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Branson 3015h, Owner'S Manual

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2

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113

42hw-201601

Chapter 2  enGIne

3015r(h)/3515r(h)/4015r(h)/F36r(h)/F42r(h) traCtOr

2

7.3.2 CyLInder BLOCk

Item

Standard

LImIt

nOte

Cylinder bore

L

Ø 88.015 ~ Ø 88.025

Ø 88.20

S

Ø 88.005 ~ Ø 88.015

Cylinder roundness

0.~.0.01

0.03

Cylindricity

0.~.0.015

0.03

7.3.3 vaLve rOCker arm

Item

Standard

LImIt

nOte

Intake & Exhaust 

rocker arm

Rocker arm shaft outer dia.

Ø 15.959 ~ Ø 15.98

Ø 18.95

Rocker arm inner dia.

Ø 19.0 ~ Ø 16.021

Ø 19.09

Oil clearance

0.020.~.0.062

0.14

Pushrod bending

0.03 or less

0.25 or less

-

Tappet

Tappet stem outer dia.

Ø 14.224~Ø 14.249

Ø 14.18

Tappet guide hole inner dia.

Ø 14.260~Ø 14.280

Ø 14.30

Oil clearance

0.011.~.0.056

0.12

Item

Standard

LImIt

nOte

Piston outer dia.

A

Ø 87.965~Ø 87.975

Ø 87.90

C

Ø 87.960~Ø 87.965

Minimum clearance between piston and cylinder block

0.040.~.0.070

-

Top clearance

0.8

-

Piston and piston pin

Piston pin outer dia.

Ø 30.0 ~ Ø 29.991

Ø 29.90

Piston pin hole inner dia.

Ø 30.0 ~ Ø 30.008

Ø 30.02

Oil clearance

0.~.0.017

0.12

7.3.4 pIStOn

Summary of Contents for 3015h

Page 1: ... is highly recommended to use only BRANSON genuine parts which are manufactured under strict quality assurance policy for premium quality durability and reliability BRANSON is always committed to provide best quality products through extensive research study and development Information in this manual is subject to change without notice for improvement of the product Please keep this manual in a sa...

Page 2: ...oughout this manual Make sure to follow such instructions Their design and meanings are as follows MEANINGS OF SAFETY SYMBOLS This symbol indicates potentially hazardous situation which if not observed may result in death or moderate injury DANGER This symbol indicates the most serious hazardous situation which if not observed may result in death or serious injury This symbol indicates potentially...

Page 3: ...al is structured as follows Lower section Upper section CHAPTER 3 CLUTCH 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 3 DISASSEMBLY 3 1 CLUTCH HOUSING REMOVAL 1 Park the tractor on level ground and apply the hand brake 2 Disconnect the negative battery cable 3 Drain the transmission fluid 4 Remove the hood and propeller shaft 5 Disconnect the hydraulic hose wiring connector and various cables bet...

Page 4: ...ication This indicates the publication category and date of this manual Page number Each page is given with the corresponding number Example 3 8 4 Other information The component names used in this manual are set to reflect their functions so they may not be consistent with the ones in other materials such as the part list and user s manual labels and decals Also as the figures and diagrams in thi...

Page 5: ...Table of contents ELECTRIC SYSTEM HYDRAULIC SYSTEM FRONT AXLE TRANSMISSION CLUTCH MEC MODEL ENGINE GENERAL INFORMATION 1 2 3 4 5 6 7 INDEX 8 ...

Page 6: ......

Page 7: ...ngine number 1 16 5 1 4 Hourmeter 1 16 6 Components of tractor 1 17 6 1 Front and rear exterior view 1 17 6 2 Interior view 1 18 7 Tractor specifications 1 20 7 1 Exterior dimensions 1 20 7 2 Major specifications 1 21 7 3 Driving speed 1 23 8 Periodic inspection 1 24 8 1 Periodic maintenance schedule table 1 24 8 2 Inspection Description 1 26 8 2 1 Fueling into fuel tank 1 26 8 2 2 Checking engine...

Page 8: ...ork place should be properly illuminated When working in or under the machine make sure to have a protected lighting equipment 6015W103A CAUTION Have a fire extinguishing system ready in your work place Have a fire extinguisher in your work place DANGER Sufficient ventilation When grinding or sanding a painted surface or working near the exhaust gas pipe the work area should be sufficiently ventil...

Page 9: ...nts and parts 1 1 3 Tool 1 1 2 Working clothes and other safety gears 6015W105A 6015W106A CAUTION Wear proper working clothes to ensure your safety DANGER Have a proper support and lifting equipment ready always 6015W104A Never work on the tractor only with a wood support or other type of block or jack Do not use any lift or crane with insufficient rated load capacity Make sure to wear working clo...

Page 10: ...ative battery cable during in specting the electric system Otherwise It can cause a serious accident 1 1 7 Electric system 6015W110A 1 1 4 Standard parts lubricant grease and oil 6015W107A CAUTION Use only the specified standard parts Otherwise It can shorten the service life and cause an unexpected problem to the vehicle CAUTION Before delivering the machine to your custom er make sure to inspect...

Page 11: ...les away during fueling Keep flammables such as a cigarette match and lighter away from the vehicle during fuel ing Otherwise it can cause a fire leading to a burn K20W150A DANGER Add fuel or oil only after the engine is suffi ciently cooled down Never add fuel or oil while the engine is run ning or hot Otherwise Hot fuel or oil can cause a fire K20W153A K20W152A CAUTION Stop the engine during ins...

Page 12: ...ous types of hazard waste pro duced from the tractor including fuel coolant brake fluid oil filter battery and etc Have harmful waste disposed by a specialized refuse disposal company according to the ap plicable law and regulations K20W155A DANGER Keep flammables away during battery inspection Keep flammables away from the vehicle while checking and charging the battery Otherwise the battery can ...

Page 13: ...R h F42R h TRACTOR 1 14 15 16 12 13 10 11 1 2 3 4 5 6 7 8 9 To ensure safe work check the location of the safety decals and always keep the safety precautions Keep the safety decals intact If any decals is damaged or missing attach a new decal 2 Location of decals F42W105A ...

Page 14: ...rator s manual before operation 2 Before starting the engine make sure that everyone is at a safe distance from the tractor and that the PTO is OFF 3 Do not allow passengers on the tractor at any time 4 Before allowing ohterpeople to use the tractor have them read the operator s manual 5 Check the tightness of all nuts and bolts regularly 6 Keep all shields in place and stay away from all moving p...

Page 15: ...ITION AND STOP THE ENGINE TZE5140000B3 WARNING 8 No TZE5170000B3 TO AVOID PERSONAL INJURY OR DEATH FROM ROLL OVER TZE5170000B3 1 BRANSON recommends the use of a Roll Over Protective Structures ROPS and seat belt in almost all applications 2 Remove the ROPS only when it substantially interferes with operation or itself presents a safety risk Examples include work in orchards and vineyards ALWAYS RE...

Page 16: ...r the structure must be replaced NTE5220000C4 K5FB B 14 No NTE5150000C4 K5FB B Use seat belt NTE5150000C4 12 No TZE4100000B4 MEC MODEL WARNING CONNECT THE LEFT BRAKE WITH RIGHT BRAKE WHILE ON THE ROAD DISCONNECT CONNECT CONNECT ROD TZE4100000B4 13 No TZE5770000B3 7 5 I H C B TO AVOID PERSONAL INJURY OPERATING ON SLOPES 1 If descending a slope never disengage the clutch or shift levers to neutral D...

Page 17: ... bolt Item No grade or 4 T 7T 9 T 8 8 T 10 9 T 12 9 T M6 8 8 0 9 6 4 11 1 1 8 1 9 0 9 5 13 1 3 10 14 1 4 9 M8 20 2 0 14 7 25 2 6 18 4 14 1 4 10 3 23 2 3 17 33 3 3 25 40 2 9 29 M10 42 4 3 30 9 52 5 3 38 3 28 2 9 20 6 45 4 5 33 65 6 5 50 70 7 0 50 M12 68 6 9 50 1 84 8 6 61 9 44 4 5 32 4 80 8 0 60 115 11 5 85 125 12 5 95 M14 120 12 88 5 140 14 103 2 125 12 5 90 180 18 0 133 195 19 5 145 M16 180 18 13...

Page 18: ...and steering oil 34 ℓ 8 98 u s gal 37 ℓ 9 77 u s gal TF500 Texaco TDH oil 1893 Chevron tractor hydraulic fluid Front axle oil 6 4 ℓ 1 69 u s gal SAE 90 Gear oil If the ambient temperature is below 50 F 10 C use diesel fuel for winter season 3 3 Electric device service 1 When disassembling or repairing any part applied with voltage disconnect the negative battery cable first 2 When disconnecting th...

Page 19: ...ng When assembling a snap ring on a shaft or in a hole ensure its sharply angled side to point the direction of force as shown in the first figure When installing a spring pin insert its split portion in the direction to be forced as described in the second figure above 1 2 3 4 When the oil grooves are engaged with the thrust washer be careful with assembly 6 6015W114A Replace the split pin with a...

Page 20: ... any oil and stain left on the surface Never use gasoline Cut the second step of the nozzle so that it can drop beads 3 to 3 5 mm wide Fit the tube to the tool and use this tool to ap ply liquid sealant onto the mating surface 6015W118A Liquid seal ant Cut second step Mating surface 3 3 5 mm CAUTION Spread liquid sealant Otherwise it can leak Apply sealant to the inner side of the attached surface...

Page 21: ...mblem for damage When necessary clean or replace them Follow all the instructions in the Danger Warning and Caution decals Clean the area around the exhaust manifold and engine muffler 4 1 3 Checking when seating on driver s seat Check the brake and clutch pedals Check the parking brake Check the steering wheel 4 1 4 Checking when turning ignition switch Check the function of the lamps and indicat...

Page 22: ... stamped on the left side surface of the rear axle case F42W101A 5 1 4 Hourmeter 5 1 3 Engine number Example TANE0002 The engine number is stamped on the cylinder block and is specified on the decal which is attached to the cylinder block on the left side of the engine Also the decal indicating the engine model and standards is attached on the top of the engine cylinder head cover F42W103A K25W104...

Page 23: ... h F36R h F42R h TRACTOR 1 6 7 8 9 10 5 4 3 1 2 6 Components of tractor 6 1 Front and rear exterior view 1 Head lamp 2 Handle 3 Side step 4 Rear view mirror 5 Turn signal lamp 6 ROPS assembly 7 Combination lamp 8 Top link 9 Draw bar hitch assembly 10 Lower link F42W106A ...

Page 24: ...gnal Light switch 3 PTO ON OFF switch 4 Emergency switch 5 Main switch 6 Accel lever 7 Clutch pedal 8 Brake pedal 9 Accel pedal 10 Parking brake lever 11 Main gear shift lever 12 Position control lever 13 Differential lock pedal 14 Stop valve knob 15 4WD lever 16 Range gear shift lever 17 PTO gear shift lever F42W108A F42W109A MEC MODEL ...

Page 25: ...ing brake lever 3 Turn signal light switch 4 Accelerator lever 5 Cruise switch 6 PTO ON OFF switch 7 Emergency switch 8 Main switch 9 HST pedal Forward 10 HST pedal Reverse 11 Position control lever 12 Stop valve knob 13 4WD lever 14 Parking brake lever 15 Range gear shift lever 16 Seat adjust lever 17 PTO gear shift lever HST MODEL ...

Page 26: ...tor specifications 7 1 Exterior dimensions Size mm in Model A B C D E F G 3015R h 3515R h F36R h 2 614 102 9 1 671 65 79 3 426 134 88 306 12 05 1 151 45 31 1 151 45 31 1 431 56 34 4015R h F42R h 2 643 104 06 1 671 65 79 3 426 134 88 335 13 19 1 201 47 28 1 165 45 87 1 451 57 13 E F G A D B C F42W107A ...

Page 27: ...e crankcase ℓ u s gal 4 3 1 14 Coolant ℓ u s gal 5 0 1 32 Transmission case ℓ u s gal MEC MODEL 34 8 98 HST MODEL 37 9 77 Front axle ℓ u s gal 6 4 1 69 Dimension Overall length mm in with F weight 3 426 134 88 Overall width mm in 1 431 56 34 1 451 57 13 Overall height mm in 2 614 102 9 2 643 104 06 Wheel base mm in 1 671 65 79 Min ground clearance mm in 306 12 05 335 13 19 Tread Front mm in 1 151 ...

Page 28: ... control Pump flow capacity LPM 52 3 point hitch CAT 1 Max lift force at lifting point kg 1 500 PTO PTO hydraulic Ø 35 mm 6 splines Revolution rpm 1st 560 2nd 780 Draft system Pin mounting type Driving speed Forward km h MPH MEC MODEL 1 2 22 6 0 7 14 1 HST MODEL 0 29 27 0 18 18 MEC MODEL 1 22 23 69 0 76 14 72 HST MODEL 0 30 7 0 19 07 Reverse km h MPH MEC MODEL 1 1 21 5 0 7 13 4 HST MODEL 0 29 27 0...

Page 29: ... 0 2 9 3 7 4 6 6 0 8 8 11 4 14 1 0 76 1 10 1 43 1 76 2 06 3 01 3 90 4 81 6 31 9 20 11 94 14 72 1 1 1 6 2 1 2 6 3 0 4 4 5 7 7 0 9 2 13 4 17 4 21 5 1 16 1 69 2 19 2 70 3 16 4 60 5 97 7 37 9 66 14 09 18 27 22 54 0 7 1 0 1 3 1 6 1 9 2 7 3 6 4 4 5 7 8 4 10 9 13 4 0 72 1 05 1 36 1 68 1 96 2 86 3 71 4 58 6 00 8 76 11 35 14 01 MEC MODEL Shift position Speed Forward AND REVERSE TIRE SIZE RANGE SHIFT km h M...

Page 30: ...ansmission fluid R 4 Transmission fluid filter R HST filter 5 Front axle fluid R 6 Radiator cleaning CL At the time the coolant is replaced 7 Fuel oil filter and element C R 8 Coolant R Check before every work Replace every year 9 Air cleaner element CL R R 10 Fan and radiator cleaning CL 11 Battery solution R Replace every two years 12 Battery specific gravity C 13 Fuel pipe and connection C R 14...

Page 31: ...es C 21 Tightening bolts Nuts C 22 Cooling fan belt A 23 Clutch MEC MOEDL A 24 Brake A 25 Engine breed pipe C 26 Engine crankcase cleaning CL 27 Intake exhaust valves C 28 Fuel injection valve C 29 Generator motor C 30 Hydraulic system C Meanings of symbols R Replace C Check A Adjust CL Clean Inspection should be done every 50 hours If the tractor is not used much inspect every year Replace parts ...

Page 32: ... and watch out for any smoke or flame around Make sure to fuel only with the engine stopped F42W111A CAUTION Make sure that no dust enters the fuel filler hole If the fuel tank becomes empty air may en ter the fuel system causing an engine start ing problem Add fuel to the tank before it be comes empty When fueling be careful not to spill it If spilled wipe it out thoroughly After daily work top u...

Page 33: ...o check the oil level and oil condition The oil level should be between the min and max lines and the oil color should not be too dark or too light If not normal add engine oil up to the max line on the dipstick Refer to 8 2 8 Changing engine oil in this chapter 1 2 3 4 5 WARNING Never mix different types of oil but use the only engine oil specified by BRANSON SAE 15W 40 Final Tier4 grade CJ or hi...

Page 34: ... Cleaning radiator dust grill Check the front of the hood or side grill for dust and clean them accordingly Open the hood and unscrew the fix bolt 1 and then pull out the dust grill 2 to sideway to remove Then remove dust from the dust grill 1 2 CAUTION Check and clean the dust grill after stopping the engine CAUTION Clean the grille and dust grill to prevent the engine from overheating and let su...

Page 35: ...ghten it to 50 N m 37 lb ft Add clean oil with proper viscosity to the crankcase 1 2 3 F42W118A CAUTION Make sure to stop the engine before chang ing engine oil Make sure that the engine is sufficiently cooled down enough to touch by a hand F42W120A 5 Run the engine for a while and check the oil filler hole 3 and drain plug for oil leakage Specified amount of engine oil 4 3 ℓ 1 14 u s gal Lubrican...

Page 36: ...y hand Start the engine and check the filter base for oil leakage Stop the engine and check the oil level If the level is too low add more oil 1 2 3 4 5 6 CAUTION Be sure to use the only BRANSON genuine oil filter not to damage the engine Replace the oil filter only after the engine is stopped and cooled down 8 2 10 Replacing HST filter HST MODEL Turn the filter element 1 counterclockwise to remov...

Page 37: ... Replace the transmission fluid hydraulic oil filter element 2 Before adding clean oil replace the seal and tighten the drain plug to 5 kg m 36 lb ft 5 6 8 2 11 Replacing transmission hydraulic filter Remove the filter element 1 by unscrewing it Apply clean oil onto the seal ring of a new filter element and tighten this filter element Start the engine and check the filter base for fuel leakage Sto...

Page 38: ... for a moment to activate the hydraulic pressure function Stop the engine 7 8 Transmission fluid hydraulic oil amount MEC MODEL 34 ℓ 8 98 u s gal HST MODEL 37 ℓ 9 77 u s gal Check that the clutch pedal moves by itself when depressing it slightly and releasing it UHH SOD 1 F42W127A F42W128A Make sure that the machine is parked on level ground Depress the clutch pedal 1 slightly and then release it ...

Page 39: ...ck nut F42W130A 8 2 15 Adjusting fan belt tension Stop the engine remove the ignition key and apply the parking brake Check the tension of the fan belt 1 Loosen the tension adjusting bolt 2 Place a stick or pipe between the alternator 3 and cylinder block Push the alternator outwards to adjust the fan belt tension Tighten the adjusting bolt 1 2 3 4 5 6 CAUTION Stop the engine before adjusting the ...

Page 40: ...witch to crank the engine Then check if fuel flows through the bleeding bolt If fuel without bubbles flows out stop cranking the engine and tighten the bleeding bolt com pletely If the engine is still hard to be started loos en one to two nozzle holders and crank the en gine to bleed the system 8 2 17 Cleaning air cleaner element Open the air cleaner cover 1 and pull out the air cleaner element 1 ...

Page 41: ...en it can explode Heat the battery to 16 C 60 F before charging it The battery cannot be charged when the en gine speed is below 1 000 RPM It can be charged with the engine running at 1 500 RPM or higher speed F42W135A 8 2 19 Checking radiator and intake hoses Check the condition of the air intake hose 1 and radiator hose 2 every six months or 200 hours of use whichever comes first Check the hose ...

Page 42: ... 2 Check the target positions and apply a proper amount of grease on them before beginning your work Make sure to apply grease on them especially after working in a wet field Grease applied components Front Back of front axle bracket 1 Left Right of front axle 2 Left Right of brake rod 3 Lift link and more 4 F42W141A F42W139A F42W142A F42W140A F42W143A ...

Page 43: ...F42W146A 8 2 21 Adding anti freeze If the tractor is equipped with a cabin turn the heater control dial to the right end To release pressure unscrew the radiator cap 1 slightly Then unscrew it completely To collect coolant place a container under the drain hole 1 2 3 CAUTION Never remove the cap when the coolant tem perature is over the boiling point To release pressure unscrew the radiator cap 1 ...

Page 44: ...are Fuse 7 10 A Spare Fuse 8 5 A Spare Fuse 9 20 A Head lamp Fuse 10 20 A Turn signal lamp Fuse 11 10 A Hazard lamp Fuse 12 10 A PTO Fuse 13 10 A Stop solenoid MEC MODEL Cruise HST MODEL Fuse 14 5 A DPF 3015R 3515R 4015R A fuse is to protect circuits from electric overload The relay control current is high load current which flows through a circuit To prevent damage to the electric system never us...

Page 45: ...ure wear If it is excessive it can reduce traction and increase wheel slip The specified tire pressure is different not only by working environment and load but also by tractor models Make sure to follow the specified standard inflation pressure set in this manual 1 2 3 Standard Front wheel 2 0 kg cm2 28 44 psi Rear wheel 1 3 kg cm2 18 49 psi With loader Front wheel 3 0 kg cm2 42 67 psi Rear wheel...

Page 46: ...ter initial 4 and 8 hours of operation Then check tightness of the bolts every 100 hours of use F42W150A Item Torque value Front wheel Hub bolt 18 20 kg m 130 144 lb ft 176 196 N m Rim disc mounting bolt 22 24 kg m 158 173 lb ft 216 235 N m Rear wheel Hub bolt 1 17 21 kg m 122 151 lb ft 167 206 N m Rim disc mounting bolt 2 17 21 kg m 122 151 lb ft 167 206 N m ...

Page 47: ...cification 2 21 4 4 1 DPS sensor 2 21 4 4 2 EGTS Sensor Exhaust Gas Temperature Sensor 2 22 4 4 3 DPF Check LED Lamp 2 24 4 4 4 CAN communication 2 27 4 4 5 PC RS232 communication Low speed data download and Reprogram 2 29 4 4 6 PC USB2 Communications high speed data download 2 30 4 4 7 RTC Real Time Check power supply Warranty for 5 years 2 30 4 5 Note 2 31 4 5 1 Running temperature range 2 31 4 ...

Page 48: ...3 7 Gears 2 83 6 4 The engine assembly 2 84 6 4 1 Caution before assembling the engine 2 84 6 4 2 Cylinder block 2 84 6 4 3 Crankshaft 2 84 6 4 4 Piston and Connecting rod 2 85 6 4 5 Gear case flange 2 86 6 4 6 Oil pump 2 86 6 4 7 Camshaft 2 87 6 4 8 Injection pump 2 87 6 4 9 Idle gear 2 88 6 4 10 Gear case 2 89 6 4 11 Frame and oil suction pipe 2 89 6 4 12 Oil pan 2 89 6 4 13 Oil seal housing 2 8...

Page 49: ...ylinders 3 Bore Stroke mm 88 94 Displacement cc 1 715 Combustion System IDI Indirect Injection Intake System Natural Aspirated Turbo charged Horse Power kW HP 22 30 25 7 35 29 4 40 Compression Ratio 21 3 1 Direction of Rotation CCW from Flywheel Side Cooling System Pressurized Radiator Lubricant Capacity ℓ 4 3 Starter V kW 12 2 2 Alternator V A 12 50 Dimension L W H mm 690 527 911 Specifications c...

Page 50: ...2 42hW 201601 CHAPTER 2 ENGINE 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 1 2 Engine dimensions F42W221A A1700T2 F42W222A A1700N4 N5 3015R h 3515R h 4015R h ...

Page 51: ...2 42hW 201601 CHAPTER 2 ENGINE 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 2 F42W223A A1700T2 F42W224A A1700N4 F36R h F42R h ...

Page 52: ...Fuel injection pump 6 Alternator 7 After treatment device 3015R h 3515R h 4015R h 8 DP sensor 3015R h 3515R h 4015R h 9 Starter motor 10 Flywheel 11 Turbo chager The pictures show the locations of the major external engine components the filters and other service and maintenance points Some external components will be at different locations for different engine models The pictures are only a refer...

Page 53: ...lues and enforcement time are different by each power category In U S the EPA emissions regulations must be satisfied 1 4 1 EPA emissions regulations value in U S Output kW Emissions regulations NOx NMHC CO PM 19 37 Final Tier 4 4 7 5 0 0 03 Unit g kW hr 1 4 2 The emissions certificate decal and attached location F42W226A The engine which is exported to the U S EPA area attach the following decal ...

Page 54: ...EL INJECTION QUANTITY AND ROTATION RESTRICTION DO NOT RELEASE EPA certificate engine attach seal cap in injection quantity control device and removing the seal cap to change the injection quantity by final buyer is illegal If the fuel adjusting devices need to re adjust make sure that emission and engine performance are the same level as the certificate values NOTE MAKE SURE TO MAINTAIN Based on l...

Page 55: ...uel level and refill Clean the fuel tank Check the fuel filter and hose related coolant Replace the fuel filter element Fuel injection valve Pressure check adjustment Fuel injection pump Adjust injection timing Lubricating system Check the lubricating oil level Replace the lubricating oil 1st time Replace the lubricating oil filter 1st time Coolant system Check the coolant level Check the clogging...

Page 56: ...nfavorable conditions than gasoline engine so should be used the proper oil If defective oil is used or lubricating oil is not changed regularly accelerated wear of moving components and engine life may be seriously shortened Oil viscosity grade use the class SAE 15W 40 above API CJ 4 level Final Tier4 or above API CG 4 level StageⅢA Please refer to next graphic and use the proper oil K25W229A Bef...

Page 57: ...lue 40 48 and use a lower viscosity at low temperature K25W231A After purchasing fuel OORZ GUXP WR VWDQG a GD V After 3 4 days 3XW D VXFWLRQ SLSH KDOIZD LQWR WKH GUXP DWHU DQG GXVW DFFXPXODWH LQ WKH ORZHU SRUWLRQ RI WKH GUXP K25W232A The contaminated fuel can be a cause of starting failure and the engine will emit bluish white exhaust The fuel that contains water and dust can cause a serious failu...

Page 58: ...ter such as tap water etc Hard water such as well water causes scale deposits on the coolant system This reduces the cooling efficiency and raises the coolant temperature too high causing seizures between the piston and the liner Use an anticorrosive for prevent rot at summer season and use a coolant for prevent freezing at winter season The anti freezing liquid to dilute to 40 60 based on the qua...

Page 59: ...l filter Replace the lubricating oil and oil filter every 250 hrs after replacing it at first 50 hrs 2 Check cleaning the radiator pin 3 Cleaning the air cleaner 4 Check the tension of the V belt 2 2 8 Check every 500hrs 1 Replace the fuel filter Replace the fuel filter every 500 hrs after replacing it at first 50 hrs 2 Replace the air cleaner elements 2 2 9 Check every 1 000hrs 1 Check correct th...

Page 60: ...ch and terminal of motor Correction 3 Gearing failure of pinion and ring gear Correct or replace the pinion 4 Starter failure Correction or replace 5 Tightening failure of batteries code connection area Re tighten Pinion not engages with ring gear and does rotate 1 Starter installation failure Re installation 2 Failure of plunger dimensions adjustment Correction 3 Pinion sleeve spring failure Repl...

Page 61: ...f the accelerator lever Correct acceleration lever and cable 2 Air inhalation in injection pump Air bleeding 3 Injector failure Correction or replace 4 Injection timing failure Correction 5 Injection pump failure Correction or replace Engine power output low 1 Improper valve clearance Correction 2 Adhesion failure of the valve Check the valve and valve sheet 3 Cylinder head gasket gas leak Replace...

Page 62: ...shing or replace the crankshaft 3 Seizure of metal Replace the metal or polishing the crankshaft Connecting rod metal 1 Wearing to crankshaft pin metal Replace the metal 2 Wearing to crankshaft pin Replace the crankshaft 3 Bending to connecting rod Correction or replace 4 Seizure of crankshaft pin metal Replace the metal or polishing the crankshaft 5 Oil supply shortage by clogging the oil line Cl...

Page 63: ...sket Replace Lubricating oil consumption excessive Oil up 1 Cylinder and piston excessive clearance Replace 2 Wearing to piston ring ring groove Replace the piston ring 3 Inappropriate piston ring setting inlet location Correct the location 4 Clogging the air breather Clean up 5 Excessive refill of lubricating oil Correction Oil Down 1 Loosing the valve stem and valve guide Replace 2 Cylinder head...

Page 64: ...lace the appropriate oil 6 Engine temperature is low Warm up Smoke excessive White exhaust smoke 1 Injection timing is late Correction 2 Compression pressure is low Correction 3 Water inhalation in fuel Replace 4 Air intake quantity shortage Correction 5 Lubricating oil enter into the combustion chamber Correction Black exhaust smoke 1 Injection timing is too late Correction 2 Becoming overload Co...

Page 65: ...f accumulating SOOTs continuously engine back pressure becomes higher and then come into critical situation To avoid this situation the lamp will be running to know you what remove SOOT from DPF Thus DPF Data Logger is available for logging temperature and pressure of DPF and running lamp in each critical situation 4 2 DPF Data Logger 4 2 1 Installation It can be operated the date in initial insta...

Page 66: ...50mA 5V 0 2V DPS Sensor 0 5V EGTS Sensor 1 Kohm pull up in logger CAN Communication CAN low high to communicate with scanner 250Kbps for DPF status check RS232 communication Communication to download data stored in DPF data logger or to reprogram and check DPF condition LED Lamp Warn the DPF conditions working 1 Amp 4 3 2 Hardware block diagram of DPF data logger 4 3 Features Input Output 4 3 1 Da...

Page 67: ...NTRODUCTION Check the pressure difference between DPF inlet and outlet to measure the collected SOOTs CIRCUIT 6 16B 1 5 5 5 Nവ Q 9 5T 5 Nവ UIL UIL Q K25W236A TABLE 6XSSO YROWDJH 9FF 2XWSXW VLJQDO URXQG 7R LJK GLDJQRVWLFV NOMINAL OUTPUT CHARACTERISTICS OUTPUT Vcc DIFFERENTIAL PRESSURE kPaD s LJK FODPS 7R RZ GLDJQRVWLFV K25W237A ...

Page 68: ...e 5V 10 3 How to check 1 Turn off ignition switch 2 Separate pressure sensor from connector 3 Separate hose from pressure sensor 4 Loosen bolts and separate pressure sensor from car 4 DPS sensor installation torque 1 0 1 2 kgf m 4 4 2 EGTS Sensor Exhaust Gas Temperature Sensor INTRODUCTION Check the temperature of the exhaust gas from DPF and data logger records the temperature of the exhaust gas ...

Page 69: ...cc Open Ground of Sensor 95 Vcc Open Signal and Ground 95 Vcc Short Signal to Ground 5 Vcc PART CHECK EGTS 1Kohm D1 H4 1 2 1 2 5V Logger K25W241A 1 SCANNER 1 DIAGNOSTIC 4 Engine 1 DPF Logger 1 Self check 10 Exhaust gas Temperature Voltage 11 Exhaust gas Temperature Voltage 2 How to check 1 Turn off ignition switch 2 Separate EGTS sensor from connector 3 Measure resistance at normal temperature by ...

Page 70: ...hW 201601 CHAPTER 2 ENGINE 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 4 4 3 DPF Check LED Lamp INTRODUCTION Check lamp to show the DPF conditions CIRCUIT 1 RDG 7 R K25W242A WIRING L 2 Logger IG KEY K25W243A ...

Page 71: ...1 DPF Logger 2 Change setting 1 DPS Warning Pressure F1 Increase or F5 Decrease Setting2 emergency pressure time setting only super user can set using scanner SCANNER 1 DIAGNOSTIC 4 Engine 1 DPF Logger 2 Change setting 2 DPS Warning Time F1 Increase or F5 Decrease Setting3 emergency exhaust temperature setting only super user can set using scanner SCANNER 1 DIAGNOSTIC 4 Engine 1 DPF Logger 2 Chang...

Page 72: ...p driving even though lamp blinks Continuous CAUTION 1 Go to service shop for a inspection when lamp blinking 2 Check sensor in service shop Every 0 5 sec CHECK 1 Go to service shop for a inspection when lamp blinking 2 Carry out a cleaning of DPF Every 2 0 sec DPF Cleaning DPF check lamp blinking in every 2 seconds indicates that engine operation hour exceed setting value to make alarm for DPF cl...

Page 73: ...INTRODUCTION A circuit connecting to scanner which helps check a condition of DPF and repair CIRCUIT 5 7 9 9 w 5 വ Q 7 5 5 9 5 K25W245A WIRING CAN tranceiver TLE 6250 120 ohm SCANNER HIGH LOW G 2 G 1 CAN 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 SCAN TOOL SIDE CONN 0 5 0 5 6 14 Logger OBDII connector K25W246A ...

Page 74: ...erminal in IG key off or on 2 Ignition key on 3 Press a power button on scanner 4 SCANNER 1 DIAGNOSTIC 4 Engine 1 DPF Logger 1 Auto check 5 It indicates an error between Logger and CAN communication when displaying 00 value on data list 6 Call customer service department for inspection of scanner if communication is not running ...

Page 75: ...to USB Interface module to PC and start to download HEX file when turn IG_KEY ON while running reprogram execution file provided 4 USB1_CONNECT Signal to detect connecting RS232 to USB I F module from external 5 Data Download from Logger Select downloading times to setting key among 2 second 10 secod 60 second because it needs about 19 hours to download at a speed of 115200BR 115200 8 N 1 WIRING 9...

Page 76: ...power supply USB2 ground USB2_POSI USB2_NEG for high speed download in option and it does not connect to wire harness 3 Communication speed 1GB data will take 200 seconds to download with a speed of 12megaBR Using extra logger connecter Wiring U S B FT245RL PC B2 C2 A3 B4 USB USB USB 5 V Logger K25W248A 4 4 7 RTC Real Time Check power supply Warranty for 5 years RTC power supply Warranty for 5 yea...

Page 77: ...CHAPTER 2 ENGINE 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 2 4 5 Note 4 5 1 Running temperature range 40 C 105 C 4 5 2 Case Water proof case 4 6 Warranty 4 6 1 We guarantee DPF data logger for 5 years after shipment ...

Page 78: ...Block cylinder 3 Bearing cap 1 4 Bearing cap 2 5 Bolt bearing cap 6 Spring pin 7 Plug 30 8 Plug 12 9 Plug 50 10 Plug pt 1 4 11 Plug pt 3 8 12 Plug block heater 13 Bush cam shaft 14 Bearing ass y main std 15 Packing 16 Bolt 8 12 17 Bearing ass y thrust 20 Gasket head 21 Bolt head cylinder 23 Plug pt 1 8 27 Bolt head cylinder 28 Pin oil COMPONENTS a1700n4_etr a1700n4_utr_4 ...

Page 79: ... cap 1 4 Bearing cap 2 5 Bearing cap bolt 6 Spring pin 7 Sealing plug Ø30 8 Plug Ø12 9 Plug Ø50 10 Tapper plug pt 1 4 12 Plug block heater 13 Bush cam shaft 14 Main bearing ass y 17 Thrust bearing ass y 20 Head gasket 21 Cylinder head bolt long 23 Tapper plug pt 1 8 27 Cylinder head bolt short 28 Pin oil COMPONENTS a1700t2_etr a1700t2_utr_4 ...

Page 80: ... 4 Gear case ass y 5 Gear case 6 Oil seal 7 Lub oil filler cap 8 O ring 9 Cover 10 Packing 11 Knock pin 12 Stud bolt 14 Copper packing Ø8 16 O ring 18 Flange nut M8 19 Bolt M8 X L16 20 Flange bolt M8 L22 21 Flange bolt M8 L60 22 Flange bolt M8 L90 23 Flange bolt M8 L85 24 Flange bolt M8 L50 32 O ring COMPONENTS a1700n4_etr a1700t2_etr a1700n4_utr_4 a1700t2_utr_4 ...

Page 81: ... 3 Flange bolt M8 X L25 4 Oil pan 5 Lub oil drain plug M14 6 O ring 7 Lower cover 8 Knock pin 9 Flange bolt M8 L12 10 Flange bolt M8 L50 11 Flange bolt M8 L100 12 Flange bolt M8 L120 13 Oil seal housing ass y 14 Oil seal housing 15 Oil seal 16 Flange bolt M8 L30 17 Magnet 18 Flange bolt M10 L25 COMPONENTS a1700n4_etr a1700t2_etr a1700n4_utr_4 a1700t2_utr_4 ...

Page 82: ...Cap valve 19 Shaft ass y rocker arm 20 Support A 21 Support B 22 Spring rocker arm 23 Shaft rocker arm 24 Rocker arm 25 Screw valve 26 Nut adjusting 27 Screw stop 8 10 28 Circlip 29 Bolt stud 30 Washer 12 31 Cover head 32 Packing head cover 33 Cap bonnet 34 O ring P 35 Screw 4 10 36 Cover breather 37 Valve pressure relief 38 Gasket breather 39 Plate breather adjusting 40 Tube breather 41 Hose pali...

Page 83: ...y rocker arm 20 Support A 21 Support B 22 Spring rocker arm 23 Shaft rocker arm 24 Rocker arm 25 Screw valve 26 Nut adjusting 27 Screw stop 8 10 28 Circlip 29 Bolt stud 30 Washer 12 31 Cover head 32 Packing head cover 33 Cap bonnet 34 O ring P 35 Screw 4 10 36 Cover breather 37 Valve pressure relief 38 Gasket breather 39 Plate breather adjusting 40 Tube breather 41 Hose palin 42 Clip hose 20 43 Oi...

Page 84: ...INE 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 5 5 Intake manifold K25W2A64A 1 Manifold int 2 Packing manifold int 3 Bolt flange 8 x 30 4 Bolt stud 8 x 35 5 Nut hexagon flange 8 Tube breather COMPONENTS a1700n4_etr a1700n4_utr_4 ...

Page 85: ...ER 2 ENGINE 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 2 F42W204A 1 Manifold int 2 Packing manifold int 3 Bolt flange 8 x 30 4 Hose c suc 5 Clip hose 48 6 Clip hose 70 8 Plug pt 3 8 10 Nut flange 8 COMPONENTS a1700t2_etr ...

Page 86: ... 3515R h 4015R h F36R h F42R h TRACTOR F42W205A 1 Intake manifold 2 Packing intake manifold 3 Flange bolt M8 x L30 4 Flange nut M8 5 Intake pipe 6 Gasket intake pipe 7 Intake hose 8 Flange bolt M8 x L16 9 Hose clip Ø48 COMPONENTS a1700t2_utr_4 ...

Page 87: ...E 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 2 5 6 Exhaust manifold a1700n4_utr_4 4 K25W2A66A 1 Manifold exhaust 2 Gasket exh Manifold 3 Bolt stud 4 Nut flange 8 5 Bolt flange 8 x 80 6 Bolt stud 8 x 22 7 Gasket silencer COMPONENTS ...

Page 88: ...ACTOR F42W206A 1 Manifold exhaust 2 Gasket exh Manifold 3 Nut flange 8 4 Bolt flange 8 45 5 Bolt stud 8 50 6 Bolt flange 8 80 7 Gasket silencer 8 Silencer exhaust 9 Nut flange 8 10 Pin spring 11 Bolt flange 8 x 16 12 Bolt flange 8 40 13 Bolt stud 8 x 22 COMPONENTS a1700n4_etr ...

Page 89: ...W207A 1 Manifold exhaust 2 Gasket exh Manifold 3 Nut flange 8 4 Bolt stud 8 x 40 5 Bolt flange 8 65 6 Bolt flange 8 80 7 Bolt stud 8 x 22 8 Gasket T C in 9 Turbo charge 10 Gasket T C out 11 Bolt stud 8 x 22 12 Silencer exhaust 13 Bolt flange 10 x 16 14 Plug pt 1 4 COMPONENTS a1700t2_etr ...

Page 90: ...TOR F42W208A 1 Exhaust manifold 2 Gasket exhaust manifold 3 Flange nut M8 4 Flange bolt M8 x L65 5 Flange bolt M8 x L95 6 Stud bolt M8 x L65 7 Tapper plug pt 1 4 8 Turbo charger 9 Gasket turbo charger in 10 Stud bolt M8 x L22 11 Gasket turbo charger out COMPONENTS a1700t2_utr_4 ...

Page 91: ... gear 5 Sliding key 6 Thrust bearing camshaft 7 Hex flange bolt 8 Idle gear shaft 9 Idle gear assembly 10 Bushing idle gear 11 Bolt idle shaft 12 Fuel injection pump gear 15 Spring washer 16 Hex nut 17 Packing 18 Hydraulic pump gear cover 19 Hydraulic pump drive gear assembly 20 Ball bearing with deep groove COMPONENTS a1700n4_etr a1700t2_etr a1700n4_utr_4 a1700t2_utr_4 ...

Page 92: ...lley 8 14 Bolt V pulley 15 Bolt fly wheel 16 Fly wheel ass y single 3cyl 17 Fly wheel single 3cyl 19 Gear ring 20 Bearing ball 6302 21 Piston ass y 22 Piston 23 Piston ring ass y 24 Piston ring 1st 25 Piston ring 2nd 26 Piston ring oil 27 Pin piston 28 Ring ratainer 29 Connecting rod ass y 30 Connecting rod 33 Bush piston pin 34 Bolt connecting rod 35 Bearing crank pin COMPONENTS a1700n4_etr a1700...

Page 93: ...ew hexagon head cap 15 Oil filter 16 Oil cooler 17 Bolt oil cooler 18 Space oil cooler 19 Oil pressure control valve 20 Bracket oil filter 21 Packing oil filter 22 O ring 23 Flange bolt M8 x L20 24 Bracket oil cooler 25 Flange bolt M6 L12 26 Oil suction pipe 27 Packing oil suction pipe 28 Flange bolt M8 x L35 29 Flange bolt M8 x L16 34 Guide dipstick 36 Dipstick 37 Oil pressure switch COMPONENTS a...

Page 94: ...Connecting hose 13 90 Elbow 14 Hose clip Ø20 15 Oil filter 16 Oil cooler 17 Bolt oil cooler 18 Space oil cooler 19 Oil pressure control valve 20 Bracket oil filter 21 Packing oil filter 22 O ring 23 Flange bolt M8 x L20 24 Bracket oil cooler 25 Flange bolt M6 L12 26 Oil suction pipe 27 Packing oil suction pipe 28 Flange bolt M8 x L35 29 Flange bolt M8 x L16 30 Nozzle jet 31 Check valve 32 Copper p...

Page 95: ... x L18 12 Connecting hose 13 90 Elbow 14 Hose clip Ø20 15 Oil filter 16 Oil cooler 17 Bolt oil cooler 18 Space oil cooler 19 Oil pressure control valve 20 Bracket oil filter 21 Packing oil filter 22 O ring 23 Flange bolt M8 x L20 24 Bracket oil cooler 25 Flange bolt M6 L12 26 Oil suction pipe 27 Packing oil suction pipe 28 Flange bolt M8 x L35 29 Flange bolt M8 x L16 30 Nozzle jet 31 Check valve 3...

Page 96: ...stat 7 Flange bolt M8 L18 8 Copper packing Ø16 9 Sensor glow plug 10 Copper packing Ø10 11 Coolant temp Sensor 12 Flange bolt M8 L60 13 Flange bolt M8 L55 14 V pully 15 V belt 16 Spacer cooling fan 17 Flange bolt M8 L35 18 Taper plug pt 3 8 19 Cooling hose A 20 Cooling hose B 21 90 Elbow 22 Hose clamp Ø25 23 Hose clamp Ø22 24 Joint pt 1 4 COMPONENTS a1700n4_etr a1700t2_etr a1700n4_utr_4 a1700t2_ut...

Page 97: ...R 2 5 11 Fuel injection pump K25W2A71A 1 Fuel injection pump ass y 2 Support 3 Hook 4 E type retaining ring 5 Bracket pump A 6 Bracket pump B 7 Screw hexagon head cap 8 Bolt flange 8 x 16 9 Nut flange 10 Key woodruff COMPONENTS a1700n4_etr a1700t2_etr a1700n4_utr_4 a1700t2_utr_4 ...

Page 98: ... assembly 10 Bracket fuel pipe 11 Bracket rubber fuel pipe 12 Bracket plate 13 Fuel pipe assembly A 14 Fuel pipe assembly B 15 Fuel pipe assembly C 16 Fuel pipe assembly D 17 Return pipe assembly 18 Packing joint 19 Hex mounting nut 22 Return hose 23 Hose clip 24 Joint 25 Hex flange nut COMPONENTS a1700n4_etr a1700t2_etr a1700n4_utr_4 a1700t2_utr_4 ...

Page 99: ...ER 2 ENGINE 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 2 5 13 Fuel system F42W213A 1 Fuel filter ass y 2 Bracket fuel filter 3 Bolt flange 4 Bolt flange 5 Hose fuel ass y 6 Hose clip Ø13 COMPONENTS a1700n4_etr a1700t2_etr ...

Page 100: ...TER 2 ENGINE 3015R h 3515R h 4015R h F36R h F42R h TRACTOR F42W214A 1 Fuel filter ass y 2 Bracket fuel filter 3 Flange bolt M8 x L16 4 Flange bolt M8 x L16 5 Fuel hose 6 Hose clip Ø13 COMPONENTS a1700n4_utr_4 a1700t2_utr_4 ...

Page 101: ...TER 2 ENGINE 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 2 F42W219A 1 Starter 2 Stud bolt M12 x L30 3 Spring washer 4 Nut M12 5 Caution plate 5 14 Start motor COMPONENTS a1700n4_etr a1700t2_etr a1700n4_utr_4 a1700t2_utr_4 ...

Page 102: ...36R h F42R h TRACTOR K25W2A53A 1 Alternator 12V 45A 1 Alternator 12V 70A 36 Bolt 10 36 Bolt 8 37 Nut 10 37 Nut 8 38 Bracket 39 Washer 41 Washer lock 42 Washer 42 Washer 43 Plug thermostart 44 Connector 49 Bolt 8 30 5 15 Alternator and electric system COMPONENTS ...

Page 103: ...5R h 4015R h F36R h F42R h TRACTOR 2 F42W215A 1 Dpf 2 Dpf supprort A 3 Nut flange 8 4 Stud bolt 5 Gasket 6 Bolt flange 7 Dpf supprort B 8 Bolt flange 9 Dpf bracket 10 Bolt flange 11 Bolt flange COMPONENTS 5 16 DPF application system a1700n4_utr_4 ...

Page 104: ...6R h F42R h TRACTOR F42W216A 1 Dpf system 2 Dpf fixed housing 3 Stud bolt M8 x L25 4 Gasket 5 Flange nut M8 6 Flange bolt M8 x L20 7 Dpf support 8 Flange bolt M10 x L30 9 Dpf fixed bracket 10 Flange bolt M8 x L25 11 Flange bolt M8 x L16 COMPONENTS a1700t2_utr_4 ...

Page 105: ...R 2 ENGINE 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 2 F42W217A 1 Temperature sensor 2 DPF diff pressure sensor 3 Hose A diff Pressure sensor 4 Hose B diff Pressure sensor COMPONENTS 5 17 DPf s sensor option a1700n4_utr_4 ...

Page 106: ...201601 CHAPTER 2 ENGINE 3015R h 3515R h 4015R h F36R h F42R h TRACTOR F42W218A a1700t2_utr_4 1 Temperature sensor 2 DPF diff pressure sensor 3 Hose A diff Pressure sensor 4 Hose B diff Pressure sensor COMPONENTS ...

Page 107: ... mounting bolts 3 to remove the bonnet 2 Disconnect the steering cylinder hose 1 ground wire 2 accelerator cable 3 and fuel hose 4 from right side of the engine 3 Disconnect the steering cylinder hose 1 hydraulic pump suction hose 2 steering unit hose 3 and hydraulic pipe 4 from left side of the engine 4 Remove the start motor 1 5 Disconnect the hydraulic suction pipe 1 generator wiring connector ...

Page 108: ... h 4015R h F36R h F42R h TRACTOR K42W223A K42W224A 6 Remove the exhaust pipe 1 and DPF assembly 2 7 Remove the battery 1 K42W225A 8 Remove the air cleaner 1 and reservoir tank 2 Remove the oil cooler 3 HST MODEL K42W226A 9 Remove the ECU 1 A42W201A ...

Page 109: ...227A 10 Disconnect the radiator hose Upper 1 Lower 2 K42W229A K42W230A K42W231A 12 Disconnect the positive battery line 1 and negative battery line 2 Then disconnect glow plug wiring 3 fuel solenoid connector 4 and oil pressure switch connector 5 and organize the engine wiring into the instrument panel 13 Remove the propeller shaft 1 Refer to Propeller shaft disassembly and assembly in chapter 5 ...

Page 110: ... F42R h TRACTOR K42W232A K42W233A K42W234A 14 Remove the front wheel 1 and front axle 2 Refer to Disassembly and assembly in chapter 5 15 Unscrew the bracket assembly mounting bolts 1 16EA of front axle and remove the front axle bracket assembly 2 K42W236A K42W235A ...

Page 111: ...any job Disassembly procedure complicate and put the display to identity in order to prevent the damage in parts when many parts disassemble Then work can facilitate when assemble it 1 2 3 4 5 6 2 2 Lubricating oil 1 K25W249A Loosen the drain plug 1 from the bottom of the oil pan and drain the oil to the prepared vessel Don t allow hot oil to directly contact skin CAUTION Disposal of waste oil mus...

Page 112: ...A 6 2 4 Alternator Loosen the bolt and washer that hold the upper side of alternator Loosen the bolt in lower side Disassemble the alternator 1 2 3 K25W252A 6 2 5 After Treatment Device ATD Loosen the bolts that hold the ATD Loosen the nuts that connect the ATD and DPF fixing housing Disassemble the ATD When disassembling the ATD should be careful because ATD is heavy 1 2 3 K25W253A 6 2 6 Exhaust ...

Page 113: ... 4 K25W255A 6 2 8 Fuel drain line Disassemble the fuel drain hose Loosen the bolts that hold the fuel drain pipe and remove the drain pipe 1 2 K25W284A 6 2 9 Fuel injection valve Injector Disassemble the injectors Disassemble the sealing washers and nozzle spaces cup from the injectors Do not re use the sealing washer and the nozzle space cup 1 2 3 6 2 10 Glow plug K25W256A Disassemble the wire ha...

Page 114: ... 4 5 K25W258A 6 2 12 Water pump Loosen the bolts that hold the V pulley Disassemble the V pulley Loosen the bolts that hold the water pump Disassemble the water pump and packing Do not re use the packing 1 2 3 4 5 K25W259A 6 2 13 Oil Filter Disassemble the oil filter using by tool 1 K25W260A 6 2 14 Oil Cooler Loosen the clamps that hold the hoses Disassemble the hoses Disassemble the bolt that hol...

Page 115: ...e bolts that hold the rocker arm shaft Disassemble the rocker arm shaft 1 2 6 2 17 Push rod K25W261A Loosen the nuts that hold the head cover Disassemble the head cover Disassemble the packing from head cover Do not re use the packing 1 2 3 4 K25W263A Disassemble the push rod Arrange the push rod in order from front side after disassemble it ...

Page 116: ... upper plain of cylinder block and the lower plain of the cyl inder head CAUTION K25W265A K25W267A 6 2 19 Fuel filter Loosen the clamp that holds hose connecting fuel filter pump and fuel injection pump Loosen the bolts that hold the fuel filter bracket Disassemble the fuel filter and fuel filter bracket 1 2 3 K25W268A 6 2 20 Oil pan Loosen the bolts that hold the oil pan Disassemble the oil pan D...

Page 117: ...of frame Loosen the 2 bolts that hold the oil suction pipe Disassemble the oil suction pipe 1 2 3 4 5 K25W271A 6 2 22 Starter Loosen the bolts that hold the starter motor Disassemble the starter motor 1 2 6 2 23 Flywheel K25W272A Loosen the bolts that hold the flywheel Disassemble the flywheel 1 2 K25W273A 6 2 24 Mounting flange Loosen the bolts that hold the mounting flange Disassemble the mounti...

Page 118: ... Disassemble the crank pulley 1 2 6 2 27 Gear case K25W276A Loosen the bolts that hold the gear case Disassemble the gear case Clean the liquid packing on gear case flange and gear case 1 2 3 K25W277A 6 2 28 Fuel injection pump Loosen the bolt that holds the fuel injection pump gear Disassemble the fuel injection pump gear Loosen the bolts that hold support bracket Disassemble the support bracket ...

Page 119: ...5W279A 6 2 30 Cam shaft assembly Loosen the bolts that hold the cam shaft Disassemble the cam shaft with turning it Cam shaft will be damaged if forcibly disassemble 1 2 3 6 2 31 Oil Pump K25W280A Loosen the bolts using by hexagon wrench Disassemble the oil pump Do not re use the O ring and packing 1 2 3 K25W281A 6 2 32 Gear case flange Loosen the bolts that hold the gear case flange Disassemble t...

Page 120: ...ain bearing cap Disassemble the crank shaft 1 2 6 3 Main Parts Inspection Maintenance 6 3 1 Cylinder head Disassemble the valve cotter spring retainer by the valve spring with disassembly tools Disassemble the intake valve and exhaust valve Keep those disassembled parts by matching cylinders 1 2 3 Disassembly Check the cylinder head Before cleaning the cylinder head check that whether or not gas l...

Page 121: ...e head and if less than the limit replace it Specification 1 2 mm Limit 0 5 mm 0DUJLQ RQWDFW VXUIDFH K25W285A Intake exhaust valve valve guide Valve Valve sheet contact surface Valve guide Measure the distance between the valve guide and valve stem If the distance is more than limit replace the valve or valve guide or either parts Specification 0 04 0 05 mm Limit 0 2 mm K20W257A Valve guide and th...

Page 122: ...onsumption CAUTION Valve spring Squareness free length transformation etc of valve spring are direct cause of damage such as valve stem uneven wear etc Therefore check certainly it when disassembling If the measurement value is over the limit replace Item Specification Limit Free length A 46 mm Inclination B 1 2 mm Spring load 12 2 kg 39 6 mm K20W260A Cylinder head assembly Clean the cylinder head...

Page 123: ...d exactly because it is related with timing of the valve open close and the engine performance 1 Rocker arm shaft outer diameter and rocker arm Inner diameter If the measurement of the shaft outer diameter and rocker arm Inner diameter is over the limit replace it K20W263A Item Specification Limit Shaft Outer Diameter 18 959 18 98 18 95 Rocker arm inside diameter 19 0 19 021 19 09 clearance 0 02 0...

Page 124: ...on Limit Tappet outer diameter 14 227 14 249 14 18 Guide inside diameter 14 260 14 280 14 30 clearance 0 011 0 056 0 12 mm Tappet s contacting condition to camshaft If uneven wear disfigurement or damage is serious replace the tappet K20W265A K20W266A Put the push rod on the surface plate and measure the bending degree by gap gauge If it is over the limit replace it Limit Below 0 3 mm Tappet Push ...

Page 125: ...ean And assemble it toward top of the piston to be saw the mark on top and make sure it moves well When the piston ring assemble ring s cut direction shouldn t be in side pressured area and make it cross each other by 120 degree Measure each main area and replace it if it is over limit Measure the piston ring clearance Item Specification Limit First Ring 0 25 0 40 1 5 Second Ring 0 50 0 70 1 5 Oil...

Page 126: ...e limit replace it K20W271A Item Specification Limit Twist and parallel degree by 100 mm 0 05 mm 0 08 mm Measure the parallel and twist degree of big end and small end If the measurement value is over the limit replace it Item Specification Limit Big end inside diameter 53 0 53 019 Metal thickness 1 485 1 500 Crank pin outer diameter 49 950 49 964 49 91 Oil clearance 0 036 0 095 0 15 Check big end...

Page 127: ...ng rod Assemble the piston pin stop ring When the piston is needed to replace make sure the piston pin has to be replaced too 1 2 3 4 5 6 K20W274A 6 3 5 Crank shaft K20W275A If there is any crack or damage replace it Measure every main part and if it is over the limit replace the main bearing If necessary replace the crankshaft Item Specification Limit Crank journal outer diameter 53 950 53 964 53...

Page 128: ...d of the crankshaft and put the dial gauge on it Measure the crankshaft side side clearance Replace the thrust bearing or crankshaft if it is over the limit K25W287A 6 3 6 Cam shaft Check the camshaft s figure Check the wear on contacting surface between the tappet and the cam Also check the cam gear damage Check the camshaft bending degree Measure the camshaft bending degree Fix both journal side...

Page 129: ...k by cylinder gauge and camshaft outer diameter Item Specification Cam height intake 37 98 38 02 exhaust 37 98 38 02 mm K20W279A Flywheel side Intermediate bearing Gear side K20W280A Cam height Check the camshaft journal Check the height of intake exhaust cam 6 3 7 Gears 3 4 6 2 1 5 K25W288A Check the Gears Check each gear s tooth side and replace them if there is any damage or wear check the gear...

Page 130: ...re worked within the factory specification And check the drive part Check removed parts and spare parts after assembling 6 4 The engine assembly 6 4 1 Caution before assembling the engine Put down the cylinder block head plate used the support on the work bench 6 4 2 Cylinder block 6 4 3 Crankshaft Assembly procedure K25W289A K25W290A K25W291A Cylinder block and bearing cap assemble with the new m...

Page 131: ...proce dure A Assemble the bearing cap bolt tentatively B Assemble the bearing cap bolt according to assembling procedure 1 8 Tightening torque 12 5 kg m Check the crankshaft rotation WARNING Check the clearance of crankshaft side K25W292A Check the clearance of crankshaft side by dial gauge The clearance of crankshaft side 0 090 0 271 mm 1 2 6 4 4 Piston and Connecting rod Assembly procedure K25W2...

Page 132: ...rocedure A Assemble the bearing cap bolt tentatively B Assemble the bearing cap bolt according to assembly procedure Tightening torque 7 5 kg m 12 Check the crankshaft rotation 6 7 8 9 10 11 Check the clearance of connecting rod side K25W296A Check the clearance of connecting rod and cap Use clearance gage Side clearance 0 15 0 35 mm 1 2 6 4 5 Gear case flange Apply the liquid gasket on the gear c...

Page 133: ...el injection pump and it in gear case flange Assemble the key radius type on the fuel injection pump shaft Line up the injection pump gear and B mark of idle gear See 5 3 9 and then assemble the bolt and spring washer to hold fuel injection pump tentatively Line up the injection timing of injection pump Reference the section 2 Assemble the nuts to hold the fuel injection pump Assemble the support ...

Page 134: ...he indicator of dial gage line up 0 mark in dial gage by swing the fuel injection pump Tighten the 3 bolts that hold fuel injection pump After adjusting injection timing check the injection timing again Disassemble the dial gage Assemble the timing check plug 3 4 5 6 7 8 9 6 4 9 Idle gear Apply the lubricating oil on the bush Assemble the idle gear Check the mark A B C Assemble the idle gear shaft...

Page 135: ...ightening torque 2 7 kg m Apply the liquid packing on the frame Use Loctite 5060 or similar product Assemble the frame Assemble the bolts to hold frame Tightening torque 2 7 kg m 1 2 3 4 5 K25W269A 6 4 13 Oil seal housing Apply the liquid packing on the oil seal housing Use Loctite 5060 or similar product Assemble the oil seal housing Tighten the bolts to oil seal housing Tightening torque 2 7 kg ...

Page 136: ... K25W275A 6 4 15 Flywheel Assemble the flywheel Assemble the flywheel bolt within the factory specification and follow procedure A Tighten the bolt Tightening torque 3 0 kg m B And then tighten the bolt again to hold the flywheel Tightening torque 9 0 kg m 1 2 K25W272A 6 4 14 Mounting flange Assemble the mounting flange Tighten the bolts to hold mounting flange Tightening torque 2 7 kg m 1 2 K25W2...

Page 137: ...oil B Assemble the cylinder head bolt tentatively C Assemble the bolt according to factory procedure Tightening torque 5 2kg m D Disassemble to 360 deg E Re tighten the bolt Tightening torque 6 8 kg m F Tightening it into 90 degree by using angle mapper Actual tightening torque 12 0 1 0 kg m 1 2 6 4 18 Push rod K25W2A01A Assemble the push rod in socket of tappet in order Lubricate the lubricating ...

Page 138: ...ng torque 6 0 kg m 1 2 3 K25W2A03A Rotate the engine until the first cylinder stay on TDC Line up the mark of crank pulley and the mark 0 of gear case Install the gauge between rocker arm and valve stem Adjust the clearance with rotating the adjustment bolt 1 2 3 K25W2A02A Valve clearance engine cooled status Intake valve Exhaust valve 0 3 mm 0 3 mm NOTE Lower 60 C 140 F 4 Tighten the adjustment b...

Page 139: ...cylinder 1 and 3 Rotate the crankshaft to rotation direction of engine 360 degree Adjust the intake valve of cylinder 3 Adjust the exhaust valve of cylinder 2 1 2 3 4 5 6 K25W2A06A K25W2A07A 6 4 20 Cylinder head cover Assemble the new gasket and head cover Tighten the nuts to hold the head cover Tightening torque 2 0 kg m 1 2 6 4 21 Glow plug Tighten the glow plug Assemble the connector and tighte...

Page 140: ...n the bolts to water pump Tightening torque 2 7 kg m Assemble the V pulley Tighten the bolts to V pulley Tightening torque 2 7 kg m 1 2 3 4 K25W284A K25W258A 6 4 24 Intake manifold Assemble the intake manifold with new packing Tighten the bolts and nuts to hold the intake manifold Tightening torque 2 7 kg m 1 2 6 4 25 Fuel drain pipe Assemble the new packing Tighten the nuts after install the drai...

Page 141: ... Oil filter Assemble the oil filter using by tool If it is new part put the lubricating oil in the oil filter 1 2 K25W254A C865W2A7A 6 4 28 Exhaust manifold Assemble the exhaust manifold with new gasket Tighten the bolts and nuts to hold exhaust manifold Tightening torque 2 7 kg m 1 2 6 4 29 Fuel filter Assemble the fuel filter bracket with fuel filter Tighten the bolts to hold the fuel filter Con...

Page 142: ...old alternator are re tightened after adjusting the tension of V belt 1 2 3 4 K25W251A K25W271A 6 4 32 V belt Adjust the tension of alternator after that tighten the adjust bolt and bolts 1 6 4 33 After Treatment Device ATD Assemble ATD Tighten the bolts to hold the ATD When assembling the ATD should be careful because ATD is heavy 1 2 K25W250A K25W252A 6 4 34 Lubricating system Supply the lubrica...

Page 143: ...ecomes normal operation condition Avoid the overload or continuous high speed operation Avoid the no load high speed operation Avoid the sudden acceleration or sudden stop of the engine Must comply with check and inspection procedure 1 2 3 4 5 6 5 3 Running in operation checklist Must comply with the following information while the initial running in operation 1 Check the lubricating oil level fre...

Page 144: ...el in injection pump returns fuel tank through fuel return hose via over flow valve The injection pump is cooled and lubricated by the fuel circulation Remaining fuel also returns fuel tank through over flow hose after collecting in the injection pump Water in the fuel reduces pump useful life Therefore must manage not to enter water dirt into the fuel system 7 9 10 11 12 13 3 4 5 6 1 2 8 K25W2A09...

Page 145: ...essure is adjusted to 120 5kg cm2 affixes it in injector tester and every second 4 6 time fabricates the lever Check the spray condition and if it is abnormal injector replace or clean 1 Check whether the spray condition is good 2 The case which is defective disassemble the injection valve and replace the injector tube or assembly 3 After the spray stopped check whether or not after drop 4 The cas...

Page 146: ...ning pressure is standard value Standard pressure Opening pressure Standard value Adjusting pressure standard value 5 10 kg cm2 Limit pressure Above standard value 10kg cm2 4 The case which is defective disassemble the injector and replace the thickness of the shim And then injection opening pressure adjusts standard value Check and adjustment of the injection opening pressure 5 If you can t adjus...

Page 147: ...ext method Checking a clearance of between out rotor and pump body by thickness gauge Check a clearance of pump body outer rotor and inner rotor by thickness gauge Item Standard Clearance mm 0 03 0 09 K25W2A11A Outer rotor Pump body Thickness gauge K25W2A12A Pump body Thickness gauge Straight edge Clearance of between out rotor and pump body Clearance of pump body outer rotor and inner rotor After...

Page 148: ...er Ω in between the terminal and the body and check whether or not applying an electric current If applying an electric current it is normality and if not applying an electric current replace the switch The thin rod puts in oil hole and slightly presses At this point If applying an electric current it is normality and if not applying an electric current replace the switch When inflicting an air pr...

Page 149: ...etc Do not confusion In this case engine rotates at low speed and coolant temperature does to make fall naturally Then after supplies the coolant and removes the cause Thermostat constantly maintain the coolant temperature and is used to improve thermal efficiency by preventing heat loss When heating the thermostat in water check the valve open temperature Valve open temp 72 0 C 2 C start open 85 ...

Page 150: ...ull in coil test of magnetic switch solenoid The case which connects battery between S M terminal if plunger comes in and the pinion comes out the pull in winding is normality If the pinion does not come out replace the magnetic switch B S K20W2A62 Battery Start Switch Basic Wiring Circuit Basic Solenoid Circuit Solenoid Bat Cranking Motor Neutral Safety Switch Start Switch Hold in Winding pull in...

Page 151: ...f electronic switch Earth of armature coil field coil Seizure of metal Electric current does not flow and does not rotate Disconnection of armature coil field coil Disconnection of brush pigtail Contamination of armature connection defect between brush and armature by Highmica etc Electric current is small current and number of rotation is low Neither the torque is much strong Connection defect of...

Page 152: ...h 4015R h F36R h F42R h TRACTOR 6 7 2 Alternator Item Content Type Rectifier Alternator Capacity 12 0V 50A Motor velocity 1 000 18 000 rpm Regulator setting voltage 14 7 0 3V Temperature compensate 7 3mV C K25W2A14A Base circuit diagram Specification ...

Page 153: ...and slip rings for wear dirt or damage If brushes and slip rings are good alternator is damaged internally Disassemble alternator and test components 1 2 3 4 5 K20W2A79 Alternator output voltage test on engine running condition K20W2A80 Ignition circuit test at Ignition key on condition Unplug Ignition terminal of regulator connector from voltage regulator Connect positive voltmeter lead to Igniti...

Page 154: ... assembly 1 Standard about 27 5Ω 20 C K25W2A16A 2 Check the earth of rotor coil Confirm that whether or not conductivity between slip ring and earth If it is electric conduction replace the rotor assembly K25W2A17A Stator Check the conductivity of stator Confirm that whether or not conductivity between coil and lead If it is not electric conduction replace the stator assembly 1 K25W2A18A 2 Check t...

Page 155: ...uld be change according to temperature condition and using condition in work machine Consequently select the battery which satisfied specification and must use it Total wire resistance of battery cable must be less than 2 1000Ω If total wire resistance is out of standard value it is cause of breakdown and functional loss in starter If wire resistance of starter must be more than standard value Rec...

Page 156: ...f cm Crankshaft V pulley clamping bolt M14 1 5 19 750 1150 100 Glow plug M10 1 25 12 275 25 Injection valve M20 1 5 22 750 50 Valve adjusting screw clamping bolt M8 1 25 270 30 Balancer housing clamping bolt M8 1 25 12 270 30 Idle gear shaft clamping bolt M8 1 25 12 270 30 Nozzle Return pipe Nut M12 1 5 17 370 50 Nozzle jet bolt M8 1 25 13 170 50 Injection pump gear clamping bolt M12 1 25 19 900 1...

Page 157: ...00 50 240 40 530 70 420 60 690 30 550 30 M 12 530 70 420 60 900 100 720 80 1130 70 900 60 M 14 780 70 620 60 1350 150 1080 120 1850 150 1480 120 M 16 1250 150 1000 120 1900 200 1520 160 2580 220 2060 220 M 18 1750 150 1400 120 2650 250 2120 200 3800 300 3040 240 M 20 2450 250 1960 200 3700 400 2960 320 5400 400 4320 320 PT Plug Size 1 8 1 4 3 8 1 2 3 4 Aluminum 150 20 200 30 250 30 350 50 460 50 C...

Page 158: ...025 Ø 8 1 Oil clearance 0 040 0 055 0 15 Exhaust valve Valve stem outer dia Ø 7 96 Ø 7 97 Ø 7 9 Valve guide inner dia Ø 8 010 Ø 8 025 Ø 8 1 Oil clearance 0 040 0 055 0 15 Valve guide projection from head surface 13 Valve sinking depth Intake valve 0 7 1 Exhaust valve 0 7 Thickness of valve head Intake valve 1 2 0 5 Exhaust valve 1 2 Intake valve timing Open b TDC 9 19 Close a BDC 37 47 Exhaust val...

Page 159: ...r arm inner dia Ø 19 0 Ø 16 021 Ø 19 09 Oil clearance 0 020 0 062 0 14 Pushrod bending 0 03 or less 0 25 or less Tappet Tappet stem outer dia Ø 14 224 Ø 14 249 Ø 14 18 Tappet guide hole inner dia Ø 14 260 Ø 14 280 Ø 14 30 Oil clearance 0 011 0 056 0 12 Item Standard Limit Note Piston outer dia A Ø 87 965 Ø 87 975 Ø 87 90 C Ø 87 960 Ø 87 965 Minimum clearance between piston and cylinder block 0 040...

Page 160: ...nd clearance 0 45 0 65 1 5 Oil ring Ring groove width 3 02 3 04 Ring width 3 97 3 99 Ring and ring groove clearance 0 03 0 07 End clearance 0 20 0 40 1 5 7 3 6 Connecting Rod Item Standard Limit Note Crankpin side Crank pin pushing inner dia Ø 53 0 Ø 53 019 Crank pin metal thickness 1 487 1 50 Crank pin outer dia Ø 49 95 Ø 49 964 Ø 49 91 Oil clearance 0 038 0 095 0 15 Piston pin side Piston pin bu...

Page 161: ...ate Camshaft journal outer diameter Ø 44 916 Ø 44 930 Ø 44 89 Oil clearance 0 070 0 130 Flywheel side Camshaft journal outer diameter Ø 44 950 Ø 44 964 Ø 44 89 Oil clearance 0 066 0 110 7 3 7 Camshaft Item Standard Limit Note Crank journal Crankshaft journal outer dia Ø 53 950 Ø 53 964 Ø 53 91 Bearing metal thickness 1 987 2 000 Oil clearance 0 036 0 095 0 15 Bending 0 02 or less 0 02 or less 7 3 ...

Page 162: ... BranSOn tractors Co Ltd MEMO ...

Page 163: ...ctional view of clutch assembly 3 2 1 2 Clutch pedal components 3 3 1 3 Clutch pedal play adjustment 3 4 2 Sectional view for major components 3 5 2 1 Clutch housing 3 5 2 2 Clutch release 3 7 3 Disassembly 3 8 3 1 Clutch housing removal 3 8 3 2 Clutch disassembly 3 8 ...

Page 164: ...te the hollow shaft A does not rotate as it is fixed to the clutch disc assembly However as the solid shaft B is connected to the flywheel with the PTO sleeve it rotates continuously As a result the PTO shaft connected to the solid shaft B is driven independently regardless of the driving shift condition The clutch is to deliver or cut off power from the engine to the transmission When the clutch ...

Page 165: ...3 CHAPTER 3 CLUTCH 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 42hW 201601 3 1 2 Clutch pedal components 3 1 4 2 F42W302A 1 Clutch pedal 2 Brake shaft 3 Clutch rod 4 Release shaft ...

Page 166: ...se it Measure its free play 1 2 Item Standard Clutch pedal free play 25 35 mm 0 98 1 38 in 1 3 Clutch pedal play adjustment If the free play is out of the specification unscrew the mounting nut 2 of the clutch rod and turn the turn buckle 3 to adjust the free play Then tighten the mounting nut 3 UHH SOD 1 F42W127A F42W128A ...

Page 167: ...utch housing F42W303A 1 Clutch housing 2 Sleeve PTO 3 Spring pin 4 Hexagon socket bolt 5 Clutch disc ass y 6 Clutch cover ass y 7 Bolt w washer 8 Spring pin 9 Stud bolt 10 Spring washer 11 Hex nut 12 Hex bolt 13 Hex bolt 14 Hex bolt SW 15 Pin 16 Cotter pin 17 Cover assy 18 Hex flange bolt 19 Pin rubber COMPONENTS MEC MODEL ...

Page 168: ...sing 2 Damper pto 3 Spring pin 4 Hexagon socket bolt 5 Stud bolt 6 Spring washer 7 Hex nut 8 Hex bolt 9 Hex bolt 10 Hex bolt sw 11 Pin 12 Cotter pin 13 Cover assy 14 Hex flange bolt 15 Pin rubber 1 3 4 2 8 6 15 10 12 9 5 6 7 13 14 11 10 A42W301A HST MODEL 42hW 201601 COMPONENTS ...

Page 169: ...2 O ring 3 Oil seal 4 Hex flange bolt 5 Sleeve bearing 6 Release bearing ass y 7 Yoke clutch shift 8 Bolt 9 Release shaft main clutch 10 Clutch pedal 11 Clutch road 12 Plain washer 13 Cotter pin 14 Spring 15 Stopper 16 Lock clutch pedal 17 Bolt 18 Safety switch clutch 19 Rod 20 Rod 21 Turn buckle 22 U nut COMPONENTS ...

Page 170: ...elated parts including the fuel hose and main wiring connector between the engine and vehicle body 8 Unscrew the mounting bolt 1 from the cutch housing and engine mounting flange Then push the front axle section to separate it from the clutch housing 9 For more detailed disassembly procedures refer to the instructions for engine removal in Chapter 2 Item Torque value M14 nut 10 9T 16 5 kg m 119 34...

Page 171: ... the PTO sleeve 2 Item Torque value PTO sleeve mounting bolt 2 3 2 6 kg m 17 19 lbf ft 4 As necessary remove the release bearing 1 sleeve 2 clutch shift yoke 3 release shaft 4 and parking brake lever 5 from the clutch housing K42W304A K42W305A K42W306A K42W307A 4 As necessary unscrew the mounting bolts to remove the PTO damper 1 HST MODEL ...

Page 172: ... BraNSON tractors Co ltd MEMO ...

Page 173: ...ift gear 4 31 4 5 Main P T O shaft 4 33 4 6 PTO drive shaft 4 35 4 7 Fork main shift mec model 4 36 4 8 Lever ass y range shift 4 37 4 9 Front drive shaft 4 38 4 10 4WD lever 4 39 4 11 Fork lever PTO 4 40 4 12 Ring gear diff gear ass y 4 41 4 13 Differential 4 42 4 14 Driving part rear axle 4 43 4 15 Brake 4 44 4 16 Brake pedal 4 45 5 Disassembly and service 4 47 MEC MODEL 5 1 Clutch housing remov...

Page 174: ...h 0 746 13 982 MPH HST MODEL Shuttle type Hydrostatic Main shift HST Range shift 3 speeds constant mesh Shifting gear and driving speed CVT 7 16 11 2 24 Forward driving 0 29 27 km h 0 18 18 MPH Reverse driving 0 29 27 km h 0 18 18 MPH 8 16 12 4 24 Forward driving 0 30 7 km h 0 30 7 MPH Reverse driving 0 30 7 km h 0 30 7 MPH PTO shift Type Independent PTO Stage 2 Revolution 1st 560 rpm 2nd 780 rpm ...

Page 175: ... 4015R h F36R h F42R h TRACTOR 0 1 5 9 0 1 5 9 1 2817 5 0 68 5 9 5 2 1 3 0 5DQJH VKLIW 372 6 7 372 372 372 VKLIW 372 87 3 2 1 4 3 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 4 F42W417A 1 2 Power transfer 1 2 1 Transmission assembly diagram MEC MODEL ...

Page 176: ...TER 4 TRANSMISSION 42hW 201601 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 1387 2817 5 0 1 5 9 1 0 68 5 9 5DQJH VKLIW 372 6 7 372 VKLIW 372 87 3 0 372 372 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 a42w401a HST MODEL ...

Page 177: ...4 42hW 201601 CHAPTER 4 TRANSMISSION 4 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 1 2 2 Power flow chart 7 372 372 87 1 1 5217 7 5 5 5 7 5 L 21 2 F42W418A MEC MODEL ...

Page 178: ...4 CHAPTER 4 TRANSMISSION 42hW 201601 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 372 372 87 1 1 67 DPSHU 5217 7 5 5 5 7 5 L 21 2 a42w402a HST MODEL ...

Page 179: ...R h 4015R h F36R h F42R h TRACTOR 2 Structure and operating principle 2 1 Main shift MEC MODEL 5 2 1 3 2 1 4 3 7 7 7 7 7 7 7 7 7 7 7 4 SE UI TU OE 8 1 4 2 3 5 7 6 10 9 F42W419A 5 2 1 3 2 1 4 3 7 7 7 7 7 7 7 7 7 7 7 4 SE UI TU OE F42W420A forward reverse ...

Page 180: ...in shift 3rd Forward Main shaft Hub Sleeve 37T gear 44T gear Main shift drive shaft 40T gear 37T gear Sleeve Hub Main shift driven shaft Main shift 4th Forward Main shaft Hub Sleeve 37T gear 44T gear 33T gear Sleeve Hub Main shift driven shaft Main shift 1st Reverse Main shaft Hub Sleeve 28T gear 26T gear Idle shaft 35T gear Main shift drive shaft 28T gear 49T gear Sleeve Hub Main shift driven sha...

Page 181: ...e HST to turn the HST motor shaft 2 As the HST motor shaft is connected to the range shift drive shaft 6 rotation of the range shift drive shaft turns the 26T gear 3 which then turns the range shift drive shaft 5 through the engaged 29T gear 4 Therefore the amount of depression of the forward driving pedal determines the hydraulic pressure quantity for the HST input shaft pump shaft and this chang...

Page 182: ... gear of the main shift drive shaft which is engaged with the 37T gear of the forward driving gear As a result each gear fixed to the main shift drive shaft with splines receives this rotating power Also to select the reverse driving the sleeve is moved to the left to be engaged with the reverse driving gear As a result the 28T gear of the reverse driving gear is engaged with the 26T gear 6 of the...

Page 183: ...ash plate of the HST pump shaft starts to tilt toward the positive x axis from 0 neutral position gradually the amount of hydraulic oil delivered to the HST motor shaft is increased resulting in increase of the vehicle speed When the swash plate moves toward the negative x axis from 0 the delivery direction of hydraulic oil is reversed resulting in reverse rotation of the HST motor shaft Therefore...

Page 184: ...peed the 2nd gear 5 of the range shift driven gear is pushed to the right to be engaged with the 52T gear 4 Then the rotating force reduced at the reduction ratio by the 18T gear and 52T gear of the range shift drive shaft passes through the range shift driven gear s 2nd gear to be delivered to the countershaft To select the range shift 2nd gear mid speed the 2nd gear of the range shift driven gea...

Page 185: ...hed to the rightmost position for low speed L shift operation the spline in the 52T gear is engaged with the spline on the range shift driven 2nd gear Then the torque reduced by engagement of the 52T gear and 18T gear of the range shift drive gear shaft is delivered to the countershaft through the range shift driven 2nd gear which is fixed to the countershaft with splines For mid speed M shift ope...

Page 186: ...haft 4 36T gear 5 20T gear 8 36T range shift driven gear 2nd 7 Counter shaft 9 Low speed L Range shift drive shaft 1 26T gear 2 29T gear 3 Range shift drive gear shaft 4 18T gear 52T gear 6 36T range shift driven gear 2nd 7 Counter shaft 9 Mid speed M Range shift drive shaft 1 26T gear 2 29T gear 3 Range shift drive gear shaft 4 34T gear 36T range shift driven gear 2nd 7 Counter shaft 9 ...

Page 187: ...t with splines engages the clutch hub 12 and the clutch hub is connected to the clutch disc as one unit they idle together in a normal condition When oil is drawn to the PTO clutch for PTO operation this oil pushes the internal piston so the pressure plate is compressed against the clutch disc rotating the whole PTO clutch assembly Then this rotating force is transferred to the PTO clutch shaft 5 ...

Page 188: ...e system for PTO operation As the PTO clutch 3 is engaged the 65T and 60T gears of the PTO shaft 5 which are engaged with the 14T and 18T gears of the PTO drive gear shaft 4 are rotated As the PTO hub is connected by shift operation of the PTO lever PTO torque of the 1st and 2nd gears is delivered to the PTO shaft 1387 2817 5 0 68 5 9 5DQJH VKLIW 372 6 7 372 VKLIW 372 78 3 0 372 372 7 7 7 7 7 7 7 ...

Page 189: ...drive gear 2 of the countershaft rotates constantly Therefore when the 4WD driven gear 4 of the 4WD drive shaft 3 is moved to the left to be engaged with the 4WD drive gear the 4WD drive and driven gears are engaged and rotated together Then the rotating power reduced at the reduction ratio by the 52T gear and 42T gear is delivered to the 4WD drive shaft to turn the front axle through the propelle...

Page 190: ...axle 14 Oil seal 15 Rear axle housing When rotating force arrives at the counter shaft 1 it rotates the differential case 3 through the ring gear 2 As the differential rotates the differential pinion 5 and differential side gear 7 inside the differential case to deliver the rotating force to the final pinion 9 Then the speed of the rotating force at the final pinion is reduced through engagement o...

Page 191: ...t since the wheel in mud with no friction rotates at faster speed and the wheel on road with friction does not rotate due to the differential system To prevent this situation the vehicle is equipped with the differential lock The differential lock moves the differential lock slide to fix the differential case and differential side gear together with the pin resulting in rotation of the side gear o...

Page 192: ...e shaft 3 which is fixed with the brake pedal boss and spring pin 2 starts to rotate Then as the brake shaft is connected to the brake rod 4 with the snap pin the shaft pulls the rod which then turns the brake activating brake lever 5 to operate the internal brake As this brake is a wet multi plate type it is soaked in oil for superior lubrication cooling and durability MEC MODEL ...

Page 193: ...4 21 42hW 201601 CHAPTER 4 TRANSMISSION 4 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 3 2 4 5 4 5 1 A42W408A HST MODEL ...

Page 194: ...to the differential side gear with splines rotating together and its other side is connected to the boss 4 with splines This boss is fixed to 2 discs 5 with splines as one unit Also the pressure plates 6 are installed in between the friction discs and these pressure plates are fixed to the rear axle housing Therefore when the brake pedal is depressed the brake lever is moved to rotate the cam plat...

Page 195: ...its free play 1 2 Item Standard Brake pedal free play 5 10 mm 0 19 0 39 in The free play for both pedals should be identical 3 If the free play is out of the standard unscrew the mounting nuts 2 of the brake rods LH RH on the brake shaft section and use the turnbuckle 3 to adjust the free play After adjusting the free play of the both sides tighten the mounting nuts F42W130A MEC MODEL A42W409B HST...

Page 196: ...42hW 201601 CHAPTER 4 TRANSMISSION 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 3 3 Parking brake operation 3 2 4 1 1 F42W427A 1 Brake pedal 2 Parking brake lever 3 Brake rod 4 Brake lever 3015R 3515R 4015R ...

Page 197: ... parking brake lever 2 to engage the gear tooth with the fixing plate of the brake pedal As the brake pedal is operated the brake rod 3 which is connected to the brake shaft and brake pedal is pulled to activate the brake lever 4 in order to apply braking force for the left right brakes 2 35HW401A 2 Parking brake lever 3015h 3515h 4015h ...

Page 198: ...4 26 42hW 201601 CHAPTER 4 TRANSMISSION 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 1 2 4 3 5 F42W428A 1 Parking brake lever 2 Parking brake wire 3 Brake shaft 4 Brake rod 5 Brake lever F36R F42R ...

Page 199: ...vates the left brake lever 5 while the right brake rod on the brake pedal side which is fixed to the brake shaft with the spring pin activates the right brake lever to produce braking force for each brake Also the parking brake is coupled with the brake pedals Therefore pulling the parking brake lever with the brake pedals depressed can achieve sufficient braking force more easily 2 1 35HW402A F36...

Page 200: ...onal view for major components 4 1 Shaft F R DRV mec model F42W401A 1 Shaft F R drv 2 Ball baring 3 Spacer 4 Ball baring 5 Gear backward drv 6 Synchro ring 7 Spring 8 Hub 9 Key 10 Sleeve 11 Snap ring 12 Ball baring 13 Spacer 14 Gear forward drv 15 Snap ring 16 Ball baring 17 Oil seal COMPONENTS ...

Page 201: ...flange bolt 8 Ball bearing 9 Gear 2 main shift 10 Snap ring C type 11 Spacer shaft main shift 12 Gear 1 main shift 13 Gear 4 main shift 14 Gear 3 main shift 15 Nut lock 16 Ball bearing 17 Spcer 18 Gear M shift drvn 2 19 Sleeve 20 Synchro ring 21 Spring 22 Hub 23 Key 24 Sleeve 25 Gear M shift drvn 1 26 Gear M shift drvn 4 27 Spacer 28 Gear M shift drvn 3 29 Shaft M sthift 30 Snap ring C type 31 Bal...

Page 202: ...le ass y mec model F42W403A 1 Knob shuttle 2 Lever shuttle 3 Cover rubber 4 Shaft shuttle 5 Spring pin 6 Bush 7 O ring 8 Arm shuttle 9 Plate 10 Hex flange bolt 11 Shaft fork shuttle 12 Fork shuttle 13 Shifter shuttle 14 Steel ball 15 Spring 16 O ring 17 Bolt 18 Cover 19 Hex flange bolt COMPONENTS ...

Page 203: ...4A 1 Ball bearing 2 Range shift drive gear 3 Range shift drive shaft 4 Ball bearing 5 Niddle bearing 6 Range shift driven gear 2nd 7 Snap ring 8 Sleeve 9 Range shift driven gear 1nd 10 Four wheel drive gear 11 Stop nut 12 Taper roller bearing 13 Snap ring 14 Spacer 15 Taper roller bearing 32207c COMPONENTS MEC MODEL ...

Page 204: ... 4 Gear range c 5 Range driven shaft 6 Ball bearing 7 Ball bearing 8 Snap ring 9 Snap ring 10 Range driven gear 11 Range shaft 12 Snap ring 13 Ball bearing 14 Niddle bearing 15 Collar 16 Gear range c driven 17 Range shift driven gear 2nd 18 Sleeve 19 Range shift driven gear 1nd 20 Four wheel drive gear 21 Stop nut 22 Taper roller bearing 23 Snap ring 24 Spacer 25 Taper roller bearing 32207c COMPON...

Page 205: ...haft 2 Oil seal 3 Snap ring 4 Ball bearing 5 Joint 6 Snap ring 7 Clutch hub 8 Ball bearing 9 PTO clutch ass y 10 PTO clutch shaft 11 Stop screw 12 Snap ring 13 Ball bearing 14 O ring 15 Clutch input pipe 16 O ring 17 Sleeve 18 Seal ring 19 PTO valve 20 Elbow 21 Spring washer 22 Hex bolt 23 O ring 24 Connector 25 Hose COMPONENTS MEC MODEL ...

Page 206: ...oint 2 Snap ring 3 Snap ring 4 Ball bearing 5 Main pto shaft 6 Ball bearing 7 Joint 8 Snap ring 9 Clutch hub 10 Ball bearing 11 Pto clutch ass y 12 Stop screw 13 Pto clutch shaft 14 Snap ring 15 Ball bearing 16 Sealring 17 Sleeve 18 Clutch input pipe 19 O ring 20 O ring 21 Pto valve 22 Spring washer 23 Hexagon socket bolt 24 O ring 25 Connecter 26 Elbow HST MODEL COMPONENTS ...

Page 207: ...1 Joint 2 Snap ring 3 Ball bearing 4 Shaft PTO drive 5 Snap ring 6 Seal cap 7 Ball bearing 8 Bush 9 Gear PTO1 10 Hub PTO 11 Sleeve PTO 12 Bush 13 Gear PTO2 14 Washer 15 Snap ring 16 Shaft PTO drive 17 Oil seal 18 O ring 19 Cover PTO 20 Snap ring 21 Hex flange bolt 22 Ball bearing 23 Plate 24 Hex flange bolt COMPONENTS ...

Page 208: ...lange bolt 3 Main shift lever 4 Spring pin 5 Main shift knob ass y 6 Screw 7 Main shifter 8 Main shift fork shaft 9 Spring pin 10 Main shift fork 11 Main shifter 12 Main shift fork shaft 13 Main shift fork 14 Pin 15 Steel ball 16 Spring 17 O ring 18 Bolt 19 Band 20 Main shift lever lower 21 Boots 22 Snap ring 23 Spacer 24 Spring 25 Ball 26 Pin 27 Case main shift COMPONENTS ...

Page 209: ...RACTOR 4 8 Lever ass y range shift F42W408A 1 Range shift fork shaft 2 Range shifter 3 Spring pin 4 Range shift fork 5 Hex bolt w washer 6 Shaft range shift 7 O ring 8 Range shift lever 9 Spring pin 10 Range shift knob k3 11 Screw 12 Steel ball 13 Spring 14 O ring 15 Bolt COMPONENTS ...

Page 210: ... 2 Propeller shaft 3 4nd drive joint 4 Oil seal housing 5 O ring 6 Oil seal 7 Snap ring 8 Ball bearing 9 4dn drive shaft 10 Ball bearing 11 Steel ball 12 Spring 13 4dn driven gear 14 Stop O ring 15 Shaft cover front 16 Shaft cover boots 17 Hose band 18 Shaft cover back 19 Stop O ring 20 Hex flange bolt 21 Spring pin 22 Spring pin COMPONENTS ...

Page 211: ... h F36R h F42R h TRACTOR 4 10 4WD lever F42W410A 1 4nd lever 2 O ring 3 Front wheel shift arm 4 Spring pin 5 4nd lever link 6 Washer 7 Snap pin 8 Spring washer 9 PTO lever shaft 10 4nd lever 11 Washer 12 Snap ring 13 Front wheel drive knob ass y 14 Screw COMPONENTS ...

Page 212: ... lever PTO F42W411A 1 Shaft PTO change 2 O ring 3 Change arm PTO 4 Spring pin 5 Washer 6 PTO change lever 7 PTO knob ass y 8 Screw 9 PTO lever link 10 Washer 11 Snap pin 12 PTO fork 13 Spring 14 Steel ball 15 PTO fork shaft 16 Seal cap 17 O ring 18 Stop bolt 19 Plate 20 Hex plange bolt COMPONENTS ...

Page 213: ...y F42W412A 1 Differential ass y 2 Ring gear ass y 3 Differential case right 4 Differential case left 5 Differential shaft 6 Differential side gear r 7 Differential side gear l 8 Pinion differential 9 Differential stop slider 10 Roller 11 Bolt 12 Spring pin 13 Thrust washer 14 Washer 15 Bolt 16 Thrust washer COMPONENTS ...

Page 214: ...per roller bearing 2 Spacer 3 Spring holder 4 Bearing support 5 Screw 6 Stop plate 7 Washer ass y hex bolt 8 Ball bearing 9 Shim 10 Shim 11 Shim 12 Shim 13 Snap ring 14 Spring holder 15 Differential pedal 16 O ring 17 Differential spring 18 Differential fork 19 Spring pin 20 Spring pin 21 O ring 22 Adapter COMPONENTS ...

Page 215: ...ng rear axle right 2 Final pinion right 3 Final gear right 4 Housing rear axle left 5 Rear axle 6 Oil seal 7 Taper roller bearing 8 Taper roller bearing 9 Final gear left 10 Rock nut 11 Ball bearing 12 Final pinion left 13 Snap ring 14 Spring washer 15 Hex nut 16 Bolt 17 Bolt 18 Stud bolt 19 Pin 20 Stud bolt 21 Washer 22 Hex nut 23 Bolt COMPONENTS ...

Page 216: ...ACTOR 4 15 Brake F42W415A 1 Brake ass y left 2 Brake ass y right 3 Cam plate left 3 Cam plate right 4 Disk 5 Pressure plate 6 Boss 7 Snap ring 8 Steel ball 9 Spring 10 Brake lever bush 11 Brake inside arm 12 Dry bush 13 O ring 14 Plate 15 Hex bolt w washer 16 Brake lever COMPONENTS ...

Page 217: ...F42R h TRACTOR 4 16 Brake pedal 5 6 7 F42W416A 1 Brake rod ass y 2 Brake shaft ass y 3 O ring 4 Dry bush 5 Brake pedal 6 Spring pin 7 Spring pin 8 Brake pedal 9 Return spring 10 Washer 11 Snap ring 12 Rubber stopper 13 Pin 14 Snap pin 15 Stop lamp switch COMPONENTS MEC MODEL ...

Page 218: ... h TRACTOR 2 5 6 4 3 1 13 14 8 11 10 9 7 12 2 3 4 8 9 A42W413A 1 Brake shaft ass y 2 Washer 3 Snap ring 4 Brake rod ass y 5 Pin 6 Snap pin 7 Brake pedal 8 Dry bush 9 O ring 10 Spring pin 11 Spring pin 12 Rubber stopper 13 Stop lamp switch 14 Return spring HST MODEL COMPONENTS ...

Page 219: ...2W413A K42W414A K42W415A K42W411A K42W412A 1 Remove the engine assembly 5 Remove the steering column assembly 1 6 Disconnect the combination lamp wiring connector 1 and remove the fender assembly 2 LH RH 2 Remove the dashboard R L 1 and instrument panel cover 2 3 Remove the bonnet hinge assembly 1 4 Pull out the spring pin 1 2EA to remove the F R shuttle lever 2 ...

Page 220: ...k 2 8 Remove the transmission case cover 1 floor mat 2 LH RH dust cover assembly 3 9 Remove the brake rod 1 brake pedal 2 footstep support assembly 3 and clutch pedal 4 10 Remove the release bearing sleeve 1 and lift the shuttle shaft 2 to separate it from the fork 11 Unscrew the clutch housing transmission case mounting bolts 1 8EA nuts 2 2EA and remove the clutch housing 3 ...

Page 221: ...42W424A K42W425A 12 Remove the release yoke 1 release shaft 2 and shuttle shaft 3 from the clutch housing 1 Remove the clutch housing assembly 5 2 Transmission case assembly disassembly 2 Remove the high pressure hose 1 of front outlet valve 3 Remove the PTO valve 1 and disconnect the PTO clutch input pipe 2 ...

Page 222: ...430A 5 Remove the 4WD lever link 1 and fuel tank rear supporter 2 Then unscrew the plug 3 to remove the spring and steel ball from in the hole 4 Remove the filter low pressure pipe 1 and hydraulic filter 2 6 Unscrew the rear axle case transmission case mounting bolts 1 6EA nuts 2 3EA to remove the transmission case assembly 3 ...

Page 223: ...on A of the PTO clutch pack into the groove of the case The brake plate 2 of the PTO clutch pack is set apart from the PTO clutch and fixed into the groove while the rear PTO is in operation Only the PTO clutch pack body is rotated in this state When the rear PTO is turned off in this state the PTO clutch pack stops rotating as well However it may be rotated further by inertia of the rotating rear...

Page 224: ...36R h F42R h TRACTOR K42W436A K42W437A K42W439A 4 Unscrew the plug 1 to remove the spring 2 steel ball 3 5 Remove the main shift drive shaft bearing 1 and main shift 2nd drive gear 2 When installing the main shift 2nd gear its long boss A should face the plate Notes ...

Page 225: ...42W441A K42W442A K42W443A K42W444A 6 Remove the main shaft assembly 1 and F R fork shaft 2 simultaneously 7 Remove the ball bearing 2 spacer 3 reverse drive gear assembly 4 snap ring 5 synchronizer ring 6 Hub Sleeve assembly 7 snap ring 8 Forward drive gear assembly 9 from the main shaft 1 in order ...

Page 226: ...6R h F42R h TRACTOR K42W445A K42W446A K42W447A K42W448A 8 Remove the PTO clutch shaft snap ring 1 and sleeve 2 Then remove the PTO clutch shaft 3 joint 4 clutch hub 5 PTO clutch assembly 6 simultaneously 9 Remove the main PTO shaft snap ring 1 2EA and main PTO shaft 2 ...

Page 227: ...e stop ring 1 and remove the spring pressure plate plate disc brake pis ton case Notes PTO clutch pack components disassembly 10 Unscrew the plug 1 and remove the spring and steel ball Then remove the main shift fork cover 2 11 Pull out the spring pin 1 and remove the main shift fork shaft main shift fork 1 2nd 2 3 4th 3 and anti pairing pin 4 ...

Page 228: ...ring 1 Then remove the main shift drive shaft assembly 2 and main shift driven shaft assembly 3 simultaneously 13 Remove the ball bearing 2 main shift 2nd drive gear 3 snap ring 4 2EA main shift 1st drive gear 5 main shift 4th drive gear 6 snap ring 7 2EA and main shift 3rd drive gear 8 from the main shift drive shaft 1 in order K42W455B K42W456A ...

Page 229: ... Remove the range shift drive shaft 1 14 Unscrew the mounting nut 1 and remove the ball bearing 2 spacer 3 main shift 2nd driven gear 4 synchronizer ring 5 sleeve 6 main shift 1st driven gear 7 spacer 8 main shift 4th driven gear 9 synchronizer ring 10 sleeve 11 main shift 3rd driven gear 12 from the main shift driven shaft 13 in order ...

Page 230: ...ing removal K42W410A K42W411A 1 Remove the engine assembly K42W413A 4 Remove the steering column assembly 1 2 Remove the dashboard R L 1 and instrument panel cover 2 3 Remove the bonnet hinge assembly 1 K42W414A K42W415A 5 Disconnect the combination lamp wiring connector 1 and remove the fender assembly 2 LH RH ...

Page 231: ...h F42R h TRACTOR 6 Remove the footstep 1 and fuel tank 2 K42W416A 9 Remove the HST arm connecting plate 1 HST arm 2 and elbow 3 A42W415A K42W417A 8 Remove the brake rod 1 brake pedal 2 A42W414A 7 Remove the transmission case cover 1 floor mat 2 LH RH dust cover assembly 3 ...

Page 232: ...F36R h F42R h TRACTOR A42W416A A42W417A A42W418A A42W419A A42W420A 10 Unscrew the clutch housing transmission case mounting bolts 1 6EA nuts 2 4EA and remove the clutch housing 3 11 Unscrew the HST mounting bolts 1 6EA and remove the HST 2 from the transmission case ...

Page 233: ...tch housing assembly 2 Remove the HST assembly 3 Remove the HST pedal pedal assembly 1 4 Remove the high pressure hose 1 of front outlet valve 5 2 Transmission case assembly disassembly 5 Remove the PTO valve hydraulic hose 1 HST filter 2 hydraulic oil suction pipe 3 and hydraulic filter 4 7 Remove the 4WD lever link 1 and fuel tank rear supporter 2 Then unscrew the plug 3 to remove the spring and...

Page 234: ... the PTO clutch pack is set apart from the PTO clutch and fixed into the groove while the rear PTO is in operation Only the PTO clutch pack body is rotated in this state When the rear PTO is turned off in this state the PTO clutch pack stops rotating as well However it may be rotated further by inertia of the rotating rear implement To pre vent such rotation by inertia the PTO clutch is equipped w...

Page 235: ...4 63 42hW 201601 CHAPTER 4 TRANSMISSION 4 3015R h 3515R h 4015R h F36R h F42R h TRACTOR A42W431A A42W432A A42W433A A42W434A 2 Remove the plate 1 3 Remove the range shift drive shaft 1 ...

Page 236: ...igher part of boss A section toward ball bearing side A42W439A 2 During the range shift C drive gear installation make sure that the lower part of boss A section toward ball bearing side A42W438A 4 Remove the range shift drive gear shaft 1 ball bearing 2 range shift driven gear 29T 3 snap ring 4 and range shift C drive gear 36T 5 from the range shift drive gear shaft in order Notes ...

Page 237: ...36R h F42R h TRACTOR K42W445A K42W446A K42W447A A42W440A 5 Remove the PTO clutch shaft snap ring 1 and sleeve 2 Then remove the PTO clutch shaft 3 joint 4 clutch hub 5 PTO clutch assembly 6 simultaneously 6 Remove the main PTO shaft snap ring 1 2EA and main PTO shaft 2 ...

Page 238: ...2W441A K42W476A Pull out the stop ring 1 and remove the spring pressure plate plate disc brake pis ton case Notes PTO clutch pack components disassembly 7 Pull out the spring pin 1 and remove the range shift shifter 2 Then remove the range shift fork shaft 3 and range shift driven gear 2nd 4 simultaneously ...

Page 239: ...d the caulking part of the counter shaft mounting nuts 1 to unscrew the mounting nuts Then remove the counter shaft in the rear axle case by tapping outside direction Remove the differential system assembly first Mounting nut tightening torque 78 4 98 N m 8 10 kgf m 57 6 72 lb ft Notes 9 Remove the needle bearing 1 snap ring 2 spacer 3 range shift C driven gear 4 range shift driven gear 2nd 5 snap...

Page 240: ...l hst model K42W463A K42W464A 1 Pull out snap ring 1 and remove the 4WD gear 2 2 Pull out snap ring 1 and remove the 4WD shaft 2 oil seal housing in the clutch housing side direction K42W462A When installing the range shift drive gear its long boss A should face the clutch housing Main shift driven shaft disassembly Notes ...

Page 241: ...W467A K42W468A K42W469A 3 Remove the spring pin 1 from the outside of the transmission case 4WD lever 2 and front wheel shift arm 3 5 4 Rear axle case disassembly 1 Remove the ROPS 1 2 Remove the position control knob 1 and lever cover 2 3 Remove the range shift lever knob 1 PTO lever knob 2 and lever cover 3 ...

Page 242: ...crew the seat bracket mounting bolts 1 4EA and remove the seat bracket 2 and seat 3 simultaneously 5 Remove the top link 1 lift link assembly 2 and lower link 3 6 Unscrew the hydraulic cylinder case mounting bolts 1 5EA nuts 2 5EA to remove the hydraulic cylinder case 3 7 Remove the PTO shift lever 1 range shift lever 2 and 4WD lever 3 ...

Page 243: ...ring pin 1 and remove the range shift shifter 2 Then remove the range shift fork shaft 3 and range shift driven gear 2nd 4 simultaneously 9 Pull out the snap ring 1 and remove the range shift driven gear 1st 2 4WD gear 3 and snap ring 4 When installing the 4WD gear its higher boss A should face the range shift driven gear 1st Notes K42W478B ...

Page 244: ...e counter shaft mounting nuts 1 to unscrew the mounting nuts Then remove the counter shaft in the rear axle case by tapping outside direction Remove the differential system assembly first Mounting nut tightening torque 78 4 98 N m 8 10 kgf m 57 6 72 lb ft 5 4 1 Rear axle drive section disassembly 1 Remove the brake lever plate 1 and brake lever 2 ...

Page 245: ...A K42W485A K42W486A 2 Unscrew the rear axle housing mounting bolts 1 7EA and nuts 2 2EA to remove the rear axle housing assembly 3 3 Pull out the snap ring 1 of the rear axle housing final pinion to remove the final pinion 2 Unscrew the lock nut 3 and remove the rear axle 4 final gear 5 and taper roller bearing 6 ...

Page 246: ...15R h F36R h F42R h TRACTOR K42W487A K42W488A K42W489A K42W490A When installing the final gear its higher boss A should toward the inside Notes 5 4 2 Brake assembly disassembly 1 Remove the rear axle housing assembly 1 2 Remove the pressure plate 1 and disc 2 ...

Page 247: ...APTER 4 TRANSMISSION 4 3015R h 3515R h 4015R h F36R h F42R h TRACTOR K42W491A K42W492A K42W493A K42W494A K42W495A K42W496A 3 Remove the spring 1 cam plate 2 and steel ball 3 4 Remove the inner arm 1 in the rear axle case ...

Page 248: ...bly 1 Remove the PTO cover 1 and seal cap 2 2 Pull out the snap ring 1 and remove the plate 2 and PTO drive gear shaft 3 3 Unscrew the PTO fork shaft mounting bolt 1 and remove the PTO shift shaft mounting plate 2 Then pull out the PTO shift shaft 3 to remove it from the PTO fork groove 4 Pull out the PTO fork shaft 1 and remove the PTO fork 2 steel ball 3 and spring 4 ...

Page 249: ... gear 2nd 6 and washer 7 5 4 4 differential system disassembly 1 Remove the rear axle case from the transmission Then remove the rear axle housing and hydraulic cylinder case 2 Pull out the differential lock pedal spring pin 1 and remove the differential lock pedal 2 in the arrow direction Then remove the differential fork 3 and differential spring 4 K42W4A4A K42W4A5A K42W4A66A K42W4A7A K42W4A8A K...

Page 250: ...plate 2 to the screw groove to fix the screw firmly Tightening torque 78 4 98 N m 8 10 kgf m 57 6 72 lb ft IMPORTANT 4 Unscrew the bolts 1 and remove the mounting plate 2 bearing support 3 and spring holder 4 Pull out the snap ring 5 on the opposite side and remove the shim 6 ball bearing 7 and differential system assembly 8 K42W4B1A K42W4B2A K42W4C1A 3 Remove the PTO drive gear shaft 1 K42W4A9A ...

Page 251: ...Invert the rear differential system assembly to remove the taper roller 1 2 Unscrew the differential system case 1 mounting bolts 1 and remove the ring gear 2 3 Remove the ball bearing 1 and differential lock hub 2 4 Unscrew the differential system case 2 mounting bolts 1 and remove differential system case 2 2 When installing the final gear its higher boss A should toward the inside Notes ...

Page 252: ... 6 Pull out the differential shaft 2 mounting spring pin 1 and differential shaft 2 2 to remove the pinion drive gear 3 and thrust washer 4 7 Remove the side gear 1 and washer 2 IMPORTANT 8 Install in the reverse order of removal Check the backlash of the ring gear using a dial gauge Specified value 0 15 0 25 mm 0 0059 0 0098 in After adjustment of backlash there should be no lateral free play of ...

Page 253: ...hooting 5 6 4 Sectional view for major components 5 7 4 1 Center pin support 5 7 4 2 Tie rod 5 8 4 3 Ring gear and differential gear 5 9 4 4 4WD gear case 5 10 4 5 spacer 5 11 4 6 Front drive shaft 5 12 5 Disassembly and service 5 13 5 1 Front axle case assembly removal 5 13 5 2 Front axle case component disassembly 5 17 5 2 1 Front gear case 5 17 5 2 2 Front differential 5 23 5 2 3 Front differen...

Page 254: ... 0 0059 0 0079 in 1 2 3 4 5 Pinion drive torque 0 032 0 16 kgf m 0 314 1 568 N m 0 230 1 152 lbf ft Front gear case Front final gear and final pinion backlash 0 15 0 3 mm 0 0059 0 0118 in 6 1 2 Tightening torque for major components Major components Torque value Knuckle arm and tie rod end Slotted nut 137 2 N m 14 0 kgf m 100 8 lbf ft Front axle case and front gear case Hex bolt 112 7 9 8 N m 11 5...

Page 255: ... ring gear 2 of the front differential rotating together at the reduced speed and the differential case 3 integrated with the ring gear is rotated as well Then as the differential pinion shaft is rotated together the differential pinion gear and differential side gear are engaged with each other rotating together Therefore this rotating force is transmitted to the front 1st shaft 4 since it is fix...

Page 256: ...nuckle section The knuckle section is a part to perform driving and steering functions in the front axle section and it knuckle arm front gearbox revolves around the fixed king pin section front gear case Four vertically set ball bearings and three laterally set ball bearings withstand vertical and lateral load applied to the front axle Also the rotating parts of the front spindle and front gear b...

Page 257: ...s of the tires at the center of the hub of the front axle as shown in the figure 3 Measure the rear width between the front tires with the same method 4 Subtract the front width A from the rear width B The value should be 4 8 mm 0 157 0 315 in Front 5 If the result is out of the specification unscrew the tie rod end mounting nut 1 from the knuckle arm and turn the rod 2 to adjust the distance betw...

Page 258: ...cessively Poorly adjusted toe in Excessive inflation pressure Adjust the toe in Adjust the tire pressure to the proper level It is hard to steer the vehicle Poorly adjusted toe in Damaged tie rod Defective steering cylinder connection and PST valve Adjust the toe in Replace the tie rod Check and repair the hydraulic line Noise is generated from the front axle Damaged internal gear Insufficient fro...

Page 259: ...2R h TRACTOR 5 4 Sectional view for major components 4 1 Center pin support F42W501A 1 O ring 2 Bush 3 Front Axle Supprot Ass y 4 Nipple grease 5 O ring 6 Bush 7 O ring 8 Rear Axle Supprot Ass y 9 Plate 10 Hex Flange Bolt 11 Spring Washer 12 Hex Bolt 13 Case COMPONENTS ...

Page 260: ... h 3515R h 4015R h F36R h F42R h TRACTOR 4 2 Tie rod 1 552 7 3 1 552 7 3 F42W502A 1 Tie rod ass y L 2 Tie rod ass y R 3 Nut 4 Nut 5 Nut 6 Cotter pin 7 Ring 8 Cover 9 Clip 10 Cover 11 Grease nipple 12 Knuckle arm L 13 Knuckle arm R COMPONENTS ...

Page 261: ...earing 3 Snap ring 4 Collar 5 O ring 6 Bush 7 Oil seal 8 Nut 9 Case 9 Case 10 Front first shaft 10 Front first shaft 11 Front first shaft 11 Front first shaft 12 Snap ring 13 Ball bearing 14 Differential case 15 Hex flange bolt 16 Ball bearing 17 Liner 18 Differential gear 14 19 Differential gear 10 20 Liner 21 Shaft differential pinion 22 Spring pin 23 Pin COMPONENTS Q25W502B ...

Page 262: ...nion 10 Snap ring 11 Shim 0 2T 12 Shim 0 3T 13 Shim 0 5T 14 Housing front gear 15 Lock nut 16 Ball bearing 17 Gear brvel 49T 18 Snap ring 19 Shim 0 2T 20 Shim 0 5T 21 O ring 22 Housing front bearing 23 Ball bearing 24 Oil seal 26 Front spindle 27 Bolt w washer 28 Gear front second shaft 29 Front second shaft 30 Seal 31 Ball bearing 32 Gear bevel 11T 33 Bearing 34 Bolt m14x1 5P 35 Spring washer 36 ...

Page 263: ...5 11 42hW 201601 CHAPTER 5 FRONT AXLE 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 5 4 5 spacer F42W503A 1 O ring 2 Pin 3 Spring Washer 4 Bolt COMPONENTS ...

Page 264: ...2 Propeller shaft 3 4th drive joint 4 Oil seal housing 5 O ring 6 Oil seal 7 Snap ring 8 Ball bearing 9 4th drive shaft 10 Ball bearing 11 Steel ball 12 Spring 13 4th driven gear 14 Stop O ring 15 Shaft cover front 16 Shaft cover boots 17 Hose band 18 Shaft cover back 19 Stop O ring 20 Hex flange bolt 21 Spring pin 22 Spring pin COMPONENTS ...

Page 265: ...ssembly removal 1 Park the tractor on firm level ground K25W502A 2 Unscrew the drain plug 1 on the bottom of the front axle case to drain oil from the front axle case Oil capacity for front axle 6 4ℓ 1 69 u s gal 3 Remove the propeller shaft 1 F42W504A Notes F42W505A Propeller shaft disassembly and assembly F42W506A F42W507A F42W508A ...

Page 266: ...ut the shaft cover FRT 6 in the front bracket Pull out the coupling pin 7 and remove the coupling 8 from the bevel pinion 1 2 3 9 3 7 11 6 5 5 10 11 8 Propeller shaft 4 F42W509A Propeller shaft disassembly and assembly Check the O rings 11 2 EA in the pro peller shaft If any one is faulty replace it with a new one Apply grease to the surface of a new O ring and be careful not to miss any O ring CA...

Page 267: ... front axle case is shifted so the body starts to lean Therefore fit a wooden wedge block A between the front axle case and front axle bracket before removing the front tires CAUTION F42W511A F42W512A F42W513A 5 Support the front axle case with a portable hydraulic jack or hoist Then unscrew the mounting bolts 1 of the front and rear supports to separate the supports from their front axle bracket ...

Page 268: ...y K25W509A 7 Unscrew the slotted nut 1 of the tie rod end from the front axle case assembly and unscrew the PST cylinder mounting bolt 2 to separate the PST cylinder 3 When re installing the PST cylinder apply Loctite to the threads of its mounting bolt Item Torque value PST cylinder mounting bolt 88 2 N m 9 0 kgf m 64 8 lbf ft Slotted nut 264 6 N m 27 kgf m 194 4 lbf ft F42W515A ...

Page 269: ...se assembly Then pull out the support front 2 and support rear 3 to remove them K20W520A 5 2 Front axle case component disassembly 5 2 1 Front gear case K25W511A 1 Unscrew the front bearing case mounting bolts 1 and remove the front spindle 2 and front bearing case 3 assembly together Item Torque value Mounting bolt 51 9 6 9 N m 5 3 0 7 kgf m 38 2 5 0 lbf ft ...

Page 270: ... front gearbox 4 to separate it K25W513A Item Torque value Mounting bolt 88 2 N m 9 0 kgf m 64 8 lbf ft K25W512A K25W514A 4 Remove the bearing seal 1 ball bearing 2 and front 2nd shaft 3 from the front gearbox by lifting them up K25W515A 5 Lift up the bevel gear 1 from the front gearbox to remove it K25W517A During the front 2nd shaft installation make sure that the long side section A of the spli...

Page 271: ...Apply grease to the O ring 3 of the front axle case when re installing it Notes Item Torque value Support bolt 1 88 2 N m 9 0 kgf m 64 8 lbf ft 7 Pull out the snap ring 1 for hole and remove the shim 2 and front 1st shaft pinion 3 At this moment check the amount of the shims between the snap ring and bearing so that the same amount of the shims can be fitted during assembly K25W520A K25W521A ...

Page 272: ... and front 2nd shaft gear 2 to 0 15 0 3 mm 0 006 0 012 in using 0 2T 0 3T and 0 5T shims 3 Notes 1 1 3 K25W553A 8 Remove the oil seal 1 from the front gear case Then remove the deep groove ball bearing 2 and front 2nd shaft gear 3 K25W523A K25W522A 9 Unscrew the front spindle mounting lock nut 1 from the front bearing case assembly K25W524A ...

Page 273: ...5 21 42hW 201601 CHAPTER 5 FRONT AXLE 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 5 10 Remove the bearing 1 and front final gear 2 Then remove the adjust shim 3 K25W525A K25W526A 1 2 3 K25W554A ...

Page 274: ...ounting bolt and tighten the bolt to the specified torque Then bend the lock washer to press it against the bolt head 2 Apply grease to the O ring of the front bearing case and fit it to the front gearbox 11 Separate the front spindle 1 and front bearing case 2 from each other K25W528A 12 Pull out the snap ring for hole 1 from the front bearing case and remove the deep groove ball bearing 2 K20W53...

Page 275: ... K25W530A 2 Pull out the snap ring 1 and adjusting shim 2 to remove the differential case assembly 3 from the front axle case 4 K25W533A Item Torque value Mounting bolt 29 4 N m 3 0 kgf m 21 6 lbf ft apply loctite to the threads of the bearing re tainer mounting bolt during re installation Notes Item Torque value Mounting bolt 88 2 N m 9 0 kgf m 64 8 lbf ft apply grease to the o ring 5 of the fron...

Page 276: ...2R h TRACTOR 3 Unscrew the seal collar 1 from the drive pinion pull out the oil seal 2 and remove the taper roller bearing 3 K20W542A 4 Pull out the collar 1 and snap ring 2 Then remove the drive pinion 3 by pushing into the front axle case hole K20W545A K20W544A K20W543A ...

Page 277: ... M8 10 9T 34 3 N m 3 5 kgf m 25 2 lbf ft 5 2 3 Front differential assembly disassembly 2 Remove the ball bearings 1 from both sides of the differential case assembly 3 Pull out the spring pin 1 from the knock pin hole of the differential case Then remove the differential pinion shaft 2 and differential pinion gear 10 3 together And then remove the differential side gear and liner 4 4 Assemble in t...

Page 278: ... BranSon tractors Co ltd MEMO ...

Page 279: ...case assembly 6 32 4 8 1 Hydraulic cylinder case 6 32 4 8 2 Safety valve 6 33 4 8 3 Stop valve also as slow return valve 6 34 4 9 Hydraulic filter and strainer 6 35 4 9 1 Hydraulic filter 6 35 4 9 2 HST filter HST MODEL 6 36 4 10 HST Hydrostatic Transmission HST MODEL 6 37 4 10 1 HST passage composition 6 37 4 10 2 Exterior dimension 6 38 4 10 3 Circuit diagram 6 39 4 10 4 HST pump 6 40 4 10 5 HST...

Page 280: ...mbly 6 86 7 6 Steering valve disassembly 6 87 7 7 Hydraulic pump disassembly 6 89 7 8 HST HST MODEL 6 91 7 9 Relief valve block disassembly 6 96 8 Inspection adjustment and test 6 97 8 1 PST valve 6 98 8 1 1 Relief valve pressure test 6 98 8 2 PTO valve 6 98 8 2 1 Sequence valve pressure test 6 98 8 3 Front outlet valve 6 99 8 3 1 Relief valve pressure test 6 99 8 4 HST neutral setting HST MODEL 6...

Page 281: ...EMBLY 3 7 3 I WKH ORDGHU YDOYH LV DWWDFKHG SOHDVH FKHFN WKH RSHUDWRU PDQXDO PST VALVE PTO VALVE 3 64 3 5 7 FRONT OUTLET VALVE SPECIFICATIONS PTO VALVE 2SHUDWLQJ IORZ 2SHUDWLQJ WHPS 0D SUHVVXUH GUDXOLF RLO a 30 62 9 NJI FP r a r 2SHUDWLQJ SUHVVXUH NJI FP DW 30 FRONT OUTLET VALVE 3 7 7 7 NJI FP SAFETY VALVE CONTROL VALVE SPECIFICATIONS FRONT OUTLET VALVE 5DWHG SUHVVXUH 2SHUDWLQJ WHPS 0D SUHVVXUH GUD...

Page 282: ...03D 2SHQ FHQWHU 1RQ ORDG UHDFWLRQ r 7 a NJI FP 5 3 7 3 5 a NJI FP 5 3 7 3 5 FRONT SCV ASSEMBLY 3 7 3 I WKH ORDGHU YDOYH LV DWWDFKHG SOHDVH FKHFN WKH RSHUDWRU PDQXDO PST VALVE PTO VALVE 3 64 3 5 7 FRONT OUTLET VALVE SPECIFICATIONS PTO VALVE 2SHUDWLQJ IORZ 2SHUDWLQJ WHPS 0D SUHVVXUH GUDXOLF RLO a 30 62 9 NJI FP r a r 2SHUDWLQJ SUHVVXUH NJI FP DW 30 FRONT OUTLET VALVE 3 7 7 7 NJI FP SAFETY VALVE CONT...

Page 283: ... can be divided into two parts implement section and steering PTO section Firstly the implement section receives hydraulic oil from the primary gear pump 13 cc rev and supplies this oil to the SCV valve if equipped or front outlet valve for load operation SCV rear valve if equipped for rear implement operation and control valve which is the lift valve for the 3 point hitch in order Secondly the st...

Page 284: ...12 Oil cooler 13 HST For the HST model the hydraulic circulation circuit of the primary gear pump 13 cc rev is the same to the one for the mechanical model However these two models have different methods for hydraulic pressure delivery of the secondary gear pump 7 0 cc rev Hydraulic oil supplied from the secondary gear pump is used to operate the PST valve and PTO valve Then it is carried from the...

Page 285: ...ure 3 4 MPa 35 kgf cm2 498 psi Max temperature 95 203 Steering input torque when energized Filter Nominal 10 µm 12 8 13 5 MPa 130 137 kgf cm2 1 857 1 959 psi at 8 ℓ min 1 47 N m 0 15 kgf m 1 08 lbf ft Reference Primary pump Secondary pump Theoretical discharge volume 13 0 cc rev 7 0 cc rev Maximum pressure 210 kgf cm2 210 kgf cm2 Revolving speed 500 2 500 rpm 500 3 000 rpm Turning direction when s...

Page 286: ...0 185 kgf cm2 Nominal flow 30 ℓ min Max pressure 210 kgf cm2 3 5 Rear SCV valve 3 6 PTO valve Sequence valve setting pressure 16 0 kgf cm2 Operating flow 5 19 ℓ min Max pressure 40 kgf cm2 3 7 HST HST MODEL Displacement Pump 0 28 1 cc rev Motor 28 1 cc rev Pump swash plate angle 0 18 Power input rotate direction C W View on shaft end Charge relief set pressure 5 7 kgf cm2 Filter 10 µm Neutral valv...

Page 287: ...te Min 4 400 kcal h 3 8 Oil cooler HST MODEL Type Double rod double acting type Rod O D Ø 30 mm Cylinder I D Ø 55 mm Stroke 184 4 mm Relief setting pressure 130 kgf cm2 3 9 PST cylinder Filtering area 4 972 cm2 Max fineness 110 8 µ 3 10 Hydraulic filter Filtering area 2 677 cm2 Rated flow 30 LPM Fineness 20 µ 3 11 HST filter HST MODEL ...

Page 288: ...linder according to the FF UHY FF UHY 3 5 7 PST VALVE PTO VALVE FRONT OUTLET VALVE F42W622A turning direction of the steering wheel Then the corresponding PST cylinder is extended or retracted to turn the vehicle to the desired direction Then oil used from the PST cylinder is returned to the tank through the steering valve return hose and PTO valve and it is recirculated by the pump to be used aga...

Page 289: ...e and operating principle 1 Dust seal 2 Retaining ring 3 Quad ring 4 Thrust bearing 5 Ball 6 Pin 7 Spacer 8 Center spring 9 Washer 10 O ring 11 O ring 12 Spring pin 13 Gerotor set 14 Bearing race 15 Drive 16 End cap 17 Gland bushing 18 Plate 19 Cap screw 20 Housing 21 Spool 22 Sleeve 23 Plate spring 24 Spool 25 Bushing 26 Spring 27 Control screw 28 Plug 29 O ring 30 Heli coil Cross section X X Cro...

Page 290: ...he right turn among the holes of the sleeve and spool are aligned to supply hydraulic oil to the steering cylinder for right turn When the steering wheel is stopped the spool is stopped simultaneously but the sleeve turns 10 degrees further before stopping This is because the leaf spring binds the spool and sleeve and it exerts a force to return the relative positions of the spool and sleeve to th...

Page 291: ...and is supplied to the PTO valve side When the steering wheel is turned counterclockwise the sleeve is turned counterclockwise approx 10 degrees behind the spool so the oil holes of the spool and sleeve for the left turn operation are aligned Therefore hydraulic oil at the port P is passed through the spool sleeve and Gerotor and is supplied to the right port of the PST cylinder through the port L...

Page 292: ... Gerotor and is supplied to the left port of the PST cylinder through the port R On the other hand hydraulic oil at the right port of the PST cylinder is flowed through the port L returned through the return holes of the spool and sleeve for right turn and port T and delivered to the PTO valve When the PST cylinder is moved to the left or right end and there is no more space to move further pressu...

Page 293: ...s sucked through the port R and is flowed to the Gerotor through the sleeve and spool Then after hydraulic oil is pressurized in the Gerotor it is flowed into the left side of the check valve through the spool and sleeve and leaves the right side of the valve Finally it passes through the spool sleeve and port L and flows into the right port of the PST cylinder to complete the manual left turn ope...

Page 294: ... O ring 9 Bushing 10 Stop ring type C The PST cylinder is a double rod double acting type cylinder which performs double rod operation for steering without a need of a separate tie rod Item Specifications Type Double rod double acting piston Rod O D mm ø 30 Cylinder I D mm ø 55 Cylinder O D mm ø 65 Stroke mm 184 4 Weight 7 8 kg Relief setting pressure 130 kgf cm2 10 4 8 2 1 5 6 7 9 3 F42W613A ...

Page 295: ...ted engine RPM Primary pump 13 cc rev X 2 600 rpm 33 8 lpm Secondary pump 7 0 cc rev X 2 600 rpm 18 2 lpm Item Main pump primary pump Steering pump secondary pump Theoretical discharge volume 13 cc rev 7 0 cc rev Maximum pressure 210 kgf cm2 Rotating direction Counterclockwise Clockwise Operating oil TF 500 Usable oil temperature range 20 100 Relief setting pressure 160 5 kgf cm2 Max usable turnin...

Page 296: ...nce valve 3 DRV valve F42W616A The PTO valve is installed to the rear right side of the transmission case It receives oil from the PST valve to lubricate and operate the PTO clutch and it is turned ON and OFF by the PTO switch Item Specification Operating flow 5 19 ℓ min Operating pressure Max 40 kgf cm2 Sequence valve setting pressure 16 0 kgf cm2 Operating temperature range 20 C 100 C F42W617A P...

Page 297: ...The flow P sent from the PST valve is led to the main spool through the Ø1 3 orifice and is trapped while oil discharged from the PTO clutch passes through the main spool to be returned to the tank The port T of the PST valve discharges hydraulic oil continuously regardless of movement of the steering wheel and all of this oil is flowed to the port P of the PTO valve The PTO valve consists of the ...

Page 298: ...tial engagement of the PTO clutch and reduction of shock After a certain period of time hydraulic oil of 16 kgf cm2 is delivered to the piston to achieve the maximum level of the delivered torque of the PTO clutch The DRV valve 3 is connected in the middle of the port PC line in which pressure is applied for the piston when the PTO is activated This valve delays engagement of the PTO clutch to red...

Page 299: ...ipped with single acting cylinders As shown in the circuit diagram above when hydraulic oil is applied to the port connected to the single acting cylinder this single acting cylinder is extended When hydraulic oil is applied to the opposite direction hydraulic oil is trapped so the relief valve of 180 185 kgf cm2 is opened to protect the circuit However the port connected to the single acting cyli...

Page 300: ...ve assembly is installed under the front section of the step on the right side It is connected to the main gear pump primary pump to receive hydraulic oil at a high pressure from the gear pump before any other components mainly for operation of an external implement such as a loader 5 5 DUU RYHU SOXJ 6 3RUW ಯ3 ರ 6 3RUW ಯ ರ DXJH SOXJ 5HOLHI YDOYH 3 3 7 F42W620A ...

Page 301: ... after it Passing hydraulic oil to the next device for its use from the valve is called Carryover and this is done through the port C carryover port Also the front outlet valve assembly is equipped with the relief valve main 180 185 bar This valve is opened to protect the hydraulic circuit when excessive pressure is applied in the hydraulic circuit by external shock during rear implement or lift o...

Page 302: ...f equipped through carryover operation The internal spool is operated according to the position of the control lever to lift or lower the lift arm or set it in the neutral status COMPONENTS 12 13 17 14 1 2 3 10 T2 7 8 9 16 6 17 4 15 18 5 19 11 K25W633A 1 Body 2 Main spool 3 Main spring 4 M Check poppet 5 M Check spring 6 M Check plug 7 L Check spring 8 L Check 9 L Check seat 10 Plate A 11 Plate B ...

Page 303: ...ition of the lower link the main spool of the valve is pushed in by the link structure set in the hydraulic cylinder case Then hydraulic oil is supplied to the cylinder to lift the lift arm and lower link On the contrary if the position ordered by the position control lever is lower than the current position of the lower link the main spool of the control valve is pushed out by the link structure ...

Page 304: ...ve spring is removed it opens the spool and is sucked into tank As the unload valve is opened by the pressure a the oil in the pump is returned to the tank and the pressure drops The load check valve and mechanical check valve are kept closed 4 b 7 3 5 6 a 1 2 Q25W623A 1 Safety valve 2 Slow return valve 3 Load check valve 4 Mechanical valve 5 Main spool 6 Unload valve 7 Oil tank ...

Page 305: ...closed by the spring force As the pressure in the pump rises oil flows through the flow passage in the spool and opens the load check valve to flow into the cylinder rapid lifting The mechanical check valve is kept closed 1 Safety valve 2 Slow return valve 3 Load check valve 4 Mechanical valve 5 Main spool 6 Unload valve 7 Oil tank 4 b 7 3 5 6 a 1 2 ㆣ ᜤ 㪛 Q25W624A Operation Oil flow ...

Page 306: ...ool closer to the neutral position Then the mechanical valve open slightly and the oil flow of main spool to return oil back to the tank But the majority of oil is led into the cylinder to reduce shock occurred by lifting operation 1 Safety valve 2 Slow return valve 3 Load check valve 4 Mechanical valve 5 Main spool 6 Unload valve 7 Oil tank 4 5 b 7 3 6 a 1 2 ㆣ ᜤ 㪛 Q25W625A Operation Oil flow ...

Page 307: ...tank as in the neutral state As oil in the hydraulic cylinder moves the spool the mechanical valve which is directly connected to the main spool with the pin is opened to return the oil back to the tank 4 b 7 3 5 6 a 1 2 ㆣ ᜤ 㪛 Q25W626A 1 Safety valve 2 Slow return valve 3 Load check valve 4 Mechanical valve 5 Main spool 6 Unload valve 7 Oil tank Operation Oil flow ...

Page 308: ...ssure applied to the spool is released so the spool is returned to its original position by the spring Therefore oil in the cylinder is returned back to the tank the lift arm is lowered and the spool is returned to the neutral position by the feedback rod 4 7 2 Control lever operation 4 1 2 3 Q25W627A 1 Lift arm 2 Control lever 3 Control valve 4 Feedback rod ...

Page 309: ...the cylinder Then the piston lifts the lift arm However as the feedback rod installed to the lift arm is operated to provide a lifting signal in this state the spool of the control valve is returned to the neutral position even with the control lever still in the lifting position Therefore the spool is returned to the neutral position during the lowering operation as well 1 Lift arm 2 Control leve...

Page 310: ... 8 Hydraulic cylinder case assembly 4 8 1 hydraulic cylinder case r r 2 6 5 r HYHU RSHUDWLRQ DQJOH 9 8 1 3 4 7 K20W6a35A components 1 Safety valve 2 Lowering speed control valve 3 Cylinder assy 4 Lift Lowering valve 5 Piston rod 6 Lift crank 7 Lift arm 8 Draft lever assy 9 Position lever assy ...

Page 311: ...hrough the lift solenoid valve of the control valve If the lift arm is overloaded by this oil pressure in the circuit rises continuously In other words if impact pressure is applied from an external source to an implement and this pressure is over a certain limit the safety valve is opened to drain oil back to the tank in order to protect the internal circuit of the hydraulic implement Relief valv...

Page 312: ...lowering or adjust the lowering speed of the hydraulic lift When turning the handle counterclockwise the lowering speed of the lift arm increases Turning it clockwise slows down the lowering speed Also when turning it clockwise to its end the oil flow passage is blocked so the lift arm is stopped at the current position K25W643A KHFN YDOYH 6WHHO EDOO K25W644A ...

Page 313: ... gear pump Hydraulic oil is flown through the hole on the top of the oil filter cartridge and is passed from the outside to the inside of the filter Then it is flowed in through the hole in the middle of the cartridge JMUFS FMFNFOU JMUFS FMFNFOU IPMF PG UPQ K20W622A Filtering area 4 972 cm2 Number of folds 55 Folding width 195 17 55 folds Bursting strength 4 5 bar Max fineness 110 8 µ Min fineness...

Page 314: ...ed from the PTO valve side passes through the HST filter it is filtered before it returns into the oil cooler for cooling and flows into the HST A42W607A Replace after initial 50 hours and then every 300 hours of use Notes Filtering area 2 677 cm2 Number of folds 75 Folding width 105 17 75 folds Rated flow 30 ℓ min Bursting strength 17 kgf cm2 Fineness 20 µ SPECIFICATIONS A42W648B ...

Page 315: ...to the transmission The input shaft of the HST is connected to the spring damper which is installed to the flywheel of the engine with the spline to receive turning force from the engine Its HST pump is driven by receiving this turning force through the input shaft of the HST and hydraulic oil led into the HST is sent to the hydraulic motor to supply new rotating force to the transmission As the H...

Page 316: ... 6 HYDRAULIC SYSTEM 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 4 10 2 eXTERIOR DIMENSION 3 2 ULQJ SRUW 3 2 ULQJ SRUW 3 2 ULQJ SRUW pg β pg α B α β 97 5 85 91 MAX 91 MAX 85 5 61 105 0 05 18 18 α β 26 5 0 2 265 5 300 A42W609B ...

Page 317: ...015R h 3515R h 4015R h F36R h F42R h TRACTOR ⴏ Sj5 便 㨏ⴏ W E Sj4 俀 Sj5 便 Sj4 俀 4 3 1 5 6 7 2 A42W610B 4 10 3 Circuit diagram 1 HST pump 2 Oil cooler 3 Neutral valve 4 Neutral valve 5 Charge relief valve 6 Main relief valve 7 HST motor Forward Reverse ...

Page 318: ...the motor shaft in the HST is changed to enable forward or reverse driving The inclination of the swash plate in the pump is adjusted within the range of 18 18 and its angle determines the driving direction and vehicle speed A42W611A 4 10 5 HST motor 1 Piston 2 Shaft The motor in the HST has a shape similar to the pump but it is equipped with the fixed swash plate making it a fixed capacity type A...

Page 319: ...ted in the circuit continuously For this the pump for charge continuously supplies oil to the low pressure side circuit in which oil is returned from the motor The setting pressure of the charge relief valve is 5 7 kgf cm2 When pressure rises due to surplus oil or load in the high pressure side the charge relief valve opens to send oil to the oil tank During forward or reverse driving high pressur...

Page 320: ...6 42 42hW 201601 CHAPTER 6 HYDRAULIC SYSTEM 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 4 10 7 Neutral valve C865W715A 㨏ⴏ ⓘᜏ ྻ ⱜᴈႷཏ ⴏ Speed Reverse Distance Forward Neutral section K25W662B ...

Page 321: ... the swash plate to 0 for the neutral setting To solve this problem the neutral valve is installed to obtain the minimum range to keep the neutral state When the angle of the swash plate is close to but not exactly 0 a small amount of oil is discharged to the motor In this case the neutral valve drains this oil through its orifice to prevent internal pressure rise before it reaches the motor This ...

Page 322: ...d the pump is also increased As a result hydraulic pressure rises gradually and eventually exceeds the setting pressure of the return spring of the neutral valve Then the spool of the neutral valve is moved to close the orifice leading oil to the motor through the internal circuit Forward reverse driving ⴏ Sj5 便 㨏ⴏ W E Sj4 俀 Sj5 便 Sj4 俀 A42W616B HST Motor Forward Reverse HST Pump Neutral valve spo...

Page 323: ...ated during forward or reverse driving oil in the high pressure side circuit is delivered to the low pressure side circuit to prevent damage of the internal circuit due to load On the other hand oil supplied by the charge pump is sent to the low pressure circuit through the check valve on the neutral valve side ⴏ Sj5 便 㨏ⴏ W E Sj4 俀 Sj5 便 Sj4 俀 A42W617B High pressure line Main relief valve Low pres...

Page 324: ...ER 6 HYDRAULIC SYSTEM 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 4 10 9 HST PEDAL and LINK COMPONENTS 1 2 4 7 8 3 12 5 6 9 10 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 18 27 28 29 30 31 32 33 18 34 35 A42W618B A42W645B ...

Page 325: ...nnecting joint is rotated for the amount of movement of the pedal in the reverse direction for the forward backward driving The connecting joint is connected to the swash plate of the HST While it is turned clockwise or counterclockwise it determines the driving direction forward reverse and driving speed Also the connecting joint is engaged with the neutral control bracket 21 This neutral control...

Page 326: ...ting joint 3 clockwise Changing the angle of the HST swash plate 0 18 Turning and lowering the neutral control bracket 4 clockwise Detecting the forward condition of the safe start neutral switch 4 Pulling the HST accelerator cable 6 Increase of the engine speed Lowering the reverse driving pedal 1 and lifting the forward driving pedal 2 Turning the connecting joint 3 counterclockwise Changing the...

Page 327: ...trol lever is moved its link moves the control valve spool in the hydraulic cylinder case to the lifting or lowering position As soon as the lever stops moving the spool is returned to its neutral position to stop the 3 point hitch 4 11 OIL COOLER HST MODEL A42W622B 67 ILOWHU 67 2 ULQJ ERVV W SH 3 A42W623B The oil cooler is installed to the face of the radiator in the engine compartment Oil is hea...

Page 328: ...st load resistance of an implement during draft work with an implement such as a plow and cultivator When an implement is loaded load is applied to the top link connection A through the top link When the top link connection is applied with load it pushes the top link hinge at the point B Then the bracket 2 is pushed forward to push the connecting link DF 4 Therefore the lower section of the link D...

Page 329: ...op valve Remove and clean the control valve Impossible to drive forward or backward HST MODEL Damaged power train Clogged HST internal circuit Incorrectly set neutral position of HST pedal Insufficient hydraulic oil amount Clogged HST filter Faulty HST Check and adjust the power train Check if the check valve relief valve etc and clean them accordingly Set the HST neutral range correctly Add oil C...

Page 330: ... Support steering 2 Hex flange bolt 3 PST valve ass y 4 Column steering 5 Hex flange bolt 6 Hex flange bolt 7 Cover shaft 8 Steering wheel ass y 9 Plain washer 10 U nut 11 Steering cap 12 Pipe assy steering 13 Shaft steering 14 Snap ring 15 Ball bearing 16 Snap ring 17 Column bush COMPONENTS 11 10 9 8 7 5 4 6 6 4 3 2 1 17 13 14 12 15 14 16 A42W624A ...

Page 331: ...01 CHAPTER 6 HYDRAULIC SYSTEM 6 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 6 2 P S T cylinder K25W606A 1 P S T cylinder ass y 2 Hex flange bolt 3 Hex flange bolt 4 Cover P S T cylinder 5 Hex flange bolt COMPONENTS ...

Page 332: ...6 54 42hW 201601 CHAPTER 6 HYDRAULIC SYSTEM 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 6 3 P S T pipe 1 Hose 2 Hose 3 Hose 4 Hose COMPONENTS 4 1 2 3 A42W625A ...

Page 333: ...3015R h 3515R h 4015R h F36R h F42R h TRACTOR 6 4 HYD pump 1 1 3 57 5 6 66ಬ F42W603A 1 Hyd pump 2 Elbow 3 Packing 4 Elbow 5 Stud bolt 6 Hyd pump 7 O ring 8 Joint 9 Elbow 10 Packing 11 Spring washer 12 Hex nut 13 Hex bolt 14 Bolt w washer COMPONENTS ...

Page 334: ...5 Case HYD cylinder F42W604A 2 Bolt w washer 3 Plug 4 O ring 5 Control valve ass y 6 O ring 7 Bolt w washer 8 Pin 9 Case hyd cylinder 10 Snap ring 11 Roller 12 Hex nut 13 Clabis ass y 14 Stud bolt 15 Bracket switch 16 Spring washer 17 Hex nut 18 Bolt w washer 19 Pin 20 Air breather COMPONENTS ...

Page 335: ...1601 CHAPTER 6 HYDRAULIC SYSTEM 6 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 6 6 Relief valve 1 Valve relief 2 O ring 3 O ring 4 O ring 5 Elbow 6 Washer ass y hex bolt COMPONENTS F42W605A 3015R h 3515R h 4015R h ...

Page 336: ...aft ass y 5 Snap ring E 6 Bush 7 Boss B ass y 8 Link 1 ass y 9 Cotter pin 10 Plain washer 11 Hex flange bolt 12 Bracket ass y 13 Bracket scv lever 14 Hex flange bolt 15 Bracket 16 Cover relief 17 Scv PTO 3sd 18 Scv 2port 19 O ring 20 O ring 21 Stud bolt 22 Spring washer 23 Hex nut 24 O ring 25 Joint 1 2 26 Joint arm 1 2 27 O ring 28 Elbow COMPONENTS F36R h F42R h ...

Page 337: ...ss y 2 O ring 3 Ring 6 Piston 7 Rod piston 8 Spring pin 9 O ring 10 Hex bolt 11 Plug 12 Ring backup 13 O ring 14 Bush 15 Shaft lift link 16 Hex flange bolt 17 Plate 18 Crank lift 19 Arm lift 20 Cam ass y 21 Hex flange bolt 23 Hex flange bolt 24 Snap ring C type 25 Bonded seal 26 Ring backup 27 O ring 28 Bush 29 Collar COMPONENTS ...

Page 338: ...PTER 6 HYDRAULIC SYSTEM 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 6 8 Safty valve K25W612A 1 Safety valve ass y 2 Nut 3 Bolt 4 O ring 5 Body safety valve 6 O ring 7 Spring 8 Ball guide 9 Steel ball 10 O ring COMPONENTS ...

Page 339: ... HYDRAULIC SYSTEM 6 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 6 9 Stop valve K25W613A 1 Stop V V 2 Stop bolt 3 O ring 4 Nut 5 O ring 6 Body stop V V 7 Steel ball 8 O ring 9 Spring 10 Ring backup 11 Knob 12 Hex nut COMPONENTS ...

Page 340: ...on type K25W614A 1 Shaft position lever 2 D control shaft 3 Bush 4 Snap ring E 5 Plate 6 Snap ring 7 Link ass y 8 Plate 9 Snap ring 10 Roller 11 Link B ass y 12 Spring 13 Link 14 Link ass y in 15 Link feed back 16 Snap ring E 17 Link 18 Pin feed back 19 Spring washer 20 O ring 21 O ring 22 Link position COMPONENTS ...

Page 341: ...h F42R h TRACTOR K25W615A 1 Connector 2 Bonded seal 3 Bracket 4 Bracket 6 Bolt 7 Bracket A 8 Plate friction 9 Lever D control 10 Plate A 11 Lever P control 12 Spring 13 Hex nut 14 Knob ass y draft control 15 Screw 16 Knob ass y positoin control 17 Screw 18 Arm lever COMPONENTS ...

Page 342: ...3 Hinge D top link 4 Hex nut 5 Nipple 6 Pin hinge 7 Bolt w washer 8 Hex flange bolt 9 Plate 10 Plate hinge 11 Plate 12 Bolt w washer 13 Support D hinge 14 Plate 15 Hex flange bolt 16 Plate ass y 17 Snap ring E 18 Plate ass y 19 Hex fix nut 20 Rod 21 Link ass y out 22 Snap ring E 23 Spring pin 24 Body 25 O ring 26 Hinge top link COMPONENTS ...

Page 343: ... F42R h TRACTOR 6 12 HYD piping 1 Rubber hose 2 Spring a 3 Hose clamp 4 Pipe ass y lower pressure 5 Hex flange bolt 6 Hose band 7 Lower pressure hose 8 Front out valve 9 Elbow 10 Elbow 11 O ring 12 Nipple 13 Hose 14 Higher hose 15 Pipe ass y higher pressure COMPONENTS K42W611B ...

Page 344: ...ULIC SYSTEM 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 6 13 HYD filter F42W609A 1 Filter 2 Filter cover 3 O ring 4 Lower pressure pipe filter 5 Hex flange bolt 6 O ring 7 Filter cover bracket 8 Hex flange bolt COMPONENTS MEC MODEL ...

Page 345: ...2R h TRACTOR 6 2 1 7 12 7 3 4 5 8 8 9 10 11 13 14 7 A42W626A 1 Filter 2 Filter cover 3 O ring 4 Lower pressure pipe filter 5 O ring 6 Filter cover bracket 7 Hex flange bolt 8 Bracket 9 Bolt w washer 10 Filter cover 11 Filter 12 Hex flange bolt 13 Elbow 14 Hose COMPONENTS HST MODEL ...

Page 346: ...h TRACTOR 6 14 HYD PUMP HST MODEL 4 6 14 13 10 11 9 1 1 2 3 5 7 12 8 A42W627A 1 Mission case 2 Plate 3 Hst 28cc 4 Parallel pin 5 Parallel pin 6 Hex flange bolt 7 O ring 8 O ring 9 Parallel pin 10 Snap ring 11 Hex bolt w washer 12 Hex bolt w washer 13 Adaptor 3 8 14 Elbow COMPONENTS ...

Page 347: ...HAPTER 6 HYDRAULIC SYSTEM 6 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 6 15 OIL COOLER HST MODEL 1 Oil cooler 2 Bracket oil cooler l 3 Bracket oil cooler 4 Hex flange bolt 5 Elbow 6 Hose COMPONENTS 67 7 5 67 A42W628B ...

Page 348: ...e assembly disassembly and assembly K42W614A K42W615A K42W616A K42W617A K20W6A06A position draft control type K20W6A07A position draft control type 1 Remove the fender and plate of under the seat 2 Remove the hydraulic cylinder case assembly 1 3 Disconnect the hydraulic pipe 1 and remove the top link bracket assembly 2 and rear relief valve 3 ...

Page 349: ...he control valve 1 from the hydraulic cylinder cover 6 Remove the safety valve 1 from the hydraulic cylinder cover K20W6A08A K20W6A09A K20W6A10A 4 Unscrew the hydraulic cylinder cover mounting bolts 1 to remove the hydraulic cylinder cover 2 K42W618A position control type K42W619A position control type ...

Page 350: ...ntrol valve assembly 1 K20W6A13A position draft control type K20W6A14A position draft control type K42W620A position control type K42W621A position control type 8 Unscrew the lever retaining nut 1 Then remove the bracket A 2 spring 3 bracket A 2 plate 5 P lever 4 plate 5 bracket A 2 plate 5 D lever 6 friction plate 7 and bracket 2 in order ...

Page 351: ...side Then disconnect the lift arm 2 K42W622A 10 Remove the cam assembly 1 from the left side and pull out the snap ring Then disconnect the lift arm 2 K20W6A19A K20W6A20A 12 Unscrew the plate 1 and pull out the lift link shaft 2 to the right K25W6A18B 11 Disconnect the draft control rod 1 K42W623A K42W624A position draft control type ...

Page 352: ... new one K20W6A26A Notes K20W6A24A K20W6A25A Insert the lift link shaft from the right to the left side aligning the matching mark on the lift link shaft with the matching mark on the lift crank K20W6A23A IMPORTANT 13 Pull out the E type snap ring 1 for the lift crank link Then remove the lift crank 2 and piston rod 3 together 14 Unscrew the hex bolt 1 and remove the piston assembly 2 to separate ...

Page 353: ...g 1 and pull out the E snap ring 2 Then remove the position link 3 position feedback link 4 connecting link 5 and position lever shaft 6 16 Pull out the snap ring 1 and disconnect the draft load control link 2 and D control shaft 3 17 Assemble in the reverse order of disassembly position draft control type position draft control type position draft control type ...

Page 354: ...6A34A K20W6A35A K20W6A36A 1 Unscrew the control valve mounting bolts 1 from the hydraulic cylinder cover to remove the control valve 2 2 Unscrew the hex nut 1 from the control valve to separate the clevis assembly 2 and plate 3 3 Remove the main spool 1 main spring 2 load check 3 load check seat 4 and load check spring 5 from the control valve ...

Page 355: ...6R h F42R h TRACTOR K20W6A37A K20W6A38A K20W6A39A 4 Unscrew the main check plug 1 and remove the main check poppet 2 and main check spring 3 5 Unscrew the unload plug 1 and remove the plate 2 unload spring 3 and unload check 4 6 Assemble in the reverse order of disassembly ...

Page 356: ...47A 3 Check if the O rings for the hydraulic cylinder and hydraulic cylinder cover are missing or damaged Apply grease on them before their installation a NJI FP 7LJKWHQLQJ WRUTXH 7LJKWHQLQJ WRUTXH a NJI FP K25W6A48A 4 When installing the safety valve 1 and lowering speed control valve 2 check if their O rings are missing or damaged Also apply grease on them before installation 7LJKWHQLQJ WRUTXH a...

Page 357: ...k shaft and lift arm align their matching marks 7LJKWHQLQJ WRUTXH a NJI FP 7LJKWHQLQJ WRUTXH a NJI FP K25W6A54A 9 When installing the hydraulic cylinder cover apply liquid gasket A on it in advance K25W6A55A 10 When installing the hydraulic cylinder apply LOCTITE on it and follow the specified tightening torque 7LJKWHQLQJ WRUTXH a NJI FP 7LJKWHQLQJ WRUTXH a NJI FP K25W6A56A 11 When installing the ...

Page 358: ...ification specified in the figure When installing the cam assembly turn it counterclockwise for 5 mm from the end of the long hole 7LJKWHQLQJ WRUTXH a NJI FP 7LJKWHQLQJ WRUTXH a NJI FP 2 1 K25W6A60A 15 When installing the rear SCV make sure that its O ring is not missing or damaged 16 When installing the SCV tighten its nut to the specified torque 200 250 kgf cm 17 When installing the quick couple...

Page 359: ...g height 47 5 49 269 273 5 16 3 17 3 14 8 10 3 2 If the lifting angle or lowering angle is out of the specified range adjust it with the clevis adjusting nut Initial setting value Y 29 mm or Z 13 mm with X 10 mm Repeat adjustment 2 to 3 times for precise setting K25W6A62A 3 Apply LOCTITE to the adjusting nut before its installation Excessive lifting height decrease the length Y and Z Insufficient ...

Page 360: ...from the back of the tractor and unscrew the mounting nuts 2 and disconnect the connecting bracket 3 to remove the rear SCV valve assembly K20W6A41A 2 Remove the rubber bellows 1 and pull out the retaining pin 2 Then remove the arm 3 K20W6A42A 3 Remove the covers 1 2 K20W6A43A F42W636B f series au 4 ports standard 15 series us 4 ports optional 35HW602A f series eu 2 ports standard ...

Page 361: ...AULIC SYSTEM 6 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 4 Pull out the spool 1 in the arrow direction K20W6A44A K20W6A45A K20W683A 4 Unscrew the relief valve 1 from the other side to remove it Then pull the spool 2 to remove it ...

Page 362: ...1A K42W634A K42W632A K42W633A 7 5 PTO valve disassembly 1 Disconnect the PTO valve wiring 1 connector and hydraulic pipe 2 and unscrew the mounting bolts 3 to remove the PTO valve assembly 2 Unscrew the mounting nuts 1 from the PTO valve assembly to remove the solenoid valve 2 3 Remove the sequence valve 1 ...

Page 363: ... h 3515R h 4015R h F36R h F42R h TRACTOR K42W635A K42W636A K20W6A09A 5 Remove the magnet housing 1 of the PTO solenoid Remove the internal valve and spool as well K20W6A10A K42W637A 6 Assemble in the reverse order of disassembly 4 Remove the DRV valve 1 ...

Page 364: ... K42W641A K42W640A K42W642A 4 Assemble in the reverse order of disassembly 7 6 Front outlet valve disassembly 1 Disconnect the hydraulic hose from the front outlet valve and unscrew the bracket mounting bolts to remove the front outlet valve 1 assembly 2 Remove the carry over plug 1 3 Remove the relief valve ...

Page 365: ...valve disassembly 1 Remove the upper dashboard part 1 and column cover 2 3 Remove the hydraulic hoses 1 from the steering valve assembly 2 Unscrew the steering valve assembly mounting bolts 1 under the steering wheel and push down the steering valve assembly to remove it K42W643A a42w629a a42w631a a42w630a ...

Page 366: ...ssembly to remove the end cap 2 The bolt A among the end cap mounting bolts is longer than the other ones Make sure to in stall it correctly IMPORTANT K20W6A20A 5 Remove the spacer 1 and gerotor set 2 in order K20W6A21A 6 Pull out the drive 3 and remove the plate 4 spool and sleeve assembly 5 thrust bearing 6 O ring 7 grand bushing 8 and retaining ring 9 in order ...

Page 367: ...aulic pump assembly 2 Unscrew the housing mounting bolts 1 and remove the rear cover 2 K20W6B6A 3 Separate the shaft holding block 1 and each housing 2 from the cabin 4 Remove the drive gear 3 driven gear 4 and front cover 5 The seal 1 of the shaft holding block should face the housing when assembling it IMPORTANT K20W6B8A 5 Assemble in the reverse order of disassembly Item Torque value Mounting b...

Page 368: ...nting bolts 1 and remove the rear cover 2 3 Separate the shaft holding block 1 from the housing 2 4 Remove the drive gear 3 driven gear 4 and front cover 5 The seal 1 of the shaft holding block should face the housing when assembling it And open section of the seal should face the suction side of the housing IMPORTANT 5 Assemble in the reverse order of disassembly Item Torque value Mounting bolt 2...

Page 369: ... 10 mm L shape wrench 2 Unscrew eight HST front cover mounting bolts 1 to remove the front cover 2 Front cover disassembly 3 Remove the plug 1 spring 2 spring seat 3 and spool 4 from the upper section of the front cover Then remove the main relief valve 5 10 mm L shape wrench 8 mm L shape wrench K25W662A Align the grooves A of the valve plate with the knock pin 1 of the HST case during as sembly N...

Page 370: ...older 1 from the inner upper section of the front cover Then remove the spring 2 and check valve 3 c865w769a 5 Remove the valve plate 1 on the motor side Then separate the cylinder block 2 and piston assembly 3 Set the valve plate grooves A on the motor side toward the cylinder block during assem bly groove in section A two both directions Notes c865w770a A42W635A ...

Page 371: ...6 93 42hW 201601 CHAPTER 6 HYDRAULIC SYSTEM 6 3015R h 3515R h 4015R h F36R h F42R h TRACTOR c865w772a c865w773a Cylinder block c865w771a Valve plate c865w774a Piston assembly ...

Page 372: ...g snap ring direction A42W646A A42W636A c865w776a K25W673A K25W677A 7 Remove the valve plate 1 on the pump side Then remove the cylinder block 2 piston 3 set plate 4 and shoe plate 5 after separate the cylinder block and piston assembly Set the valve plate grooves A on the pump side toward the cylinder block during assembly groove in section A one rotating direction Notes c865w779a K25W676A ...

Page 373: ...6R h F42R h TRACTOR 8 Remove the pump shaft cover 1 And pull out the snap ring 2 from the inside and disconnect the pump shaft 3 K25W681A K25W680A 9 Remove the cover 1 M6 bolt 3 EA 5 mm L shape wrench Pump shaft disassembly Swash plate disassembly A42W639A A42W638A A42W637A ...

Page 374: ... to remove the swash plate 2 M6 bolt 3 EA 4 mm L shape wrench A42W641A A42W640A K42W654A K42W655A K42W656A 7 10 Relief valve block disassembly 1 Disconnect the hydraulic hose 1 of the relief valve block from the back of the tractor and unscrew the mounting bolts 2 to remove the relief valve 3 2 Remove the relief valve ...

Page 375: ...ature Oil warming up procedure 1 Lower the 3 point hitch completely 2 Idle the engine at a low speed 3 Pull the SCV lever If equipped backwards to set the system in the relief status 4 Pull the lever backwards until the suction line becomes too hot to touch The oil temperature at this point should be ap prox 38 43 100 110 Notes Do not place the SCV lever or joystick lever into the extending or ret...

Page 376: ...kgf cm2 12 74 MPa 1 849 psi If the measurement is out of the standard resetting the relief valve or replace the PST valve 8 1 pst valve 8 1 1 Relief valve pressure test 8 2 PTO valve 8 2 1 Sequence valve pressure test 1 Unscrew the port G1 plug PF1 4 C of the PTO valve and connect an adapter hydraulic pressure gauge and hydraulic hose 2 Start the engine and run it at 2 600 rpm 3 Check the pressure...

Page 377: ...e specified value adjust the relief valve or replace the front outlet valve K42W661A 8 4 hst neutral setting hst model A42W642A A42W643A 1 Lift the vehicle off the ground so that the wheels idle above the ground 2 Set the engine to idle speed 3 Set the range shift lever to the low position 4 Check if the wheels rotate forward or backward with the HST pedal released 5 If the wheels rotate in the fo...

Page 378: ...edal fully Then measure the pressure of the high pressure relief valve for forward driving 4 If the measurement is out of the standard 380 kgf cm2 check the high pressure relief valve and HST body 5 Perform the same measurement for the reverse driving side 1 Pressure measuring port of high pressure relief valve forward driving PT 3 8 2 Pressure measuring port of high pressure relief valve reverse ...

Page 379: ...t controller 7 27 5 2 7 Flasher unit 7 29 5 2 8 cruise controller HST model 7 30 5 2 9 Safe start switch MEC model 7 31 5 2 10 PTO engagement switch 7 32 5 2 11 Stop lamp switch 7 33 5 2 12 Safety start neutral switch HST model 7 33 5 2 13 Starter 7 34 5 2 14 Alternator 7 35 5 2 15 Engine oil pressure switch 7 35 5 2 16 Coolant temperature sensor preheating 7 36 5 2 17 Coolant temperature sensor m...

Page 380: ......

Page 381: ...C 12 V 70 A PTO engagement switch Rated current 14 V 15 A Safety switch 12 V 10 A Preheat controller Voltage range DC 8 16 V Flasher unit Voltage range DC 10 16 V Direct signal lamp front 12 V 21 W 5 W Combination lamp rear 12 V 27 W 12 V 8 W 12 V 21 W 5 W Head lamp HS1 12V 35W 35W Horn 12 V 350 2 Hz 110 5 dB Fusible link 60 A X 2 EA Cruise controller HST MODEL DC 12V 1A Safety start neutral switc...

Page 382: ......

Page 383: ...UFS UFNQ TFOTPS MPX MUFSOBUPS 4UBSUFS ENGINE LH 3015R h 3515R h 4015R h ENGINE RH 3015R h 3515R h 4015R h ENGINE RH F36R h BONNET HINGE ASSEMBLY 4BGF TUBSU TXJUDI 0 VFM TFOTPS 150 FOHBHFNFOU TXJUDI 4UPQ MBNQ TXJUDI 0 0JM QSFTTVSF TXJUDI VFM DVU PGG TPMFOPJE YIBVTU HBT UFNQ TFOTPS JGGFSFOUJBM QSFTTVSF TFOTPS PSO 8BUFS UFNQ TFOTPS MPX VTJCMF MJOL VTF CPY 8BUFS UFNQ TFOTPS FUFS 4BGFUZ TUBSU OFVUSBM T...

Page 384: ......

Page 385: ...7 21 6 1 03 5 5 5 20 1 7 21 03 5 0 7 5 3 1 5 5 20 1 7 21 03 5 0 7 5 3 1 7 2 7 5 5 20 1 7 21 03 5 7851 2 5 5 5 20 1 7 21 03 6723 03 75 5 7 03 75 5 86 6 81 7 7 7 7 7 8 6 85 5 5 6 85 5 7 7 5 5 7 7 5 03 6 6723 03 6 U 3 7 5 1 1 6723 62 5 6 7 1 5 725 2 5 87 6 7 6 6 86 3 5 5 372 9 9 372 5 3 3 372 1 6 7 3 5 3 6 7 6 7 167580 17 3 1 3 0 7 5 3 1 5 03 86 86 86 5 1 75 5 2 5 77 7 77 86 9 1 6 11 5 6 1625 7 03 6 ...

Page 386: ... 5 5 20 1 7 21 03 5 0 7 5 3 1 7 2 7 5 5 20 1 7 21 03 5 7851 2 5 5 5 20 1 7 21 03 6723 03 75 5 7 03 75 5 86 6 81 7 7 7 7 7 8 6 85 5 5 6 85 5 7 7 5 5 7 7 5 03 6 6723 03 6 U 3 7 5 1 1 6723 62 5 6 7 1 5 725 2 5 87 6 7 6 6 86 3 5 5 372 9 9 372 5 3 3 372 1 6 7 3 5 3 6 7 6 7 167580 17 3 1 3 0 7 5 3 1 5 03 86 86 86 5 1 75 5 2 5 77 7 77 86 9 1 6 11 5 6 1625 7 03 6 1625 86 251 251 7 3 2 5 372 1 0 17 6 3015R...

Page 387: ...ition Symbol Description Symbol Description Battery Diode Fusible link Gauge Fuse Lamp Relay Feed pump Switch Fuel cut off solenoid Starter Horn Alternator Beacon Glow plug Water temp sensor ᅻ Symbol Color B Black Y Yellow G Green W White L Blue R Red Br Brown Gr Gray Or Orange Lg Light green BW Black primary White secondary YG Yellow primary Green secondary Primary Secondary T ...

Page 388: ...6 6 7 6 7 2 5 2 5 67 57 5 5 7 5 7 03 5 785 6 1625 5 POWER GROUND F42W703A There are two fusible links at the end of the wiring 3 0R above the battery in the left section of the circuit diagram The fusible link on the wiring 3 0Y is to supply main power to the glow relay When the glow relay is energized power is supplied to the glow plug to operate it The fusible link on the wiring 3 0W is related ...

Page 389: ...2 5 86 7 3 1 5 725 3 6 7 67 57 5 5 3 67 57 5 5 3 6 5 5 5 5 3803 5 86 5 5 20 1 7 21 6 7 7 86 5 86 86 6 81 7 7 8 6 85 5 5 6 85 5 7 7 5 5 6723 03 6 5 1 1 6723 62 5 6 7 1 5 725 2 87 6 7 6 6 372 1 0 17 6 86 3 5 5 372 5 3 372 1 6 7 3 5 3 6 7 6 7 167580 17 3 1 86 86 86 5 1 75 5 5 86 2 5 8 3803 8 87 0 1 7 9 9 7 5 7 03 5 785 6 1625 POWER GROUND F42W704A ...

Page 390: ... it is connected to the fuel feed pump through the 5 A fuse and wiring 0 85RG to run the fuel feed pump with the ignition switch ON Fourthly it is connected to the fuel cut off solenoid through the 10 A fuse and wiring 0 85RY to supply and cut off fuel depending on the position of the ignition switch ON OFF Fifthly it is delivered to the brake lamp switch switch through the 20 A fuse Sixthly it is...

Page 391: ...enerator is not operated properly after heating operation is not performed It receives the manual preheating signal from the ignition switch through the wiring 0 85L It receives the coolant temperature signal through the wiring 0 5LB It receives the ignition switch ON signal through the wiring 0 5RB It sends power to the preheat indicator on the instrument cluster through the wiring 0 5LW and inst...

Page 392: ... clutch pedal to stop PTO when the clutch pedal is depressed Therefore when the PTO switch is set to the Manual position depressing the driving clutch pedal stops the PTO The wiring 0 5YB is passed through another switch before it is connected to the PTO relay This is the PTO engagement switch which is installed to the 3 point hitch lift arm lever When setting the 3 point hitch to the lifting posi...

Page 393: ...wiring 0 85YL It is sent to the instrument cluster through the connecting wiring E to inform the driver with the PTO operation status before it reaches the PTO valve Therefore the PTO indicator on the instrument cluster can be turned on properly even when the PTO is not operated due to malfunction of the PTO valve Also when the PTO selection switch is set in the LINK position the PTO indicator on ...

Page 394: ...d by controlling electricity supplied to its negative terminal 4 Parking indicator optional The parking indicator is connected to the parking switch through the wiring 0 5YG The parking indicator on the instrument cluster is operated by controlling electricity supplied to its negative terminal 5 One side brake warning lamp optional The one side brake warning lamp is connected to the one side brake...

Page 395: ...fore the charge warning lamp is turned off when the generator charges normally 9 Tachometer The hourmeter and tachometer have two input terminals and two output terminals One input terminal is supplied with ignition ON power the instrument cluster input power The other input terminal is connected to the terminal P alternating current wave terminal of the generator through the connecting wiring D t...

Page 396: ... lamp high beam through the wiring 1 25GL It is also connected to the high beam indicator on the instrument cluster 3 Low beam The terminal No 1 of the combination switch is connected to the head lamp low beam through the wiring 1 25GB As shown in the circuit diagram the high beam and low beam bulbs are integrated into one unit which receives power for both beams 4 Position Tail lamp The terminal ...

Page 397: ...to the front combination lamp rear combination lamp and left turn signal indicator on the instrument cluster to make each lamp flicker The flasher unit has two input power wirings One is the wiring 1 25RW which receives power from the terminal ACC of the ignition switch It branches off after the turn signal lamp fuse 20 A and is connected to the flasher unit The power from the terminal ACC is used...

Page 398: ... 86 9 1 6 11 5 6 1625 7 03 6 1625 86 3 2 5 K25W736B When the ignition switch is turned to the ON position power flows through the wiring 3 0WR to be delivered to the DPF logger through the fuse No 11 5 A If a faulty condition is detected by the differential pressure sensor of the DPF the corresponding signal is delivered to the instrument cluster through Ⓖ to turn on the DPF warning lamp ...

Page 399: ... 5 When re installing the battery connect the positive cable first and then the negative cable firmly loose battery terminal can cause a spark or poor charging performance if the cable terminal is contaminated clean it thorough ly and apply grease on it Notes keep flames or sparks away from the battery it can ex plode due to gas production during its operation as the battery discharges naturally c...

Page 400: ... Never attempt to modify electric wirings of the ma chine it can cause a fire WARNING Inspection order for electric sys tem and circuit failure Battery Fusible link Fuse ignition relay switch load Notes 5 1 2 Fuse Fuse Fusible Link Slow blow Fuse 6015W702A 6015W703A 6015W704A If any electric part is malfunctioning check the fuse first 1 Make sure to use the fuse with the specified capacity 2 Check...

Page 401: ...n switch clockwise to the first position ON is selected When turning it to its end the engine is started When releasing the switch as soon as the engine is started the switch is automatically returned to the ON position Connector and wiring diagram Item Terminal symbol B BR1 BR2 C1 C2 E Switching position OFF 2 C 1 R B 2 R B E 1 C B R W 5 S V A B 3 S V A B W 3 S V A Y B 2 S S V A R B 3 S V A W B 3...

Page 402: ...of the engine compartment If malfunction occurs in any electric system but the battery is intact check the condition of the fusible link first There are two 60 A fusible links One is for main power and the other one is for preheating F42W708A 5 2 3 Fuse box The fuse box is installed on the left lower section of the bonnet hinge assembly F42W147A F42W148A A42W704A MEC MODEL HST MODEL ...

Page 403: ...0 A 20 A Spare Fuse 7 20 A Head lamp Fuse 8 20 A Turn signal lamp Fuse 9 10 A Harzard lamp Fuse 10 10 A PTO Fuse 11 10 A Stop solenoid MEC MODEL Cruise HST MODEL Fuse 12 5 A DPF 3015R h 3515R h 4015R h F42W709A 5 2 4 Relay 5P 1 Safe start relay PTO 2 Starter relay 3 PTO relay 4 Cruise relay The relay 5P is installed on the upper left section of the bonnet hinge assembly to supply power to function...

Page 404: ...elay is installed on the upper middle section of the bonnet hinge assembly to supply power to the glow plug F42W710A K20W783a Connector and test 㧗ᮧᜏ D 87 30 85 86 87a 1 1 2 2 3 3 5 5 4 4 6015W709A Item Testing Location Result terminal terminal Resis tance Approx 87 Ω Resis tance Conti nuity 0Ω present Ω not present CIRCUIT ...

Page 405: ...0 86 87 85 30 86 87 6015W711A CIRCUIT 5 2 6 Preheat controller F42W711A The preheat controller is installed on the upper right section of the bonnet hinge assembly It receives a signal from the coolant temperature sensor to adjust the preheating time turns on the preheat indicator on the instrument cluster and detects a signal from the generator to turn off the charge warning lamp Connector and ci...

Page 406: ...7 7 1387 6 1 287387 6 1 21 URZ 03 21 2 TIME CHART F42W714A Item Water temp sensor resistance kΩ Time sec Remarks T1 Indicator ON time sec 19 5 30 14 0 3 5 9 6 15 10 0 3 0 1 2 40 4 0 1 5 T2 Preheating time sec 4 5 5 30 0 8 0 Relay 37 Ω 2 8 40 5 0 1 3 T3 After heating time sec 1 2 40 120 30 0 6 60 5 0 1 3 VFX 6 21 21 67 57 67 57 5 6 5 2 2 03 ODPS P 1 5 725 7 5 7 03 6 1625 F42W713A Contact diagram ...

Page 407: ...e of the preheat controller on the upper right section of the bonnet hinge assembly It makes the turn signal lamps blink when the flasher switch is operated F42W715A Connector and circuit diagram 5 81 7 F42W716A K20W727A NO PIN NAME 1 RIGHT FLASHER LAMP 2 LEFT FLASHER S W 3 RIGHT FLASHER S W 4 BATTERY 5 LEFT FLASHER LAMP 6 IG 7 HAZARD S W 8 GND ...

Page 408: ... lower section of the hood hinge to control the cruise control relay and cruise control lamp for the cruise control operation A42W706A ི ཱི ུ ཱུ ཱ A42W707A 5 2 8 cruise controller hst model Connector and circuit diagram Xqlw A42W708A KEY S W ON Cruise switch Brake switch Brake switch Cruise switch Brake R Brake L Cruise relay Cruise lamp ...

Page 409: ...nder the left foot rest This switch is to prevent the engine from starting when the clutch pedal is not depressed Connector and test START SWITCH AVS 0 85YB MG640333 PTO SWITCH AVS 0 85BR PTO SWITCH AVS 0 85BG START SWITCH AVS 0 85RY ST YB PT BR ST RY PT BG ྙ ྚ ྜ ྛ K20W728A Item Connection Status Result ㅡ Re sis tance 1 3 Clutch pedal depressed 0Ω 2 4 F42W717A ...

Page 410: ...ement switch The PTO engagement switch is installed to the side of the lift arm on the left side of the hydraulic cylinder case When the PTO selection switch is set to the LINK position this switch stops the PTO as soon as it detects the lift arm reaching the set height Connector K20W729A F42W719A F42W720A ...

Page 411: ...stop lamps of the rear combination lamps are turned on F42W721A MEC MODEL A42W709A HST MODEL The stop lamp switch is installed under the left foot rest A42W710A 5 2 12 Safety start neutral switch hst model The safe start neutral switch is installed on the rear section of forward pedal This switch detects the pedal position and to prevent the engine from starting when the switch is not neutral Conn...

Page 412: ...2W756A 5 2 13 Starter F42W722A The starter is installed to the rear left section of the engine K20W732b Specification Nominal power 2 2 kw Voltage 12 V Rated time 30 sec Rotation Clockwise when seeing from pinion side Weight Approx 5 2 kg MAGNET SWITCH SPEC RUSH CURRENT 60A or less 11V 20 C HOLDING CURRENT 15A or less 11V 20 C ...

Page 413: ... Approx 12 V 2 Ground Chassis 5 2 15 Engine oil pressure switch F42W724A The engine oil pressure switch is installed to the cylinder block on the right side of the engine When pressure is built in the engine the contact of the oil pressure switch is connected to send a signal to the instrument cluster assembly When the pressure in the engine drops below 0 5 0 1 kgf cm2 the engine oil pressure warn...

Page 414: ...g to the coolant temperature to the instrument cluster to display the coolant temperature on the coolant gauge K20W739A Measuring circuit Resistance by coolant temperature K20W738A Temperature 30 15 10 20 40 Resistance difference Ω 19 5 9 6 3 4 2 4 1 2 Sensor test Item Connection Status Result ㅡ Resis tance 1 Ground Chassis Resistance changed by coolant temperature DC power 2 Ground Chassis Igniti...

Page 415: ...1A Resistance by coolant temperature Temperature C 35 50 80 100 105 115 120 140 Resistance kΩ 670 350 118 6 63 5 54 5 42 2 5 36 2 22 Measuring circuit K20W742A P o t e n t i o n m e t e r T h e r m o s t a t u n i t Galvano meter 5 2 18 Fuel cut off solenoid The fuel cut off solenoid is installed behind the injection pump in the right section of the engine to allow or block fuel entering the engin...

Page 416: ...trument cluster to display the fuel level 5 2 19 Fuel sensor Feature K20W774A F42W729A 5 2 20 Glow plug The glow plug is installed to the engine cylinder head to heat the intake air in the pre combustion chamber in order to facilitate engine starting The current of the glow plug should be 10 A within 5 seconds after it is applied with DC 11 V and its temperature should rise to 800 in approx 4 5 se...

Page 417: ...tch ON Horn operated Approx 4 7 Ω 4 Connec tor A Connec tor B 1 2 GW B 3 4 6015W7f3A Q25W803A F42W731A The combination switch is installed to the left side of the dashboard for operation of the head lamp high low beam turn signal lamps and horn Connector and wiring diagram K20W748A 5 2 22 Combination switch Head lamp Turn signal lamp Horn Item B1 T 1 2 Item B2 R L Item B3 H Wiring color RY Y Or Br...

Page 418: ...d front upper side of the radiator in the front section of the engine compartment and it receives information from various engine sensors to maintain the optimum engine combustion condition for emission control CIRCUIT CONNECTOR 1 25 1 25 0 5 0 85 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 1 2 1 3 8 16 7 15 6 14 5 13 4 12 3 11 2 10 1 9 2 1 3 2 0 5 0 5 0 5 0 5 K25W722A ...

Page 419: ... low to SCANNER G4 CAN_GND Ground of CAN communication PC RS232 COMM For industrial data download or Reprogram A2 TX_TIL TX 232 TTL communication from logger 0 USB A1 RX_TIL RX 232 TIL communication from USB to logger B1 USB1_SENSING Signal of USB1 connection A4 RS232_GND Ground of RS232 communication PC USB COMM For superuser high speed data download B2 USB2_POS USB2 positive of notebook max 200m...

Page 420: ... logger to control the combustion process If a large amount of PMs is accumulated so the pressure difference between the inlet and outlet is over the limit post injection is performed into the cylinders to burn PMs in order to keep the proper pressure level in the DPF The exhaust gas temperature sensor is installed to the rear section of the DPF This sensor measures the temperature of the exhaust ...

Page 421: ...01 CHAPTER 7 ELECTRIC SYSTEM 7 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 5 2 26 Instrument cluster Configuration and performance specifications ۈۋۍڋڏڐ گڮڌٻڪگګ ۈۋۍٻڠڋڏڐ ڟکڍٻڪگګ 3 2 4 5 1 F42W758A 211 725 K25W725A ...

Page 422: ... A5 E G OIL PRESSURE A6 CHARGE A7 GLOW A8 DPF A9 SPARE 3 A10 SPARE 2 A11 PARKING A12 PARKING A13 ILLUMINATION A14 IGN 13 5V A15 GND A16 HOUR METER A17 J A18 K A19 L SPARE A20 PIN NO NAME REMARKS B B1 SPARE 1 B2 Q T B3 4WD B4 PTO B5 LIFT B6 HIGH SPEED B7 NEUTRAL B8 TURN L B9 TXD B10 RXD B11 BATT REGULAR POWER B12 IGN 13 5V B13 GND B14 FUEL GAUGE UNIT B15 TEMP GAUGE UNIT B16 TACHO METER PULSE ...

Page 423: ...7 45 42hW 201601 CHAPTER 7 ELECTRIC SYSTEM 7 3015R h 3515R h 4015R h F36R h F42R h TRACTOR circuit 7 2 38 6 6 7 21 02 5 5 72 7 2 38 6 127 5 K25W727B ...

Page 424: ...3 5 Zone 3 Fuel gauge Performance specifications PTO RPM PTO 540 rpm 2 600 rpm Operating range 0 3 500 rpm Indicator characteristics Position rpm 1 000 2 000 2 500 2 860 3 000 Tolerance rpm 50 100 100 50 50 A Frequency Hz 163 4 326 8 408 5 467 3 490 2 B Frequency Hz 179 358 447 6 512 537 1 Zone 540rpm PTO 1ST 540E rpm PTO 2ND Type LCD type Rated voltage DC 12V Max displaying time 9999 9 hours Time...

Page 425: ...olor Green Green Blue Red Red Red Yellow Red Yellow Lamp LED 7 3015R h 3515R h 4015R h F36R h F42R h TRACTOR Type STEPPER MOTOR Operational voltage DC 12 V Indicator characteristics Position 43 70 107 115 120 138 Resistance Ω 240 5 103 2 38 34 1 30 5 21 2 Tolerance 3 5 3 5 3 5 3 5 3 5 3 5 Zone 4 Temp gauge 5 Indicator ...

Page 426: ...h F36R h F42R h TRACTOR F42W737A F42W735A 5 3 Lamp bulb replacement 5 3 1 Head lamp 1 Pull the cap 1 out to disconnect it F42W736A 2 Loosen the screw 2 and release the spring holder 3 Then remove the socket with bulb 3 Bulb specification HS1 12 V 35 W 35 W 6015W7d4A ...

Page 427: ...OR 5 3 2 Front turn signal lamp 1 Unscrew the front and rear lens mounting screws 1 F42W738A 744 35 744 3 5 1 744 563 4 1 K20W791B 2 Replace it with a new one Bulb specification 12 V 21 W 5 W F42W739A F42W740A 2 Remove the bulb 2 by pressing and turning it clockwise 3015R h 3515R h 4015R h ...

Page 428: ...7 50 42hW 201601 CHAPTER 7 ELECTRIC SYSTEM 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 2 1 7 35 7 3 5 1 7 563 4 1 K20W7A09B Bulb specification 12 V 21 W 12 V 5 W F42W759A F36R h F42R h ...

Page 429: ...met assembly 1 clockwise to remove it F42W760A 2 Remove the bulb Bulb specification 12 V 21 W 12 V 12 W 5 W F42W761A Lens disassembly F42W762A K20W796A 1 Unscrew the lens mounting screws 1 of the rear combination lamp and pull the lens 2 to remove it F42W763A 2 Remove the bulb 1 by pressing and turning it socket disassembly F36R h F42R h ...

Page 430: ... F36R h F42R h TRACTOR K20W798A 3 Replace the bulb with a new one Bulb specification Right 12 V 21 W 5 W brake tail lamp Left 12 V 12 W turn signal lamp F42W741A F42W742A 1 Unscrew the mounting nuts 1 of the rear combination lamp in the fender 3015R h 3515R h 4015R h ...

Page 431: ...RACTOR F42W743A F42W744A F42W745A F42W747A F42W746A 3 Replace the bulb with a new one Bulb specification Ⓐ Left 12 V 27 W turn signal lamp Ⓑ Middle 12 V 8 W Backup Work lamp Ⓒ Right 12 V 21 W 5 W brake tail lamp 2 Press the each socket assembly 2 and turn it counterclockwise to remove ...

Page 432: ......

Page 433: ... 3 372 63 5 63 5 3 1 5 DPF CONTROLLER FUSE COVER GLOW RELAY PREHEAT FEED PUMP FLASH UNIT ENGINE CONTROL UNIT WARING G FUSE BOX FUSEBOX 11P CLUTCH SAFETY S W HAZARD LAMP S W COMBINATION S W 3P TRANSFER S W DIDOE LINK DIDOE IND PTO VALVE FUEL SENSOR PTO ENGAGEMENT S W REAR COMBINATION LAMP L REAR COMBINATION LAMP R IMPLEMENT CONNECTOR FUEL STOP SOL 1 GND GENERATOR GENERATOR P TERMINAL GENERATOR B TE...

Page 434: ...3 680 7202 0 0 FUSE COVER FUSE BOX 312 1FW 3 FR S W STARTER GLOW RELAY PREHEAT FEED PUMP FLASH UNIT ENGINE CONTROL UNIT WARING G HAZARD LAMP S W COMBINATION S W 3P TRANSFER S W DIDOE LINK DIDOE IND KEY S W PTO VALVE FUEL SENSOR PTO ENGAGEMENT S W REAR COMBINATION LAMP L REAR COMBINATION LAMP R IMPLEMENT CONNECTOR FUEL STOP SOL 1 GND GENERATOR GENERATOR P TERMINAL GENERATOR B TERMINAL DIDOE GENERAT...

Page 435: ...3 0 0 5 62 3 62 3 62 3 FUSE COVER GLOW RELAY PREHEAT FLASH UNIT ENGINE CONTROL UNIT COMBINATION S W GENERATOR GENERATOR P TERMINAL GENERATOR B TERMINAL DIDOE GENERATOR STARTER FUSIBLE LINE PREHEAT FUSIBLE LINE POWER WATER TEMP SENSOR PREHEAT WATER TEMP SENSOR INSTRUMENT PANEL B INSTRUMENT PANEL A 2 GND CLUTCH SAFETY S W PTO VALVE FUEL SENSOR PTO ENGAGEMENT S W REAR COMBINATION LAMP L REAR COMBINAT...

Page 436: ...80 7202 0 0 62 3 680 7202 0 0 FUSE COVER FUSE BOX 312 1FW 3 FR S W STARTER GLOW RELAY PREHEAT FEED PUMP FLASH UNIT ENGINE CONTROL UNIT WARING G HAZARD LAMP S W COMBINATION S W 3P TRANSFER S W DIDOE LINK DIDOE IND KEY S W PTO VALVE FUEL SENSOR PTO ENGAGEMENT S W REAR COMBINATION LAMP L REAR COMBINATION LAMP R IMPLEMENT CONNECTOR FUEL STOP SOL GENERATOR GENERATOR P TERMINAL GENERATOR B TERMINAL DIDO...

Page 437: ...7 59 CHAPTeR 7 eLeCTRiC SYSTem 42hW 201601 7 3015R h 3515R h 4015R h F36R h F42R h TRACTOR 5 4 2 Bonnet wiring diagram Wiring G F42W751A 7 HORN 02 251 WIRING A 0 7 7 7 HEAD LAMP R 7 7 HEAD LAMP L 7 7 ...

Page 438: ......

Page 439: ...h 3515R h 4015R h F36R h F42R h TRACTOR 6 Sectional view for major components 6 1 Battery F42W752A 1 Battery stop bracket 2 Stop rod 3 Washer 4 Hex flange nut 5 Bracket DPF logger 6 Hex flange bolt 7 DPF logger 8 Screw COMPONENTS 3015R h 3515R h 4015R h ...

Page 440: ...7 62 42hW 201601 CHAPTER 7 ELECTRIC SYSTEM 3015R h 3515R h 4015R h F36R h F42R h TRACTOR F42W753A 1 Battery 2 Battery stop bracket 3 Stop rod 4 Washer 5 Hex flange nut COMPONENTS F36R h F42R h ...

Page 441: ...Meter 3 Screw 4 Dashboard L 5 Combination switch 6 Dashboard R 7 Front wheel s w 8 Start switch ass y 9 Emergency switch 10 Urethane 11 Column cover 12 Bolt 13 Relay 14 Hex flange bolt 15 Hex flange bolt 16 Controller 17 Flasher unit 18 Glow relay 19 Hex bolt 20 PTO connect switch 21 Screw COMPONENTS K42W703A MEC MODEL ...

Page 442: ...714a 1 Cap 2 Meter cover 3 Meter cover assy 4 Meter 5 Screw 6 Dashboard r 7 Dashboard l 8 Bolt 9 Urethane 10 Column cover 11 Combination switch 12 Switch cruise 13 Front wheel s w 14 Start switch ass y 15 Emergency switch 16 Relay 17 Hex bolt 18 Hex flange bolt 19 Glow relay 20 Controller 21 With a flash unit 22 Controller 23 Hex flange bolt 24 Pto connect switch 25 Screw COMPONENTS ...

Page 443: ...42R h TRACTOR 6 3 fender F42W754A 1 Fender R ass y 2 Fender L ass y 3 Fender grip 4 Hex flange bolt 5 Hex flange bolt 6 Fender support bracket 7 Hex flange nut 8 Hex flange nut 9 Direction lamp ass y 10 Combination lamp R 11 Combination lamp L COMPONENTS 3015R h 3515R h 4015R h ...

Page 444: ...nder R ass y 2 Fender L ass y 3 Fender grip 4 Hex flange bolt 5 Hex flange bolt 6 Fender support bracket 7 Hex flange bolt 8 Hex flange nut 9 Hex flange nut 10 Bracket 11 Combination lamp 12 Hex flange nut 13 Reflector 14 Combination lamp R 15 Combination lamp L 16 Tapping screw COMPONENTS F36R h F42R h ...

Page 445: ... Pedal ass y front 9 Pedal ass y rear 10 Spring pin 11 Pedal cover 12 Damper 13 Snap pin 14 Plain washer 15 Switch FR 16 Bolt w washer 17 Cruise magnet 18 Hex flange bolt 19 Joint 20 Hexagon socket bolt 21 Arm ass y 22 Ball bearing 23 Snap ring 24 Bush 25 Shaft 26 Bolt w washer 27 Holder assy spring 28 Spring 29 Bolt 30 Hex nut 31 Wire 32 Snap pin 33 Rod assy 34 Bracket assy cruise 35 Snap pin COM...

Page 446: ...eheat Alternator Instrument panel Light bulb Fuse Flasher unit The engine cannot be started start motor operated The engine cannot be started start motor not operated The engine can be started without depressing the clutch pedal The engine cannot be stopped The preheat indicator does not come on The preheat indicator does not go off The charge warning lamp does not come on The charge warning lamp ...

Page 447: ...Chapter 8 INDEX ...

Page 448: ...el line 1 34 Checking instrument cluster signals 1 28 Checking lamps 1 28 Checking radiator and intake hoses 1 35 Checking seat belt 1 28 Checking toe in 1 39 Checking when seating on driver s seat 1 15 Checking when starting engine 1 15 Checking when turning ignition switch 1 15 Checking work place 1 15 Circuit configuration by major function 7 10 Circuit diagram 6 39 Circuit diagram for hydrauli...

Page 449: ...ust manifold 2 66 Exhaust manifold 2 95 Exterior and names of parts 2 3 Exterior dimension 6 38 Exterior dimensions 1 20 F Features Input Output 2 20 Finishing up and checking 1 4 Flasher unit 7 29 Flywheel 2 71 Flywheel 2 90 For safe operation 1 2 F R shuttle shift 4 10 Frame and oil suction pipe 2 71 Frame and oil suction pipe 2 89 Front and rear exterior view 1 17 Front axle case assembly remov...

Page 450: ...15 Inspection Description 1 26 Inspection adjustment and test 6 97 Installation 2 19 Instrument cluster 7 43 Instrument cluster and sensors 7 16 Intake manifold 2 68 Intake manifold 2 94 Interior view 1 18 Internal structure and operating principle 6 11 Introduction 2 19 K Knuckle section 5 4 L Lamp bulb replacement 7 48 Location of decals 1 7 Logging data 2 19 Lubricating oil 2 10 Lubricating oil...

Page 451: ...lay 5P 7 25 Relief valve block disassembly 6 96 Relief valve pressure test 6 98 Relief valve pressure test 6 99 Relief valve pressure test 6 99 Replacing engine oil filter 1 30 Replacing HST filter HST MODEL 1 30 Replacing transmission hydraulic filter 1 31 Rocker arm assembly 2 92 Rocker arm shaft 2 69 RTC Real Time Check power supply Warranty for 5 years 2 30 Running temperature range 2 31 S Saf...

Page 452: ...of electric system 7 21 Signal lamp 2 19 Specification 2 3 Specification 4 2 Specifications 5 2 Standard bolt nut tightening torque 2 111 Standard parts lubricant grease and oil 1 4 Starter 2 71 Starter 2 96 Starter 7 34 Steering valve 6 10 Steering valve disassembly 6 87 Stop lamp switch 7 33 Stop valve also as slow return valve 6 34 Structure and operating principle 4 7 Structure and operation 6...

Page 453: ...R Visual check 2 10 W Warranty 2 31 Warranty condition of emission regulations value 2 8 Waste disposal 1 6 Water pump 2 68 Water pump 2 94 We guarantee DPF data logger for 5 years after shipment 2 31 Wiring diagram 7 55 Work place 1 2 Working clothes and other safety gears 1 3 ...

Page 454: ... BraNSON tractors Co Ltd MEMO ...

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