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The Mahindra Group Mahindra USA, Inc. 9020 Jackrabbit Road Houston, Texas 77041 1-877-499-7771 www.mahindrausa.com
■ Mahindra USA, Inc. ■ 5203 Aeropark Drive ■ Houston, TX 77032 ■ (281) 449-7771 ■ www.mahindrausa.com
 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;

1) Designed,built,and equipped so as to confirm with all applicable regulations adopted by the

United States Environmental Protection Agency and the California Air Resource Board.
2) Free from defects in materials and workmanship which cause the failure of a warranted part to be
identical in all material respects to the part as described in the engine manufacturer's
application for certification for period of five years or 3000 hours of operation, whichever occurs first ,
for all engines rated at 19 kw and greater, except as noted below. In the absence of a device to measure
hours of use, the engine shall be warranted for a period of five years. For all engines rated less than
19 kw, and for constant speed engine rated under 37 kw with rated speeds higher than or equal to 3000
rpm, the period of two years or 1500 hours of operation, whichever occurs first, shall apply. In the
absence of a device to measure hours of use, the engine shall be warranted for a period of two years.
If a warranted part fails because of a defect during the terms of this warranty,Daedong-USA will repair
or replace it at any authorized Daedong-USA dealer.Any other parts damaged by the failure of a
warranted part will also be repaired or replaced.The repair and/or replacement will be made at no
charge to the owner for parts,labor and diagnosis.Any such part repaired or replaced under the
warranty shall be warranted for the remaining warranty periods.

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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.
Use of non-genuine Daedong parts does not invalidate the warranty.However Daedong-USA INC. is not
liable for parts,which are not genuine Daedong parts.

RESPONSIBILITY AND LIMITATIONS.

These warranties are subject to the following;

DAEDONG-USA INC.RESPONSIBILITIES.

During the emission warranty period,if a defect in material or workmanship of a warranted parts or
component is found.Daedong-USA INC.will provide;

-New,remanuctured,or repaired parts and/or components required to correct the defect.

Items replaced under this warranty become the property of Daedong-USA INC.

-Labor,during normal working hours,required to make the warranty repair.

This includes diagnosis and labor to remove and install the engine,if necessary.

Owner’s Warranty Responsibilities.

As the Daedong-USA INC.off-road compression-ignition engine owner,you are responsible for the
performance of the required maintenance listed in your Owner’s Manual.
Daedong-USA INC.recommends that you retain all receipts covering maintenance on you Daedong engine
but Daedong-USA INC.cannot deny warranty solely for the lack of receipts or for your failure to ensure
the performance of all scheduled maintenance.However,if the lack of required maintenance was the
reason for the repair,then the claim will be denied.

You are responsible for presenting your Daedong engine to a Daedong-USA INC.dealer as soon as a
problem exists.The warranty repairs should be completed in a reasonable amount of time,not to exceed 30
days.

As the Daedong engine owner,you should also be aware that Daedong-USA INC.may deny you warranty
coverage if your Daedong engine or parts has failed due to abuse,neglect,improper maintenance or
unapproved modifications.if you have any questions regarding your warranty rights and responsibilities,
you should contact Daedong-USA INC.
Division at 1801 Quality Drive(Tel.No;1-252-291-6111)

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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.
-Damage resulting from accident or an Act of God.
-Failure that are a direct result of a lack of performance of required emission control maintenance as
outlined in your Owner’ Manual.
-Parts or accessories used in applications for which they were not designed or not approved for use on the
engine by Daedong-USA INC.
-Parts not supplied by Daedong-USA INC. or damage to other parts caused directly by non-Daedong
parts or non-equivalent parts.
-The charge for diagnostic labor which does not lead to the determination that a warrantable condition
exists.
- Daedong-USA INC. is not responsible for incidental or consequential damages such as downtime or
loss-use of engine powered equipment.
-Although you purchase the equipment on which Daedong engine is mounted, if the equipment is not
manufactured by Daedong, you will make contact with purchasing dealer.

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 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. Daedong-USA, INC. must warrant
the emission control system on your engine for the periods of time listed below provided there has been
no abuse, neglect or improper maintenance of your engine.

Your emission control system may include parts such as the fuel-injection system and the air induction
system. Also included may be hoses, belts, connectors and other emission-related assemblies.

Where a warrantable condition exists, Daedong-USA, INC. will repair your off-road compression ignition
engine at no cost to you including diagnosis, parts, and labor.

MANUFACTURER’S WARRANTY COVERAGE;

The 2003 and later off-road compression-ignition engines;

For all engines rated under 19 kW and for constant speed engines rated under 37 kW with rated speeds
greater than or equal to 3,000 rpm, the warranty period is 1,500 hours or 2 years of use, whichever first
occurs, after date of delivery to initial owner.
For all other engines rated at or above 19 kW, the warranty period is 3,000 hours or 5 years of use,
whichever first occurs, after date of delivery to the initial owner. If any emission-related part on your engine
is defective, the part will be repaired or replaced by Daedong-USA, INC.

OWNER’S WARRANTY RESPONSIBILITIES;

—As the off-road compression ignition engine owner, you are responsible for the performance of the
required maintenance listed in your Owner’s Manual. Daedong-USA, INC. recommends that you retain
all receipts covering maintenance on your off road compression ignition engine, but Daedong-USA, INC.
cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all
scheduled maintenance.

—As the off-road compression ignition engine owner, you should however be aware that Daedong-USA,
INC. may deny you warranty coverage if your off-road compression ignition engine or a part has failed
due to abuse, neglect, improper maintenance or unapproved modifications.

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— 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. dealer as soon as a problem exists. The
warranty repairs should be completed by the dealer as expeditiously as possible.

— If you have any questions regarding your warranty rights and responsibilities, you should contact
Daedong-USA, INC. at 1801 Quality Drive (Tel.No ; 1-252-291-6111)

— Although you purchase the equipment on which Daedong engine is mounted, if the equipment is not
manufactured by Daedong, you will make contact with purchasing dealer.

MAINTENANCE RECOMMENDATION

Some Daedong-USA, INC off-road compression ignition engines are certified by the United States
Environmental Protection Agency and California Air Resource Board to comply with smoke and gaseous
emission standards prescribed by federal laws at the time of maintenance.

The engine is certified if it has a special certification label. A Daedong engine dealer can also inform you
if the engine is certified.

Efficiency of emission control and engine performance depends on adherence to proper operation and
maintenance recommendations and use of recommended fuels and lubricating oils. It is recommended that
major adjustments and repair be made by your authorized Daedong engine dealer.

Various chemical fuel additives, which claim to reduce visible smoke, are available commercially.
Although additives have been used by individuals to solve some isolated smoke problems in the field,they
are not recommended for general use. Federal smoke regulations require that engines be certified without
smoke depressants.

The corrective step taken immediately on discovery of worn parts, which may affect emission levels, will
help assure proper operation of emission control system. The use of genuine Daedong parts recommended.
Suppliers of non-Daedong parts must assure the owner that the use of such parts will not adversely affect
emission levels.

Regular maintenance intervals, along with special emphasis on the following items, are necessary to keep
exhaust emissions within acceptable limit for the useful life of the engine.

Refer to the maintenance intervals. If the engine is operation under severe conditions, adjust the
maintenance exhaust emissions within acceptable limit for the useful life of the engine.

The following is an explanation of maintenance for emission-related components.

See the Maintenance schedule for specific interval for the following items.

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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.

TURBOCHARGER – Check for any unusual sound or vibration in the turbocharger. Inspect inlet and
exhaust piping and connections. Check bearing condition and perform maintenance as described in the
Maintenance Schedule.

Slow engine response and low power may indicate a need for adjustment or repair.
Your Daedong engine dealer is equipped with the necessary tools, personnel, and perform this service.

Owner is encouraged to keep adequate maintenance records, but the absence of such, in and of itself, will
not invalidate the warranty.

The machine or equipment owner may perform routine maintenance, repairs and other non warranty
work or have it done at any repair facility. Such non-warranty work need not be performed at a
designated warranty station in order for the warranty to remain in force.

CUSTOMER ASSISTANCE – EMISSION CONTROL SYSTEM WARRANTY;

Daedong-USA INC. aims to ensure that the Emission Control Systems Warranty is properly administrated.
In the event that you do not receive the warranty service to which you believe you are entitled under the
Emission Control System Warranty, call or write.

Daedong-USA, INC.
at 1801 Quality Drive
Tel. No ; 1-252-291-6111
Fax. No ; 1-252-291-9161

-Authorized dealers are recommended for major maintenance and repair work as they are staffed with
trained personnel, proper tools and are aware of the latest maintenance methods and procedures.
Owners and others who desire to perform their own work should purchase a Service Manual and obtain
current information from their Daedong engine dealer .

-In case of purchasing the equipment on which Daedong engine is mounted, if the equipment is not
manufactured by Daedong, the equipment owner will make contact with purchasing dealer.

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 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.
Please note that in some cases differences can exist between this manual and your tractor due to the
manufacture’s policy of constant product improvement.
In the event that you strike a problem not covered by this manual please contact your nearest dealer
who will assist you in resolving your problem.

CALIFORNIA Proposition 65 Warning

The Engine Exhaust from this product contains chemicals known to the

WARNING state of California to cause cancer,birth defects or other reproductive harm

WARNING SIGNS IN THIS MANUAL

The following warning signs in this manual draw additional attention to items of importance for the
safe and correct operation of the tractor.

SIGN MEANING OF THE SIGN

Danger Serious hazard with a very high level of risk of either serious injury or death

Warning Hazard or unsafe practice that can lead to severe injury or death.

Caution Hazard or unsafe practice that can lead in injury or death.

Instructions for the correct operation of the machine which,

Important
if followed, will ensure that it performs at it’s best

All information,illustrations and specifications in this manual are based on latest information
available at the time of publication.The right is reserved to make changes at any time without notice.

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 CONTENTS

Sr. No. Description Page No.

1. Tractor Identification --------------------------------------------------------------------------------- 9

2. About this manual ------------------------------------------------------------------------------------- 10
3. Introduction & Description --------------------------------------------------------------------------- 11~12

4. Owner assistance -------------------------------------------------------------------------------------- 13

5. ROPS (Roll over protection structures) ------------------------------------------------------------ 14~16
6. Safety instructions, Do’s & Don’ts ----------------------------------------------------------------- 17~29
7. Safety signs -------------------------------------------------------------------------------------------- 30~32
8. Universal symbols ------------------------------------------------------------------------------------- 33

Section A
9. Controls, Instruments & Operations ---------------------------------------------------------------- 34~55

Section B
10. Lubrication & maintenance ------------------------------------------------------------------------ 56~75

Section C
11. Specifications ----------------------------------------------------------------------------------------- 76~79
12. Fuel saving Tips -------------------------------------------------------------------------------------- 80~85
13. Wiring Diagram -------------------------------------------------------------------------------------- 86
14. Power Train ------------------------------------------------------------------------------------------- 87
15. Tractor History Card --------------------------------------------------------------------------------- 88
16. Service record ----------------------------------------------------------------------------------------- 89
17. Daily operating Log ----------------------------------------------------------------------------------- 90
18. Part replacement record ------------------------------------------------------------------------------ 91

All information, illustrations and specifications in this manual are based on latest information available at
the time of publication. The right is reserved to make changes at any time without notice.

8
 TRACTOR IDENTIFICATION

The engine number is stamped on the left hand side of the engine block.
The chassis number is shown on the left hand side of the tractor as shown in the drawing.

Stamped position of the

Engine type or Number

Stamped position of the chassis number

Illustration A

WARRANTY OF THE PRODUCT.

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.
Tractor model
Tractor serial number
Tractor engine number
Part number and description
Quantity required.

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 ABOUT THIS MANUAL

This manual has been prepared to assist you in following/adopting the correct procedure for running-
in operation and maintenance of your new Mahindra Tractor.

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 .

To maintain this condition and ensure trouble free performance. it is important that the routine
services, as specified in this manual, are carried out at the recommended intervals.

Read this Manual carefully and keep it in a convenient place for future reference.

If at any time you require advice concerning your Tractor, do not hesitate to contact your Authorized
Mahindra dealer/Distributor.

He has trained personnel, genuine parts and necessary equipments to undertake all your service
requirements.

Mahindra policy is one of continuous improvement, and the right to change prices, specifications or
equipments at any time without notice is reserved.

All data given in this book is subject to production variations.

Dimensions & weight are approximate only and the illustrations do not necessarily show Tractors in
standard condition.

For exact information about any particular Tractor, please consult your Mahindra dealer/Distributor.

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 Introduction & Description

► TRACTOR AN INTRODUCTION
The word, ’Tractor’ has been derived from ‘Traction’ which means pulling.
A Tractor is required to pull or haul an equipment, implement or trolley which are coupled to the
Tractor body through suitable linkage. A Tractor can also be used as a prime mover as it has a
power outlet source which is also called 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.

If you need any information not given in this manual, or require the services of a trained mechanic,
please get in touch with the Mahindra Dealer/Distributor in your locality. Dealer/Distributors are kept
informed of the latest methods of servicing Tractors. They stock genuine spare parts and are backed
by the Company’s full support.

Through this manual. The use of the terms

LEFT, RIGHT, FRONT and REAR must be
understood, to avoid any confusion when
following the introductions. The LEFT and
RIGHT means left and right sides of the
Tractor when facing forward in the driver’s
seat, Reference to the FRONT indicates the
radiator end of the Tractor, while the REAR,
indicates the drawbar end (illustration B)

When spare parts are required, always specify

the Tractor and engine serial number when
ordering these parts. (See illustration A). This
will facilitate faster delivery and help ensure
that the correct parts for your particular
Tractor is received. The tractor serial number
is punched on a plate attached to the left hand
side of the engine body (illust. A), For easy
reference, we suggest you to write the number illustration A
in the space provided in the owner’s personal data.
( Front, Rear,Left,Right Portion)

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► DESCRIPTION
■ General construction
The transmission case, Engine and Front Axle Support are bolted together to form a rigid unit.
■ Front Axle & Wheels
The 4WD front axle is a center-pivot, reverse Eliot type. The front wheel drive mechanism is
incorporated as a part of the axle.
The front wheel drive power is taken off the rear transmission and transmitted to the differential in the
front axle where the power is divided into right and left and to the respective final cases.
In the final cases, the transmitted revolution is reduced by the level gears to drive the front wheel.
The 4WD mechanism with level gears provides wider steering and greater durability.
■ Engine
The tractors are fitted with fuel efficient engine with 4 cylinders manufactured by Daedong
■ Transmission with HST (Hydrostatic Transmission)
The Tractor is fitted HST with 3 Range and can be selected Speed range by HIGH-LOW selector lever.
The Tractor has Two pedals for forward/reverse control . Tractor with Independent Power Take Off
is fitted with electro-hydraulic Clutch Assy. The Rear PTO and Mid PTO can be operated both or
separately by a lever.
■ Brakes
Mahindra tractors are provided with independent disc brakes operated by two road travel.
A foot brake lever is fitted for parking.
■ Rear axle & Wheels
This is mounted on ball bearings and is enclosed in removable housing which are bolted to the
transmission case. 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
It consists of Hydrostatic Power steering system, which has a hydraulic cylinder and single type
hydraulic pump
■ Electrical System
A 12 Volt Battery is used to activate the Engine through the Starter Motor and the Electrical system
comprising Horn, Head Lamp, Turn signal lamp, Taco-meter, Hour meter, Brake lamp, Gauge lamp,
Hazard Lamp. General or Alternator, Fuse box also from part of the Electrical system.

12
 OWNER ASSISTANCE

We at Mahindra and your Mahindra Dealer/Distributor wants you to be completely satisfied with
your investment.
Normally any problems with your equipment will be handled by your
Dealer/Distributor’s Service Departments, however, misunderstanding can occur.
If you feel that your problem has not been handled to your satisfaction, we suggest the following.

Contact the owner or General Manager of the Dealership, explain the problem, and request assistance.
When additional assistance is needed, Your Dealer/Distributor has direct access to your office.
If you cannot obtain satisfaction by doing this, contact the Mahindra. Office and
provide them with;

• Your name, address and telephone number

• Model and Tractor serial number

• Dealer/Distributor Name & Address

• Machine purchase date and Hours used

• 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.

13
 (ROPS) Roll Over Protective Structures

► ROLL OVER PROTECTIVE STRUCTURES (ROPS)

Mahindra Tractors are equipped with a frame for the protection of operators.
In the case of cab tractors the frame is incorporated in the cab structure.
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.
Included in these tests were all mounting bases and bolts or other fasteners.

DANGER

For ROPS frames to be effective and protect the operator, the seat belt provided must be
worn in order to keep operators within the ROPS protected area in the event of a roll over.
Failure to use the seat belt can still cause serious injury or death.

On some models the ROPS frame has a fold down feature, which can be used to enter low
buildings etc.
Take care when lowering the upper section of the ROPS frame and take extreme care while
driving the tractor with the ROPS frame lowered.
Do not wear the seat belt with the ROPS lowered and please remember that the fold down facility
is for special circumstances only and must not be lowered for general use.

Use of the tractor with the ROPS lowered can cause fatal injuries.

As the ROPS frame or cab together with the seat belt was designed to meet certain standards,
they must be maintained in good order and condition.
To achieve this objective, both the structure and the seat belt should be inspected on a regular
basis (every time the tractor is serviced)

In the event that the seat belt is damaged or frayed, it should be replaced and in the event that the
ROPS frame or any part of the mounting structure is damaged or cracked, the faulty component
must be replaced with a new unit.
Such a unit must meet all of the test criteria of the original unit.
Fitment of an inferior item or items affects the certification of the entire ROPS structure and the
effectiveness of the structure in the event of an accident.
Drilling or welding of the ROPS structure is forbidden.

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► 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 & seat mountings. Before you operate a Tractor, replace all damaged
parts.

► DO NOT WELD, DRILL OR STRAIGHTEN THE ROPS

Never attach chains, ropes to the ROPS for pulling purposes; this will cause the
Tractor to tip backwards. Always pull from the Tractor drawbar. Be careful
when driving through door opening or under low overhead objects. Make sure
Warning
there is sufficient overhead clearance for the ROPS fatal injuries

If the ROPS is removed or replaced, make certain that the proper hardware is
used to replace the ROPS and the recommended torque values are applied to
Warning the attaching bolts

Always wear your seat belt if the tractor is equipped with ROPS
Warning

15
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
& check whether it is properly locked in its position.
Figure 1 identifies the seat fitted to your Tractor.

► FOR SLIDING SEAT

■ Sliding Seat type
Lift lever (A) and slide the seat to the position you want. Release the lever.
Make sure the seat is locked in position.

Check whether the seat properly locked in its position before driving the tractor.
Danger

Always use the seat belt when the ROPS is installed.Do not use the seat belt if a
foldable ROPS is down or there is no ROPS.Check the seat belt regularly and
Danger replace if frayed or damaged

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 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.
A signal word―DANGER, WARNING OR CAUTION―is used DANGER
with safety alert symbol. DANGER identifies the most serious
hazards. Safety signs with signal Word ―DANGER OR
WARNING―are typically near specific hazards. General WARNING
precautions are listed on CAUTION safety signs.
CAUTION

READ SAFETY INSTRUCTION

Carefully read all safety instructions given in this manual for your
safety. Tempering with any of the safety devices can cause serious
injuries or death. Keep all safety signs in good condition. Replace
missing or damaged safety signs.
Keep your tractor in proper condition and do not allow any
unauthorized modifications to be carried out on the Tractor, which
may impair the function/safety and affect Tractor life.

PROTECTION CHILDREN
Keep children and others away from the Tractor while operating.
BEFORE YOU REVERSE
- Look behind Tractor for children.
- Do not let children to ride on Tractor or any implement.

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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. The ROPS, mounting hardware, and seat belt should be
checked after the first 100 hours of Tractor and every 500 hours
thereafter for any evidence of damage, wear or cracks. In the event of
damage or alteration, the ROPS must be replaced prior to further
operation of the Tractor.
The seat belt must be worn during machine operation when the
machine is equipped with a certified ROPS.
Failure to do so will reduce or eliminate protection for the operator in
the event of a roll over.

PRECAUTION TO AVOID TIPPING

Do not drive where the Tractor could slip or tip.
Stay alert for holes and rocks in the terrain, and other hidden
hazards.
Slow down before you make a sharp turn.
Driving forward out of a ditch or mired condition could cause
Tractor to tip over backward. Back out of these situations if possible

PARK TRACTOR SAFELY

Before working on the Tractor ;
Lower all equipment to the ground.
Stop the engine and remove the key

KEEP RIDERS OFF TRACTOR

Do not allow riders on the Tractor.
Riders on Tractor are subject to injury such as being stuck by
foreign objects and being thrown off of the Tractor

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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.

STAY CLEAR OF ROTATING SHAFTS

Entanglement in rotating shaft can cause serious injury or death.
Keep PTO shield in place at all times.
Wear close fitting clothing. Stop the engine and be sure PTO drive is
stopped before making adjustments, connections, or cleaning out PTO
driven equipment.

ALWAYS USE SAFETY LIGHTS AND DEVICES

Use of hazard warning lights and turn signals are recommended when
towing equipment on public roads unless prohibited by state or local
regulations.
Use slow moving vehicle (SMV) sign when driving on public road
during both day & night time, unless prohibited by law

PRACTICE SAFE MAINTENANCE

Understand service procedure before doing work.
Keep the surrounding area of the Tractor clean and dry.
Do not attempt to service Tractor when it is in motion.
Keep body and clothing away from rotating shafts.
Always lower equipment to the ground. Stop the engine.
Remove the key. Allow Tractor to cool before any work repair is
caused on it.
Securely support any Tractor elements that must be raised for
service work.
Keep all parts in good condition and properly installed.
Replace worn or broken parts. Replace damage/missing decals.
Remove any buildup of grease or oil from the Tractor.
Disconnect battery ground cable(−) before making adjustments on
electrical systems or welding on Tractor

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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. Battery gas can explode.
Never check battery charge by placing a metal object across the poles.

PREVENT ACID BURNS

Sulfuric acid in battery electrolyte is poisonous. It is strong enough to
burn skin, cause holes in clothing and cause blindness if found entry
into eyes.
For adequate safety always;
1.Fill batteries in a well-ventilated area.
2.Wear eye protection and acid proof hand gloves
3. Avoid breathing direct fumes when electrolyte is added.
4. Do not add water to electrolyte as it may splash off causing severe
burns.
If you spill acid on yourself;
1.Flush your skin with water.
2.Flush your eyes with water for 10-15 minutes.
Get medical attention immediately.

SERVICE TRACTOR SAFELY

Do not wear a necktie, scarf or loose clothing when you work near moving
parts. If these items were to get caught, severe injury could result.
Remove rings and other jeweler to prevent electrical shorts and entanglement
in moving parts.

20
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.

TRACTOR RUNAWAY
1. The tractor can start even if the transmission is engaged position causing Tractor to runaway
and serious injury to the people standing nearby the tractor.
2. For additional safety keep the pull to stop knob (fuel shut off control) in fully pulled out position.
Transmission in neutral position, Foot brake engaged and PTO lever in disengaged position
while attending to Safety Starter Switch or any other work on Tractor.

SAFETY STARTER SWITCH

1. Master brake pedal operated safety switch is provided on HST Tractors which allow the starting
system to become operational only when the master brake pedal is fully pressed.
2. Do not By-pass this safety starter switch or work on it. Only Authorized Dealers are
recommended to work on safety starter switch.
3. On some models Safety Starter switch is provided on transmission High-low shifter lever and in
PTO shifter lever. The tractor can be started only if High-low shifter lever is in neutral position.

Safety Starter Switch is to be replaced after every 2000 hours/4 years,

whichever is earlier
Caution

21
 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.

Ensure that only trained and competent operators use this tractor and ensure that they are fully
conversant with the machine and aware of all it’s control and safety features.

Operators should not operate the tractor or associated machinery while tired or untrained.

To avoid accidents please ensure that the operator wears clothing which will not get entangled in the
moving parts of the tractor or machine and protect him or her from the elements.

When spraying or using chemicals, please ensure that clothing and protective equipment is worn
which prevents respiratory or skin problems.
For full details consult the manufacturer of the chemicals.

To avoid lengthy exposure to noise ensure that ear protection is worn.

If adjustment to the tractor or machinery need to be made ensure the tractor or machine are turned off
beforehand.

Use of certified Roll Over Protection Structure (ROPS) is a must while operating a tractor.
Use of seat belt is a must while operating a tractor.

In summary, ensure at all times that the safety of the operator and any other worker is paramount.

22
 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. Check to ensure that the all controls and preventative mechanisms of the Tractor and implement
work correctly and effectively.
4. Ensure that an adequate set of the correct tools is available for maintenance and minor repairs.
5. Ensure that all service work and repairs are carried out on a flat area with a concrete or similar
floor.
Do not carry out service work on a tractor until it is switched off, and the parking brake applied
and wheels choked.
Where a tractor is started in a confined area, ensure that the area is well ventilated as exhaust
gases are very harmful, and can cause death.
6. Do not work under raised implements.
7. When changing wheels or tires ensure that a suitable wheel stand is placed under the axle prior
to removing the wheel and the wheels are chocked.
8. Where guards or shields need to be removed to perform a service or repair, ensure that the
guard or shield is correctly reinstalled before starting the Tractor.
9. Never refuel near an open flame or with an overheated engine. Ensure to turn off Engine
before refueling.
10. The cooling system operates under pressure, take care when removing the Radiator cap on a
hot engine to prevent being scalded by steam or hot water.
Do not add water in the radiator
when the engine is hot.
Add water to the radiator only after the engine cools down completely.
11.To prevent fires keep the tractor including the engine clean and free from inflammable material
and well away from fuels and other inflammable material.

23
► 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.
(2) After mounting the implement, ensure that all sway chains are correctly adjusted and, where
PTO shafts are used that the shaft is fitted and secured correctly.
(3) Where heavy implements are used, ensure that the combination is well balanced or use proper
ballast to achieve balance.
(4) Before leaving the tractor at any time, lower the implement, stop the PTO shaft where
applicable, set the parking brake and switch off the engine.
(5) While operating the implements with the PTO keep all bystanders away from any moving parts
and do not attempt to make adjustments while the machine is running.
(6) Only the driver should ride on the Tractor with the ROPS frame fitted and with the seat belt
properly fastened.
(7) Where young children are present, particular care should be taken and the tractor should not be
moved until the whereabouts of all children is known.
(8) Only trained operators should operate the Tractor and so taking care to ensure that other
workers are not injured. In particular they should take care during dusty operations, which will
reduce visibility substantially.
(9) Never start the tractor unless the transmission is out of gear, the operator is in the seat and all
round safety has been checked.
(10) Only operate the tractor seated in the drivers seat and never turn or brake suddenly at high
speed as this can cause a roll-over and serious injury or death.
(11) When traveling on a public road ensure that the tractor and driver both meet all laws relating to
safety and licensing. When traveling with wide implements use red flags on the extremities and
observe all legal including escort requirements.
(12) When operating under adverse conditions, hilly terrain or on bad ground adjust the speed of the
tractor to suit the conditions, safety comes first. Never drive down hill at high speed or with the
transmission in neutral. Use of the braking capacity of the engine as well as the service brakes.
Do not try to change gear going up or down a steep slope, select the correct gear before
starting.
(13) Take care when traveling uphill with a heavy implement to ensure that it does not overbalance
and tip up the front end.
(14) Never remove or modify the seat belt.
(15) Never remove, modify or repair the ROPS frame.

PLEASE REMEMBER THAT A LITTLE BIT OF EXTRA CARE CAN PREVENT SERIOUS
INJURY OR TEATH AND AVOID DAMAGE TO YOUR TRACTOR.

24
► 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.

■ The Tractor
1. Read the operator’s manual carefully before using the tractor. Lack of operating knowledge can
lead to accidents.
2. Use an approved rollover bar and seat belt for safe operation. Overturning of a tractor without a
rollover bar can result in death or injury.
3. Do not remove ROPS (Roll Over Protective Structure). Always use the seat belt.
4. Fiberglass canopy does not give any protection.
5. To prevent falls, keep steps and platform clear of mud and oil.
6. Do not permit anyone but the operator to ride on the Tractor. There is no safety place for extra
riders.
7. Replace all missing, illegible or damaged safety signs.
8. Keep safety signs clean of dirt and grease

■ Servicing the Tractor

1.Keep the tractor in good operating condition for your safety. An improperly maintained Tractor can be
hazardous.
2. Stop the engine before performing any service on the tractor.
3. The cooling system operates under pressure, which is controlled by the radiator cap.
It is dangerous to remove the cap while the system is hot.
First turn the cap slowly to stop and allow the pressure to escape before removing the cap entirely.
4. Do not smoke while the refueling the tractor. Keep away any type of open flame.
5. The fuel in the injection system is under high pressure and can penetrate the skin. Unqualified
persons should not remove or attempt to adjust a pump, injector, nozzle or any part of the fuel
injection system.
Failure to follow these instructions can result in serious injury.
6. Keep open flame away from battery or cold weather starting aids to prevent fire or explosions.
7. Do not modify or alter or permit anyone else to modify or alter this tractor or any of its
components or any tractor functions

25
■ Operating the tractor
1. Before starting the tractor apply the parking brake, place the PTO (Power Take Off) lever in the
“OFF” position, the hydraulic control levers in the downward position, the remote control valve
levers in the neutral position( if fitted) and the transmission in neutral.
2. Do not start the engine or controls while standing besides the tractor. Always sit on the tractor
seat when the engine or operating controls.
3. Safety starter switch.
In order to prevent the accidental starting of the tractor, a safety switch has been provided. The
starting system of the tractor is connected through this switch, which becomes operative only when
the master brake pedal is depressed. On some models shuttle shifter lever and PTO button should
also be in neutral position for completing the starting circuit. 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.
5. Do not get off or climb the tractor while it is in motion.
6. Shut off the engine, remove the key and apply the parking brake before getting off the tractor.
7. Do not operate the tractor in an enclosed building without adequate ventilation. Exhaust fumes can
cause death.
8. Do not park the tractor on a steep slope.
9. If power steering or Engine seizes to operate, stop the tractor immediately.
10. Pull only from the swinging draw bar or the lower link drawbar in the down position. Use only a
drawbar pin that locks in place. Pulling from the tractor rear axle carriers or any point above the
rear axle may cause the Tractor’s front end to lift.
11. If the front end of the tractor tends to rise when heavy implements are attached to the three-point
linkage, install front end or front wheel weights. Do not operate the tractor with a light front end.
12.Always use hydraulic position control lever when attaching equipments/implement and when
transporting equipment. Be sure that the hydraulic couplers are properly mounted and will
disconnect safely in case of accidental detachment of implement.
13.Do not leave equipment/implement in the raised position.
14.Use the flasher/ Turn signal lights and Slow Moving Vehicle (SMV) signs when driving on public
roads during both day and night time, unless prohibited by law.
15. Dim tractor lights when meeting a vehicle at night. Be sure the lights are adjusted to prevent the
blinding on the eyes of coming vehicle operator.
16.Emergency stopping instruction; If tractor fails to stop even after application of brakes, Pull the
knob of fuel shut off control rod.

26
■ 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. Lock the tractor brake pedals together when transporting on roads to provide proper wheel braking.
4. Keep the tractor in the same gear when going downhill as used when going uphill. Do not coast
or free wheel down hills.
5. Any towed vehicle and/or trailer whose total weight exceeds that of the towing Tractor, must be
equipped with its own brakes for safe operation.
6. When the tractor is stuck or tires are frozen to the ground, back out to prevent upset.
7. Always check overhead clearance, especially when transporting the tractor.
■ Operating the PTO (Power Take Off)
1. When operating PTO driven equipment, shut off the engine and wait until the PTO stops before
getting off the tractor and disconnecting the equipment.
2. Do not wear loose clothing when operating the power take-off or near rotating equipment.
3. When operating stationery PTO driven equipment, always apply the tractor parking brake and
block the rear wheels from front and rear side.
4. To avoid injury, always move down flip part of PTO. Do not clean, adjust or service PTO
driven equipment when the tractor engine is running.
5. Make sure the PTO master shield is installed at all times and always replace the PTO shield cap
When the PTO is not in use.
■ Diesel fuel
1. Keep the equipment clean and properly maintained.
2. Under no circumstances should gasoline, alcohol or blended fuels be added to diesel fire or
explosive hazard. Such blends are more explosive than pure gasoline. In a closed container,
such as a fuel tank. DO NOT USE THESE BLENDS.
3. Never remove the fuel cap or refuel the tractor with the engine running.
4. Do not smoke while refueling or when standing near fuel.
5. Maintain control of the fuel filler pipe when filling the tank.
6. Do not fill the fuel tank to capacity. Allow room for expansion.
7.Wipe up spilled fuel immediately.
8.Always tighten the fuel cap securely.
9.If the original fuel tank cap is lost, replace it with genuine cap. A none approved cap may not be safe.
10.Do not drive equipment near open fire.
11.Never use fuel for cleaning purpose.
12.Arrange fuel purchases so that winter grade fuel are not held over and used in the spring.

N.B: It is suggested that after repairs if any of the Safety Decal/sign is peeled/defaced, the same
may be replaced immediately in interest of your safety.

27
 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.
DO-Fit new sealing rings when the filter elements are changed.
DO-Watch the oil pressure gauge or warning light and investigate any abnormality immediately.
DO-Keep the radiator filled with clean water and in cold weather use anti-freeze mixture. Drain
the system only in an emergency and fill before starting the engine.
DO-Ensure that the transmission is in neutral before starting the engine.
DO-Keep all fuel in clean storage and use a filter when filling the tank.
DO-Attend to minor adjustments and repairs as soon as necessity is apparent.
DO-Allow the engine to cool before removing the radiator filler cap and adding water, remove the
radiator cap slowly.
DO-Shift into low gear when driving down steeps hills.
DO-Latch the brake pedals together when driving on a highway.
DO-Keep draft control lever fully down when not in use.

Don’ts-For safe operation

DON’T-Run the engine with the air cleaner disconnected.
DON’T-Start the tractor in an enclosed building unless the doors and windows are open for proper
ventilation.
DON’T-Operate the tractor or engine while lubricating or cleaning.
DON’T-Allow the tractor to run out of diesel fuel otherwise it will be necessary to vent the system.
DON’T-Temper the fuel injection pump, If seal is broken the warranty becomes void.
DON’T-Allow the engine to run idle for a long period.
DON’T-Run the engine if it is not firing on all cylinders.
DON’T-Ride the brake or master brake pedal. This will result in excessive wear of the brake lining.

28
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.
DON’T-Use the governor Control Lever (Hand throttle) while driving on roads.
DON’T-Move the hydraulic levers rearward.

29
 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.

DECALS ON THE DASH COVER

30
DECALS ON THE CHASSIS

31
DECALS AROUND THE SEAT

32
 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

Hazard
Transmission
Fuel level warning
oil pressure

Engine
Stop Neutral Turn signal
control

Transmission
Lights Fan
oil temperature

Power take
Horn Parking brake
off engaged

Power
Engine oil
take off Work lamps
pressure
disengaged

Differential
Air filter
Lift arm/raise lock

See
Battery charge Lift arm/lower operator’s
manual

33
 Section - A

Controls,
Instruments
And
Operations

The following pages in this section detail the location and function of various instruments, switches
and controls on your Tractor. Even if you operate other Tractors, you should read through this
section of the manual and ensure that you are thoroughly familiar with the location and function of
all the features of your New Tractor.

Do not start the engine or attempt to drive or operate the Tractor until you are fully accustomed to
all the controls. 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
will give long life and dependable service for which it was intended

34
 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.
When the key is released it will return to the ON position

► HEAD LAMP, TURN SIGNAL SWITCH AND HORN

■ HEAD LAMP SWITCH
High and low beam are operated On the main switch
Position ①. Low beam
Position ②. High beam
■ TURN SIGNAL SWITCH
Pull the turn signal lever down to signal a left turn.
Push the turn signal lever up to signal a right turn.
■ HORN
Push the Red button.

35
► HOUR METER
The hour meter consists of digits with the last digit
indicating 1/10th 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
Shows the amount of fuel in the tank when the ignition
switch is ON.

► WATER TEMPERATURE GAUGE

Shows the water temperature with the ignition switch ON.
C is low to normal temperature
H is high temperature
If the pointer is in the red H segment the engine is
overheating.
Refer this book to rectify the problem.

► HAZARD WARNING SIGNAL SWITCH

Push the hazard warning signal once to operate the hazard
warning light. (Left and right turn indicators flash).
Push the hazard warning light switch again to switch off the
hazard warning lights.

► CRUISE CONTROL SWITCH

Push this switch once to engage the cruise control.
The switch illuminates (in addition to the cruise control indicator
lamp on the instrument panel) when the cruise control is engaged.
Push this switch again to disengage the cruise control.

36
►WARNING 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. If it comes on while
the engine is running, stop the engine and get expert advice.

PTO monitor Lamp

Shows the revolution of PTO
Refer to monitor lamp on Page 38.

Fuel Level : If it comes on while the engine is running, Fill the tank with fuel.

High beam lamp is operated on the combination switch.

Low beam lamp is operated on the combination switch

Parking brake lamp is operated when footbrake is engaged.

Glow signal Lamp indicates preheating

4WD drive lamp is operated on when front-wheel drive is engaged.

Check lamp is operated when the key switch is set to ON position and a safety start
condition is not satisfied.

Cruise Control Lamp is operated on when cruise control is engaged.

37
 ► 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.
– Release the forward speed control pedal.
■ Disengaging Cruise Control
To disengage the cruise control you can either press the
cruise control switch or depress the Master brake pedal.

► PTO MONITOR LAMP

■ THE PTO MONITOR LAMP on the dash panel indicates the state of the PTO shaft.
1. If the monitor glows: The PTO is rotating
2. If the monitor is off: The PTO is off
3. If the monitor blinks: The PTO is presently stationary but will instantly
start rotating when implements lowered.

Two switches operate the independent PTO. PTO monitor Lamp

1. PTO ON/OFF SWITCH: PTO ON/OFF switch is
located on the LHS. on the steering column and can be
identified easily with its built in red colored indicator.
When the switch is pushed down to start the PTO
indicator glows to
indicate that the switch and the PTO are in ON position,
If the switch is pushed down again the indicator goes off
signaling that the PTO is OFF.
2. PTO Control SWITCH: This switch is located
near the starting key location on the dash panel. There are
three positions marked for this switch.
■ OFF at the center
■ MANUAL at the left
■ AUTO AT THE RIGHT.
The PTO shaft will not rotate if either of the two switches is in OFF position.
The following table explains how the PTO operates at the two
different (Manual & Auto) positions of the PTO Control switch
with the PTO ON/OFF switch in the on position.
38
 HYDRAULIC
PTO PTO PTO MONITOR
POSITION PTO
ON/OFF CONTROL LAMP ON THE
CONTROL SHAFT
SWITCH SWITCH DASH PANEL
LEVER.
Manual Either raised
On Glows Rotates
Mode or lowered
Auto Either raised
On Blinks Stationary
Mode or lowered
Auto
On Raised Blinks Stationary
Mode
Auto
On Lowered Glows Rotates
Mode

■ From the table above we learn about the safety features of the PTO. When the monitor on the dash
panel is blinking it indicates to the operator that the PTO is in the on position but temporarily not
rotating because the implement is lifted off the ground
The PTO will start rotating instantaneously when the implement is lowered to the ground.
■ The operator must use this blinking signal to clear the area around the tractor off
bystanders/onlookers as the rotating blades of certain implements can accidentally cause injuries to
the persons standing near the tractor.
■ The stopping of the PTO when the implement is lifted off the ground with the position control
prevents the damage to the implement or the PTO shaft.

1.When the PTO control switch is in manual position the PTO does
not stop rotating until turn off the PTO ON/OFF switch. If working on
hard soils, pavements with a rotary implement the PTO ON/OFF
switch must be put to the OFF position to stop the PTO from rotating ,
If this is not done the rotating blades of the implement will push on
Warning the hard ground below and in turn push the tractor toward causing
accident which can lead to serious injuries or death.
2. Extra precaution must be taken to clear the area of bystanders/onlookers when using PTO driven
implements. The rotating blades of the implements can cause serious injuries on contact. The
warning that is indicated by the blinking PTO monitor is to make the operator aware that the
PTO is in on position and will instantly start rotating if the implement is lowered.
3.In no case the specified rotating speeds indicated by the implement manufacturer be crossed
as the same can lead to serious damage to the tractor/equipment and can lead to serious injuries
to persons around.

39
► 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.

► SPEED CONTROL PEDAL

The Speed Control Pedal is located in RHS of the Operator floor.
Depress the forward speed control pedal to move forward.
Depress the reverse speed control pedal to move backward.
The speed control pedal will return in neutral position
and the tractor will stop when the speed control pedal is released.

40
 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
important risk of injury.

► MASTER BRAKE PEDAL (A)

The master brake pedal is located on the RHS of the operator.
It is used for two functions.
- To stop the tractor
- To release cruise control

► PARKING BRAKE LEVER (B)

Connect the brake pedals, push them down while
pulling the park brake up to engage.
Press the parking brake pedal and push
the Brake pedal to release.

► TURN BRAKE PEDAL (C)

■ Tight Turns in the field
To make a tight turn at low speed, use both the steering wheel and the turn brake pedal at the same time.
For left turn, use the left turn brake pedal and for right turn, use the right turn brake pedal.

Perform tight turns only at a slow safe speed.

Doing so at a high speed can cause rollovers and very serious injury or death.
Caution

A connecting latch is provided to connect the right and left brake pedals for high
speed or road use.
In the interest of safety always use it on the road or at high speed as using one side
only can cause rollovers.
Caution
When servicing the tractor ensure that the adjustment on both sides in the same.

41
 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.

SUB GEAR LEVER (RANGE SHIFT LEVER)

► DIFFRENTIAL LOCK PEDAL

The Differential Lock Pedal is located below the
LHS of the Seat.
In case of wheel slippage use the diff-lock
by pushing down on the diff lock pedal.
To release it remove the foot from the pedal.

Tractor will be difficult to turn if the Diff-lock is engaged, ensure the lock is disengaged
before turning the steering wheel.
Danger

Tractor will be difficult to turn if the Diff-lock is engaged, ensure the lock is
disengaged before turning the steering wheel.
Danger

Do not use high engine RPM when engaging Diff lock If the diff lock does not
release after removing the foot from the diff lock pedal alternatively brake with
important the left and right brake until it gets released.

42
► 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.

Do not use front wheel drive at

high speed or on the road as Always stop the machine when
premature wear of components using the front wheel drive lever.
important will result. important

Use of front wheel drive improves traction performance.

► DRIVER’S SEAT
To adjust the seat backwards and forwards lift the lever at
the front of the seat and set it to the desired position (Please refer to page 17 of how to adjust the seat)

■ Operating the Safety Switch

If you do not sit the your seat when you operate the Tractor,
Engine will turn off.

■ Seat Belt
-Release the Seat Belt
Press button C and Pull the Male Fitting A from the Buckle B.
-Adjusting the Seat Belt
Make Sure the belt is across your hip and not over your stomach.
To adjust the male fitting A :
1. Pull toggle D down the strap by the required distance.
a. To make the strap longer, pull end E as far as it will go.
b. To make the strap shorter, pull end F as far as it will go.
43
► 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

Your tractor is equipped with 1 Speed PTO to suit range of applications and conditions.

POSITION ON OFF
MODEL

MID PTO 2000 rpm -

4010HST
REAR PTO 540 rpm -

* Mid PTO Lever is located * Rear PTO Lever is located

on the RHS of Operator. on the LHS of Operator.

Always stop the machine when engaging or disengaging the PTO or changing PTO
speed. Let the PTO driven implement come to a complete stop before changing.
important

Do not operate any implement at a high speed than is specified for it.
When making adjustments to the implement stop the engine to avoid serious injury.
Caution When leaving the tractor stop the engine, and remove the key. Set the parking brake.

44
► 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.
To ensure a consistent working depth the adjustable stop (A)
can be set to ensure that the implement returns to the same
depth every time.

To raise the implement : Pull the lever backward.

To lower the implement : Push the lever forward.

After finishing the work, always lower the implement to the ground and switch off
the engine, Set the parking brake to avoid injuries and accidents .
Warning

► LOWERING SPEED CONTROL KNOB FOR THE 3 POINT HITCH

This knob controls the downward speed of the
hydraulics three point linkage and is located below the Seat.

To slow the downward speed- Turn the knob clockwise.

To increase the downward speed, turn the knob anticlockwise.

To lock the knob clockwise.

Do not over tighten the knob.

45
 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)

The Hydraulic Remote Control Valve Lever is located below
the RHS of the Operator
Move the lever up or down and hold. This will raise or
lower the implement
Important:
-Do not hold the lever in the “pull” or “Push” position once
the remote cylinder has reached the end of the stroke as this
will cause oil to flow through the relief valve. Forcing oil
through the relief valve for extended periods will overheat the oil.
-When Using the tractor hydraulic system to power front loader, do not operate the boom and bucket
cylinders simultaneously.

► HYDRAULIC REMOTE CONTROL VALVE COUPLER CONNECTING & DISCONNECTING.

(IF EQUIPED)
■ Connecting
1.Clean both couplers.
2.Remove dust plugs.
3.Insert the implement coupler to the tractor hydraulic coupler
4.Pull the implement coupler slightly to make sure couplers are
firmly connected.

■ Disconnecting
1.Lower the implement first to the ground to release
hydraulic pressure in the hoses.
2.Clean the couplers
3.Relieve pressure by moving hydraulic control levers
with engine shut off. Pull the hose straight
from the hydraulic coupler to release it
4.Clean oil and dust from the coupler, then replace the dust plugs.
46
► OPERATING THE 3 POINT LINKAGE (TPL)

47
► 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

Lengthening or shortening the top link will change the angle of
the implement. The locating hole of the top link varies with the
type of implement used. The most common locations are the 2nd
and 3rd hole from the top.

► ADJUSTMENT OF THE LIFT ROD

Adjust the length of the lift rod by screwing the Adjusting
Handle (Turnbuckle) in or out. Adjust the length of the lift rod
as necessary to set the implement in its working position parallel Lift Rod
to the ground.

Adjusting Handle

Lower Link

48
► 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.
Position can create unbalance causing the Tractor to roll-over & Result the death
Danger
or serious injury.

► MOUNTING IMPLEMENT
If the PTO is used, remove the safety cover off the PTO shaft.
Adjust the yoke rod on the lower links to suit the implement
in use. Attach the left lower link, then attach the right lower
link using the adjusting handle on the leveling box if required.
Attach the top link. Attach the PTO shaft to the tractor if used,
making sure that it is locked in place.
Adjust the check chains to suit the implement and tighten the
locknuts. To remove an implement reverses the procedure Rear PTO Shaft Cover

Do not attach a PTO shaft with the engine running and ensure all safety shields are
in place.
Caution

49
 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.
(5) Put the main gear lever in neutral
(6) Insert the ignition key and turn it on
(7) Ensure that the warning lights are working
(8) Always turn the ignition key to left for a moment & release it.
The automatic heater will start working as will be indicated by a light on the instrument
panel .As the lamp goes off turn the key to the start position to start the engine.
(9) Ensure that all the warning lights are off with the engine running.

Never turn the key to the start position while the engine is running as this can
cause serious damage to the starter and engine flywheel.
Only engage the starter for a period of not more than 10 seconds.
If Engine does not start, rest the starter for about 20 seconds and try again for a
Important maximum of 10 seconds.If the engine does not start after repeated attempts,
refer to the fault tracing guide.

Especially in cold weather, always allow the tractor to idle for a while to warm
up & build up sufficient oil pressure to ensure normal operating temperature for
Important longer engine life.

► STOPPING THE ENGINE

-After light work let the engine idle for a while and turn the key off.

After long or heavy work allow the engine to idle for 5- 10 minutes and turn the
key off.
Important

50
► 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
Cold weather will change the viscosity of the oil, resulting in a reduced oil pumping capacity, which
can cause damage to the engine if it is not warmed up correctly. It also causes problems with the
hydraulic system and the synchromesh in the transmission.

Correct times for warming up are:

Temperature Time for warming up

Above 50°F 5~10 min.
50°F~ 32°F 10~20 min.
32°F~14°F 20~30 min.
14°F~-4°F 30~40 min.
Below –4°F Over 40 min.

Ensure the handbrake (Foot brake) is on during the warming period.

Failure to warm up correctly can result in problems.
Important

When the engine is warm up engage the range gear levers to the required position.
Push down on the brake pedals and release the handbrake.
Increase the engine revolutions and press down the forward or reverse pedal smoothly.

► STORING ENGINE IN OPERABLE CONDITION FOR 3 MONTHS OR MORE

When the engine is not operated during storage of three months or more, internal engine parts can rust
and lose oil film. As a result, the engine can seize when it is started after storage.
To prevent such a rust, the engine must be operated periodically during storage.

51
 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.
Danger Take special care when towing large or wide implements.
Do not carry passengers.
At all times observe local legislation and road rules.

► TIGHT TURNS IN THE FIELD

Disconnect the latch connecting left and right brake pedals
to allow the use of individual pedals.
To make a tight turn use both the steering wheel and the
brake pedal at the same time.
For a left turns use the left pedal and a right turn the right pedal.

Perform tight turns only at a slow safe speed.

Doing so at a high speed can cause rollovers and very serious injury or death.
Caution

► NORMAL BRAKING AND PARKING

Let the engine come back to idle and at the same time press the
master brake pedal.
When the tractor has come to a halt, lower any implement to the
ground, and put the range gear in neutral.
Apply the parking brake, stop the engine, and remove the key.
Illustration

Always apply the park brake when parking.

Failure to do so can cause accidents and damage.
Caution As an extra precaution when parking on a slope, chock the rear wheels.

52
► 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.
Adjust the throttle to the required speed.

► DRIVING DOWNHILL
Use the engine’s ability to brake when traveling downhill.
Never rely on the brakes only and never travel downhill with the gears in neutral.

When operating in hilly terrain the risk of the rollover is increased substantially, please
drive with extra care.
When towing trailers in hilly terrain ensure that they are equipped with brakes, use a
Warning lower gear to get maximum engine braking and do not change gears on a down hill run

► OPERATION OF THE DIFF LOCK

While the diff lock is a very useful feature, care should be taken in its use as misuse can lead to
dangerous situations.
The diff lock would only be used in situations where traction is lost on one of the rear wheels.

Use low engine revolutions when using the diff lock.

If the diff lock does not release after removing the foot from the pedal use the left and
right brake pedals in turn to release it.
Warning Do not try to engage or use the diff lock on tight turns as serious damage can result.

► CHECK DURING DRIVING

Constantly monitor the warning lights on the dash and if any
comes on stop the tractor to determine the cause.
If the oil pressure light comes on check the oil level first of all.
If the oil level is OK ask a qualified dealer to check the
reason for the light coming on.
If the alternator warning light comes on check all
connections and ensure that the fan belt is not broken.
If all connections and the fan belt are intact consult your
dealer to determine the cause of the problem.
53
► 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.

► ENGINE COOLING WATER

If the gauge indicates that the engine is running hot, stop the tractor and
check the coolant in the radiator.

► TRAILER SOCKET (Seven Terminal Electrical Socket type)

Trailer Socket is located on the Left of the Rear Side.
To operate the Electrical systems of implements,
trailer lighting, warning lamp etc.

Allow the engine to cool down before opening radiator cap as serious burns may
result due to hot steam & boiling water.
Danger

Also check to ensure that the fins in the radiator core are not clogged or that the tractor has a
broken or stretched fan belt.

When traveling on public or farm roads connect both brake pedals and allow for the
weight of any mounted implement to ensure that the unit is not unbalanced.
Also allow for the width when passing other road users.
Where fitted use the hazard lights provided.
Caution
Strictly follow the local traffic regulations.

When operating near others with an implement attached take particular care to
allow for the width of the implement and avoid accidents.
Caution

54
► 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

TYPE DIVISION TYRE TREAD

FRONT 8.0-16 46.19inch (1170mm)

AG
REAR 12.4-24 42.94inch (1090mm)

FRONT 10-16.5 53.13inch (1349.5mm)

IND
REAR 43x16.00-20 48.06inch(1220mm)

55
 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.

56
 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
Remove the radiator cap and ensure that the
coolant is up to the filler neck and that it is
clean with the correct anti-freeze or anti
corrosion inhibitor in it.
If the coolant is a rusty color, drain the
system completely and refill with the
correct mixture of water and anti-freeze or
corrosion inhibitor.

► ENGINE OIL
Pull out the stick, wipe it and dip in the oil sump. Ensure that oil level is between the upper and lower
mark near the upper mark. If too low add oil, but never excess 100hrs of service interval

Do not overfill the crankcase with oil.

important

57
 ► 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
The Fuel Filler is located on the Rear of the Seat.
Use the fuel gauge to check the fuel level and top
up if too low.
It is a good practice to refill the tank immediately
after use to avoid condensation

► TYRE PRESSURE
The air pressure used in the tires has a direct
bearing on the life of the tire and its
performance in the field.
Ensure that the tire pressures are correct and in
accordance with the table on page 55.
To make a visual judgment see the drawing on the right.

It is strongly recommended that tire pressures are checked with a proper gauge only &
visual inspections are relied upon.
important

Excess tire pressure can cause accidents!

Danger
58
► 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
Check the operation of all gauge, switches, horn, lights and indicators.
► INSTALLING LOADER
1.Connect P port of loader control valve to the line on the tractor marked P(from the PTO valve)
2.Connect the T port on the loader control valve to the line on the tractor marked T
3.Connect the remaining line from the control valve to the line on the tractor marked P1
( to the transmission housing)
► DETACHING THE LOADER (LOADER VALVE OR LOADER CONNECTING PORT)
1.Detach the hydraulic hoses of loader
2.Assemble the cap (PF3/8) with pipe comp (PF3/8).

59
 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)
Division

Daily

Item 10 15 20 25 30 35 40 45 50 55 60 Frequency Comment

50
0 0 0 0 0 0 0 0 0 0 0

To correct
Every 150 hours
Engine oil ○ ● ● ● ● or 12months after
level on
the
first 50hours
dipstick

Air cleaner △ △ △ △ △ ● Clean every 100

hours
Radiator
coolant
○ Check daily top
up if required
See page
68.

Radiator ○ Check daily for

damages leakage

Fuel ○ Everyday and

before work
Fill tank
Engine

Fuel filter ○ ● ○△○△○●○△○△○ Every 300 hours

or 12months

Fan belt ○ Check daily

See page
72.
Battery ○ ○ ○ ○ ○ ○ Check daily
Every 150 hours
Oil filter ● ● ● ● or 12months after
first 50 hours
Loose nuts
and bolts
○ Check daily Tighten

Radiator
hose clamp
○ Tighten if
required

These intervals are for operation under normal conditions and need to be reviewed
under severe conditions to a greater frequency
Caution

60
 Service interval(hour meter,mark)
Division

Daily
Item Frequency Comment
50 10 15 20 25 30 35 40 45 50 55 60
0 0 0 0 0 0 0 0 0 0 0

Every 500
hours or
Trans
mission oil
○ ● ★ ● 12months
after first
50 hours

Free play of
brake pedal ○ Check
daily

State of both
brake pedals ○ Check
daily

Operation of
each lever ○ Check
daily

Free play of About 50mm

steering ○ Check
daily (1.97 in) on
wheel circumstance
Chassis

Check
Toe-in ★ ★ after every 0 to 4mm
(0~0.157in)
300 hours
Grease in Grease
front wheel ○ ○ every
hub 300hours
Replenish
every 50
hours
Grease each
nipple
○ ○ ○ ○ ○○ ○ ○ ○ ○ ○ ○ (everyday
in dusty
conditions
)
Check the Adjust
steering ○ ○ ○ every 300
wheel joint hours

Tighten if
Wheel nut loose Front :
fastening ○ Check
daily
116-130(ft-
1bs) Rear :
torque 268-282 (ft-
1bs)

61
 Service interval(hour meter,mark)
Division

Daily
Item 15 20 25 30 35 40 45 50 55 60 Frequency Comment
50 100
0 0 0 0 0 0 0 0 0 0

Operation of
the ○ Check
daily
instrument
Adjustment
of the throttle ○ ○
pedal

HST oil
Filter
● ● Change
every 500
hours
Hydraulic oil
● ●
Chassis

filter

Check after
every
100hrs .
4WD front
axle housing ● ○ ○ ○ ○ ● Replace
every
Replace if
leaking
oil
500hrs
after first
50hrs

Check after
Rubber pipes ○ ○ ○ ○ ○ ○ every 100
hours

62
► FILLING DIAGRAM & CAPACITY TABLE

No. Filling point Fillings Quantity Liter (gal.)

MODEL 4010 HST
1 RADIATOR Fresh clean Water(L.L.C) with an antifreeze,
mixed in ratio of minimum 50% 7ℓ(1.85 US gal)

2 ENGINE API : CD/CE grades

° °
Above:25 C(77 F)…SAE30 or 10W-30
° ° ° °
0 C to 25 C(32 F to 77 F)…SAE20 or 10W30 5 ℓ (1.32 US gal)
° °
Below 0 C(32 F)…SAE 10W or 10W-30
MAHINDRA HEAVY DUTY SAE 15W-40

3 TRANSMISSION CASE See next page * 35ℓ(9.25 US gal)

4 FRONT AXLE (API GL-4 Grades)Gear oil #80 or #90
MAHINDRA EP GEAR OIL SAE 80W-90

5 FINAL DRIVE CASE(B) (API GL-4 Grades) Gear oil #80 or #90 8.2ℓ(2.166US gal)
MAHINDRA UNIVERSAL TRACTOR
FLUID
6 BALL JOINT Grease As required

7 FUEL TANK Diesel fuel 33ℓ(8.717 US gal)

63
► RECOMMENDED TRANSMISSION OIL
① RPM Tractor Hydraulic Fluid or Textron TDH Premium (CALTEX)
② TDH Oil or TDH Oil special (TEXACO)
③ Chevron 1000THF (CHEVRON)

► OPENING METHOD OF EACH COVER

► OPENING METHOD OF FAN COVER

guide hook lock

Pull the lower center lever of the front grille counter clock wise, pull the lower edges of hood panel
upward, and pull the whole panel forward till guide hook lock is hooked to groove.

▶ Opening the Side cover

To open, grasp the side cover, Pull the forward panel
upward to separate from guide support pin (1).
And pull the side panel forward again,

► FUEL
Use clean diesel fuel only .

As diesel fuel equipment is susceptible to contamination by

dust or water,
important Ensure that all dust and water is kept well away from the fuel tank.

64
► BLEEDING THE FUEL SYSTEM (① Fuel Filter)-
1. Raise the engine cover.
2. Make sure there is fuel in the fuel tank. ①
3. Make sure the fuel cock on the fuel filter is set to ON.
4. Open the fuel cock on the fuel injection pump.
5. Using the starter key, turn the engine until air free fuel
flows from the fuel cock on the fuel injection pump.
6. Close the fuel cock on the fuel injection pump.
7. The engine is now ready to start. If the engine runs
smoothly for a short time and then begins to run
roughly, leave at idle until it runs smoothly.

► BLEEDING THE FUEL SYSTEM (② Fuel Filter)

1. Close the fuel cock.
2. Remove the fuel filter element.
②
3. Wash the fuel filter element in clean diesel fuel.
If necessary, replace it.
4. Fit cleaned or new fuel filter element
5. Open the fuel cock.
6. Bleed the fuel system

Fuel Filter Element

Never use petrol, thinners or any other similar inflammable material to clean the

important fuel filter.

65
► 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 & drain oil. Replace and check the sump plug and refill
he engine with oil to the correct level on the dipstick
(approx. 1.85 gal)
The grade of oil to be used will depend on
the ambient temperature.
The tractor is shipped from the factory with 15W/40.
For summer use over 77℉ use SAE 30
For temperatures from 32℉-77℉ use SAE20 or 15W/40.
For temperatures below 32℉ use SAE 10W.

When changing the oil always change the filter.

Always use the same oil, as using different oils or specifications can cause damage.
important Dispose off the old oil as per local regulations.

► CHANGING THE TRANSMISSION OIL

1. Allow the transmission oil to cool.
2. Remove the drain plug from bottom of the transmission and drain the oil.
3. Replace and check the drain plug.
4. Refill the transmission to the correct level on the dipstick with new oil : Qty 35ℓ(9.25 US gal)

Always use the same grade and specified oil as Replacements.

important Dispose off the old oil as per local regulations.

66
► 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. Remove the dip stick from the filter hole and fill with Front Axle Oil Capacity 8.2ℓ (2.17 US gal)
and allow time for the oil to drain into the final drives.
5. Check the oil level with the dipstick and replace the Fill/Lever Plugs on both final drives and tighten

Some operators have found that when they fill with the correct amount of oil and dip
it,the oil level on the dipstick is too high due to the fact that it takes a while for the
oil to run into the final drives.
important
Opening the Vent plugs helps to speed this up.

► CLEANING AND CHANGING FILTERS

► ENGINE OIL FILTER
Using a filter wrench turn the filter
anti clockwise to remove it.
Lightly smear the rubber seal on the new
filter with oil to ensure, turn it clockwise
until the seal contacts the base and then turn it
another 2/3 turn to tighten it.

67
► 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 2/3rd turn
further to tighten it check for leaks.

► CHANGING THE COOLANT

(1) Open the tap in front of the gear pump to drain the coolant.
(2) Open the radiator cap at the same time.
(3) To give a thorough clean run a hose into the radiator and flush it out.
(4) Close the tap and refill the radiator with a coolant mixture of water and corrosion inhibitor
or anti freeze.
(5) Start the engine and allow it to run for approx 5 minutes, check the water level again and top up
if required

Do not remove the radiator cap on a hot engine.

Allow the engine to cool down and then turn the cap slowly to ensure, that
Caution there is no excessive pressure in the radiator.

Serious burns, can result from the contents of pressurized, hot radiators.
Allow the engine to cool down completely before opening radiator cap.
Caution

68
► 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.
In case of loss of solution due to evaporation or overflow, replace with the original mixture ratio.

Water or air under high pressure can distort the cooling fins on the radiator and
reduce its efficiency.
important

► GREASING THE TRACTOR

Grease the tractor according to the service schedule (page 61)
Ensure that grease nipples are cleaned well before any attempt is made to grease them.

* Speed Control Pedal Rod * Front Axle Ball Joint

* Pivot Metal

69
► 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
Loosen the locknuts to adjust the brake.
Turn the Turnbuckle counterclockwise to increases the
free play, or turn the Turnbuckle clockwise to decreases.
Tighten the locknut and confirm to fix the Nuts.
Check that the free play is correct and the same on both
pedals to ensure even braking .

Uneven adjustment of the left and right pedal will result in one sided braking
when the pedals are connected and can cause serious accidents, especially at high
speeds.
Caution
Double check to ensure free play is the same on both pedals

► ADJUSTING THE THROTTLE LEVER

If this lever is either loose or difficult to move please consult your dealer for rectification of the problem.

► ADJUSTING TOE-IN
If the toe-in adjustment is incorrect it can cause severe shaking of both the steering wheel and the entire
tractor. The correct toe in is 0.08~0.24in.
We recommend that this adjustment is made by the dealer.

70
► 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.
Caution

► BATTERY MAINTENANCE
Low temperatures will affect the performance of batteries so take particular care of it in winter.
For long-term storage of the tractor remove the battery and keep it in a cool dry room.
If it is on the tractor while stored, disconnect the negative terminal.
Batteries will self discharge if left for a period of without use time.
To keep them in good condition charge them once a month in summer and every second month in winter.
When replacing the original battery, ensure that the replacement battery is the same size.
Failure to do so can cause problems with the electrical circuit.

► BATTERY CHARGING
-A boost charge is only for emergencies.It will partially charge
the battery at a high rate and in a short time.
-When using a boost-charged battery,It is necessary to recharge
the battery as early as possible.
Failure to do this will shorten the battery’s service life.

71
 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.

► FAN BELT ADJUSTMENT

1.Loosen the alternator pivot bolt.
2.Move the alternator in order to increase or
decrease the belt tension.Tighten the alternator
pivot bolt and the link bolt to 22 N.m (16 lb ft)

► SERVICING THE AIR CLEANER

■ Cleaning the Air Cleaner Dust Valve
Check that the Dust Valve is not blocked.
Inspect the rubber flaps for cuts and nicks and check that
the rubber is not perished. Renew if necessary.
To remove dust from the dust valve, squeeze it between
thumb and fingers. Wipe around the dust valve to remove
dust collected on the outside.

■ Cleaning/Changing the Element

Release the two clips on the Air Cleaner end cover
and Remove the element.
Dust Valve
Remove dust by blowing compressed air through the element.
Check the element for damage, if necessary, change the elements.
Check all hoses for condition and tightness.

Never beat the element on a stone or concrete floor/wall to clean it.

Check all connections and hoses especially on the clean side of the air cleaner to ensure
no dusty air can enter the engine.
Check the element for flaws by putting a light inside the element.
important When reassembling make sure all surfaces seal correctly to keep dust out.
When working in dusty conditions increase the service frequency.

► Replace the element after cleaning it 5 times or it is damaged.

72
► 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.

Caution Damaged radiator hoses can cause hot water burns and in severe cases seize the engine.

► CHECKING THE WIRING HARNESS AND FUSES

Loose wires make inferior connections and damaged wires can cause short circuits, fires burnt wiring
or reduce efficiency of components.
Replace or repair any faulty wiring or insulation.
If a fuse burns out again after it has been replaced, do not replace it with wire or a high capacity fuse,
find the cause and rectify it or get an auto electrician to do so.
Where insulation is chafed or peeled off, recover the area with a good quality insulation tape. Where
wiring comes out of it’s fitting replace it correctly with the standard fitting.

Incorrect wiring or fuses can cause fires to both the tractor and surrounding area so
get the dealer to check it annually.
Likewise fuel pipes and wiring age with use.
important Ask your dealer to check it at least once every 2 years and replace as required

► REPLACING FUSES
The circuit has 8 blade type fuses in its wiring circuit
(See diagram on page 86)
When a fuse has blown replace it with one of the same value.
Using a large capacity fuse or wire burn out the wiring system.
Use fuse tongs to replace fuses

► MAIN FUSES
The wiring harness is equipped with 3 main fuses who’s
function is to preserve the wiring.
However when a main fuse blows the entire circuit is dead.
Always check the reason & rectify before replacing the
fuse of the same value.
To indicate that the fuse is blown it will be discolored. Fuse Case

73
 Always check the reason for a blown fuse otherwise the new fuse is also likely to
blow.
important NEVER EVER USE WIRE in place of correct grade fuse.

► SERVICE PRIOR TO DAILY AND SHORT TERMS STORAGE.

Wash the tractor and keep it clean.
Fill the tank to avoid condensation and rust.
Lower any attached implement to the ground before parking the tractor.
For long-term storage consult your dealer

74
 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.
This will ensure effective starting when the tractor is required.
When the outside temperature is below 32℉, replace the Antifreeze completely or drain the coolant to
protect the engine from damage from frozen coolant.

When washing the tractor ensure that the water does not get near electrical
components or the oil filter points.
To prevent short circuits remove the ignition key.
important
Do not wash the tractor when the engine is running.

Long-term storage.
When the tractor will not be used for a long time carry out the cleaning as for short term storage.
Drain the oil and replace with new oil.
Run the engine for approx. 5 min. to ensure that it has new oil throughout the engine.
Drain the coolant from the radiator and remove the ignition key.
Attach a tag both the key and the steering wheel saying” No coolant”.
Lubricate all grease and oil points on the tractor.
Check the pressures and add a small amount of extra pressure.
Lower any implement to the ground or store in a shady dry place.
Place a piece of wood under each tire to preserve the tire.

After refilling the engine with the coolant run the engine for approx. 5-10 min. at
1500-2000rpm every month as a corrosion prevention measure.
Either removes the battery or the negative terminal as mouse damage to wiring can cause
short circuits and fires.
important
Remove the ignition key and store in a safe place.

Re-use after long term storage.

Carry out a full check of all oils and coolant.
Refit the battery and run the engine at idle for 30 min. to ensure optimum engine life.

75
 Section - C

Specifications

The specifications on the following pages are given for your information and guidance.
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. For
exact information about any particular Tractor, please consult your Mahindra Authorized
Dealer/Distributor.

76
 SPECIFICATIONS
Model: 4010 HST
ENGINE CLUTCH
Four strokes, Indirect injection, water-cooled Type : Damper
Diesel Engine.
Model : 3B183LW (DAEDONG)
TRANSMISSION
No. of cylinders : 3 Type : synchro mesh
Displacement : 1,826cm3 No. of gears : 3 Speed forward,
Bore : 87 mm (3.43 in) 3 Speed reverse
Stroke : 102.4 mm ( 4.03 in) with high and low
Compression Ratio : 22:1 selection lever with
Horse Power (HP) : 38/ 2700rpm HST unit
(Manufacturing rating) STEERING
Rated Speed : 2,600 rpm Type : Hydraulic power
High idle rpm : 2800 rpm (Power steering)
Low idle rpm : 1000 rpm
Fuel injection pump : Indirect POWER TAKE OFF
Cylinder sleeve : Dry Mid mounted : 6 splines
Air Cleaner : Dry Filter element, paper Rear mounted : 6 splines
element filtering Diameter : 1⅜ in.
Firing order : 1-2-3 Standard PTO : Rear -540/2,775 engine rpm
Exhaust Muffler : Horizontal Round. Mid – 2000rpm
Accelerator : Hand Accelerator BRAKES
Foot operated, independent with provision of
ELECTRICAL STARTING AND LIGHTING inter lock for simultaneous operation.
Battery Capacity : 12V 80AH A foot brake is fitted for parking.
Starter : Solenoid Engaged. Inner dia. : 160 mm (6.30 in)
Key Start with Safety , Outer dia. : 210 mm (8.23 in)
starter switch Number of lining : 4 each side
Alternator :12V 50A Total brake thickness : 1.96 in
Instrumentation : Hour meter, Tacometer
Fuel gauge. HYDRAULIC SYSTEM
Water Temperature Gauge. 3 Point linkage : Category 1
Warming Lights. (Adjustable outside check chains)
Lighting: : Head lights,
Turn Signal Indicator Lamp,
Rear Parking, Brake Lamp
Tail Lamp

77
► MAIN SPECIFICATIONS
MODEL 4010 HST
Engine Maker DAEDONG
Model 3B183LW

Type Water cooled 4 cycle 4 cylinder diesel

Out put (HP/rpm) 4010 HST – 38HP / 2600rpm

Number of Cylinder 3
Displacement (cm3) 1,826 cm3

Bore and Stroke 4010 HST - 87 mm X 102.4 mm

Compression ratio 4010 HST – 22:1

Firing order 1-2-3

Injection pump indirect
Lubrication type Forced circulation

Cooling system Water cooled, Forced circulation

Coolant capacity 7ℓ(1.85 US gal)

Air cleaner Dry Dual Element
Muffler Horizontal
Fuel Diesel fuel
Fuel Tank capacity 34 ℓ(9.0 US gal)
Electrical Battery 12V80AH
Starting system Starter motor with pre-heater
Starter Capacity 2.0KW
Drive Train Alternator 12V 50A
Hydraulic, + Mechanical
Transmission
3 range gear with constant-mesh
MFWD(4WD) Standard
Differential lock Bevel gears with diff-Lock
Brakes Wet disc brake, mechanical
Steering hydraulic
78
 MODEL 4010 HST

Clutch Main Damper

PTO 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
R1
Rear 12.4-24
Front 10-16.5
R4
Rear 43x16.00-20
Front Center pin
Axle type
Rear Central axle

Implement Operation Hydraulic

Mounting method 3-Point hitch
Drawing method Trailer hitch
3-Point hitch category Category 1
Hydraulic-control Position

79
 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.
(b) If the rubber ring is cut or expanded then change it with an appropriate one.
Fix the rubber at the proper location & check for leakages if any.
(c) If air is leaking through the hose connection, check & rectify other leakages, too.

Note: If air cleaning system is not properly maintained, it will lead to early wear of piston rings
& sleeves. This will lead to problems like loss of engine power,, excessive oil consumption
fuel consumption.

B) Engine

1) put the engine oil on load after the engine is heated & the water temperature gauge indicates
the needle to be in the green zone.
2) If excessive black smoke is visible, then the paper element of air cleaner, Fuel injection
Pump or nozzles should be checked.
3) Do not run the engine without load for more than 2 minutes. It is better to stop the engine
rather than run it idle. This will help in saving of fuel.

C) Brakes.

1) If the Tractor has to be stopped for a long period, it is advisable to bring the transmission in
neutral position.
2) Do not over ride the brake pedals.
3) While coming down from a slope, reduce the engine throttle & use low gear. Do not depend
only on the brakes for stoppage.

D) Fuel system

1) Always use filtered diesel for the fuel system

2) At the end of the day’s working, it is preferable to fill the diesel tank so that it may prevent
condensation.
3) Change the filter, if the system gets choked. Do not change both the filters at the same time.
If the above directives are not adhered to, the fuel injection pump & injection nozzle will lose
its life early. Also, it will lead to excessive black smoke & excessive diesel consumption.

80
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. Adjust, If required.
2) Check the coolant level in the radiator fins always clean.
3)Replace the radiator cap with a genuine cap only, if required.
4) Do not remove the thermostat but replace with a new one, if required.
5) Do not change the radiator water often.
Note:
1) Always stop any fuel or oil leakages.
2) Carry out the regular maintenance failure to do so might increase the fuel consumption by 25%.
3) Carry out the torque of cylinder head bolt & adjustment of valve clearance regularly. Consult
your dealer for this.
4) Check the tire pressure & inflate, as recommended.
5) Always buy genuine spares from the authorized Dealer/Distributor.
6) Always carry out the service of the Tractor by your authorized Dealer/Distributor.

For any other information, contact your nearest Authorized Dealer/Distributor.

81
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 Low battery Charge the battery
enough to turn the engine Bad earth Clean the earth lead and tighten
Thick oil Drain and replace with correct oil

Starter operates OK but Air in fuel system Bleed the system

Engine

does not start the engine Clogged fuel filter Clean or replace both filters
No fuel being supplied Fill tank or turn tap on
Glow plug disconnected or Contact dealer for repair.
not working

Engine revolutions are Air in the fuel system Bleed the system
irregular Faulty injector Contact dealer for repair.
Fuel pipe leak

The engine stops at low Poor fuel injection Contact dealer for repair
revolution Faulty injection pump Contact dealer for repair
Wrong valve clearance Contact dealer for repair
Wrong idle setting Contact dealer for repair
Faulty injector Contact dealer for repair

The engine stops suddenly Lack of fuel Fill the tank and bleed the fuel
system
Faulty injectors Contact dealer for repair
Seized engine due to lack
of oil, the wrong oil or lack
of coolant

The engine overheats Lack of coolant Refill with coolant

Broken or misadjusted fan Adjust or replace
belt
Clogged air filter element Clean or replace air filter
Clogged radiator Clean the core
Low oil Replace the oil to correct grade

82
 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
Engine

the engine carbon coated and sticking

Low compression
Leaking valve seat Contact dealer for repair
Incorrect valve gap Contact dealer for repair
Faulty timing Contact dealer for repair
Fuel shortage Contact dealer for repair
Fill the tank and check fuel
Clogged air cleaner quality
Clean the element

Oil warning light comes on Low oil level Fill to correct level
with the engine running Wrong oil Change to correct oil
Faulty light or switch Replace faulty part
Clogged oil filter Contact dealer for repair

Alternator light comes on Wiring fault Contact dealer for repair

with the engine running Faulty alternator Contact dealer for repair
Low water level or faulty Top up or replace
battery
Broken or loose fan belt Replace or adjust

83
 SYMPTOM CAUSE REMEDY
Brake not working Incorrect free play Worm Adjust to correct free play
Brake

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 Engine revs. too low Increase engine revs.
Hydraulic
system

Lack of transmission Top up the oil to the correct

Oil level
Air leaking in from a pipe Repair or replace pipe or
replace O ring on joint and
tighten
Clogged suction filter
Faulty pump
Clean and change oil
Faulty hydraulic valve
Contact dealer for repair
Faulty cylinder
Contact dealer for repair
Contact dealer for repair
Oil leak from pipe Loose pipe joint Cracked Tighten joint
pipe Replace or repair pipe

When lifting the relief The stopper has slipped Adjust the stopper
valve whistles down
For any other hydraulic problems please consult your dealer who has the correct equipment to
diagnose and repair the system

84
 SYMPTOM CAUSE REMEDY
Steering wheel shaking Wrong toe-in Adjust toe-in
Unequal tire pressure Inflate both to correct pressure
Steering
wheel

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
needed
Faulty alternator Contact dealer for repair
Faulty regulator Contact dealer for repair
Broken or loose fan belt Replace or adjust

Before anything else,check the electrolyte level of the battery and the connections.Top up it
required and clean and retighten the terminal
Electric instruments

Dim head lights Low battery Charge or replace

Faulty wiring Repair or replace as needed

Headlights not working Blown bulb Replace bulb

Blown fuse Replace fuse
Faulty contact Repair or replace and check the
earth

Horn not working Faulty horn button Replace button

Faulty wiring Repair or replace
Faulty horn Replace

Indicator not working Blown bulb Replace bulb

Faulty flasher unit Replace unit
Faulty wiring Repair or replace

85
► Drawing for fixing position of the fuse
► Wiring diagram of the electric instrument

* Main Fuse

1 Light / Horn 15A

2 Panel 5A
3 Turn Signal Lamp 10A
4 Working Light 7.5A
5 Hazard 10A
6 Coupler 15A
A Head lamp 12V/55W/60W 7 Controller Glow Timer 5A
Meta panel Light 8 PTO, Cruise,
B 12V/3.4W 7.5A
(Instrument) Engine Stop
Turn Signal Lamp 12V/21W 9 Stop Lamp 5A
C
Tail Lamp) 21/5W 10 Spare -
Stop Lamp 21/5W 11 Spare -
D
Turn Signal Lamp 12V/21W 12 Spare -
E Working Lamp 12V/25W 13 Spare -

86
◎ POWER TRAIN

38PS

87
 TRACTOR HISTORY CARD

JOB CARD NATURE OF W/CLAIM NO.

DATE PARTS REPLACEMENT REMARKS
NO. DEFECT AND DATE

88
 SERVICE RECORD

DATE TRACTOR HOURS NATURE/TYPE OF REPAIR/SERVICE CARRIED OUT

89
 DAILY OPERATION LOG

JOB MACHINE HOURS FUEL ENGINE OIL

DATE REMARKS
DONE START END CONSUMPTION TOPPED UP

90
 PART REPLACEMENT RECORD

PART PART
DATE Q’TY COST DATE Q’TY COST
DESCRIPTION DESCRIPTION

91
 4010 HST
Operator’s Manual for Tractors
Code No.
1265-940-001-0
Printed on December. 2011
1st Edition
Click here to go on Operator's Manual - Engine
INDEX 4010 Gear / HST
Main Menu

The Mahindra Group Mahindra USA, Inc. 9020 Jackrabbit Road Houston, Texas 77041 1-877-499-7771 www.mahindrausa.com
 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. This manual makes users familiar with the diesel engine and provides use-
ful information on safety, operation, and maintenance of the diesel engine.

In addition, this engine should be maintained in proper ways according to the Owner's Manual in
order to operate the engine with excellent performance, high efficiency, economy, and long-term
usage. If the information you seek is not found in this manual, your DAEDONG diesel engine dealer will be
happy to help you. Please feel free to contact DAEDONG IND. CO.,LTD / DAEDONG-USA, INC. with your
questions/concerns.

< NOTE >

Make sure to read this manual carefully and keep it handy for future reference.
When leasing or transferring this tractor, deliver this manual together with the tractor.
The specifications in this manual are subject to change without notice.
 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. Follow the advice provided with the warning.

This indicates that a condition may result in damage to your

vehicle or its equipment if the caution is not heeded. Follow
CAUTION the advice provided with the caution.

This mark indicates emphasis on notable characteristics of

working procedures, and information about technology for
IMPORTANT easier operation.

This indicates that interesting or helpful information is being

NOTE provided.
 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. We then require that all employees understand and implement the system. Furthermore, we will
improve the quality management system continuously to satisfy requirements of ISO9001, 2000/KS A9001,
and 2001 and observe national and international laws and regulations in the manufacturing process.

At the same time, we will set and achieve additional mid- and long-term quality goals internally. Our chief of
quality assurance unit has responsibility and authority from the CEO for periodically examining the effective
operation of the quality management system to take actions for any discrepancy.
 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.

We will achieve environmental goals based on policies that contribute to the protection of the environment
by improving related regulations continuously. We publish those policies to the public and interested parties
and examine periodically whether the environment management system is understood by all employees and
implemented effectively, taking actions to correct any discrepancy.
 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.

Our chief of service unit has responsibility and authority from the CEO for periodically examining the effective
operation of product safety and management policies and taking actions to correct any discrepancies.
 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” and observing internal standards including the requirements of health regulations and
OHSAS18001;1999 to achieve additional safety and health goals internally.

We publish those policies to all employees and interested parties and examine periodically whether all em-
ployees understand and implement effectively the safety and health management system, taking actions to
correct any discrepancies.
 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. To contribute to the protection of the global environment, we measure environmental performance
periodically and make the information available to customers and interested parties. We establish and
achieve environmental goals internally to secure the transparency of environment management.

In addition, we set guidelines on "usage and disposal' for our customers to protect the environment.

1. Customers using this product should read this manual carefully and avoid any overloaded work. Overloaded work
may reduce the service life of products, and emissions combusted incompletely due to overloaded work are a major
cause of air pollution, which is the environment of the earth where we breathe.

2. When you replace the used engine oil with new oil, don’t dispose of the used oil in just any place which can cause
great soil or water pollution. Please bring the used oil to our local distributor to be disposed lawfully.

3. Use the product with proper operation, and if the service life of the product ends, don't leave or dispose it in just any
place.Products left out or disposed improperly by customers generate rust or oil, which may pollute soil or water.
Therefore, when disposing out-of-service products, never fail to let authorized "collectors for used wasted agri-ma-
chineries" collect them to dispose lawfully.
 SAFETY PRECAUTION....................... 1

PRECAUTION BEFORE OPERATION .... 2

OPERATION THE ENGINE .................. 3

BREAK-IN AND CHECK ..................... 4

SECTION MAINTENANCE ................................. 5

TROUBLESHOOTING ......................... 6

SPECIFICATION ............................... 7

INDEX ............................................. 8

9
 SAFETY PRECATIONS

PRECAUTIONS BEFORE OPERATION ...................... 1-2

1
1-2 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.
Be sure to observe these regulations
as well as the descriptions in the
Safety shoes
manual text.
T91O101A 051O101B
The following should never be
allowed to operate this machine. An Please wear appropriate working
clothes. 1. Thoroughly read and understand
unexpected accident can occur.
z Those under the influence of
this manual before operating the
alcohol engine. Contact your DAEDONG
dealer if you have any questions.
z Pregnant woman who is ready to Cigarette
deliver 2. It is the owner’s responsibility to
Muffler
train other operators before they
z Those under 16
use this engine. All operators
z Inexperienced operator To w e l t u c k e d should read and understand this
around the waist
z Those who are fatigued, sick, or manual.
under the influence of medicine; Slippers
others who are not qualified for any T91O102A
reasons to operate this machine
You may be entangled in moving
Do not operate the machine while parts or slip on the machine due to
fatigued. Take a rest if necessary. the above-mentioned clothing, which
may cause serious injuries.
 SAFETY PRECATIONS 1-3

7. Make sure that all drains and caps

are tightly closed and all fluid 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. Loose parts are the
operator’s responsibility and may
051O102B 051O103B
cause damage or injury if ignored.

3. Exhaust fumes are poisonous and fuel. Fuel mixtures will damage
can cause illness, brain injury, or the engine and may cause an
even death due to lack of oxygen. explosion.
Therefore, operate the engine 6. Confirm that the engine is stopped
where there is good ventilation and when repairing the machine,
there are no people or cattle. performing maintenance work, or
4. Don't operate diesel engines in a refilling the fuel. Don't open the
place where may be combustible caps of the radiator or auxiliary
vapors. Responsibility for operating tank while operating the engine or
the engine safely in dangerous just after the engine is stopped.
places must be assumed by the If opened, hot water is ejected,
machine managers and workers which may cause burning injuries
5. Use diesel fuel only. Never mix to people around. Open the
gasoline or alcohol with diesel radiator cap 10 minutes after the
engine is stopped.
1-4 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.

051O104B 051O105B

8. When separating or dissembling 10. To prevent injury and equipment

connecting pipes, joints, or related damage when servicing the
parts, remove the pressure from engine; always use the proper
the systems for air, engine oils, tools, know how to use them
or coolants. When removing correctly and keep them in good
a component in a pressurized condition. Wear eye protection.
system, be careful of the pressure. 11. Dispose of all fluids and haza-
For example, do not use your hand rdous materials in accordance
to check pressure leakage. There with local environmental regula-
may be damages due to oil or fuel tions and common sense. Never
with high pressure. drain oils, coolants or fuels
onto the ground. Do not place
fluids, filters or batteries in with
 SAFETY PRECATIONS 1-5

household wastes. Determine

the appropriate disposal method
before removing hazardous
materials from the engine.

T91O117A T91O118A

12. When checking the battery, keep 14. Do not allow the battery fluid to
flammable items, such as lighter, contact your skin and clothing.
cigarette, etc., away from the In case of acid contact with eye,
machine. skin, or tools, rinse thoroughly
13. Hydrogen gas from batteries with water. Get medical attention
may cause an explosion, which immediately if acid contacts your
may cause injuries or damages. eye or is swallowed. The battery
has acid that can burn your skin,
eyes, or clothing.
1-6 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 first. When should be installed again after
connecting the cable, start with the work is done. You can be
the positive (+) terminal. Doing trapped or entangled into the
so can cause a short circuit engine system and get injured.
which leads to skin burning or
fire.
- Use only a recommended
battery.
- Do not mix the positive and
negative battery cables.
 PRECAUTIONS BEFORE OPERATION

EXTERIOR VIEW .......................................................... 2-2

SERVICING ................................................................... 2-3 2 2
2-2 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 (10) Fan Drive Pulley (15) Oil Pressure Switch
(16) Oil Drain Plug
 PRECAUTIONS BEFORE OPERATION 2-3

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.
3. Make and model number of the ma-
051O202B
chine in which the engine is installed.
(1) Engine Serial Number

Your dealer is interested in your new

tractor and has the desire to help
you get the most value from it. After
reading this manual thoroughly, you
will find that you can do some of the
regular maintenance yourself.
The engine serial number is stamped
on the mounting surface of the injec-
tion pump.
 OPERATING THE ENGINE

PRE-START ENGINE CHECKS .................................. 3-2

STARTING AND STOPPING THE ENGINE ................. 3-2
CHECK DURING OPERATION .................................... 3-3
3
3
3-2 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” position. (Only for this en- ately and see page 3-4 for trouble-
fore starting – See page 4-2 for de- gine with engine filters) shooting instructions.
tails. 2. Set the speed control lever at 6. Run at a moderate speed until the
about half throttle. engine reaches a normal operating
IMPORTANT temperature before doing work.
3. I n s e r t t h e k e y i n t o t h e s t a r t e r
z Before installing the engine, switch, and turn it to "ON" position. 7. The oil pressure light should re-
be sure that the equipment is Keep the position until the preheat main off during operation. If the
on firm, level ground. light comes on, stop the engine im-
indicator goes off.
z Do not run the engine on gra- mediately to avoid the possibility of
dients. ① Verify that the oil pressure and severe engine damage, and check
z Never use starting fluid or gas- charge lights are on. the following:
oline in the air intake. Engine ② The engine may be started with z Correct oil level.
damage will result, and an ex- out preheat in normal tempera- z Verify that the engine contains
plosion may occur. ture (above 15oC), but with pre-
clean oil of the proper viscosity.
heat for 15 or 10 seconds in cold
z Check for faulty wiring.
temperature (-23 oC)(Provided
it may be varied according to
the installed condition of the en- CAUTION
gine.). To avoid personal injury :
4. Turn the key to the “START” posi- z Keep children or non-essential

tion to engage the starter motor. bystanders away from the en-
Release the key immediately as gine while it is running.
the engine starts.
5. Verify that the oil pressure and
charge lights are now off. If either
 엔진의
OPERATING THE 작동
ENGINE 3-3

CHECK DURING OPERA-

STOPPING TION

IMPORTANT While operating the engine, keep

checking whether all parts of the en-
z Do not turn the starter switch gine are operating smoothly and
to “START” while the engine is properly.
running.
z If the engine does not start in
10 seconds, wait 30 seconds COOLING SYSTEM
and repeat the starting se- If steam or coolant is escaping from
quence. Never run the starter the overflow tube; stop the engine,
motor continuously for more allow it to cool, and check the follow-
than 20 seconds. 051O301B ing and correct as needed.
z Always warm up the engine 1. Check for cooling system leaks.
(1) SPEED CONTROL LEVER
before working. Using a cold (2) ENGINE STOP SOLENOIDE 2. Check for obstructions that block
engine will shorten its life. (A) "IDLING" (B) "OPERATION" cooling air.
z If the temperature may be low-
1. Disengage any load from the en- 3. Clean any dirt or debris from the
er below -15oC (5oF), separate
gine. Return the speed control le- radiator core (fins & tubes).
the battery from the machine,
ver to the “IDLE” position.
and keep it indoors. Then use 4. Check and adjust the fan belt ten-
it when starting the engine. 2. Turn the starter switch to “OFF” sion.
and remove the key. Return the
5. Ensure that the system is filled to
engine stop solenoide to the
the correct coolant level with the
“START” position for the next start.
proper mix of anti-freeze and wa-
ter.
6. Check the radiator cap for proper
type and condition.
3-4 디젤엔진
DIESEL ENGINE

CAUTION OIL PRESSURE LAMP STOP THE ENGINE IMMEDIATELY:

To avoid personal injury : The oil pressure lamp comes on 1. If the engine speed suddenly
z DO NOT remove the radiator when the oil pressure drops below a changes.
cap or the coolant reserve tank safe level. If the lamp comes on dur- 2. If there is an unusual noise.
ing operation. If the lamp is on while
cap while the engine is hot. 3. If the engine exhausts suddenly
the engine is operated at or above
Pressurized steam or cool- 1,000 rpm, immediately stop the en- darkens.
ant will escape and cause se- gine and check the following items. 4. If the oil pressure or temperature
rious injury to you and any by- light come on.
standers. Open the cap at least 1. Check the engine oil level (page
10 minutes after the engine is 5-4)
stopped.
FUEL
The fuel tank should never be al-
lowed to become completely emp-
ty. An empty tank will allow air into
the fuel system; and the engine will
not operate without bleeding the fuel
system.

EXHAUST SMOKE
The engine exhaust should be color-
less during normal operation within
the rated output of the engine. Con-
tinuous dark emissions or smoke
may indicate improper usage or an
engine malfunction.
 엔진의
OPERATING THE 작동
ENGINE 3-5

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 damage. Replace as needed.
run in this condition. Shut the engine
down immediately.

HOW TO TELL WHEN THE EN-

GINE RUNS BACKWARDS
1. Oil pressure will drop suddenly.
The oil pressure light will come on.
2. T h e s o u n d o f t h e e n g i n e w i l l
change. Exhaust gases will come
out of the air intake.
3. A loud knocking sound will be
heard.
 BREAK-IN AND CHECKS

DAILY CHECKS ............................................................ 4-2

BREAK-IN ..................................................................... 4-2
PERIODIC CHECKS ..................................................... 4-3
4
4
4-2 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. Change engine oil and oil filter af-
ter first 50 hours of operation (See
NOTE pages 6-3 to 6-4).
All service and maintenance 2. In cold weather, always allow the
should be done on a firm, level engine to warm up before using.
surface.

ITEM PAGE
Parts which had trouble in -
previous operation
Oil or water leaks 5-7
Engine oil level
and contamina- 5-4
By walking tion
around Amount of fuel 5-4
the ma- Amount of coolant 5-8
chine Dust in air cleaner 5-12
Damaged parts
and loosened -
bolts and nuts
Color of exhaust 3-4
By start- fumes
ing the
engine Unusual engine 3-5
noise
 BREAK-IN AND CHECKS 4-3

SERVICE INTERVALS

NO. CHECK ITEM RUN HOUR RUN AGE SINCE THAN PAGE
50 100 150 200 300 400 600 800 1YR 2YR
1 Engine oil Change ⊙ ○ Every 150 Hr 5-5
2 Engine oil filter Replace ⊙ Every 150 Hr 5-6
3 Engine starting system Check ○ Every 50 Hr -
4 Tightening torque Check ○ Every 50 Hr -
5 Battery Check ○ Every 100 Hr 5-12
Clean ○ Every 100 Hr 5-12
6 Aircleaner element
Replace ○ Every 1 Year 5-12
Fuel filter element(Oil Clean ○ Every 100 Hr 5-4
7 and water seperate) Replace ○ Every 400 Hr 5-4
8 Fan belt Adjust ○ Every 100 Hr 5-14
9 R a d i a t o r h o s e a n d Check ○ Every 600 Hr 5-9
clamp Change ○ Every 2 Year 5-10
Check ○ Every 100 Hr 5-2
10 Fuel line
Replace ○ Every 2 Year 5-2
Check ○ Every 200 Hr -
11 Intake air line
Replace ○ Every 2 Year -
12 Engine valve clearance Adjust ○ Every 800 Hr -
13 Cooling system Flush ○ Every 2 Year -
14 Coolant(Anti-freeze) Replace ○ Every 2 Year 5-11
15 Fuel airbleeding Check Service as required -
16 Radiator screen Clean Daily -

The items marked ⊙ must be done after the first 50 hours of operation. The fuel injection pump, noz-
zle, alternator, starter, compressor, gear pump and hydraulic valve should be checked and repaired
NOTE only by KIOTI Dealer/Distributor. If they are serviced by an unqualified person, the vehicle's safety
cannot be guaranteed any longer since changes made may not conform to KIOTI requirements.
 MAINTENANCE

FUEL ........................................................................... 5-2

ENGINE OIL .................................................................. 5-4
RADIATOR (OPTIONAL) .............................................. 5-7
5
AIR CLEANER (OPTIONAL) ...................................... 5-12
BATTERY (OPTIONAL) .............................................. 5-12
FAN BELT ................................................................... 5-14
LONG-TERM STORAGE ............................................ 5-15 5
5-2 DIESEL ENGINE

FUEL
CHECKING THE FUEL LINES
Use Diesel Fuel No.2. IMPORTANT
CAUTION Always use clean fuel. Use a
strainer if necessary.
To avoid serious injury:
Do not let the fuel tank run
Do not mix gasoline or alcohol
empty.
with diesel fuel. This mixture
Clean up fuel spills promptly
may damage the engine and
and properly to eliminate a fire
can cause an explosion.
hazard.
Stop the engine while refuel-
ing to avoid fire or explosion.
051O501B
Avoid open flames and sparks
while refueling.
(1) Air vent cock (2) Fuel pump

FUEL LEVEL CHECK AND REFU-

ELING
CAUTION
1. Always refuel before the fuel level
To avoid serious injury:
reaches “EMPTY”.
always stop the engine and al-
2. Use diesel fuel only. Other fuels low it to cool before servicing
and fuel mixtures will degrade per- the fuel system. Repair fuel
formance and may damage the leaks promptly to avoid fire or
engine. Use the correct grade of explosion.
diesel fuel for the ambient temper-
ature.
 MAINTENANCE 5-3

REPLACING THE FUEL FILTER

Check the fuel lines after every 100 IMPORTANT
hours of operation.
Replacing the fuel filter 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. Re- tor wear.
place hoses and clamps every 2
years regardless of engine usage.
3. Bleed air from the fuel system af-
ter service.
T91OA26A

IMPORTANT (1) Fuel cock (7) Filter container

(2) Fuel filter container (8) Screw ring
Plug ends of open fuel lines
(3) O-ring (A) Close
during service to prevent dirt (4) Filter element (B) Open
and other contaminants from (5) Spring (C) Bleeder
entering and damaging the fuel (6) O-ring
system.
1. Replace the fuel filter cartridge ev-
ery 400 hours.
2. Apply a thin layer of fuel oil on the
gasket. Install and hand-tighten.
5-4 DIESEL ENGINE

ENGINE OIL
CHECKING ENGINE OIL LEVEL

For your own safety and maximum CAUTION

service life of the machine, make
a thorough daily inspection before To avoid personal injury:
starting the engine. Be sure to stop the engine be-
fore checking the oil level.
CAUTION
To avoid personal injury: 1. Park the machine on a flat sur
Be sure to check and service face.
the tractor on a flat place with 2. Check the engine oil before start-
the engine stopped and the T91OA04A
ing the engine or wait 5 minutes or
parking brake “ON”. more after the engine has stopped.
(1) Oil Inlet (2) Oil gauge
3. To check the oil level, draw out the
(A) Oil level is acceptable within this range.
dipstick, wipe it clean, replace it,
WALK AROUND INSPECTION and draw it out again.
Look around and under the tractor IMPORTANT Check to see that the oil level is
for such items as loose bolts, trash When using oil of a different between the two notches. If the
build-up, oil or coolant leaks, or bro- brand or viscosity from the level is too low, add new oil to the
ken or worn parts. previous one, remove all of the prescribed level at the oil inlet.
old oil. Never mix two different
types of oil.
Do not start the engine if the
amount of oil is insufficient.
 MAINTENANCE 5-5

CHANGING ENGINE OIL

4. Engine oil quantity 1. Change the oil after the first 50

Model Quantity Model Quantity hours of operation.
3C093LWS
3.2ℓ
3C093LWG
3.8ℓ
2. Remove the drain plug from the oil
3C100LWS 3C100LWG pan and allow all of the oil to drain.
3A139LW Draining the oil will be easier when
3A150LW 5.8ℓ 3B183LW 5.5ℓ
3A165LW
the engine is slightly warm.
4A200LW 3. Ensure that the oil level on the dip-
8.0ℓ 4B243LW 7.7ℓ
4A220LW stick is at the upper mark.
4A200TLW 8.3ℓ 4A220TLW 8.3ℓ 4. Change the oil after every 150
hours of operation thereafter.
5. Use SAE 15W40 oil or equivalent.
6. Always drain the oil completely
when changing. Never mix differ-
ent oils or engine damage may re-
sult.
5-6 DIESEL ENGINE

REPLACING THE OIL FILTER

NOTE
Swipe off any engine oil stained
on the machine.

1
3

051O601B 051O602B

(1) Oil Drain Plug (2) Oil Filter

(3) Remove wiht filter wrench(Hand-tighten
only)
1. Replace oil filter with at least every 5. The level of engine oil is lowered
other oil change. when replacing cartridges. So,
2. Remove the filter using a filter check whether any oil leakage is in
wrench. sealed places when operating the
engine for a while, and then check
3.Apply a thin layer of clean oil to the
the oil level. If necessary, replenish
gasket on the new filter.
oil.
4. Screw the new filter on. Hand-
tighten only. If the gasket contacts
with the sealed place, fasten it
with hands. If you fasten it with
wrenches, the fastening force may
be greater than necessary.
 MAINTENANCE 5-7

RADIATOR (OPTIONAL)
CHECKING LEVEL,ADDING
AND CHANGING COOLANT
Radiators must be handled and in- CAUTION
stalled properly to avoid coolant 1
leaks. It should be a daily routine To avoid personal injury:
to check the engine coolant level. always stop the engine and al-
Check it before each use while the low it to cool before changing
engine is cold. the coolant or performing any
other cooling system service.

WARNING
To avoid personal injury:
Do not remove the radiator cap 051O603B

or coolant reserve tank cap (1) Pressure Cap

while the engine is hot. Escap-
ing steam or coolant will cause
serious injury to you or any 1. Without a reserve tank, remove
bystanders. Always check the the radiator cap while the engine is
engine coolant level when the cold. The coolant level should be
engine is cold. just below the filler neck.
2. If equipped with reserve (expan-
sion) tank, the coolant level should
be between “FULL” and “LOW”.
5-8 DIESEL ENGINE

CHANGING COOLANT

1. To discharge coolants, always

open plugs for discharge that are

;;;;;
1
located on the side of the crank
case and lower part of radiator,

;;;;;
A and open the radiator cap, too.

;;;;;
You cannot discharge coolant ful-
ly when the cap is closed. (To dis-
charge coolant from reservoir tank,
B separate the overflow pipe from
the radiator cap.)
051O604B 051O605B

(1) Coolant Drain Plug (1) Coolant Reserve Tank 2. COOLANT QUANTITY
(2) Coolant Drain Cock (A) Full (B) Low
Model Quantity Model Quantity
3. If necessary, add the proper mix of 3C093LW
IMPORTANT 3C100LW
1.6ℓ 4A200LW 3.9ℓ
pure water and anti-freeze. Cool-
Do not use dirty water or sea-
ing system drain cocks are located 3A150LW 3.3ℓ 4A200TLW 4.0ℓ
water for coolant.
at the bottom of the radiator and
Check radiator cap condition
on the side of the engine. They 3A139LW 3.3ℓ 4A220LW 3.6ℓ
and tighten securely after ser-
must be closed securely during
vice.
operation. (If there is any leakage, 3A165LW 2.8ℓ 4A220TLW 3.8ℓ
Do not overfill the reserve
refer to pages 5-9.)
tank, if equipped.
3B183LW 3.0ℓ 4B243LW 3.9ℓ
When coolant is added, start
the engine and check again be-
fore it gets hot. It may require ※ The coolant mentioned above is
additional coolant. applied only for the engine.
 MAINTENANCE 5-9

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. Refill with fresh cool- Flush the radiator core with fresh wa-
ant loss and may cause overheat- ant. If a blockage persists, contact ter to remove external dirt and de-
ing. your dealer or professional radia- bris. Cleaning should only be done
4. Coolant(Radiator cleaner and anti- tor service. when the system is cold.
freeze).
Season Coolant CHECKING RADIATOR HOSES
Summer Pure water and ra-
1. Inspect radiator hoses every 6
diator cleaner months or 200 operating hours;
Winter whichever comes first.
Pure water and an-
(When temperature
ti-freeze (Refer to Check for leaks and repair or re
drops below 0 (32°
P5-10)
F)or all season place promptly. Tighten hose
clamps regularly.
IF COOLANT OVERFLOW PER- Hoses that are cracked, swol
SISTS: len or brittle must be re placed
as failure is eminent. Hose fail
1. Clean dirt and debris from the radi-
ure will result in engine over
ator guard, if equipped, and the ra-
heating and possible injury.
diator core (fins and tubes) to en-
sure that cooling air flow is not ob- 2. Replace cooling system hoses ev-
structed. ery 2 years. New hose clamps
should always be used when re-
2. Check and adjust the fan belt (see
placing hoses.
page 5-14).
3. If a cooling system blockage is
suspected, drain and flush the
5 -10 DIESEL ENGINE

CLEANING THE RADIATOR

IF ENGINE OVERHEATING OCCURS
If the coolant is overheated to around “Troubleshooting” section of this
or above boiling point, follow instruc- manual to determine the cause.
tions below. If a warning buzzer or Make repairs and adjustments as 2
lamp is turned on, follow instructions required.
below.
1. Safely stop the machine. Remove 1
any load from the engine and re-
duce the engine speed to idle.
2. Allow the engine to idle for 5 min-
utes before shutting it down. 051O606B
3. After shutdown, allow the engine to
(1) Radiator Hose (2) Hose Clamp
cool before troubleshooting and re-
pair. Stay away from an overheat-
ed engine until it cools as steam or Clean the cooling system every 500
hot coolant may escape violently hours or as needed. Cleaning may
without warning. be required more often in severe ser-
vice conditions. Always clean the
4. After shutdown, allow the engine to system when replacing the engine
cool before troubleshooting and re- coolant.
pair. Stay away from an overheat-
ed engine until it cools as steam or IMPORTANT
hot coolant may escape violently Use water only to clean the ra-
without warning. diator core. Never use tools or
5. After the engine cools, consult the any other hard object that will
damage fins and tubes. Leaks
or degraded performance will
likely occur.
 MAINTENANCE 5 -11

ANTI-FREEZE

Freezing temperatures can quick- IMPORTANT NOTE

ly and severely damage the engine
if the cooling system is unprotected. The coolant mixture should This data is the industry stan-
Use antifreeze when temperatures not exceed 50% anti-freeze by dard for a typical ethylene glycol
fall below 32oF (0oC). volume. based antifreeze. These volumes
of anti-freeze, when mixed with
1. Only use permanent anti-freeze in Anti- Freezing Point Boiling Point pure water, will reduce the freez-
this engine. freeze o
C o
F o
C o
F ing point of the coolant mixture
2. Completely drain and flush the Vol%) as shown.
cooling system with clean water 40 -24 -12 106 222 When adding coolant during dai-
before adding anti-freeze. 50 -37 -34 108 226 ly service, use only water or an-
3. Mix the proper amounts of an- ti-freeze mixed with water to en-
ti-freeze and pure water in accor- *At 760 mmHg pressure (atmospher- sure that the mix ratio stays at or
dance with SAE J1034 and SAE ic), a higher boiling point is obtained below 50% anti-freeze.
J814C based on the expected am- by using a radiator pressure cap Keep unused anti-freeze in a
bient temperature. which permits the development of clean, tightly sealed container.
4. Mix the anti-freeze and water be- pressure within the cooling system. Do not use radiator cleaning
fore pouring it in the cooling sys- agents when anti-freeze has
tem. been added to the cooling water.
(Anti-freeze contains an anti-cor-
rosive agent, which will react with
the radiator cleaning agent form-
ing sludge which will affect the
engine parts.)
5 -12 DIESEL ENGINE

AIR CLEANER (OPTIONAL) BATTERY (OPTIONAL)

4. Dust can be cleaned from the fil- CAUTION

2
ter element with compressed air.
Always blow from the inside out, To avoid personal injury:
3 Avoid contact with battery
2 and never use air pressure greater
than 100 PSI. electrolyte. Sulfuric acid will
3 burn the skin and destroy
5. Oily or extremely dirty filters may clothing. If contact occurs,
1
be cleaned by soaking the ele- flush thoroughly with clean
ment in a detergent for 15 minutes. water. Wear eye protection.
4
Rinse thoroughly and allow to air
dry completely. Inspect the ele-
051O607B
ment for damage before reinstall- The battery may be damaged due to
(1) Aircleaner Body (3) Wing-Head Bolt ing. improper treatment. Please charge
(2) Element (4) Evacuator Valve the battery fully with the proper meth-
6. Replace the element yearly or af- od.
ter 6 cleanings.
1. Never use oil in a dry-element type 1. Keep the battery fully charged to
air filter. avoid downtime.
IMPORTANT
2. Squeeze the evacuator valve open 2. Check the electrolyte level during
Ensure that the wing nut for
to ensure that larger dust particles routine service. Add distilled water
the filter element is tight. A
are expelled from the air cleaner when the level is low. Do not over-
loose element or loose cover
body (canister) – at least weekly; fill. Flush any spillage with clean
will allow dust ingestion that
daily under dusty conditions. water to prevent injury or equip-
can severely damage the en-
3. Wipe the inside of the air cleaner ment damage.
gine. Always check air intake
body with a clean cloth when ser- clamps for tightness. 3. When recharging the battery, con-
vicing the air cleaner. nect the charger and the battery
with positive to positive and nega-
tive to negative.
 MAINTENANCE 5 -13

4. When charging the battery, always IMPORTANT

follow the charger manufacturer’s -
instructions. Be careful to observe 2 Always observe the correct
the correct polarity to prevent bat- polarity. Attaching cables to
tery damage or possible explosion. the wrong terminals will cause
1 system damage and possibly
3 injury.
+ To prevent a short circuit that
may cause injury, always re-
move the negative (ground) ca-
051O608B ble first and reconnect it last.
Never remove a battery cable
(1) Larger Red Cable(+)
(2) Ground Cable(-) while the engine is running.
(3) Battery Case Charging system damage may
result.
5 -14 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
6 7 8 kgf). load at mid-span (Point A). The
resulting belt deflection should be
0.28 to 0.35 inches.
4
5
051O610B 051O611B

(4) Hightest Level (7) Plug (1) Fan Belt (2) Bolt, Nut
(5) Lowevst Level (8) Hightest Level (A) 7~9mm
(6) Lowevst Level
1. Before long-term engine storage: Loosen both bolts that attach the al-
Remove the battery. ternator. Move the alternator to ad-
Add electrolyte, fully charge just belt tension. Retighten the bolts
the battery, and readjust the and nut after adjustment.
electrolyte level, if necessary.
Store the battery in a dry, dark
place.
Do not store on the ground or a
concrete surface.
2. Batteries will discharge even when
not in use. During long periods
of inactivity, recharge regularly to
maintain readiness and battery life.
 MAINTENANCE 5 -15

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
1. Open the drain cocks and remove engine oil liberally to valve guides
the radiator cap to drain all of the and valve stem seals before start-
coolant from the engine and radi- ing.
ator. Leave the drain cocks open.
Label the engine with a reminder
that there is no coolant in the en-
gine. If the temperature gets lower
than 0°C (32°F), coolant gets
frozen. In such conditions, be sure
to discharge the coolant from the
engine.
2. Drain the engine oil and replace
with clean oil. Run the engine for 5
minutes.
3. Repair any leaks. Ensure that all
bolts and screws are tight.
4. Separate the battery from the ma-
chine, check the electrolytes, and
recharge the battery. The battery
should be kept in a dry place with-
out direct sunlight.
5. R u n t h e e n g i n e e v e r y 2 t o 3
months with no load for 5 minutes.
 TROUBLESHOOTING

ENGINE IS HARD TO START ...................................... 6-2

ENGINE SUDDENLY STOPS RUNNING ..................... 6-3
LOW ENGINE POWER OUTPUT ................................. 6-4
6
EXHAUST SMOKE OR DARK EMISSIONS ................ 6-5
THE ENGINE MUST BE STOPPED IMMEDIATELY .... 6-6
ENGINE OVERHEATS.................................................. 6-7

6
6-2 DIESEL ENGINE

ENGINE IS HARD TO START

Possible causes Actions

Fuel is cloudy or fuel flow is re- • Check fuel tank and fuel filter.
stricted • Remove water, dirt, or other debris.
• Filter out fuel, and replace the filter if contaminated.
Air or water in fuel system • Fuel pump is not working properly due to air in the fuel filter or injection line.
Loosen the fuel cap nut and check carefully to obtain proper fuel injection pressure.
• Loosen the air vent screw from the fuel filter and fuel injection pump and bleed all air from
the fuel system.
Thick carbon deposit at injection • Water or dirt in fuel. Clean the injection nozzle and check the nozzle inject for damage.
nozzle inlet • Check that the nozzle is working properly. Install new nozzle if necessary.
Incorrect valve clearance • Adjust the valve clearance (with the engine cold).
Intake ; 0.15mm Exhaust ; 0.15mm - 3C093LWS/3C093LWG/3C100LWS
Intake ; 0.25mm Exhaust ; 0.30mm - 3A139LWS/3A150LWS/3A150LWG/3A165LWS/
3B183LWS/4A200LWS/4A220LWS/4A220LWG/
4B243LWS
Intake ; 0.20mm Exhaust ; 0.20mm - 4A200TLWS/4A220TLWS
Leaks from valve • Polish the valve.
Incorrect fuel injection timing • Adjust the injection timing.
• Injection timing: BTDC 12°(sub port)
BTDC 18˚- 3C093LWS/3C100LWS/3A139LWS/3A150LWS/3A150LWG/3A165LWS/
3B183LWS/4A200LWS/4A220LWS/4A220LWG
BTDC 24˚- 3C093LWG
BTDC 22˚(CTD, main) - 4B243LWS
BTDC 12˚(sub port) - 4A200TLWS/4A220TLWS
 TROUBLESHOOTING 6-3

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.
Battery discharged, or engine is • Replace the battery.
not running • Remove battery from the tractor and keep it in an indoor environment in cold weather.
Install the battery when you use the tractor.

THE ENGINE MUST BE STOPPED IMMEDIATELY

Possible causes Actions

Insufficient fuel • Drain and replace with proper fuel.
• Check whether there is air or leakage in the fuel system.
Faulty nozzle • Replace new part as required.
Moving parts overheating due to • Check the level of engine oil with oil gauge.
poor oil and insufficient oil • Check the lubrication system.
• When replacing engine oil, the element of the oil filter should be replaced.
• Check if the bearing clearance meets the specification.
6-4 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- • Defective valve or excessively worn ring, piston, and liner will result in low compression.
pression Replace it with a new one.
• Polish the valve.
Lack of the fuel • Check the feul system.
Moving parts overheating • Check the lubrication system.
• Check if the oil filter is working properly.
• Filter screen or element with debris will degrade the lubricant cleaning screen.
Replace the element.
• Check the injection timing
• Proper injection timing (crank angle before top dead center)
BTDC 18˚- 3C093LWS/3C100LWS/3A139LWS/3A150LWS/3A150LWG/
3A165LWS/3B183LWS/4A200LWS/4A220LWS/4A220LWG
BTDC 24˚- 3C093LWG
BTDC 22˚(CTD, main) - 4B243LWS
BTDC 12˚(sub port) - 4A200TLWS/4A220TLWS
In correct valve adjustment • Check and adjust valve clearance when the engine is cold.
Intake ; 0.15mm Exhaust ; 0.15mm - 3C093LWS/3C093LWG/3C100LWS
Intake ; 0.25mm Exhaust ; 0.30mm - 3A139LWS/3A150LWS/3A150LWG/3A165LWS/
3B183LWS/4A200LWS/4A220LWS/4A220LWG/
4B243LWS
Intake ; 0.20mm Exhaust ; 0.20mm - 4A200TLWS/4A220TLWS
Air cleaner contamination • Clean or replace the element every 100hours of operation.
 TROUBLESHOOTING 6-5

Possible causes Actions

Poor pressure of the feul injuction • Adjust to proper pressure
150 ~ 160Kgf/cm2 (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
• Check the injection pump and valve assembly. Replace as required.

ABNORMAL EXHAUST FUME COLOR

Possible causes Actions

Poor fuel governor system • Consult with a dealer for repair.
Poor fuel quality • Select good quality fuel. Use the diesel oil only.
Poor nozzle • Replace with a new nozzle if necessary.
Unstable burn • Poor spraying, improper injection timing, abnormal injection system, poor valve adjust
ment, or compression leakage, poor compression, etc. Check and repair.
6-6 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.
Exhaust smoke or dark emissions • Check the fuel injection system. Especially, check the nozzle.
appear
Overheating the bearing • Check for lubricating system leaks
Oil pressure warning light comes • Check the lubrication system.
on • Check if the engine bearing clearance meets the specification.
• Check the oil pressure relief valve
• Check the oil pressure switch
• Check the filter base gasket.
 TROUBLESHOOTING 6-7

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 • Clean dirt and debris from radiator core and radiator guard.
Cooling air obstructed • Flush and clean system. Replace parts as required.
Cooling system dirty or corroded • Flush and clean system. Replace parts as required.
Defective radiator cap • Replace defective cap.
Faulty thermostat • Check and replace thermostat nd replace, if necessary.
Defective temperature gauge or send-
• Calibrate using thermometer and replace, if necessary.
ing unit
Engine overload • Reduce load.
Leaking head gasket • Replace head gasket.
Fuel injection timing • Check and adjust timing.
Unsuitable fuel • Replace fuel with the clean fuel of the proper type and grade.

z If the engine does not start or run properly, refer to the following charts to determine the cause
NOTE and identify corrective actions.
z If the cause cannot be determined, contact your DAEDONG dealer for assistance.
 SPECIFICATIONS

SPECIFICATIONS......................................................... 7-2
7

7
7-2 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 rpm 2,800 3,600 2,800 2,600

Maximum bare speed rpm 3,000 3,690 3,000 2,800

Minimun bare idling speed rpm 1,050 1,050 1,050 1,000

Type Vertical, water cooled, 4-cycle diesel engine

Number of cylnders 3

Total displacement cc (cu) 927 (56.6) 927 (56.6) 1,007 (61.5) 1,393 (84.9)

Turbocharger - - - -

Bore and stroke mm (in) Ø 75x70 (2.95x2.76) Ø 75x70 (2.95x2.76) Ø 75x76 (2.95x2.99) Ø 80x92.4 (3.15x3.6)

Method of Combustion Vortex chamber

Compression ratio 22:1 22:1 21:1 22:1

Injection timing BTDC 18° BTDC 24° BTDC 18° BTDC 18°

Injection order 1-2-3

Injection pressure kPa (kgf/㎠) 14710-15690kPa (150~160kgf/㎠)

Intake, exhaust clearance mm Intake: 0.15 Exhaust: 0.15 Intake: 0.25 Exhaust: 0.30

Direction of rotating Counter-clockwise (view from flywheel side)

 SPECIFICATIONS 7-3

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 rpm 2,600 1,800 2,600 2,600

Maximum bare speed rpm 2,800 1,850 2,800 2,800

Minimun bare idling speed rpm 1,000 - 1,000 1,000

Type Vertical, water cooled, 4-cycle diesel engine

Number of cylnders 3

Total displacement cc (cu) 1,500 (91.5) 927 (56.6) 1,647 (100.5) 1,826 (111.4)

Turbocharger - - - -

Bore and stroke mm (in) Ø 83x92.4 (3.3x3.6) Ø 83x92.4 (3.3x3.6) Ø 87x92.4 (3.4x3.6) Ø 102.4x92.4 (4.0x3.6)

Method of Combustion Vortex chamber

Compression ratio 21.7:1 22:1

Injection timing BTDC 18°

Injection order 1-2-3

Injection pressure kPa (kgf/㎠) 14710-15690kPa (150~160kgf/㎠)

Intake, exhaust clearance mm Intake: 0.25 Exhaust: 0.30

Direction of rotating Counter-clockwise (view from flywheel side)

7-4 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 rpm 2,600 2,600 1,800 2,600

Maximum bare speed rpm 2,800 2,800 1,850 2,800

Minimun bare idling speed rpm 1,000 1,000 - 1,000

Type Vertical, water cooled, 4-cycle diesel engine

Number of cylnders 4

Total displacement cc (cu) 1,999 (122.0) 2,197 (134.1) 2,197 (134.1) 2,435 (148.6)

Turbocharger - - - -

Bore and stroke mm (in) Ø 83x92.4 (3.3x3.6) Ø 87x92.4 (3.4x3.6) Ø 87x92.4 (3.4x3.6) Ø 102.4x92.4 (4.0x3.6)

Method of Combustion Vortex chamber

Compression ratio 21.7:1 22:1

Injection timing BTDC 18° BTDC 22°(CTM, main)

Injection order 1-3-4-2

Injection pressure kPa (kgf/㎠) 14710-15690kPa (150~160kgf/㎠)

Intake, exhaust clearance mm Intake: 0.25 Exhaust: 0.30

Direction of rotating Counter-clockwise (view from flywheel side)

 SPECIFICATIONS 7-5

DESCRIPTION UNIT 4A200TLWS 4A220TLWS

POWER(Gross) HP (kw) 50 (37.3) 54 (40.3)

Rated revolution rpm 2,600 2,600

Maximum bare speed rpm 2,800 2,800

Minimun bare idling speed rpm 1,000 1,000

Type Vertical, water cooled, 4-cycle diesel engine

Number of cylnders 4

Total displacement cc (cu) 1,999 (122.0) 2,197 (134.1)

Turbocharger Turbo

Bore and stroke mm (in) Ø 83x92.4 (3.3x3.6) Ø 87x92.4 (3.4x3.6)

Method of Combustion Vortex chamber

Compression ratio 21.8:1 21.1:1

Injection timing BTDC 12° (sub port)

Injection order 1-3-4-2

Injection pressure kPa (kgf/㎠) 14710-15690kPa (150~160kgf/㎠)

Intake, exhaust clearance mm Intake: 0.20 Exhaust: 0.20

Direction of rotating Counter-clockwise (view from flywheel side)

 INDEX

INDEX............................................................................ 8-2
8

8
8-2 디젤엔진

A E
AIR CLEANER (OPTIONAL) .............................................. 5-12 ENGINE IS HARD TO START .............................................. 6-2
ANTI-FREEZE .................................................................... 5-11 ENGINE OIL ......................................................................... 5-4
ENGINE OVERHEATS ......................................................... 6-7
B ENGINE SUDDENLY STOPS RUNNING............................. 6-3
BATTERY (OPTIONAL) ...................................................... 5-12 EXHAUST SMOKE OR DARK EMISSIONS ........................ 6-5
BELT TENSION AND WEAR ............................................. 5-14 EXTERIOR VIEW ................................................................. 2-2
BELT TENSION ADJUSTING ............................................. 5-14
BREAK-IN............................................................................. 4-2 F
FAN BELT ........................................................................... 5-14
C FUEL .................................................................................... 5-2
CHANGING COOLANT ........................................................ 5-8
CHANGING ENGINE OIL..................................................... 5-5 L
CHECK DURING OPERATION ............................................ 3-3 LONG-TERM ENGINE STORAGE..................................... 5-15
CHECKING ENGINE OIL LEVEL ......................................... 5-4 LONG-TERM STORAGE ................................................... 5-14
CHECKING LEVEL, ADDING AND CHANGING LOW ENGINE POWER OUTPUT ........................................ 6-4
COOLANT....................................................................... 5-7
CHECKING THE FUEL LINES ............................................. 5-2 P
CLEANING THE RADIATOR .............................................. 5-10 PERIODIC CHECKS ............................................................ 4-3
PRE-START ENGINE CHECKS .......................................... 3-2
D PRECAUTIONS BEFORE OPERATION .............................. 1-2
DAILY CHECKS ................................................................... 4-2
 색인 8-3

R
RADIATOR (OPTIONAL) ...................................................... 5-7
REPLACING THE FUEL FILTER ......................................... 5-3
REPLACING THE OIL FILTER ............................................. 5-6

S
SERVICING .......................................................................... 2-3
SPECIFICATIONS ................................................................ 7-2
STARTING ........................................................................... 3-2
STARTING AND STOPPING THE ENGINE ......................... 3-2
STOPPING ........................................................................... 3-3

T
THE ENGINE MUST BE STOPPED IMMEDIATELY............ 6-6