING, CAUTION, IMPORTANT and NOTE. These titles indicate the following: This indicates that a condition may result in harm, serious injury or death to you or other persons if the warning is not WARNING heeded.
  • Page 98 QUALITY POLICY We, a company that exclusively designs, produces, and sells diesel engines, do our best to secure stability and reliability of products to satisfy customers fully. Additionally, in order to provide products that satisfy our customers, we strive to understand clearly the requirements of our customers from the design to service stages so we can build a quality management system.
  • Page 99 ENVIRONMENTAL POLICY DAEDONG is a company that exclusively designs, produces, and sells agri-machineries and industrial diesel engines. We have minimized environmental pollutants produced while providing products or services. That means our all managerial activities are operated in an "environment-friendly" system by saving resources and observing internal standards, including requirements of environmental regulations and ISO 14001;1996.
  • Page 100 PRODUCT SAFETY AND MANAGEMENT POLICIES We design, manufacture, and provide safe products with no defects that give satisfaction to customers, and at the same time, provide the best services. To achieve this goal, all of our employees understand the product safety and management policies fully and try to exceed the level required by national or international regulations or standards.
  • Page 101 SAFETY AND HEALTH POLICY We, a company that exclusively designs, manufactures, and sells diesel engines, inspect in advance any harmful or hazardous ’components during the manufacturing process to prevent any accident related to safety. We will operate the system by implementing a safety and management system to make a workplace with “no disasters”...
  • Page 102 NOTICE ON ENVIRONMENTAL "USAGE AND DISPOSAL" We, a company that exclusively designs, manufactures, and sells diesel engines, minimize environmental pollutants generated by our operations, and all managerial activities are operated in environment-friendly ways based on saving resources. All of our employees observe environmental regulations and related standards.
  • Page 104 SAFETY PRECAUTION ....... PRECAUTION BEFORE OPERATION ..OPERATION THE ENGINE ....BREAK-IN AND CHECK ..... SECTION MAINTENANCE ......... TROUBLESHOOTING ......SPECIFICATION ....... INDEX ..........
  • Page 106 SAFETY PRECATIONS PRECAUTIONS BEFORE OPERATION ...... 1-2...
  • Page 107 DIESEL ENGINE PRECAUTION BEFORE OPERATION The following contents describe the safety cautions, categorized into Safety helmet DANGER and WARNING. Before the initial operation, read this manual Fitted clothes carefully for your safety. The safety precautions described in this chapter Tight sleeves are applied overall to diesel engines.
  • Page 108 SAFETY PRECATIONS 7. Make sure that all drains and caps are tightly closed and all fl uid levels are correct before starting. Always check for leaks and ensure that any loose parts are repaired before operating the engine. Loose parts are the operator’s responsibility and may cause damage or injury if ignored.
  • Page 109 DIESEL ENGINE 9. If you always replace bolts with new ones when assembling, be sure to use bolts of same or cor- responding type. Even if you are forced to use bolts of different types, don't use bolts of lower grade than the current ones.
  • Page 110 SAFETY PRECATIONS household wastes. Determine the appropriate disposal method b e f o r e r e m o v i n g h a z a r d o u s materials from the engine. T91O117A T91O118A 12. When checking the battery, keep 14.
  • Page 111 DIESEL ENGINE 051O106B T91O128A 15. When disconnecting the cable 16. The cover and other parts rem- from battery terminals, start with oved for inspection and repair the negative terminal fi rst. When should be installed again after connecting the cable, start with the work is done.
  • Page 112 PRECAUTIONS BEFORE OPERATION EXTERIOR VIEW ............2-2 SERVICING ..............2-3...
  • Page 113 DIESEL ENGINE EXTERIOR VIEW 051O201B (1) Intake Manifold (6) Oil Level Dipstick (11) Oil Pan (2) Fuel Injection Pump (7) Electronic Pick-up Sensor (12) Oil Filter Catridge (3) Oil Fill Cap (8) Engine Stop Solenoid (13) Alternator (4) Speed Control Lever (9) Cooling Fan (14) Exhaust Manifold (5) Fuel Feed Pump...
  • Page 114 PRECAUTIONS BEFORE OPERATION SERVICING Should your engine require parts or service, please contact your local DAEDONG dealer. Your dealer will need the following information in order to assist you. 1. Engine make, model number and se- rial number. 2. Names and code numbers of parts to be ordered.
  • Page 116 OPERATING THE ENGINE PRE-START ENGINE CHECKS ........3-2 STARTING AND STOPPING THE ENGINE ....3-2 CHECK DURING OPERATION ........3-3...
  • Page 117 디젤엔진 DIESEL ENGINE PRE-START ENGINE CHECKS STARTING AND STOPPING THE ENGINE STARTING Always check the engine and make 1. Set the fuel cock to the “ON” or light is on, stop the engine immedi- sure it is ready for safe operation be- “OPEN”...
  • Page 118 엔진의 작동 OPERATING THE ENGINE CHECK DURING OPERA- TION STOPPING While operating the engine, keep IMPORTANT checking whether all parts of the en- Do not turn the starter switch gine are operating smoothly and to “START” while the engine is properly.
  • Page 119 디젤엔진 DIESEL ENGINE OIL PRESSURE LAMP STOP THE ENGINE IMMEDIATELY: CAUTION The oil pressure lamp comes on 1. If the engine speed suddenly To avoid personal injury : when the oil pressure drops below a changes. DO NOT remove the radiator safe level.
  • Page 120 엔진의 작동 OPERATING THE ENGINE REVERSED ENGINE ROTATION REMEDIES AND REMEDIES 1. Stop the engine immediately using While not common, it is possible for the engine stop lever. a diesel engine to run backwards. 2. Check the air cleaner and rubber The engine will lose lubrication and parts of the air intake system for be severely damaged if allowed to...
  • Page 122 BREAK-IN AND CHECKS DAILY CHECKS ............4-2 BREAK-IN ..............4-2 PERIODIC CHECKS ............. 4-3...
  • Page 123 DIESEL ENGINE DAILY CHECKS BREAK-IN Regular maintenance is an important During the engine break-in period, factor in preventing downtime and the following actions are critical to accidents. Always make the following engine performance and life. checks before operating the engine. 1.
  • Page 124 BREAK-IN AND CHECKS SERVICE INTERVALS RUN HOUR RUN AGE CHECK ITEM SINCE THAN PAGE Engine oil Change Every 150 Hr ⊙ ○ Engine oil fi lter Replace ⊙ Every 150 Hr Engine starting system Check ○ Every 50 Hr Tightening torque Check ○...
  • Page 126 MAINTENANCE FUEL ................5-2 ENGINE OIL ..............5-4 RADIATOR (OPTIONAL) ..........5-7 AIR CLEANER (OPTIONAL) ........5-12 BATTERY (OPTIONAL) ..........5-12 FAN BELT ..............5-14 LONG-TERM STORAGE ..........5-15...
  • Page 127 DIESEL ENGINE FUEL CHECKING THE FUEL LINES Use Diesel Fuel No.2. IMPORTANT Always use clean fuel. Use a CAUTION strainer if necessary. To avoid serious injury: Do not let the fuel tank run Do not mix gasoline or alcohol empty. with diesel fuel.
  • Page 128 MAINTENANCE REPLACING THE FUEL FILTER Check the fuel lines after every 100 IMPORTANT hours of operation. Replacing the fuel fi lter period- 1. Check and tighten all hose clamps. ically will significantly reduce 2. Check and replace rubber fuel injection pump and fuel injec- lines and clamps as needed.
  • Page 129 DIESEL ENGINE ENGINE OIL CHECKING ENGINE OIL LEVEL For your own safety and maximum CAUTION service life of the machine, make To avoid personal injury: a thorough daily inspection before Be sure to stop the engine be- starting the engine. fore checking the oil level.
  • Page 130 MAINTENANCE CHANGING ENGINE OIL 4. Engine oil quantity 1. Change the oil after the first 50 hours of operation. Model Quantity Model Quantity 2. Remove the drain plug from the oil 3C093LWS 3C093LWG 3.2ℓ 3.8ℓ 3C100LWS 3C100LWG pan and allow all of the oil to drain. 3A139LW Draining the oil will be easier when 3A150LW...
  • Page 131 DIESEL ENGINE REPLACING THE OIL FILTER NOTE Swipe off any engine oil stained on the machine. 051O601B 051O602B (1) Oil Drain Plug (2) Oil Filter (3) Remove wiht filter wrench(Hand-tighten only) 1. Replace oil fi lter with at least every 5.
  • Page 132 MAINTENANCE RADIATOR (OPTIONAL) CHECKING LEVEL,ADDING AND CHANGING COOLANT Radiators must be handled and in- CAUTION stalled properly to avoid coolant To avoid personal injury: leaks. It should be a daily routine always stop the engine and al- to check the engine coolant level. low it to cool before changing Check it before each use while the the coolant or performing any...
  • Page 133 DIESEL ENGINE CHANGING COOLANT 1. To discharge coolants, always open plugs for discharge that are located on the side of the crank case and lower part of radiator, and open the radiator cap, too. You cannot discharge coolant ful- ly when the cap is closed. (To dis- charge coolant from reservoir tank, separate the overflow pipe from the radiator cap.)
  • Page 134 MAINTENANCE 3. A radiator cap that is loose or has cooling system with a suitable radi- CLEANING THE RADIATOR CORE a damaged seal will result in cool- ator cleaner. Refi ll with fresh cool- Flush the radiator core with fresh wa- ant loss and may cause overheat- ant.
  • Page 135 DIESEL ENGINE CLEANING THE RADIATOR IF ENGINE OVERHEATING OCCURS If the coolant is overheated to around “Troubleshooting” section of this manual to determine the cause. or above boiling point, follow instruc- tions below. If a warning buzzer or Make repairs and adjustments as lamp is turned on, follow instructions required.
  • Page 136 MAINTENANCE ANTI-FREEZE Freezing temperatures can quick- IMPORTANT NOTE ly and severely damage the engine The coolant mixture should This data is the industry stan- if the cooling system is unprotected. not exceed 50% anti-freeze by dard for a typical ethylene glycol Use antifreeze when temperatures volume.
  • Page 137 DIESEL ENGINE AIR CLEANER (OPTIONAL) BATTERY (OPTIONAL) 4. Dust can be cleaned from the fil- CAUTION ter element with compressed air. To avoid personal injury: Always blow from the inside out, Avoid contact with battery and never use air pressure greater electrolyte.
  • Page 138 MAINTENANCE 4. When charging the battery, always IMPORTANT follow the charger manufacturer’s Always observe the correct instructions. Be careful to observe polarity. Attaching cables to the correct polarity to prevent bat- the wrong terminals will cause tery damage or possible explosion. system damage and possibly injury.
  • Page 139 DIESEL ENGINE FAN BELT LONG-TERM STORAGE BELT TENSION AND WEAR BELT TENSION ADJUSTING Low belt tension can result in engine overheating and insufficient battery charging. The correct tension can be determined by applying a 22 lb(10 kgf). load at mid-span (Point A). The resulting belt deflection should be 0.28 to 0.35 inches.
  • Page 140 MAINTENANCE LONG-TERM ENGINE STORAGE Clean the machine when storing the If the engine is not run for a pe- engine for several months or more. riod of more than 5 months, apply engine oil liberally to valve guides 1. Open the drain cocks and remove and valve stem seals before start- the radiator cap to drain all of the ing.
  • Page 142 TROUBLESHOOTING ENGINE IS HARD TO START ........6-2 ENGINE SUDDENLY STOPS RUNNING ..... 6-3 LOW ENGINE POWER OUTPUT ......... 6-4 EXHAUST SMOKE OR DARK EMISSIONS ....6-5 THE ENGINE MUST BE STOPPED IMMEDIATELY ..6-6 ENGINE OVERHEATS ..........6-7...
  • Page 143 DIESEL ENGINE ENGINE IS HARD TO START Possible causes Actions Fuel is cloudy or fuel flow is re- • Check fuel tank and fuel fi lter. stricted • Remove water, dirt, or other debris. • Filter out fuel, and replace the fi lter if contaminated. Air or water in fuel system •...
  • Page 144 TROUBLESHOOTING Possible causes Actions Engine oil is cloudy and engine • Change to correct oil grade depending on the weather (temperature). runs slowly in cold weather Low compression • Defective valve or excessively worn ring, piston, and liner will result in low compression. Replace it with new one.
  • Page 145 DIESEL ENGINE ENGINE LACKS POWER Possible causes Actions Carbon deposit at injection nozzle • Clean the inlet and needle valve carefully not to damage the nozzle inlet. inlet • Check the nozzle. Replace with a new nozzle if necessary. Leaks from valve due to low com- •...
  • Page 146 TROUBLESHOOTING Possible causes Actions Poor pressure of the feul injuction • Adjust to proper pressure 150 ~ 160Kgf/cm (14.7 ~ 15.7MPa, 2133 ~ 2276psi) Fuel injection pump wear • Avoid using poor quality fuel. This will result in pump wear. Use NO.2 diesel only •...
  • Page 147 DIESEL ENGINE SUDDEN ENGINE STOP Possible causes Actions Engine speed suddenly changes • Check the fuel system and injection timing. Unusual sound occurs • Check all moving parts. Especially, check the nozzle. Exhaust smoke or dark emissions • Check the fuel injection system. appear Overheating the bearing •...
  • Page 148 TROUBLESHOOTING ENGINE OVERHEATS Possible causes Actions Low coolant level • Check for and repair leaks. Add coolant. Loose or broken fan belt • Adjust or replace belt as required. Low oil level • Add water or replace coolant to achieve proper mix. Anti-freeze concentration too high •...
  • Page 150 SPECIFICATIONS SPECIFICATIONS ............7-2...
  • Page 151 DIESEL ENGINE SPECIFICATIONS DESCRIPTION UNIT 3C093LWS 3C093LWG 3C100LWS 3A139LWS POWER(Gross) HP (kw) 19 (14.2) 21 (15.7) 22 (16.4) 28 (20.9) Rated revolution 2,800 3,600 2,800 2,600 Maximum bare speed 3,000 3,690 3,000 2,800 Minimun bare idling speed 1,050 1,050 1,050 1,000 Type Vertical, water cooled, 4-cycle diesel engine...
  • Page 152 SPECIFICATIONS DESCRIPTION UNIT 3A150LWS 3A150LWG 3A165LWS 3B183LWS (4010) POWER(Gross) HP (kw) 30 (22.4) 21 (15.7) 34 (25.4) 38 (28.3) Rated revolution 2,600 1,800 2,600 2,600 Maximum bare speed 2,800 1,850 2,800 2,800 Minimun bare idling speed 1,000 1,000 1,000 Type Vertical, water cooled, 4-cycle diesel engine Number of cylnders Total displacement...
  • Page 153 DIESEL ENGINE DESCRIPTION UNIT 4A200LWS 4A220LWS 4A220LWG 4B243LWS (5010) POWER(Gross) HP (kw) 41 (30.6) 45 (33.6) 29 (21.6) 49 (36.5) Rated revolution 2,600 2,600 1,800 2,600 Maximum bare speed 2,800 2,800 1,850 2,800 Minimun bare idling speed 1,000 1,000 1,000 Type Vertical, water cooled, 4-cycle diesel engine Number of cylnders...
  • Page 154 SPECIFICATIONS DESCRIPTION UNIT 4A200TLWS 4A220TLWS POWER(Gross) HP (kw) 50 (37.3) 54 (40.3) Rated revolution 2,600 2,600 Maximum bare speed 2,800 2,800 Minimun bare idling speed 1,000 1,000 Type Vertical, water cooled, 4-cycle diesel engine Number of cylnders Total displacement cc (cu) 1,999 (122.0) 2,197 (134.1) Turbocharger...
  • Page 156 INDEX INDEX................8-2...
  • Page 157 디젤엔진 AIR CLEANER (OPTIONAL) ..........5-12 ENGINE IS HARD TO START ..........6-2 ANTI-FREEZE ..............5-11 ENGINE OIL ................. 5-4 ENGINE OVERHEATS ............6-7 ENGINE SUDDENLY STOPS RUNNING......6-3 BATTERY (OPTIONAL) ............5-12 EXHAUST SMOKE OR DARK EMISSIONS ......6-5 BELT TENSION AND WEAR ..........
  • Page 158 색인 RADIATOR (OPTIONAL) ............5-7 REPLACING THE FUEL FILTER ......... 5-3 REPLACING THE OIL FILTER ..........5-6 SERVICING ................2-3 SPECIFICATIONS ..............7-2 STARTING ................3-2 STARTING AND STOPPING THE ENGINE ......3-2 STOPPING ................3-3 THE ENGINE MUST BE STOPPED IMMEDIATELY .... 6-6...

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