Daedong Kioti LK30 Workshop Manual Download Page 1

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WORKSHOP MANUAL

LK30

TRACTOR

Lk30_00.p65

2007-07-26, ¿ÀÈÄ 12:03

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Summary of Contents for Kioti LK30

Page 1: ...WORKSHOP MANUAL LK30 TRACTOR Lk30_00 p65 2007 07 26 12 03 Page 1 Adobe PageMaker 6 5K Win...

Page 2: ...Lk30_00 p65 2007 07 26 12 03 Page 2 Adobe PageMaker 6 5K Win...

Page 3: ...to modify the contents in this manual especially the contents in the manual which is already distributed or published The modified information is available in KIOTI s online electronic manual system...

Page 4: ...Lk30_00 p65 2007 07 26 12 03 Page 4 Adobe PageMaker 6 5K Win...

Page 5: ...4 CHAPTER 5 CHAPTER 6 CHAPTER 7 CHAPTER 8 CHAPTER 9 CHAPTER 10 CHAPTER 11 SAFETY FIRST GENERAL ENGINE CLUTCH TRANSMISSION REAR AXLE BRAKE FRONT AXLE STEERING SYSTEM HYDRAULIC SYSTEM ELECTRIC SYSTEM I...

Page 6: ...Lk30_00 p65 2007 07 26 12 03 Page 6 Adobe PageMaker 6 5K Win...

Page 7: ...uctions when preparing tractor 0 4 2 4 Avoid fires 0 4 2 5 Cautions when handling the battery 0 5 2 6 Cautions for high pressure hoses 0 6 2 7 Use of appropriate tools and equipment 0 6 2 8 Handling o...

Page 8: ...wledge of it Read the service manual carefully before starting servicing and follow the instructions for servicing maintenance and inspection to prevent any injury 1 1 ALERT SYMBOLS In this manual the...

Page 9: ...r of wear ing clothes 2 SAFETY TIPS 2 2 WORK PLACE 2 2 1 VENTILATING SYSTEM The service should be performed in well ventilated area If the engine should be started in an enclosed place the exhaust gas...

Page 10: ...REAR AXLE REAR AXLE REAR AXLE T46W009A T46W011A 2 3 SAFETY INSTRUCTIONS WHEN PREPARING TRACTOR T46W010A 2 4 AVOID FIRES T46W012A T46W013A T46W014A Lower the implement on to the ground Stop the engine...

Page 11: ...ative battery cable first and reconnect it last to avoid sparks from an acci dental short circuit You can get injured or fire may break out Do not charge a frozen battery Charging the frozen battery c...

Page 12: ...due to the turning force when using the air impact wrench Especially be extra cautious when working on connection or socket with joint When lifting the tractor with a hydraulic jack or a hoist fix it...

Page 13: ...ade or PTO shaft Be extra careful when you are in loose clothes Be careful not to get caught by the rotating engine cooling fan You can be seriously injured if your hand or clothes is caught by the ro...

Page 14: ...The tire rims can fall out of the tires Therefore stay out of its way when checking or inflating tires Do not weld or apply heat to the tire rim or disc The tire can explode due to the rapidly increa...

Page 15: ...NDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE z The following safety decals a...

Page 16: ...and water dry with a soft cloth 3 Replace damaged or missing danger warning and caution labels with new labels 4 If a component with danger warning or caution label s is replaced make sure new label...

Page 17: ...ing wheel bolt torque 1 15 TABLE OF CONTENTS 8 2 3 Changing engine oil 1 15 8 2 4 Replacing engine oil filter 1 16 8 2 5 Replacing transmission fluid filter 1 16 8 2 6 Changing transmission fluid 1 17...

Page 18: ...nt 1 27 8 9 Every 2 years 1 28 8 9 1 Flush cooling system and chang ing coolant 1 28 8 9 2 Anti freeze 1 29 8 9 3 Replacing radiator hose water pipes 1 29 8 9 4 Replacing power steering hose 1 29 8 9...

Page 19: ...IC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE 4 1 2 265W101B 1 TRACTOR ID...

Page 20: ...EERING STEERING STEERING BARKE BARKE BARKE BARKE BARKE ELECTRIC ELECTRIC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENE...

Page 21: ...er Steering 7 14 6 PR 11 2 24 6 PR 1 34 19 14 0 83 11 89 1 22 17 45 0 76 10 84 2 830 111 4 1 314 51 7 2 250 88 6 1 640 64 6 10 8 275 43 5 1 105 1 020 1 268 40 2 49 9 2 8 9 18 1 328 2 928 500 1 102 1 5...

Page 22: ...erminal No 2 D diesel fuel No 1 D diesel fuel if temperature is below 10 C 14 F Fresh clean water with anti freeze Ethylene glycol 50 Engine oil API Service Classification CC or CD SAE 15W 40 1 2 3 4...

Page 23: ...2 46 3 53 5 79 6 92 5 123 141 181 209 246 289 Nm 7 85 8 82 16 7 19 6 31 4 34 3 kgf m 0 80 0 90 1 7 2 0 3 2 3 5 lb ft 5 79 6 50 12 3 14 4 23 2 25 3 Nm 9 81 11 2 23 6 27 4 48 1 55 8 77 5 90 2 124 147 1...

Page 24: ...NERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE 5 3 AMERICAN STANDARD SCREWS BOLTS AND NUTS WITH UNC OR UNF THREADS Grade Unit Nominal diameter 5 16 3 8 1 2 9 16 5 8 Nm 23 1 27 8 47 5 57 0 108...

Page 25: ...1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Length mm 25 4 50 8 76 2 101 6 127 152 4 177 8 203 2 228 6 254 279 4 304 8 330 2 355 6 381 406 4 431 8 457 2 482 6 508 533 4 558 8 58...

Page 26: ...Fan belt Clutch pedal free play Brake pedal free play Radiator hose and clamp Power steering hose and oil line Fuel line Intake air hose Toe in Engine valve clearance Fuel injection nozzle injection...

Page 27: ...de of Diesel Fuel Oil According to ASTM D975 Flash Point C F Min 52 125 Water and Sediment Volume Max 0 05 Carbon Residue On 10 Percent Residuum Max 0 35 Ash Weight Max 0 01 Distillation Temperatures...

Page 28: ...112B 265W113B To avoid personal injury Do not remove the radiator cap while coolant is hot When cool slowly rotate cap to the first stop and allow ample time for excess pressure to es cape before remo...

Page 29: ...en bulbs and lenses 2 Replace if broken To avoid personal injury Be sure to stop the engine before removing the screen CAUTION Grill and screen must be clean from debris to keep the engine from overhe...

Page 30: ...LE REAR AXLE REAR AXLE 1 1 1 1 1 1 1 2 1 Grease fitting Brake pedal shaft 1 Grease fitting Power steering cylinder RH LH 1 Grease fitting Lift rod 1 Grease fitting Brake pedal RH 2 Grease fitting Clut...

Page 31: ...r operate tractor with a loose rim wheel or axle Any time bolts and nuts are loosened retighten to specified torque Check all bolts and nuts frequently and keep them tight CAUTION 8 2 3 CHANGING ENGIN...

Page 32: ...ly until it contacts the mount ing surface Tighten filter by hand an additional half turn only 4 After the new filter has been replaced the engine oil normally decreases a little Make sure that the en...

Page 33: ...Fill with the new KIOTI TF65 fluid up to the upper line of the gauge See LUBRICANTS in Maintenance Section 4 After running the engine for a few minutes stop it and check the oil level again add oil to...

Page 34: ...L GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE 8 2 8 ADJUSTING CLUTCH PEDAL 1 Stop the engine and remove the key 2 Slightly depress the clutch pedal and measure fr...

Page 35: ...smission fluid doesn t leak through the seal 1 Hydraulic oil filter 3 Remove the oil filter 4 Put a film of clean transmission oil on the rubber seal of the new filter 5 Tighten the filter quickly unt...

Page 36: ...yearly or after every sixth cleaning whichever comes first NOTE Check to see if the evacuator valve is blocked with dust 1 Element 2 Cover 3 Evacuator valve 265W125A The air cleaner uses a dry elemen...

Page 37: ...should not be done in the field but in a clean place 1 Close the fuel cock 2 Unscrew the screw ring and remove the filter bowl and rinse the inside with kerosene 3 Take out the element and relace it w...

Page 38: ...TENSION 1 Bolt A Check the belt tension B To tighten 1 Stop the engine and remove the key 2 Apply moderate thumb pressure to belt between pulleys 3 If tension is incorrect loosen the alternator mount...

Page 39: ...rger positive terminal and the negative to the negative then recharge in the standard fashion 2 A boost charge is only for emergencies It will par tially charge the battery at a high rate and in a sho...

Page 40: ...the machine operation in a safe place and keep the engine unloaded idling 2 Don t stop the engine suddenly but stop it after about 5 minutes of unloaded idling 3 Keep yourself well away from the mach...

Page 41: ...wheels are in the straight ahead position 3 Lower the implement lock the park brake and stop the engine 4 Measure the distance B between tire beads at front of tire hub height 5 Measure the distance...

Page 42: ...X INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE 2 1 8 4 7 CHECKING INTAKE AIR HOSE...

Page 43: ...EVERY 50 HOURS 8 5 2 CHANGING FRONT AXLE CASE OIL REFER TO EVERY 50 HOURS 2 1 8 7 EVERY 800 HOURS 8 7 1 ADJUSTING ENGINE VALVE CLEAR ANCE Consult your local KIOTI Dealer for this service 8 6 EVERY 600...

Page 44: ...cap If the cap is loose or improperly fitted water may leak out and the engine could overheat IMPORTANT To avoid personal injury Do not remove the radiator cap when the engine is hot Loosen cap slight...

Page 45: ...that will react with the radiator cleaning agent forming sludge which will affect the engine parts 8 9 3 REPLACING RADIATOR HOSE WATER PIPES Replace the hoses and clamps See Checking Radiator Hose and...

Page 46: ...fuel and rotate the fuel cock to the air position 2 Start the engine and run for about 25 seconds and then stop the engine 3 Rotate the fule cock to open position 8 10 2 DRAINING CLUTCH HOUSING WATER...

Page 47: ...25A 10A 5A 5A 5A 5A 10A Use the designated fuse only T2546 69101 1 Protected circuit 8 10 4 REPLACING FUSE The tractor electrical system is protected from poten tial damage by fuses A blown fuse indic...

Page 48: ...oid personal injury Do not attempt to mount a tire This should be done by a qualified person with the proper equipment Always maintain the correct tire pressure Do not inflate tires above the recommen...

Page 49: ...trial 9 2 2 REAR WHEELS Rear tread width can be adjusted as shown with the standard equipped tires To change the tread width 1 Remove the wheel rim and or disk mounting bolts 2 Change the position of...

Page 50: ...should be removed when it is not needed The weight should be added to the tractor in the form of liquid ballast rear wheel weights or a combination of both 9 3 BALLAST 1 Front end weights 2 Rear whee...

Page 51: ...HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE km h mile h km h mile h Hi Lo High 1 2 3 4 1 2 3 4 Low Shuttle LK30 1...

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Page 53: ...OF CONTENTS 3 OPERATING PRINCIPLE 2 11 3 1 Body and power train 2 11 3 1 1 Cylinder head 2 11 3 1 2 Cylinder block 2 11 3 1 3 Crankshaft 2 12 3 1 4 Piston and piston rings 2 12 3 1 5 Connecting rods 2...

Page 54: ...Hydraulic pipe and electric wiring 2 43 7 1 5 Propeller shaft 2 44 7 1 6 Separating engine clutch housing 2 44 7 1 7 Removing clutch 2 45 7 1 8 Removing the fuel tank 2 45 7 1 9 Disassembling front a...

Page 55: ...AULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE 704W201B The 3A150LXB engines are vertical water cooled 4 cycle three or four cylind...

Page 56: ...0496 in 3 24 3 73 MPa 33 38 kgf cm2 469 540 psi 0 05 mm 100 mm 0 002 in 3 94 in 2 55 MPa 26 kgf cm2 370 psi Item Factory Specification Cylinder head surface flatness Top clearance Thickness of gasket...

Page 57: ...KER ARM 18 955 18 980 mm 0 7463 0 7472 in 19 000 19 025 mm 0 7480 0 7490 in Item Factory Specification Allowable Limit Rocker arm shaft O D Rocker arm bushing I D 2 1 7 TAPPET 0 020 0 062 mm 0 00079 0...

Page 58: ...D Idle gear bushing I D 2 1 10 PISTON RING 25 00 25 006 mm 0 98425 0 98448 in 0 020 0 060 mm 0 00079 0 00236 in 5 01 5 03 mm 0 19724 0 19803 in 5 97 5 99 mm 0 23504 0 23583 in 0 065 0 100 mm 0 00256 0...

Page 59: ...0031 in 0 20 mm 0 0079 in 0 20 mm 0 0079 in 0 20 mm 0 0079 in 0 5 mm 0 020 in Item Factory Specification Crankshaft alignment Clearance between Crankshaft and crankshaft bearing 1 Crankshaft O D Cran...

Page 60: ...pened completely height 8 mm 0 315 in 2 3 2 RADIATOR Radiator tightness Radiator cap tightness Fan belt tension deflection at 78 N 8 kgf 18 lbs of force 2 4 FUEL SYSTEM 2 4 1 INJECT PUMP 2 4 2 INJECTI...

Page 61: ...ws Injection pipe nuts Size x Pitch M11 x 1 25 M6 x 1 0 M9 x 1 25 M10 x 1 25 M12 x 1 25 M8 x 1 0 M10 x 1 25 M12 x 1 25 M10 x 1 25 PT1 8 M20 x 1 5 M12 x 1 5 Nm 103 0 107 9 8 8 11 8 46 1 51 0 68 6 73 6...

Page 62: ...EX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE ENGINE SPECIFICATIONS 2 6 PERFORMANCE CURVE NOTE Pe...

Page 63: ...alloy cast iron which can resist high temperature and pressure caused by combustion The intake and exhaust ports are arranged cross flow type to get high combustion efficiency by protecting the sucti...

Page 64: ...the front end is a wind type bushing Thrust bearing 1 2 of split type are mounted on both sides of the main bearing case at the flywheel side Crankshaft bearing and thrust bearings are plated with a s...

Page 65: ...nt of the injection pump and is also equipped with a ball to control the governor Fuel camshaft is made of carbon steel and cam sections are covered and tempered to provide greater wear resistance 1 T...

Page 66: ...ion pump gear 5 Idle gear 2 Fuel camshaft 6 Crankshaft gear 3 Camshaft gear 7 Crankshaft 4 Camshaft 3 1 10 FLYWHEEL The flywheel is installed on the rear end of the crank shaft and stabilizes the irre...

Page 67: ...EX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE ENGINE OPERATING PRINCIPLE 3 2 LUBRICATING SY...

Page 68: ...am shaft journal Fuel cam shaft Tappet Piston Bore Connectingrod ssmallend No 1Connectingrod ssmallend No 2Connectingrod ssmallend No 3Connectingrod ssmallend journal bearing No 1 main bearing Main oi...

Page 69: ...ow through the inlet port When the rotors rotate to C the port to which the space leads is changed from inlet to outlet At D the space decreases and sucked oil is dis charged from the outlet port 1 In...

Page 70: ...center in the opposite direction to rotation the bearing unit prevents cooling water from entering by a special mechanical seal 1 Water pump impeller 3 Water pump body 2 Mechanical seal 4 Bearing uni...

Page 71: ...cuum valve 2 opens to allow the air to enter the radiator 1 Pressure valve 2 Vacuum valve 196W229A 3 3 2 THERMOSTAT The thermostat is wax pellet type which controls the flow of the cooling water to th...

Page 72: ...d to prevent dirty fuel from reaching the injection pump and injection nozzles The filter ele ment will require occasional replacement to maintain an adequate flow This flow will vary according to the...

Page 73: ...iaphragm is pulled down by the spring vacuum in the chamber 5 causes the exhaust valve 4 to close and the atmospheric pressure in the fuel tank to force the fuel into the chamber opening the intake va...

Page 74: ...r to control the amount of fuel delivered 1 Pump element 5 Control sleeve 2 Cylinder 6 Control groove 3 Plunger 7 Sliding surface 4 Feed hole T46W237A 1 Delivery chamber 4 Feed hole 2 Plunger 5 Fuel c...

Page 75: ...el in c is larger than the amount of injected fuel in b T46W240A 1 Valve spring 4 Fuel chamber 2 Delivery valve 5 Valve face 3 Valve seal 6 Relief plunger D DELIVERY VALVE The delivery valve 2 prevent...

Page 76: ...low fuel consumption and works well with DAEDONG s combustion chamber The nozzle valve opening pres sure is about 14 7 MPa 150 kgf cm 2134 psi When the pressure overcomes the counterforce of the nozzl...

Page 77: ...ing 1 3 Governor spring 2 4 Fork lever 1 5 Fork lever 2 196W239B 3 5 GOVERNOR SYSTEM 3 5 1 DISASSEMBLED VIEW The governor serves to keep the engine speed con stant by automatically adjusting the amoun...

Page 78: ...EAR AXLE ENGINE FUEL SYSTEM 1 Governor spring 1 2 2 Solenoid guide 3 Stop solenoid 4 Pump rack 5 Rack pin T46W246C 6 Steel ball 7 Governor lever 8 Idle spring 9 Start spring 10 Idle shaft 11 Governor...

Page 79: ...fugal force of the steel ball 6 that is proportional to the engine speed is balanced with the tension of the governor spring 1 that is deter mined by the driver a stable speed is maintained E LOAD INC...

Page 80: ...r 196W244C 196W245C A Inlet air 1 Outlet port B To Inlet manifold 2 Inlet port C Heavier dust 3 Air cleaner element 4 Body 5 Evacuator 3 6 2 AIR CLEANER The air cleaner is dry cyclone type and easy to...

Page 81: ...T46W249A 3 7 PCV VALVE 3 7 1 PCV POSITIVE CRANKCASES VENTILATION The PCV system prevents air pollution by returning the unburned gases to the intake manifold through the bleeding pipe of the cylinder...

Page 82: ...Fuel pump faulty Plunger has worn or seized up Delivery valve spring broken Delivery valve not completely oil tight Needle valve stuck Needle spring broken Injection pressure maladjusted Injection pi...

Page 83: ...ant Tappet roller and pin worn Delivery valve not completely oil tight Fuel leaks from nozzle tip Fuel not spraying properly Injection pump or nozzle not functioning normally Compression pressure is d...

Page 84: ...jection delayed Compression pressure insufficient Injection too early Injection delayed Plunger does not return completely because spring is stuck or broken Plunger worn Compressed air leaks Not enoug...

Page 85: ...rn See figure replace the belt 5 2 RADIATOR WATER TIGHTNESS 1 Fill radiator with water to the specified amount and warm up the engine 2 Set a radiator tester and raise the water pressure to the specif...

Page 86: ...ozzle holder hole 4 Pull the stop lever to cut the fuel and run the engine with the starter at 250 350 rpm for 5 10 seconds 5 Measure the maximum pressure while running sev eral times 6 If the pressur...

Page 87: ...cover 4 Turn the crankshaft using the crankshaft turning socket until the intake valve of the No 2 cylinder and the exhaust valve of the No 3 cylinder move simultaneously and the rocker arm height of...

Page 88: ...ngine installed in the tractor 1 Remove the engine stop solenoid 1 704W2D4C T46W257A 2 Remove the timing check window cover of the fly wheel housing 3 Turn the crankshaft so that the mark 1FI on the f...

Page 89: ...ion timing is BTDC 19 In this case the injec tion is adjusted to 18 if adding 0 1 mm of shim under the fuel injection pump Fuel ENGINE MEASUREMENT AND ADJUSTMENT T46W2I1B 2 Shim 0 1 mm 11 To advance t...

Page 90: ...he allowable limit replace it 265W282A 1 Relief valve ball 3 Relief valve spring 2 Relief valve seat Allowable limit 30 mm 1 18 in 35 mm 1 38 in Spring free length Item Factory spec 265W281B 5 7 ENGIN...

Page 91: ...13 Main bearing case 14 Bearing case bolt 2 15 Rocker arm 16 Inlet exhaust valve 17 Cylinder head cover 18 Push rod 19 Tappet 20 Camshaft 21 Camshaft gear 22 Idle gear 23 Piston 24 Connecting rod 25 C...

Page 92: ...Lk30_02_engine 39 _A3 p65 2007 07 26 12 36 Page 40 Adobe PageMaker 6 5K Win...

Page 93: ...NG AND MAINTENANCE 7 1 1 DRAINING THE ENGINE OIL To avoid personal injury Be sure to stop the engine before changing the oil Allow engine to cool down sufficiently oil can be hot and can burn CAUTION...

Page 94: ...point between Full and Low mark on the recovery water tank 1 Drain plug 1 Radiator cap 2 Recovery tank 265W208B 265W207B Never open radiator cap when the coolant s temprature reaches boiling point Do...

Page 95: ...he tachometer cable 2 4 Disconnect the fuel hose 3 5 Remove the inlet pipe1 4 6 Remove the deliver pipe assembly 5 7 Disconnect the brake switch 8 Disconnect the steering hose R 6 9 Disconnect the oil...

Page 96: ...sembling Apply grease to the splines of the propeller shaft 1 Propeller shaft 2 Coupling 3 Cir clip 4 Propeller shaft cover 1 5 Propeller shaft cover 2 265W212A 6 O ring 7 O ring 8 Spring pin 9 O ring...

Page 97: ...4 Battery cord 5 Air cleaner assembly 6 Reservoir tank assembly 7 Water return pipe3 8 Side cover support RH Rear 9 Hydraulic pump assembly 7 1 8 REMOVING THE FUEL TANK 1 Remove the muffler 1 2 Remove...

Page 98: ...R AXLE REAR AXLE REAR AXLE 7 1 10 DISASSEMBLING OTHER ENGINE PARTS 1 Remove the gear pump assembly 1 and pump holder 2 Remove the fan belt 2 cooling fan 3 and fan pulley 3 Remove the dynamo assembly 4...

Page 99: ...he injection pipe fittings with two wrenches and remove the injection pipes 2 3 Remove the inlet manifold 1 and the fuel feed pump 4 1 Intake manifold 3 Fuel hose 2 Injection pipe 4 Fuel feed pump Ite...

Page 100: ...7B Item Nozzle Holder Assem bly Tightening torque 49 0 68 6 Nm 5 0 7 0 kgf m 36 1 50 6 lb ft 1 Philips screwdriver 2 Nozzle 3 Injection nozzle gasket 4 Heat seal 196W258B D HEAT SEAL ROMOVAL PROCEDURE...

Page 101: ...n disassembling and reassembling the nozzle piece dip it in clean fuel Install the push rod noting its direction upside down Do not tighten it too much or the needle valve will not slide easily and th...

Page 102: ...to 14 2 Lift up the cylinder head to detach 3 Remove the cylinder head gasket 265W225A 265W224A 1 Rocker arm shaft 3 Rocker arm bracket 2 Rocker arm 4 Bolt 7 2 4 ROCKER ARM ASSEMBLY 1 Loosen the bolts...

Page 103: ...there is no foreign matter on the cylinder head and the cylinder A Gear case side 1 Cylinder head gasket has a front and a back side 265W227A 196W265B Item Cylinder head bolts Tightening torque 58 8...

Page 104: ...1 Remove the injection pipes 1 and the intake mani fold 2 2 Remove the overflow pipe 3 196W269B 1 Fuel feed pump assembly 2 Cover 7 2 6 FUEL FEED PUMP AND INJECTION PUMP A FUEL FEED PUMP f f f f f Rem...

Page 105: ...ump mounting bolts and nuts A 6 Align the control rack pin 4 with the slot 5 on the cylinder and remove the injection pump 7 In principle the injection pump should not be disassembled Note for reassem...

Page 106: ...bolts and nuts to the specified torque in several steps in the correct sequence as shown in the figure 5 Tighten the idle limit spring mounting bolt Tightening torque M8 23 5 27 4 Nm 2 4 2 8 kgf m 17...

Page 107: ...EAR AXLE REAR AXLE REAR AXLE REAR AXLE 4 5 196W274B A DETACH THE GOVERNOR SPRING 1 Detach the governor spring 1 2 and speed control plate from governor lever 2 Remove the manual stop lever plate 4 Not...

Page 108: ...137 3 156 9 Nm 14 0 16 0 kgf m 101 3 115 7 lb ft 3 Unscrew the crankcase mounting bolts to remove the gear case C INSTALLATION 1 Apply the liquid gasket Three bond 1215 or equivalent to the both sides...

Page 109: ...2 is installed on the inside of governor spring 1 Be careful of the direction of the governor spring 1 The longer side should face the governor fork If the governor spring is dropped during the instal...

Page 110: ...cir clip 2 Detach the idle gear collar 2 3 Detach the idle gear 4 Detach the idle gear collar 1 1 External cir clip 2 Gear collar 2 3 Idle gear 196W282A 196W281A Item Idle gear shaft mounting bole tor...

Page 111: ...PPER 1 Align the round hole on the cam gear with the cam shaft stopper mounting bolt position 2 Remove the camshaft stopper mounting bolt 3 Detach the camshaft stopper 1 Camshaft stopper 196W283A D RE...

Page 112: ...ove the gear with crank gear removal tool or pulley removal tool 1 Oil pump assembly 1 13T gear crank gear 196W288A 196W289A Item Bolts of oil pump Tightening torque 9 8 11 8 Nm 1 0 1 2 kgf m 7 2 8 7...

Page 113: ...mounting bolts 3 Detach the oil pan by lightly tapping the groove of the pan with a dead blow hammer Note for reassembling Wipe off oil on the oil pan mounting surface apply a non drying adhesive and...

Page 114: ...o pistons in the same method as above Note for reassembling Before inserting the pistons into the cylinders ap ply engine oil to the pistons 1 Piston 196W294B Install the piston rings with their end g...

Page 115: ...176 F of oil for 10 15 minutes when inserting the piston pin into the piston Install the piston and connecting rod with the mark FW on the piston towards the flywheel and the mark on connecting rod t...

Page 116: ...en reassembling Clean the end of the crankshaft and the mating sur face of the flywheel Apply oil to flywheel screws Fit the flywheel hole to crankshaft hole and tighten the flywheel bolts to specifie...

Page 117: ...1 5 Thrust bearings 29 4 34 3 Nm 3 0 3 5 kgf m 21 7 25 3 lb ft Bearing case screw 1 M9 Item Tightening torque Mark the location line to the bearing case to pre vent interchanging IMPORTANT When reass...

Page 118: ...ad surface 2 Place a straightedge on the cylinder head and mea sure the clearance with a feeler gage as shown in the figure 3 If the measurement exceeds the allowable limit re place the cylinder head...

Page 119: ...clearance 4 If the measurement exceeds the allowable limit replace the valve guide or the valve Reference value Allowable limit 0 035 0 065 mm 0 0014 0 0026 in 0 1 mm 0 004 in A Finishing size of inl...

Page 120: ...apper 5 Turn and lap the valve back and forth on the valve seat to lap 6 Remove the compound and clean the valve and the seat 7 Apply oil on the valve face and finish to complete fitting 8 Repeat lapp...

Page 121: ...learance exceeds the allowable limit replace the rocker arm 4 If the clearance still exceeds the allowable limit after replacing the rocker arm replace the rocker arm shaft Allowable limit 0 15 mm 0 0...

Page 122: ...pump gear 2 Snap ring Allowable limit 0 9 mm 0 035 in 0 15 0 57 mm 0 0059 0 0224 in Side clearance Item Factory spec 265W260A 265W259A B IDLE GEAR SIDE CLEARANCE 1 Pull the idle gear collar 2 1 and pu...

Page 123: ...e bushing F REPLACING IDLE GEAR BUSHINGS 1 Press out the bushings using an idle gear bushing replacing tool 2 Clean the bushings and bore then apply oil to them 3 Press in the bushing using the replac...

Page 124: ...mshaft with V blocks on the surface plate at both end journals and set a dial indicator with its tip on the intermediate journal 2 Rotate the camshaft in the V block and get the ec centricity half of...

Page 125: ...ce the piston pin 265W269A C REPLACING PISTON PIN BUSHING 1 Press out the bushing using a piston pin bushing replacing tool 2 Clean the new bushing and bore then apply oil to them 3 Press in the bushi...

Page 126: ...nnecting rod 265W272A 0 05 mm 0 0020 in at 100 mm 3 94 in of gauge pin span Space between gauge pin and face plate Item Allowable limit 265W271A E PISTON RING CLEARANCE 1 Clean the ring and the ring g...

Page 127: ...Item Factory spec 265W273A 7 3 5 CRANKSHAFT A FLYWHEEL DEFLECTION AND CRANK SHAFT END PLAY 1 Set a dial indicator with its tip on the rear friction face of the flywheel near the edge 2 Turn the flywh...

Page 128: ...57 0 00409 in 51 921 51 940 mm 2 04414 2 04488 in 51 980 52 025 mm 2 04646 2 04823 in Oil clearance Journal O D Bearing 2 I D Item Factory spec 265W276A D REPLACING CRANKSHAFT BEARING 1 1 Press out th...

Page 129: ...NDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE 265W279A 265W280A 7 3 6 CYLINDER BORE...

Page 130: ...ump and measure the amount of the flattening with the scale to get the clearance 3 If the clearance exceeds the allowable limit replace the pump 265W283A 265W284A 7 3 7 LUBRICATING SYSTEM A ROTOR AND...

Page 131: ...rmostat 2 Thermostat cover 3 T46W2F3B B WATER PUMP NOTE If the coolant has leaked from the weephole shown by the arrow in the figure it means that the me chanical seal is damaged A Removal 1 Remove th...

Page 132: ...GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE 265W291A C SERVICING f f f f f THERMOSTAT VALVE OPENING TEMPERATURE 1 Suspend the thermostat in the water by a string with its end inserted b...

Page 133: ...zzle under this pressure for 10 seconds Check to see if fuel leaks from the nozzle 3 If the fuel should leak replace the nozzle 7 3 9 INJECTION NOZZLE Fuel injection pressure Factory spec 14 71 MPa 15...

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Page 135: ...5 1 7 Dual clutch 3 10 TABLE OF CONTENTS 5 1 8 Disassembling clutch assembly 3 11 5 1 9 Clutch release hub and clutch lever 3 11 5 2 Inspection for overhaul 3 12 5 2 1 Release lever height 3 12 5 2 2...

Page 136: ...AXLE 225 mm 8 86 in 7 3 7 9 mm 0 287 0 311 in 0 3 mm 0 012 in 2 0 mm 0 079 in 2 0 mm 0 079 in 0 5 mm 0 0197 in 0 5 mm 0 0197 in Clutch pedal free play Safety switch pedal movement When depressing clut...

Page 137: ...ndependently of tractor movement As a result the tractor can be started at the proper RPM after an implement is being operated The clutch is located between the engine and the transmission It is opera...

Page 138: ...s depressed to the middle of the stroke the clutch rod is pulled to rotate the clutch lever shaft Then the release fork 7 pushes the re lease hub 16 and release bearing 17 toward the flywheel Simultan...

Page 139: ...utch disc or pressure plate wraped Clutch spring weaken or broken Diaphragm spring weaken or broken Grease or oil on clutch disc facing Clutch disc or pressure plate wraped Clutch disc boss spline wor...

Page 140: ...aft begins to rotate 5 Depress the clutch pedal a little from the position found in procedure 4 6 In this position check that the clutch pedal contacts with the clutch pedal stopper bolt 7 If the clut...

Page 141: ...ction 4 After running the engine for a few minutes stop it and check the oil level again add oil to prescribed level Do not operate the tractor immediately after changing the transmission fluid Run th...

Page 142: ...ct the tachometer cable 2 4 Disconnect the fuel hose 3 5 Remove the inlet pipe1 4 6 Remove the deliver pipe assembly 5 7 Disconnect the brake switch 8 Disconnect the steering hose R 6 9 Disconnect the...

Page 143: ...assembling Apply grease to the splines of the propeller shaft 1 Propeller shaft 2 Coupling 3 Cir Clip 4 Propeller shaft cover 1 5 Propeller shaft cover 2 265W310B 6 O ring 7 O ring 8 Spring pin 9 O ri...

Page 144: ...es sure plate to insure proper dynamic balance 265W312A When reassembling Assemble the PTO clutch disc with the shorter hub toward the fly wheel Apply molybenium disulfide Three Bond 1901 or equivalen...

Page 145: ...ust ing screws Remove the clutch covers 3 Remove the clutch cover 2 8 diaphragm spring 3 pressure plate 2 6 and clutch disc assembly driving 5 in order 4 Remove the clutch cover 1 4 diaphragm spring 3...

Page 146: ...ng screw lock nut tightening torque 5 2 2 MUTUAL DIFFERENCE OF RE LEASE LEVERS 1 Insert the clutch centering tool clutch center tool guide and gauge ring 2 Measure the mutual difference of release lev...

Page 147: ...29 6 lb ft Item Adjusting screw locknut M10 265W319A 1 Adjusting screw 2 Travelling pressure plate 3 PTO pressure plate 4 Lock nut Specified 0 95 1 0 mm 0 037 0 039 in Item Clearance between pressure...

Page 148: ...d 8 18 mm 0 322 in 265W323A 5 2 7 CHECKING PRESSURE PLATE AND FLYWHEEL 1 Wash the pressure plate and flywheel with a suit able cleaning solvent to remove dirt and grease before making inspection and a...

Page 149: ...ERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE 5 2 9 THRUST BALL BEARING 1 Check the contacted is worn excessive wear 2 With inner wheel seized and outer wheel loaded check for abnormal noise...

Page 150: ...MEMO Lk30_03_clutch p65 2007 07 26 12 05 Page 16 Adobe PageMaker 6 5K Win...

Page 151: ...9 Disassemble the step 4 18 4 1 10 Disassemble the clutch housing 4 19 TABLE OF CONTENTS 4 1 11 Clutch release hub and release fork 4 19 4 1 12 Main shift cover assemble 4 20 4 1 13 Main shift group 4...

Page 152: ...Nm 0 2 0 3 kgf m 1 446 2 169 lb ft 147 0 196 1 Nm 15 20 kgf m 108 49 144 65 lb ft 0 15 0 25 mm 0 0059 0 0098 in 1 5 1 6 1 7 mm 0 0591 0 0630 0 0669 in 3 92 9 41 Nm 0 4 0 96 kgf m 2 893 6 943 lb ft 0...

Page 153: ...RIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE 27 38 20 21 36 15 27 39 19...

Page 154: ...Lk30_04_transmission 3p p65 2007 07 26 12 37 Page 4 Adobe PageMaker 6 5K Win...

Page 155: ...through a tie The clutch can be changed four ways by the main shift lever and transmits to the counter shaft 1 Main shaft 16 20T gear 2 27T gear 3 21T gear 4 28T gear 5 34T gear 6 46T gear 7 51T gear...

Page 156: ...the synchronizer key 2 is not slipped any longer by the synchronizer ring 5 it will tall from the shifter 3 and key will enter the groove of the synchronizer ring Synchronizer key shifter and synchro...

Page 157: ...Shifter 4 Spline boss 5 36T gear 6 Shuttle counter shaft 7 21T gear F Forward R Reverse 265W406B The standard 8 x 8 gear transmission consists of four forward speeds and four reverse in the main tran...

Page 158: ...R AXLE REAR AXLE REAR AXLE REAR AXLE 27 17 28 44 15 9 2 2 3 RANGE GEAR SHIFT SECTION 1 15T gear shaft 2 27T gear 3 Spiral bevel pinion shaft With high low stage employs constant mesh type shift mechan...

Page 159: ...ged the front wheel gear is in neutral and power is not trans mitted to the front wheel drive shaft 4 When the front wheel drive lever is set to engaged the front wheel shifter 3 splined with the fron...

Page 160: ...ff RH 13 Gear diff LH 14 Washer diff 15 Washer diff 16 Washer diff 3 17 Shifter diff lock 18 Bolt 19 Case bearing RH 20 Case bearing LH 21 Bolt 22 Shim 0 2 23 Shim 0 1 24 Shim 0 5 25 Bearing taper rol...

Page 161: ...her differential side gear is increased in speed by the increment of the differential pinions 3 This means that rotation of one rear axle is slowed down and that of the other rear axle is increased Th...

Page 162: ...t causes the differential lock fork 10 and differential lock clutch 7 to be moved toward the spiral bevel gear 1 The differential lock clutch 7 is engaged with the teeth of the differential case 4 to...

Page 163: ...shaft and bevel gear Improper backlash between differential pinion and side gear Collars or shims have not been installed Bearing worn or broken Bevel pinion shaft stakig nut improperly tightened Shi...

Page 164: ...n plug at the bottom of the transmission case and drain the oil completely into the oil pan 2 After draining reinstall the drain plug 3 Fill with new KIOTI TF65 fluid to the upper line of the gauge Se...

Page 165: ...onnecting the battery terminal apply a little grease to it 265W412B 1 Bonnet 3 Bolt 2 Side cover 1 2 6 3 4 5 9 7 8 4 1 3 HYDRAULIC PIPE AND ELECTRIC WIRING 1 Remove the throttle rod 2 Disconnect the e...

Page 166: ...bling Apply grease to the splines of the propeller shaft 1 Propeller shaft 2 Coupling 3 Cir clip 4 Propeller shaft cover 1 5 Propeller shaft cover 2 265W415B 6 O ring 7 O ring 8 Spring pin 9 O ring 10...

Page 167: ...the throttle lever support assembly 2 265W418B 4 1 6 FUEL TANK 1 Remove the steering wheel cap 2 Loosen the nut and tap out the steering wheel 1 3 Loosen bolts and remove the instrument cover rear 2 a...

Page 168: ...rom the hydraulic block 5 4 Loosen the bolts and then remove the hydraulic block 5 265W420A When reassembling Apply liquid gasket Three Bond 1 208D or equivalent to joint face of the power steering su...

Page 169: ...ropeller shaft case 8 When reassembling Apply grease to the sliding surface of the release hub Apply gease to the clutch lever Apply grease to O ring and oil seal 265W423A 48 05 27 46 Nm 4 9 5 7 kgf m...

Page 170: ...2 MAIN SHIFT COVER ASSEMBLE 1 Loosen the bolts 2 and remove the cover assemble 1 2 Remove the bolt 3 and tongue washer 4 3 Remove the shift lever 6 shift arm and etc When reassembling Apply liquid gas...

Page 171: ...9 Ball bearing 18 Ball bearing 1 Remove the snap ring and then remove the PTO drive shaft with bearing as a unit from bearing case 2 Loosen the bolts and Remove the bearing case with using service bol...

Page 172: ...pedal shaft 2 Remove the snap ring plain washer brake pedal pedal shaft and clutch pedal 3 Loosen the bolt and remove the split pin plain washer and front driving lever2 4 Loosen the nuts and remove...

Page 173: ...29 19 20 gear shaft 22 Spacer 30 Ball bearing 23 Thrust collar 31 Coupling 24 21 gear 265W428A 4 1 15 SHUTTLE SHIFT GEAR GROUP 1 Loosen the bolts and remove the cover 2 Loosen the bolt and Remove the...

Page 174: ...SHIFT FORK 1 Nut 5 Bolt 2 Spring washer 6 Stopper 3 Plain washer 7 Shuttle fork rod 4 Shuttle lever 1 8 Shuttle fork 265W429A 1 Loosen the nut and remove the spring washer plain washer and shuttle lev...

Page 175: ...ove the seat assembly 1 2 Disconnect the fender light connector rear light con nector and earth connector 3 Remove the grips from shuttle shift lever 2 range shift lever 3 PTO shift lever 4 position c...

Page 176: ...wer link 2 and lift rod 4 Remove the clip pin top link pin and top link 3 5 Loosen the bolts and PTO cover 4 265W431B 1 Lift rod 4 PTO cover 2 Lower link 5 TOP link holder 3 Top link holder 6 Tender s...

Page 177: ...e is increased rapidly for the connector regardless of its size of nut Min fastening value 1 6 rotation Max fastening value 1 3 rotation 53 94 68 65 Nm 5 5 7 0 kgf m 39 78 50 63 lb ft 63 74 107 87 Nm...

Page 178: ...axle case 1 from the brake case When reassembling Be sure to replace the gasket with a new one 39 23 55 90 Nm 4 9 5 7 kgf m 35 44 41 23 lb ft Mounting nuts and bolts M10 7T Item Tightening torque 265W...

Page 179: ...ce the gasket with a new one Apply grease to the steel ball seats Do not grease excessively Be sure to fix the brake cam and cam plate 265W472B 77 47 90 22 Nm 7 9 9 2 kgf m 57 14 66 54 lb ft Mounting...

Page 180: ...PTO shifter fork 16 Packing 1 Loosen the bolts and pull PTO shift arm outward 2 Loosen the bolts and nuts 3 Remove the PTO cover 4 Loosen the bolt and remove the PTO shift fork rod 5 Remove the PTO sh...

Page 181: ...ap out the 15 gear shaft to the front 4 Draw out the 27 gear and etc 4 2 9 15 GEAR SHAFT 265W438A 14 13 1 1 7 8 3 5 6 4 2 11 12 15 9 10 13 14 8 7 265W439B 265W440B 4 2 10 DIFFERENTIAL LOCK SHIFT FORK...

Page 182: ...3 Bearing cover 11 Spline boss 4 Taper roller bearing 12 Shifter 5 Bearing case 13 Inner ring 6 Shim 14 17 gear 7 Bevel pinion shaft 15 26 gear 8 Thrust collar 16 Roller bearing 4 2 11 DIFFERENTIAL SY...

Page 183: ...ng 7 3 Tap out the propeller shaft 1 12 to the front 4 Take out the 35 spur gear 17 When reassembling Replace the oil seal 8 with new one and apply grease to its inside 77 5 90 2 Nm 7 9 9 2 kgf m 57 1...

Page 184: ...ial pinion washer 4 NOTE Arrange the parts to know their original position 265W447A D SPIRAL BEVEL GEAR 1 Remove the spiral bevel gear When reassembling Check the spiral bevel gear for wear or damage...

Page 185: ...r equivalents to the inner circumferential surface of the differential pinion Install the parts to their original position Install the differential pinion washer 4 noting its groove position 265W448A...

Page 186: ...R AND SPLINE OR HUB AND SPLINE 1 Select the gear or the hub in a vise 2 Set a dial gauge lever type with its finger on the spline 3 Move the shaft or hub to measure the clearance 4 If the clearance ex...

Page 187: ...NERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE D CLEARANCE BETWEEN GEAR AND SHAFT 1 Measure the shaft O D rubbing surface 2 Measure the gear I D rubbing surface 3 Meas...

Page 188: ...flaw or wear on the gear splines 4 If there is any defect replace them 265W454A 265W455A 265W456A C SIDE CLEARANCE BETWEEN SYNCHRO NIZER RING AND GEAR IN CONTACT 1 Press the synchronizer ring against...

Page 189: ...t Reference If the thickness of shims is not known install the differential assembly with no shim at bearing sup port RH 3 side and with adequate number of shims at bearing support LH 2 side to create...

Page 190: ...the number of shims 4 at bearing sup port LH 3 and insert the removed shims to the opposite side If the backlash is less than the factory specifications decrease the number of shims 4 at bearing sup p...

Page 191: ...o the heel of the ring gear teeth decrease the shims 1 take a or a few shim s from the shims 2 and move those to the shim 3 to push the ring gear away from the pinion so that the backlash is maintaine...

Page 192: ...the allowable limit replace them 265W463A 2 0 2 9 Nm 0 2 0 3 kgf m 1 4 2 2 lb ft Turning torque of 9T bevel pinion shaft only Item Factory spec Allowable limit 0 035 mm 0 0138 in 0 05 0 151 mm 0 00197...

Page 193: ...N DIFFERENTIAL PIN ION AND DIFFERENTIAL SIDE GEAR 1 Set a deal indicator lever type on the tooth of the differential pinion 2 Hold the differential side gear and move the differ ential pinion to measu...

Page 194: ...MEMO Lk30_04_transmission p65 2007 07 26 12 05 Page 44 Adobe PageMaker 6 5K Win...

Page 195: ...er train 5 3 2 2 Principle of differential system 5 4 2 3 Differential lock system 5 6 3 TROUBLESHOOTING 5 7 4 SERVICING 5 8 4 1 Draining transmission oil 5 8 4 1 1 Rops 5 8 4 1 2 Wheel 5 9 4 1 3 Sepa...

Page 196: ...0 0685 in Differential case bore differential case cover bore to differential case boss Differential case bore Differential case cover bore Differential side gear boss Differential pinion shaft to dif...

Page 197: ...he rear wheels The direction of power transmitted is changed at right angles by the differential gear and at the same time speed is reduced by the final gear The rear axles are of the semi floating ty...

Page 198: ...a weight keeps its position and the other rack without a weight rises in the amount of the height that the pinion moves and the pinion pushes up the rack Therefore this rack rises in double amount of...

Page 199: ...E REAR AXLE REAR AXLE REAR AXLE However if the wheels on one side are on the slippery road the load difference between both differential side gears remarkably increases and the self rotating speed of...

Page 200: ...ferential system The differential lock is designed to operate the differ ential lock shift pin 3 to lock the differential case 4 and one differential side gear 5 As the differential case 4 and one dif...

Page 201: ...ion and differential side gear Bearings worn Insufficient or improper type or transmission fluid used Differential pinions or differential side gears worn damaged Differential lock binding does not di...

Page 202: ...ling plug A Oil level is acceptable within this range 1 Drain plugs 265W507B 1 To drain the used oil remove the drain plug at the bottom of the transmission case and drain the oil completely into the...

Page 203: ...ll it noting its direction Replace the nut 2 with new one and after tighten ing it to specified torque stake it firmly 265W503A 196 245 Nm 20 25 kgf m 145 181 lb ft Nut Item Tightening torque 265W502B...

Page 204: ...MEMO Lk30_05_rear axle p65 2007 07 26 12 05 Page 10 Adobe PageMaker 6 5K Win...

Page 205: ...l 6 7 4 1 2 Rear axle case 6 7 4 1 3 Brake case 6 7 4 1 4 Disassemble the brake pedals 6 8 4 1 5 Disassembling brake case 6 8 4 1 6 Brake disk wear 6 9 4 1 7 Brake plate wear 6 9 4 2 Inspection for ov...

Page 206: ...plate and ball Brake disc Plate Free Play Difference Clearance O D I D Flatness Height Thickness Thickness 20 25 mm 0 79 0 98 in Less than 5 mm 0 20 in 0 010 0 15 mm 0 00039 0 0059 in 24 9 25 0 mm 0 9...

Page 207: ...R AXLE REAR AXLE REAR AXLE 2 OPERATING PRINCIPLE 265W601A 2 1 STRUCTURE Independent mechanical wet disc brakes are used for the right and left traveling brakes They are operated by the brake pedals th...

Page 208: ...el ball Power is transmitted through the brake shafts 4 to the final reduction system The brakes are incorpo rated in the brake case 1 which is filled with trans mission oil They are designed to brake...

Page 209: ...t discs are worn by approximately several tens of microns depending on the initial contact in ini tial period 50 hours or so of use almost no wear occurs afterwards This means that brake adjustments a...

Page 210: ...ERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE Brake pedal play unevenly adjusted Brake disc is worn Cam plate warped Brake pedal play too small Ball holes of cam plate for uneven wear Brake p...

Page 211: ...place the gasket with a new one 48 02 55 90 Nm 4 9 5 7 kgf m 35 44 41 23 lb ft Mounting nuts and bolts M10 7T Item Tightening torque 265W613B 265W615B 196 13 225 55 Nm 20 0 23 0 kgf m 144 66 166 36 lb...

Page 212: ...out the brake pedal pedal shaft and clutch pedal 265W605A 1 Brake pedal LH 2 Spring pin 3 Brake pedal RH 4 Snap ring 5 Plain washer 6 Bush 7 Pedal shaft 8 Grease sipple 265W606A 4 1 5 DISASSEMBLING B...

Page 213: ...GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE 4 1 7 BRAKE PLATE WEAR 1 Measure the plate thickness with venire calipers 2 If the thickness is less than the allowable limit re place...

Page 214: ...eavy refine the brake cam with sandpaper 4 2 3 HEIGHT OF CAM PLATE AND BALL 1 Measure the dimensions of the cam plate with the ball installed 2 If the measurement is less than the allowable limit repl...

Page 215: ...the turnbuckle of brake rod to adjust 3 After adjustment tighten the turnbuckle lock nut firmly 265W603B NOTE After checking brake pedal free play be sure to engage the parking brake lever fully and c...

Page 216: ...MEMO Lk30_06_brake p65 2007 07 26 12 05 Page 12 Adobe PageMaker 6 5K Win...

Page 217: ...evel gear case gears 7 13 5 1 9 Disassembling axle 7 13 5 1 10 Disassembling spiral bevel pinion shaft and differential gear assem bly 7 14 5 1 11 Pre load of taper roller bearing on spiral bevel pini...

Page 218: ...l pinion Pinion shaft Differential pinion Differential pinion to differential side gear Shim Toe in Axial sway Rocking force Clearance O D I D Clearance O D I D Clearance I D I D O D Clearance O D I D...

Page 219: ...1 117 7 N 10 12 kgf 22 0 26 5 lbs 0 2 0 3 mm 0 0078 0 0118 in 0 15 0 35 mm 0 0059 0 0138 in 0 4 mm 0 0157 in 0 6 mm 0 0236 in 0 8 mm 0 0315 in 1 0 mm 0 0394 in 1 2 mm 0 0472 in 0 15 0 35 mm 0 0059 0...

Page 220: ...l bevel gear 11 Pinion shaft 12 Differential gear shaft LH 13 11 bevel gear 14 16 bevel gear 15 Bevel gear shaft 16 11 bevel gear 17 42 bevel gear The front axle is constructed as shown above Power is...

Page 221: ...ster camber kingpin angle and toe in 704W702A 2 Caster helps provide steering stability Caster angle c 0 704W703A 3 Kingpin angle reduces the rolling resistance of the wheels and prevents any shimmy m...

Page 222: ...st or replace Replenish Replace Replace Adjust Symptom Front wheels wander to right or left Front wheel can not be driven Noise Provable Causes Tire pressure uneven Improper toe in adjustment improper...

Page 223: ...OE IN 1 Apply specified air pressure to the tires 2 Measure the front width A and the rear width B between the front wheels while straightened to ob tain the difference toe in 3 If the toe in value is...

Page 224: ...rim and front wheel hub 265W705A 265W706B 4 4 FRONT WHEEL STEERING ANGLE 1 Inflate the tires to the specified pressure 2 Loosen the lock nut and shorten the length of stop per bolt LH 1 3 Steer the w...

Page 225: ...sides and fill ing port plug 2 to drain the oil 3 After draining reinstall the drain plugs 3 and fill ing port plug 2 When refilling Remove the filling port plug 2 and the check gauge 1 Fill with oil...

Page 226: ...ropeller shaft cov ers 5 4 Slide the covers to remove 2 Tap out the spring pin 8 and then slide the cou pling 2 to the rear When reassembling Apply grease to the splines of the propeller shaft 1 Prope...

Page 227: ...ort 4 Remove the front wheels 5 1 6 DISASSEMBLING BEVEL GEAR CASE FROM FRONT AXLE SUPPORT 1 Remove the bevel gear case mounting bolts 2 Remove the bevel gear case 3 and the front axle case 4 as a unit...

Page 228: ...hen reassembling Apply grease to the O ring of the 42 bevel gear 1 Tighten the axle flange mounting bolts and nuts di agonally in several steps Install the oil seal 16 in the bevel gear case not ing i...

Page 229: ...emove the internal snap ring 1 2 Take out the bevel gears 4 7 with ball bearings 3 6 and shims 2 When reassembling Install the same shims 2 which you removed 704W718A 1 Snap ring 5 Bevel gear case 2 S...

Page 230: ...d then remove the lock nut 10 6 Remove the taper roller bearings 8 When reassembling Replace the lock nut 10 oil seal 7 and plug 11 with new ones Apply grease to the oil seal 7 Install the same shims...

Page 231: ...e inserting the oil seal and installing the 23 bevel gear If measuring the pre load while securing the spi ral bevel shaft and taper roller bearing assembly with a vice as shown in the figure B cover...

Page 232: ...inserting the differential pinion shaft 5 to the differential case 3 Insert the longer straight pin 6 to the differential pinion shaft 5 so that it pass through the shaft 4 Install the differential ca...

Page 233: ...ace faulty parts 5 2 2 CLEARANCE BETWEEN PINION SHAFT AND DIFFERENTIAL PINION 1 Measure the pinion shaft O D 2 Measure the differential pinion I D and calculate the clearance 3 If the clearance exceed...

Page 234: ...0472 in Tooth contact More than 35 Center of tooth contact 1 3 to 1 2 of the entire width from the small end 5 2 4 TURNING FORCE OF SPIRAL BEVEL PINION SHAFT PINION SHAFT ONLY 1 Install the spiral bev...

Page 235: ...L GEAR 1 Set a dial gauge lever type with its finger on the spline of spiral bevel pinion shaft 2 Measure the backlash by moving the spiral bevel pinion shaft by hand lightly 3 If the backlash is not...

Page 236: ...m 3 Reference Thickness of adjusting shims 3 0 4 mm 0 0157 in 0 6 mm 0 0236 in 0 8 mm 0 0315 in 1 0 mm 0 0394 in 1 2 mm 0 0472 in 1 4 mm 0 0551 in Tooth contact More than 35 1 16 bevel gear 3 Shim 2 1...

Page 237: ...case A PRESS FITTING BUSHING When press fitting a new bushing observe the di mension described in the figure NOTE After replacing the bushing be sure to adjust the front axle rocking force see page 7...

Page 238: ...MEMO Lk30_07_front axle p65 2007 07 26 12 05 Page 22 Adobe PageMaker 6 5K Win...

Page 239: ...ng unit spec 8 10 2 6 2 Structure and operation 8 10 TABLE OF CONTENTS 3 TROUBLESHOOTING 8 11 4 SERVICING 8 12 4 1 Separating the steering unit 8 12 4 2 Disassembling the steering unit 8 13 4 2 1 To d...

Page 240: ...IC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE Reference Value Item Hydraulic pump Power steering unit Steering cylinder Steering wheel Type Pump capacity...

Page 241: ...e figure This system is opti mally designed for a high front wheel steering angle and a small turning radius The steering power of the steering wheel is transmit ted to the front wheel through the pow...

Page 242: ...E 2 2 HYDRAULIC CIRCUIT DIAGRAM 1 Steering controller 2 Steering wheel 3 Value plate 4 Centering spring 5 Gerotor 6 Steering cylinder 2 2 1 HYDRAULIC OIL FLOW The hydraulic pump driven by the engine w...

Page 243: ...at the given angle without motion 2 3 2 RIGHT TURN When the steering wheel is rotated to the right the movement is passed to the control valve through the drive plate Gerotor and drive link The valve...

Page 244: ...when rotating to the left as it does to the right except for the flow in and out P Pump port R Cylinder port R T Tank port L Cylinder port T 1 Steering controller 4 Centering spring 2 Steering wheel...

Page 245: ...REAR AXLE REAR AXLE REAR AXLE REAR AXLE 2 4 OPERATING OF STEERING UNIT 1 Steering case assembly 2 Dust seal 3 Retainer ring 4 Seal gland bushing 5 O ring 6 Oil seal 7 Lace bearing 8 Thrust needle bear...

Page 246: ...spool Therefore when the shaft and sleeve rotate the spool rotates with approx 10 of clearance At this moment a fluid passage is formed between the spool and the sleeve to operate the steering system...

Page 247: ...AXLE REAR AXLE REAR AXLE REAR AXLE 2 5 STEERING CYLINDER 2 5 1 STRUCTURE 1 Tube 2 Packing 3 Bush 4 Dust seal 5 Rod 6 Ring 7 Housing 8 Bearing 9 Snap ring A Rod O D B Tube I D C Tube O D D Stroke 2 5 2...

Page 248: ...to the NEUTRAL state and persists as long as the steering handwheel is at its center position for straight ahead driving 4 A diametrically extended pin is loosely fitted to the drive shaft at the cent...

Page 249: ...he steering gear box damaged Backlash between sector gear shaft and ball nut too small Air in the hydraulic pipes Low operating pressure Hydraulic pump malfunctioning Improper relief valve adjustment...

Page 250: ...REAR AXLE REAR AXLE 4 SERVICING STEERING SYSTEM SERVICING 3 1 2 4 1 SEPARATING THE STEERING UNIT 1 Remove the instrument cover support and then dis connect the connectors 2 Loosen the joint pipe and...

Page 251: ...REAR AXLE REAR AXLE 4 2 1 TO DISASSEMBLE THE GEROTOR PARTS 1 Let the port face of the tractor s body housing vised slightly with the end cap upward 265W819A Do not tighten the vise too firmly with a s...

Page 252: ...AXLE 7 Disassembling the gerotor Be careful not to drop the rotor from the outer ring of the gerotor 8 Take out spacer plate 8 and O ring 9 9 Take out drive 11 10 Remove O ring out of the housing 265...

Page 253: ...ess 265W825A 11 Take out the spool and sleeve assembly at the op posite side to the flange of the housing while push ing the inner spline of the spool with the thumb Be careful not to allow the circum...

Page 254: ...ner pin 2 and ball 3 2 Loosen relief adjusting plug 25 with the flange face of housing 20 upward and remove O ring 24 3 Remove damper collar 8 and spring 5 out 4 Take poppet 4 out of housing 20 using...

Page 255: ...ide the spring groove and mount the centering spring on the insertion tool with its both sectional ends downward At this time lift the spool up off the sleeve a little to insert easily 5 Insert the sp...

Page 256: ...housing 9 Insert O ring 6 and plate 7 installed on plate 5 into the inner spline part of the Stator star 10 Let spacer plate 8 ride on to align the bolt hole of the housing with the oil hole 11 Apply...

Page 257: ...25 to tighten with the housing 1 Screw 22 Spring 2 Retainer plate 23 Damper collar 3 Ball 24 O ring 21 Poppet 25 Adjusting plug 265W834A 4 2 5 CAUTION FOR ASSEMBLY OF THE POWER STEERING UNIT 1 Be care...

Page 258: ...g a plastic hammer Pull out the support pin from the front axle case 4 Remove the bolt 3 and pull out the cylinder sup port pin 4 from the center pin 5 Remove the steering cylinder assembly 1 Steering...

Page 259: ...2 Set a spring balance to the steering wheel to mea sure the operating force 3 If the measurement exceeds the factory specification check the performance of hydraulic relief assembly and power steeri...

Page 260: ...MEMO Lk30_08_steering p65 2007 07 26 12 06 Page 22 Adobe PageMaker 6 5K Win...

Page 261: ...9 10 TABLE OF CONTENTS 4 SERVICING 9 11 4 1 Location of hydraulic system components 9 11 4 2 Hydraulic pump 9 12 4 2 1 Disassembly of gear pump 9 13 4 2 2 Installation 9 18 4 3 Hydraulic block 9 21 4...

Page 262: ...cs Power steering Setting pressure Condition Engine speed maximum Oil temperature 40 60 C 104 140 F Max flow Relief pressure Constant flow Relief pressure 1 SPECIFICATIONS 1 1 OIL PRESSURE RELIEF ASSE...

Page 263: ...EERING BARKE BARKE BARKE BARKE BARKE ELECTRIC ELECTRIC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERA...

Page 264: ...EERING BARKE BARKE BARKE BARKE BARKE ELECTRIC ELECTRIC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERA...

Page 265: ...is divided into two parts This is often called as the tandem pump The first pump which is close to the input shaft sup plies hydraulic block assembly auxiliary double acting valve option and hydraulic...

Page 266: ...rs is applicable to both hydraulic lift and steering wheel direction control circuits The hydraulic oil flows into the IN port of the filter bracket The transmission oil is delivered into the hy draul...

Page 267: ...lve and feed back link mechanism The position of implement is determined by the position of the control lever With this system an implement can be set to any de sired point by changing the position of...

Page 268: ...ctional valve counter clockwise completely If not the relief valve will operate CAUTION 265W906A 2 6 1 RELIEF VALVE SET PRESSURE 1 Remove the plug A and set pressure gauge 15 69 16 37 Mpa 160 167 kgf...

Page 269: ...e lift arm 10 is rising oil from the hydraulic pump flows into the hydraulic cylinder through the con trol valve Then oil pushes the piston 5 out While the lift arm is lowering oil in the hydraulic cy...

Page 270: ...Hydraulic pump malfunctioning Position control rod improperly adjusted Top link length improperly adjusted Position control valve spool joint 1 improperly adjusted Hydraulic arm shaft hydraulic arm l...

Page 271: ...NG BARKE BARKE BARKE BARKE BARKE ELECTRIC ELECTRIC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL RE...

Page 272: ...NERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE A 2 1 B 4 2 HYDRAULIC PUMP 16 Nm 1 6 kgf m 11 8 lb ft Pipe mounting bolt 3 4 Item Tightening torque 265W911A 1 Disconnect the hoses 1 2 from the...

Page 273: ...LE REAR AXLE 4 2 1 DISASSEMBLY OF GEAR PUMP 265W912A 1 Disassemble the components referring to the above exploded view Mark a line on the pump for disassembly and reassembly procedure 50 Nm 5 0 kgf m...

Page 274: ...housing It is normal if there is some gear tracing The trace in the suction side is severer than that in the discharge side If the depth of the gear trace is over 0 5 mm re place the pump 2 Check the...

Page 275: ...f REMOVAL Make sure that the O ring A installed to the sec ondary pump body is not damaged CAUTION Alignment mark 1 Put an alignment mark on the side of the hydraulic pump and remove the mounting bolt...

Page 276: ...ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE 3 6 7 265W92...

Page 277: ...X INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE 2 1 A B A C 9 8 265W923A 265W924A 265W925A 265W926A...

Page 278: ...NERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE 4 2 2 INSTALLATION Make sure that the gears of the primary and sec ondary pumps and the thrust block are installed in the correc...

Page 279: ...INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE 265W931A 265W932A 265W933A 4 Install...

Page 280: ...IC ELECTRIC ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE...

Page 281: ...ipe 2 2 2 Remove the return pipe 3 3 Remove the hydraulic block mounting bolts 4 and remove the hydraulic block 5 When reassembling When connecting the pipes install new O rings at both ends of the pi...

Page 282: ...ng 1 from the direc tional valve spool shaft 2 Remove the spool shaft 2 from the valve body 265W937A 265W938A Be careful not to damage the O ring A on the spool shaft and the O ring B on the valve bod...

Page 283: ...AL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE 1 1 2 3 4 5 Relief valve body Item 49 03 58 84 Nm 5 0 6 0 kgf m 38 43 lbs ft Tightening torque 4 3 2 RELIEF VALVE 1 Unscrew the relief valv...

Page 284: ...CYLINDER BODY REMOVED FROM TRACTOR 1 Remove the control valve assembly NOTE Do not loosen adjusting section at the end of the spool unless necessary When reassembling Install the control valve paying...

Page 285: ...Align the alignment marks of the hydraulic arm and hydraulic arm shaft Apply grease to the right and left bushings of hy draulic cylinder body and O ring Take care not to damage the O ring Apply greas...

Page 286: ...er I D Item Reference value 4 6 2 CLEARANCE BETWEEN HYDRAULIC ARM SHAFT AND BUSHING 1 Measure the hydraulic arm shaft O D with an out side micrometer 2 Measure the bushing I D with a cylinder gauge 3...

Page 287: ...lant temperature sender 10 19 2 7 Fuel level sensor 10 19 2 8 Fuse box 10 20 TABLE OF CONTENTS 3 TROUBLESHOOTING 10 21 4 SERVICING 10 23 4 1 Starting system 10 23 4 1 1 Key switch 10 23 4 1 2 Start re...

Page 288: ...Lk30_10_electric p65 2007 07 26 12 06 Page 2 Adobe PageMaker 6 5K Win...

Page 289: ...ITCH SAFETY START SWITCH GLOW RELAY GLOW PLUG HORN SWITCH HORN HAZZARD HORN FLASHER UNIT WARNING LAMP SWITCH TURN SIGNAL SWITCH HEAD LAMP SWITCH REAR COMBI LAMP RH REAR COMBI LAMP LH HEAD LAMP LH HEAD...

Page 290: ...8 Preheat controller 7 Oil pressure switch 3 Alternator 4 Diode 19 Diode 6 Slow blow fuse 5 Starter Motor 11 Cluch switch 15 Turn signal lamp LH 30 Turn signal lamp RH 29 Turn signal lamp Switch 12 He...

Page 291: ...and apply a small amount of grease to prevent the terminals from corroding The battery should maintain its charge even at or be low freezing If the battery is discharged or the battery fluid is low th...

Page 292: ...RAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE Symbol Description Symbol Fuse Slow blow fuse Motor Switch Normally Open Type Switch Normally Close Type Compressor Ground...

Page 293: ...s operation and be ready to following proper inspection procedures using proper devices If necessary the technician can shake harnesses or electric parts gently while testing them Open circuit There i...

Page 294: ...ter between the SW1 and the relay If there is no or little resistance this circuit is considered to be properly connected If the circuit is open the tester shows infinite resistance B point 6 Connect...

Page 295: ...t to the jump wire Put one lead to the fuse terminal and connect the other lead to the ground wiring as shown in the figure to check the continuity Continuity Short circuit between the relay and the s...

Page 296: ...ircuits are very sensitive to ground If the ground wiring is loose or corroded it can greatly affect an electrically controlled circuit Even though the ground connection seems to be clean there might...

Page 297: ...e in harness is complete One wire strand of a harness has a high resistance against current and its voltage drops is very slight Unnecessary resistance can occur due to the follow ing causes 1 Broken...

Page 298: ...tes for 15 seconds as the pre heat relay starts to operate However the preheat indi cator does not illuminates on the instrument panel The key switch is returned to the ON position If the preheat func...

Page 299: ...runs 265WA06A 265WA07A 31 3 32 OFF ON PH ST AM M G ST 001 019 004 IC REG M 028 025 026 001 003 006 036 005 001 026 5 A 003 003 003 004 60 A 003 007 028 ON GND DIODE Charge lamp SLOW BLOW FUSE STARTER...

Page 300: ...3 022 12 023 022 023 001 1 OFF 2 B2 R L 024 024 024 FREE PUSH H B1 10A 011 003 001 ON HEAD LIGHT TAIL LIGHT STOP LAMP WORKING LANP HORN SWITCH HORN HAZZARD HORN FLASHER UNIT WARNING LAMP SWITCH TURN S...

Page 301: ...eter The flasher unit controls the blinking time of the hazard flasher lamp 265WA11A B HAZARD WARNING SWITCH The hazard light switch is a push pull type switch lo cated on the left hand side of the da...

Page 302: ...s the information of the stop to following vehicle Rated watt of the bulb is 12 V 21 W Use only the rated watt of the bulb when necessary to replace f f f f f TAIL LIGHT This light only operates while...

Page 303: ...ates the red zone you must check the cause Never operates the tractor while the gauge indicates red zone 4 Hour meter When the engine is in motion the clock starts moving For every hour passed the clo...

Page 304: ...LIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE 2 4 2 WIRING DIAGRAM 265WA16A 001 001 001 015 023 029 021 005 012 022 016 13 3 14 21 12 001 004 027 5 A ON...

Page 305: ...w 0 5 0 1 kgf cm 7 1 1 4 psi to complete the ground circuit of the oil pressure warning light When the ground circuit is completed the oil pressure warning light illuminates on the instrument panel It...

Page 306: ...op Solenoid Combination Meter Horn Flasher Head Lamp Tail Lamp 25A 20A 25A 10A 5A 5A 5A 5A 10A Use the designated fuse only T2546 69101 2 8 FUSE BOX It is installed on the firewall under the hood Func...

Page 307: ...ator defective Diode bad Fuse blown Bulb blown Wiring harness disconnected or improperly connected Fuse blown Bulb blown Wiring harness disconnected or improperly connected Fuse blown Bulb blown Wirin...

Page 308: ...nnected or improperly connected Circuit in instrument panel defective Fuse blown Coolant temperature gauge or fuel gauge or fuel gauge fuel sender defective Wiring harness disconnected or improperly c...

Page 309: ...he 4 positions of the switch are 265WA21A A KEY SWITCH TESTING Disconnect the key switch from the wiring harness connector Use an ohmmeter to test the switch With the key in the OFF position continuit...

Page 310: ...AY A RELAY TESTING To test a relay disconnect it from the circuit Use an ohmmeter to verify non energized conditions Connect the ohmmeter leads to terminals 87 and 30 There will be no continuity betwe...

Page 311: ...diwhu wxuqlqj lw wr RQ W4 Wlph wdnhq iurp RQ wr VW 265WA40A 4 1 3 GLOW PLUGS Glow plugs are heating elements used to warm the air in the combustion chambers before and during engine startup The glow p...

Page 312: ...ngine 3 Connect a battery positive cable at least 20sq to starter motor B terminal and battery positive terminal 4 Ground the motor body 5 Connect a jumper lead at least 3sq to battery posi tive termi...

Page 313: ...IC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE 265WA27A C HOLD IN TEST OF SOLENOID SWITCH 1 Disconnect the M terminal of the starter 2 Connect battery neg...

Page 314: ...GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE 265WA29A 4 2 CHARGING SYSTEM 4 2 1 CHARGING CURRENT CHECK 1 After engine starts disconnect battery positive cable then connect the am...

Page 315: ...cket to remove the old bulb 4 Insert a new bulb into the socket and turn the bulb clockwise until tightened 265WA32A 1 Screw 2 Head light 3 Bulb 12V 35W 35W 265WA30A B SWITCH REMOVAL 1 Loosen the scre...

Page 316: ...E 1 2 3 Gr 1 Right 3 Left 2 265WA33A 265WA34A 1 Rubber cover 3 Switch body 2 Ring nut B SWITCH REMOVAL Remove the rubber cover 1 Loosen the ring nut 2 then pull down the body 3 from the console 1 cent...

Page 317: ...etween terminals 1 and 2 3 If test results are not as outlined above replace the hazard light switch 4 3 5 FLASHER UNIT A TERMINAL IDENTIFICATION AND CIRCUIT This shows the terminal identification and...

Page 318: ...t bulb 1 Remove the three screws then remove the lens 2 Push in on the bulb and rotate counterclockwise in the socket to remove the old bulb 3 Insert a new bulb into the socket and turn the bulb clock...

Page 319: ...LK30 INDEX Lk30_11_Index p65 2007 07 26 12 07 Page 1 Adobe PageMaker 6 5K Win...

Page 320: ...se removal and installation 4 29 Brake case removal 6 7 Brake disc wear 6 9 6 11 Brake plate wear 6 9 By pass valve 2 17 C Cam plate flatness 6 10 Camshaft and fuel camshaft 2 13 Camshaft 2 5 Caution...

Page 321: ...tem 4 32 Dimensions 1 4 Directional valve and cap 9 22 Disassemble the brake pedals 6 8 Disassemble the clutch housing 4 19 Disassemble the hydraulic cylinder 4 26 Disassemble the middle case 4 22 Dis...

Page 322: ...25 H Handling of hazardous materials 0 6 Handling of rotating blade shaft and driving belt 0 7 Hazard light switch test 10 31 Head light switch testing 10 29 Height of cam plate and ball 6 10 High pr...

Page 323: ...e curve of engine 2 10 Piston and piston rings 2 12 Piston ring 2 6 Piston 2 61 Plate wear 6 11 Position control valve 9 24 Position control 9 7 Power steering control motor 8 8 Power steering unit sp...

Page 324: ...f engine 2 30 Troubleshooting of clutch 3 5 Troubleshooting of rear axle 5 7 Troubleshooting of brake 6 6 Troubleshooting of front axle 7 6 Troubleshooting of steering system 8 11 Troubleshooting of h...

Page 325: ...C ELECTRIC ELECTRIC INDEX INDEX INDEX INDEX INDEX HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC GENERAL GENERAL GENERAL GENERAL GENERAL REAR AXLE REAR AXLE REAR AXLE REAR AXLE REAR AXLE U Unit con...

Page 326: ...Lk30_11_Index p65 2007 07 26 12 07 Page 7 Adobe PageMaker 6 5K Win...

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