RHINO RHINO 2409 User manual

F-3790 Page 1 of 4 2-1-2005
ASSEMBLY MANUAL 2-7227
Keep with Operator’s Manual
LOADER MOUNTING KIT
2409 LOADER
KIOTI DK40 TRACTORS BEFORE S/N 261500001
MODEL FWA ROPS
DK40 BEFORE S/N 261500001 X X
GENERAL INFORMATION
Loader mounting brackets can be installed using tools
ordinarily available, including an overhead hoist with
sling, standard and metric wrenches, and a torque
wrench.
NOTE: Leave all hardware loose until loader is
completely assembled to facilitate alignment. Torque
hardware to specifications listed in loader manual.
TRACTOR PREPARATION
1. Temporarily remove tractor side panels and front
grille to prevent damage during installation of
loader mounting brackets.
2. Loosen lower side panel support by removing two
rear bolts from both left and right side of tractor.
(Retain hardware for later re-use.)
3. Remove all dust plugs from transmission housing
on left and right side of tractor.
4. Remove cap screws securing inspection cover
plate from right side of clutch housing. Leave
original gasket in place. Inspection opening will be
covered by loader mid mounting bracket.
INSTALLING LOADER MOUNTING BRACKETS
1. Install front mounting bracket (3) to tractor frame
using 5/8 x 1-1/2" cap screws (16) and 5/8" lock
nuts (12).
2. Remove 12mm cap screws from tractor side frame
where front of mid mounting bracket is to be
attached to side frame. Install mid mounting
brackets (1 & 2) to clutch housing using 14mm x
35mm cap screws (17) and 9/16" lock washers
(18), and to tractor side frame using 12mm x 60mm
cap screws (19), 1/2" flat washers (15) and 1/2"
lock washers (9).
3. Placing spacer tubes (8) between rear
reinforcement brackets (5 & 6) and rear axle
casting, fasten rear reinforcement brackets (5 & 6)
and spacer tubes (8) to axle casting using 12mm x
60mm cap screws (19) and 1/2" lock washers (9).
Attach cross tie (7) to bottom of mid mounting
brackets (1 & 2) and fasten rear reinforcement
brackets (5 & 6) and cross tie (7) to mid mounting
brackets (1 & 2) using 1/2 x 2" cap screws (13) and
1/2" lock nuts (14).
4. Tighten 14mm hardware to 109ft.·lbs. (148N·m)
torque, and tighten 12mm hardware to 70ft.·lbs.
(95N·m) torque. Refer to general torque
specifications table on page 4 for torque values for
tightening all other hardware.
5. Reinstall and tighten bolts in lower side panel
supports on both sides of tractor.
6. Reinstall tractor side panels and front grille.
INSTALLING LOADER TO MOUNTING BRACKETS
WARNING: To avoid injury during
installation of quick attach loader, do not
permit bystanders within ten feet of loader.
1. Loop chain under each lift cylinder and hook on
loader boom arm. Using overhead hoist to support
loader remove hardware securing loader to pallet.
Lift loader and remove pallet.
CAUTION: Do not damage grease fitting
on end of cylinder. Be sure chain does
not pinch lift cylinder.
2. Using overhead hoist, lower loader from vertical
shipping position to horizontal position leaving
enough room to install yoke (scraps of cardboard
may be used to protect paint). Install yoke
assembly (4) using 3/4 x 2-1/2" cap screws (10)
and 3/4" lock nuts (11). Lower loader completely to
ground.

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2-7227
INSTALLING LOADER TO MOUNTING BRACKETS
(Continued)
NOTE: Tighten hardware connecting yoke to
loader side frames snug but do not torque
completely. After loader has been mounted to
tractor and aligned with mid mounting brackets and
front mounting brackets, tighten hardware to 239-
262ft.·lb. (324-355N·m) torque.
3. Install hose or valve kit to tractor and loader. Refer
to assembly manual provided for installation
instructions.
4. Position tractor close enough so plumbing can be
connected to tractor. Route hoses loosely to allow
maximum reach. Using nylon straps reposition
overhead hoist to loader boom arms near pivot
point to side frames.
5. Operate loader control valve to extend lift cylinders
until front yoke is resting on ground and side frame
uprights will clear front tires. Shut off tractor engine
and engage tractor brakes. Reroute loader hoses
to inside of right mid mounting bracket. Remove
lock nut and washer from loader hinge and swing
each hinge open.
6. Start tractor engine, release tractor brakes and
slowly drive forward while operating lift control
levers to retract lift cylinders. Position loader so
hinges hook over mid mounting tubes. Use of
overhead hoist will facilitate positioning loader into
mid mounting tubes.
IMPORTANT: Position loader uprights so mid
mounting tubes are tight against hinges until loader
has finished rotating so loader front bumper tube
does not hit lower flange of front mounting channel.
7. With tractor in neutral, retract lift cylinders, bringing
side frame up so front yoke tube contacts lower
surface of tractor frame. Move tractor ahead until
front yoke tube engages in front mounting channel
and upright hinges can clamp around mid mounting
tube. Engage tractor brakes and shut off tractor
engine.
8. Clamp hinges to mid mounting tubes with 5/8" flat
washers, 5/8" lock washer and 5/8" hex nuts
(supplied with loader).
IMPORTANT: Be sure to use lock washers and hex
nuts to clamp hinge. Tighten nuts against hinge
securely, but not to more than 125ft.·lb. (170N·m)
torque.
9. Start tractor engine and slowly cycle lift and bucket
cylinders several times to purge air out of system,
then retract cylinders and shut off tractor engine.
Add additional tractor hydraulic fluid as specified in
tractor operator’s manual to bring level of hydraulic
fluid up to full.
INSTALLING BUCKET OR LOADER ATTACHMENT
Refer to instructions provided with bucket or
attachment to install bucket or attachment.
INSTALLING LEVEL INDICATOR
1. Attach indicator guide tube to cylinder pin. Guide
tube is positioned to outside of boom.
2. Slide level indicator rod through guide tube. Attach
other end of rod with 1/8 x 1" cotter pins and 3/8" flat
washers.
3. Locate tractor and loader on level surface. With
bottom of bucket or attachment resting on surface,
cut off excess rod flush with end of guide tube or
paint exposed rod a contrasting color.
IMPORTANT: When installation is complete, check tire
clearances with loader, mounting brackets, and bucket
or attachment. Adjust tractor tread width or steering
stops, if necessary, to provide adequate clearance.
Hinge open
Level Indicator for
Pin-On or Quick-Attach
Buckets or Attachments
Indicator
Guide
Tube Loader Right
Boom Arm
Cotter Pins
Flat Washers
Indicato
r
Rod

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2-7227
10
4
11
19
12
9
3
16
13
7
2
18
17
8
14
15
13
5
14
19
6
9
1
20
8
DO NOT USE FOR TOWING
TOWING HERE WILL PULL FRONT
LOADER SUPPORT OUT OF POCKET
CAUSING DAMAGE AND POSSIBLE
INJURY.
WARNING
39240
PARTS LIST - MOUNTING KIT
Item Part No. Description Qty.
1 51121 BRACKET, Mounting, Mid, Left 1
2 51120 BRACKET, Mounting, Mid, Right 1
3 50366 BRACKET, Mounting, Front 1
4 51137 BRACKET, Loader Front Yoke, with Decals 1
5 51125-2 BRACKET, Rear Reinforcement, Right 1
6 51125-1 BRACKET, Rear Reinforcement, Left 1
7 50382 PLATE, Mid Cross Tie 1
8 43395-8 TUBE, Spacer 4
9 41837-5 WASHER, Lock, 1/2" 8
10 41838-7 SCREW, Cap, 3/4-10 x 2-1/2" 4
11 41840-8 NUT, Lock, 3/4-10 4
12 41840-7 NUT, Lock, 5/8-11 8
13 41838-13 SCREW, Cap, 1/2-13 x 2" 4
14 41840-5 NUT, Lock, 1/2-13 4
15 42502-30 WASHER, Flat, 1/2" 4
16 41838-29 SCREW, Cap, 5/8-11 x 1-1/2" 8
17 42672-48 SCREW, Cap, 14mm-1.50 x 35mm 8
18 41837-6 WASHER, Lock, 9/16" 8
19 42672-49 SCREW, Cap, 12mm-1.25 x 60mm 8
20 39240 DECAL, Warning, Do Not Tow (Included with Item 4.) 2
FIGURE 1
Loader Mounting Kit

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INSTALLATION
INSTRUCTIONS
AMERICAN STANDARD CAP SCREWS METRIC CAP SCREWS
GENERAL TORQUE SPECIFICATIONS
USE THE FOLLOWING TORQUES WHEN SPECIAL TORQUES ARE NOT GIVEN
SAE Grade
Typ. Head
Markings
Metric Class
Typ. Head
Markings
5 8 8.8 10.9
Cap Screw TORQUE TORQUE TORQUE TORQUE
Size FT·LBS N·m FT·LBS N·m FT·LBS N·m FT·LBS N·m
Inches MIN MAX MIN MAX MIN MAX MIN MAX
6.25 7.25 8.5 10 8.25 9.5 11 13
8 9 11 12 10.5 12 14 16
14 15 19 20 18.5 20 25 27
17.5 19 23 26 23 25 31 34
26 28 35 38 35 37 47.5 50
31 34 42 46 41 45 55.5 61
41 45 55.5 61 55 60 74.5 81
51 55 69 74.5 68 75 92 102
65 72 88 97.5 86 96 116 130
76 84 103 114 102 112 138 152
95 105 129 142 127 140 172 190
111 123 150 167 148 164 200 222
126 139 171 188 168 185 228 251
152 168 206 228 203 224 275 304
238 262 322 355 318 350 431 474
274 305 371 409 365 402 495 544
350 386 474 523 466 515 631 698
407 448 551 607 543 597 736 809
537 592 728 802 716 790 970 1070
670 740 908 1003 894 987 1211 1337
MIN MAX MIN MAX MIN MAX MIN MAX
688119111215
16 20 21.5 27 23 27 31 36.5
29 35 39 47 42 52 57 70
52 62 70 84 75 91 102 123
85 103 115 139 120 146 163 198
130 158 176 214 176 216 238 293
172 210 233 284 240 294 325 398
247 301 335 408 343 426 465 577
332 404 450 547 472 576 639 780
423 517 573 700 599 732 812 992
637 779 863 1055 898 1098 1217 1488
872 1066 1181 1444 1224 1496 1658 2027
1/4 - 20
1/4 - 28
5/16 - 18
5/16 - 24
3/8 - 16
3/8 - 24
7/16 - 14
7/16 - 20
1/2 - 13
1/2 - 20
9/16 - 12
9/16 - 18
Cap Screw
Size
Millimeters
M6 x 1.00
M8 x 1.25
M10 x 1.50
M12 x 1.75
M14 x 2.00
M16 x 2.50
M18 x 2.50
M20 x 2.50
M22 x 2.50
M24 x 3.00
M27 x 3.00
M30 x 3.00
5/8 - 11
5/8 - 18
3/4 - 10
3/4 - 16
7/8 - 9
7/8 - 14
1 - 8
1 - 14
Standard American and Metric Cap Screws
NOTE: These values apply to fasteners as received
from supplier, dry or when lubricated with normal
engine oil. They do not apply if special graphite or
molysulphide greases or other extreme lubricants are
used.