Kubota B1220 Workshop Manual Download

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ELECTRICAL SYSTEM

B1220, B1620, B1820, WSM

9-M10

(EU)

(3) With OPC and PTO Gear Shift Lever Switch Type

When the main switch is turned to the

PREHEAT

position, the terminal

is connected to the terminals

and

. The glow plugs become red-hot, and at the same time, the glow plug indicator also lights on.

When the main switch is then turned to the

START

position with the safety switches on, the terminal

connected to the terminal

and

. Consequently, battery current flows to the starter motor and start the engine.

The main switch automatically returns to the

position, the terminal

is connected only to the terminal

thereby causing the starting circuit to be opened, stopping the starter motor.

When the main switch turned from the

position to the

OFF

position, the fuel cut-off solenoid moves the fuel

injection pump control rack to the

"No Fuel Injection"

position and stop the engine.

9Y1210272ELM0026US0

(1) Timer Relay 2
(2) Relay
(3) Relay
(4) Joint Connector
(5) Combination Switch
(6) Seat Switch

(7) PTO Gear Shift Lever Switch

(Mid)

(8) PTO Switch (Rear)
(9) Main Gear Shift Switch
(10) Starter Switch

(11) Parking Brake Switch
(12) Frame Earth
(13) Fuse Box
(14) Slow Blow Fuse (50 A)
(15) Battery

(16) Starter
(17) Glow Plug
(18) Timer Relay
(19) Starter Relay
(20) Key Stop Solenoid

KiSC issued 07, 2011 A

Summary of Contents for B1220

Page 1: ...WORKSHOP MANUAL TRACTOR B1220 B1620 B1820 KiSC issued 07 2011 A ...

Page 2: ...ou continue with the subsequent sections make sure that you read this section Refer to the latest version of Workshop Manual Code No 9Y021 01870 9Y021 18200 for the diesel engine tractor mechanism that this workshop manual does not include Q Servicing This section contains information below Troubleshooting Servicing Specifications Tightening Torques Checking Disassembling and Servicing All illustr...

Page 3: ...I INFORMATION KiSC issued 07 2011 A ...

Page 4: ...CONTENTS 1 SAFETY FIRST I 1 2 SAFETY DECALS I 4 3 SPECIFICATIONS I 6 4 TRAVELING SPEEDS I 7 5 DIMENSIONS I 8 INFORMATION KiSC issued 07 2011 A ...

Page 5: ...or in disengaged positions Do not start the engine when you stay on the ground Start the engine only from operator s seat WSM000001INI0015US0 SAFETY FIRST This symbol the industry s Safety Alert Symbol is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury Read these instructions carefully It is essential that you read the instructions and ...

Page 6: ...fore you disconnect hydraulic or fuel lines Tighten all connections before you apply the pressure Do not open a fuel system under high pressure The fluid under high pressure that stays in fuel lines can cause serious injury Do not disconnect or repair the fuel lines sensors or any other components between the fuel pump and injectors on engines with a common rail fuel system under high pressure Put...

Page 7: ...egulations when you discard oil fuel coolant electrolyte and other dangerous waste WSM000001INI0007US1 PREVENT ACID BURNS Keep electrolyte away from your eyes hands and clothing Sulfuric acid in battery electrolyte is poisonous and it can burn your skin and clothing and cause blindness If you spill electrolyte on yourself clean yourself with water and get medical aid immediately WSM000001INI0008US...

Page 8: ... following safety decals pictorial safety labels are installed on the machine If a decal becomes damaged illegible or is not on the machine replace it The decal part number is listed in the parts list WSM000001INI0014US0 9Y1210272INI0001US0 KiSC issued 07 2011 A ...

Page 9: ...INFORMATION B1220 B1620 B1820 WSM I 5 EU 9Y1210272INI0002US0 KiSC issued 07 2011 A ...

Page 10: ...1 in Overall width 932 mm 36 7 in 927 mm 36 5 in Overall height top of steering wheel 1235 mm 48 62 in 1255 mm 49 41 in Wheel base 1270 mm 50 00 in Minimum ground clearance 250 mm 9 84 in 270 mm 10 6 in Tread Front 778 mm 30 6 in 767 mm 30 2 in Rear 707 to 1035 mm 27 84 to 40 74 in 743 to 1035 mm 29 26 to 40 74 in Weight 460 kg 1010 lbs 510 kg 1120 lbs 520 kg 1150 lbs Clutch Dry single plate Trave...

Page 11: ...ow R AR 1 06 0 659 2 High R AR 5 91 3 67 Max speed at 3250 engine rpm 6 19 3 85 Model B1620 B1820 Tire size Rear 7 16 Farm 8 16 Farm Range gear shift lever Main gear shift lever km h mph km h mph Forward 1 Low 1 0 88 0 55 0 94 0 58 2 2 1 59 0 988 1 7 1 1 3 3 2 88 1 79 3 07 1 91 4 High 1 4 9 3 5 24 3 26 5 2 8 86 5 51 9 46 5 88 6 3 16 05 9 973 17 13 10 64 Max speed at 2950 engine rpm 16 91 10 51 18 ...

Page 12: ...INFORMATION B1220 B1620 B1820 WSM I 8 EU 5 DIMENSIONS 9Y1210272INI0005US0 KiSC issued 07 2011 A ...

Page 13: ...G GENERAL KiSC issued 07 2011 A ...

Page 14: ...PLUGS G 12 6 MAINTENANCE CHECK LIST G 13 7 CHECK AND MAINTENANCE G 17 1 DAILY CHECK G 17 2 CHECK POINTS OF INITIAL 50 HOURS G 18 3 CHECK POINTS OF EVERY 50 HOURS G 20 4 CHECK POINTS OF EVERY 100 HOURS G 23 5 CHECK POINTS OF EVERY 200 HOURS G 29 6 CHECK POINTS OF EVERY 400 HOURS G 30 7 CHECK POINT OF EVERY 800 HOURS G 32 8 CHECK POINT OF EVERY 1500 HOURS G 32 9 CHECK POINT OF EVERY 3000 HOURS G 32 ...

Page 15: ...contacting your local KUBOTA distributor always specify engine serial number tractor serial number ROPS serial number and hour meter reading 9Y1210272GEG0001US0 1 Tractor Identification Plate 2 Tractor Serial Number 3 Engine Serial Number 4 Hour Meter A B1220 B B1620 and B1820 KiSC issued 07 2011 A ...

Page 16: ... G 2 EU 2 CYLINDER NUMBER You can see the cylinder numbers of KUBOTA diesel engine in the figure The sequence of cylinder numbers is No 1 No 2 and No 3 and it starts from the gear case side WSM000001GEG0056US0 KiSC issued 07 2011 A ...

Page 17: ...parts before you measure Use only KUBOTA genuine parts for replacement to keep the machine performance and to make sure of safety You must replace the gaskets and O rings when you assemble again Apply grease 1 to new O rings or oil seals before you assemble When you assemble the external or internal snap rings make sure that the sharp edge 3 faces against the direction from which force 2 is applie...

Page 18: ... attempt to modify or remodel any electrical parts and wiring When removing the battery cables disconnect the negative cable first When installing the battery cables connect the positive cable first WSM000001GEG0062US1 1 WIRING Securely tighten wiring terminals WSM000001GEG0063US1 Do not let wiring contact dangerous part WSM000001GEG0064US1 Repair or change torn or aged wiring immediately WSM00000...

Page 19: ...e sag be required WSM000001GEG0068US1 In installing a part take care not to get wiring caught by it WSM000001GEG0069US1 After installing wiring check protection of terminals and clamped condition of wiring only connect battery WSM000001GEG0070US1 1 Grommet A Correct B Incorrect 1 Clamp Wind Clamp Spirally 2 Wire Harness 3 Clamp 4 Welding Dent 1 Wiring 2 Clamp A Correct B Incorrect 1 Wiring A Incor...

Page 20: ...echarging the battery remove it from the machine Before recharging remove cell caps Do recharging in a well ventilated place where there is no open flame nearby as hydrogen gas and oxygen are formed WSM000001GEG0071US1 3 FUSE Use fuses with specified capacity Neither too large or small capacity fuse is acceptable Never use steel or copper wire in place of fuse Do not install working light radio se...

Page 21: ...s no female connector being too open WSM000001GEG0076US1 Make certain plastic cover is large enough to cover whole connector WSM000001GEG0077US1 5 HANDLING OF CIRCUIT TESTER Use tester correctly following manual provided with tester Check for polarity and range WSM000001GEG0078US1 1 Exposed Terminal 2 Deformed Terminal 3 Sandpaper 4 Rust A Correct B Incorrect 1 Cover A Correct B Incorrect KiSC iss...

Page 22: ...s This symbol of shows color with stripe s An example Red stripe on white color W R WSM000001GEG0079US0 Color of wiring Color code Black B Brown Br Green G Gray Gy or Gr Blue L Light Green Lg Orange Or Pink P Purple Pu or V Red R Sky Blue Sb White W Yellow Y 1 Wire Color 2 Stripe KiSC issued 07 2011 A ...

Page 23: ...qts 2 4 L 2 5 U S qts 2 1 Imp qts Engine oil CF or better Refer to next page Above 25 C 77 F SAE30 10W 30 or 15W 40 0 to 25 C 32 to 77 F SAE20 10W 30 or 15W 40 Below 0 C 32 F SAE10W 10W 30 or 15W 40 4 Transmission case 10 5 L 2 77 U S gals 2 31 Imp gals KUBOTA UDT or SUPER UDT fluid 5 Front axle case 3 4 L 3 6 U S qts 3 0 Imp qts KUBOTA UDT or SUPER UDT fluid SAE80 or SAE90 gear oil 6 Greasing No ...

Page 24: ...ls specified to EN 590 or ASTM D975 are recommended No 2 D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service SAE J313 JUN87 Since this engine adopts EPA Tier 4 and Interim Tier 4 standards the use of low sulfur fuel or ultra low sulfur fuel is mandatory in EPA regulated area North America Therefore please use No 2 D S500 or S15 diesel fuel as an alternativ...

Page 25: ... 4 0 to 4 6 29 to 33 32 to 34 3 2 to 3 5 24 to 25 48 to 55 4 9 to 5 7 36 to 41 40 to 44 4 0 to 4 5 29 to 32 61 to 70 6 2 to 7 2 45 to 52 M12 63 to 72 6 4 to 7 4 47 to 53 78 to 90 7 9 to 9 2 58 to 66 63 to 72 6 4 to 7 4 47 to 53 103 to 117 10 5 to 12 0 76 0 to 86 7 M14 108 to 125 11 0 to 12 8 79 6 to 92 5 124 to 147 12 6 to 15 0 91 2 to 108 167 to 196 17 0 to 20 0 123 to 144 M16 167 to 191 17 0 to ...

Page 26: ...0 8 63 to 11 5 16 3 to 19 7 1 67 to 2 00 12 0 to 14 6 5 16 23 1 to 27 7 2 36 to 2 82 17 0 to 20 5 33 to 39 3 4 to 3 9 25 to 28 3 8 48 to 56 4 9 to 5 7 36 to 41 61 to 73 6 3 to 7 4 45 to 53 1 2 110 to 130 11 3 to 13 2 81 2 to 95 8 150 to 178 15 3 to 18 1 111 to 131 9 16 150 to 178 15 3 to 18 1 111 to 131 217 to 260 22 2 to 26 5 160 to 191 5 8 204 to 244 20 8 to 24 8 151 to 179 299 to 357 30 5 to 36...

Page 27: ...ce every 1 year G 25 2 11 Air cleaner element Double Primary element Clean every 100 Hr G 26 1 Replace every 1 year G 26 2 Secondary element Replace every 1 year G 26 12 Fuel filter element Check every 100 Hr G 26 Replace every 400 Hr G 31 13 Fan belt Adjust every 100 Hr G 27 14 Clutch Adjust every 100 Hr G 19 15 Brake Adjust every 100 Hr G 27 16 Parking brake except B1220 Adjust every 100 Hr G 28...

Page 28: ...s G 33 25 Fuel system Bleed Service as required G 36 26 Clutch housing Drain G 36 27 Fuse Replace G 36 G 37 28 Light bulb Replace G 37 G 38 No Item Indication on hour meter Interval Refer ence page Impor tant 50 100 150 200 250 300 350 400 450 500 KiSC issued 07 2011 A ...

Page 29: ...ce every 1 year G 25 2 11 Air cleaner element Double Primary element Clean every 100 Hr G 26 1 Replace every 1 year G 26 2 Secondary element Replace every 1 year G 26 12 Fuel filter element Check every 100 Hr G 26 Replace every 400 Hr G 31 13 Fan belt Adjust every 100 Hr G 27 14 Clutch Adjust every 100 Hr G 19 15 Brake Adjust every 100 Hr G 27 16 Parking brake except B1220 Adjust every 100 Hr G 28...

Page 30: ...necessary 4 When the battery is used for less than 100 hours per year check the fluid level annually 9Y1210272GEG0062US0 24 Coolant Change every 2 years G 33 25 Fuel system Bleed Service as required G 36 26 Clutch housing Drain G 36 27 Fuse Replace G 36 G 37 28 Light bulb Replace G 37 G 38 No Item Indication on hour meter After purchase Interval Refer ence page Impor tant 550 600 650 700 750 800 1...

Page 31: ...d ROPS attaching hardware 7 Check and clean the radiator screen and grille 8 Check the bolts and nuts of the tires are tight 9 Check the number plate or SMV emblem for damage and cleaner replace as necessary if equipped 10 Care of danger warning and caution labels 11 Clean around the exhaust manifold and the muffler of the engine While sitting in the operator s seat 1 Check the brake pedals and cl...

Page 32: ...changing oil filter cartridge Allow engine to cool down sufficiently oil can be hot and can burn 1 Remove the oil filter cartridge with the filter wrench 2 Apply a slight coat of oil onto the cartridge gasket 3 To install the new cartridge screw it in by hand Over tightening may cause deformation of rubber gasket 4 After the new cartridge has been replaced the engine oil normally decrease a little...

Page 33: ...htly Make sure that the transmission fluid does not leak through the seal Check the fluid level IMPORTANT To prevent serious damage to the hydraulic system Use only a KUBOTA genuine filter or its equivalents 9Y1210272GEG0008US0 Checking Clutch Pedal Free Travel 1 Stop the engine and remove the key 2 Slightly depress the clutch pedal and measure free travel at top of pedal stroke 3 If adjustment is...

Page 34: ...TO gear shift lever 3 to desired position 4 Turn the key to START position 5 The engine must not crank NOTE If the engine cranks during any of these tests adjust or replace the required safety switch 9Y1210272GEG0010US0 Checking Wheel Mounting Bolts and Nuts Tightening Torque CAUTION Never operate tractor with a loose rim wheel or axle Any time bolts and nuts are loosened retighten to specified to...

Page 35: ... to the following position as figures To be continued 1 Battery Terminals 2 Grease Fitting Brake Pedal 3 Grease Fitting Pedal Shaft 4 Grease Fitting Clutch Pedal 5 Grease Fitting Lift Rod R H 6 Grease Fitting Parking Brake Shaft Except B1220 KiSC issued 07 2011 A ...

Page 36: ...GENERAL B1220 B1620 B1820 WSM G 22 EU Continued 9Y1210272GEG0012US0 7 Parking Brake Lever Except B1220 KiSC issued 07 2011 A ...

Page 37: ... that the fluid level is between the UPPER and LOWER levels CAUTION Never remove the vent plugs while the engine is running Keep electrolyte away from eyes hands and clothes If you are spattered with it wash it away completely with water immediately and get medical attention Wear eye protection and rubber gloves when working around battery 1 Mishandling the battery shortens the service life and ad...

Page 38: ...ry positive terminal to the charger positive terminal and the negative to the negative then recharge in the normal manner 4 A boost charge is only for emergencies It will partially charge the battery at a high rate and in a short time When using a boost charged battery it is necessary to recharge the battery as early as possible Failure to do this will shorten the battery s service life 5 When the...

Page 39: ...ructions on the label attached to the case 3 Replace air cleaner element Once yearly or after every sixth cleaning whichever comes first NOTE Check to see if the evacuator valve is blocking with dust IMPORTANT The air cleaner uses a dry element never apply oil Do not run the engine with filter element removed Be sure to refit the dust cup with the arrow on the rear of cup upright If the dust cup i...

Page 40: ... arrow on the rear of cup upright If the dust cup is improperly fitted evacuator valve will not function and dust will adhere to the element Do not touch the secondary element except in cases where replacing is required Q Evacuator Valve Open the evacuator valve once a week under ordinary conditions or daily when used in a dusty place to get rid of large particles of dust and dirt 9Y1210272GEG0016...

Page 41: ... mm 0 20 in 1 Release the parking brake 2 Slightly depress the brake pedals and measure free travel at top of pedal stroke 3 If adjustment is needed loosen the lock nut and adjust the rod length 4 Retighten the lock nut securely 5 Keep the free travel in the right and left pedals equal NOTE After checking brake pedal free travel be sure to engage the parking brake lever fully and check to see that...

Page 42: ...If hoses and clamps are found worn or damaged replace or repair them at once 3 The fuel line is made of rubber and ages regardless of period of service Replace the fuel pipe together with the clamp every two years and securely tighten 4 However if the fuel pipe and clamp are found damaged or deteriorated earlier than two years then change or remedy 5 After the fuel line and clamp have been changed...

Page 43: ...if radiator hoses are swollen hardened or cracked Replace hoses and hose clamps every 2 years or earlier if checked and found that hoses are swollen hardened or cracked Q Precaution at Overheating Take the following actions in the event the coolant temperature be nearly or more than the boiling point what is called Overheating 1 Stop the machine operation in a safe place and keep the engine unload...

Page 44: ...removing the filling plug 2 up to the upper notch on the dipstick 3 6 After running the engine for a few minutes stop it and check the oil level again if low add oil prescribed level IMPORTANT Use only multi grade transmission oil Use of other oils may damage the transmission or hydraulic system Refer to LUBRICANTS FUEL AND COOLANT See page G 9 Never work the tractor immediately after changing the...

Page 45: ...028US0 Replacing Fuel Filter Element IMPORTANT When the fuel filter bowl has been removed fuel stops flowing from the fuel tank If the fuel tank is almost full however the fuel will flow back from the fuel return pipe to the fuel filter Before checking make sure the fuel tank is less than half full This job should not be done in the field but in a clean place 1 Unscrew the fuel filter bowl and rin...

Page 46: ...POINT OF EVERY 1500 HOURS Checking Fuel Injection Nozzle Injection Pressure See page 1 S17 9Y1210272GEG0031US0 9 CHECK POINT OF EVERY 3000 HOURS Checking Injection Pump See page 1 S16 9Y1210272GEG0032US0 10 CHECK POINT OF 1 YEAR Replacing Air Cleaner Primary Element and Secondary Element See page G 25 G 26 9Y1210272GEG0033US0 KiSC issued 07 2011 A ...

Page 47: ... cooling system cleaner 5 Follow directions of the cleaner instruction 6 After flushing fill with clean water and anti freeze until the coolant level is just below the radiator cap Install the radiator cap securely 7 Fill with coolant up to the FULL mark on the recovery tank 8 Start and operate the engine for few minutes 9 Stop the engine remove the key and let cool 10 Check coolant level of recov...

Page 48: ...tion regulations when disposing of antifreeze If it freezes coolant can damage the cylinders and radiator If the ambient temperature falls below 0 C 32 F or before a long term storage let out cooling water completely or mix fresh water with long life coolant and fill the radiator and reserve tank with the mixture 1 Long life coolant hereafter LLC comes in several types Use ethylene glycol EG type ...

Page 49: ...s and the engine may fail to perform as specified 6 When the LLC is mixed do not employ any radiator cleaning agent The LLC contains anticorrosive agent If mixed with the cleaning agent sludge may build up adversely affecting the engine parts 7 KUBOTA s genuine long life coolant has a service life of 2 years Be sure to change the coolant every 2 years NOTE The above data represent industry standar...

Page 50: ...install the plug again 9Y1210272GEG0039US0 Replacing Fuse B1220 1 The tractor electrical system is protected from potential damage by fuses A blown fuse indicates that there is an overload or short somewhere in the electrical system 2 If any of the fuses should blow replace with a new one of the same capacity IMPORTANT Before replacing a blown fuse determine why the fuse blew and make any necessar...

Page 51: ...s damage to the tractor electrical system Refer to the TROUBLESHOOTING section of this manual Q Protected Circuit 9Y1210272GEG0041US0 Replacing Light Bulb B1220 1 Head lights Take the bulb out of the light body and replace with a new one 2 Other lights Detach the lens and replace the bulb 9Y1210272GEG0042US0 Fuse No Capacity A Protected Circuit 1 Slow blow fuse 50 A Check circuit against wrong bat...

Page 52: ...3US0 Light Capacity Head lights H8 35 W Tail light Stop light 5 W 21 W Turn signal Hazard light 21 W Instrument panel light 1 7 W Hazard light switch indicator 0 6 W Work light Front position light 5 W Number plate light 5 W 1 Head Light 2 Front Position Light 3 Number Plate Light 4 Tail Light Stop Light 5 Turn Signal Light Hazard Light 6 Brake Stop Light 7 Instrument Panel 8 Hazard Light Switch K...

Page 53: ... Piston Ring Tool Code No 07909 32121 Application Use exclusively for removing or installing the piston ring with ease WSM000001GEG0013US0 Diesel Engine Compression Tester for Injection Nozzle Code No 07909 30208 Assembly 07909 30934 A to F 07909 31211 E and F 07909 31231 H 07909 31251 G 07909 31271 I 07909 31281 J Application Use to measure diesel engine compression and diagnostics of need for ma...

Page 54: ...d leaks from cooling system Remarks Adaptor 1 BANZAI Code No RCT 2A 30S WSM000001GEG0017US0 Connecting Rod Alignment Tool Code No 07909 31661 Application Use to check the connecting rod alignment Applicable range Connecting rod big end I D 30 to 75 mm dia 1 2 to 2 9 in dia Connecting rod length 65 0 to 300 mm 2 56 to 11 8 in WSM000001GEG0020US0 Nozzle Tester Code No 07909 31361 Application Use to ...

Page 55: ...0 07 mm 0 001 to 0 003 in Red 0 05 to 0 1 mm 0 002 to 0 006 in Blue 0 1 to 0 2 mm 0 004 to 0 009 in WSM000001GEG0022US0 Red Check Code No 07909 31371 Application Use to check cracks on cylinder head cylinder block etc WSM000001GEG0023US0 Flywheel Puller Code No 07916 32011 Application Use exclusively for removing the flywheel with ease WSM000001GEG0018US0 KiSC issued 07 2011 A ...

Page 56: ...gasket D Flange Material Steel E Hex nut 27 mm 1 1 in across the plat F Adhesive application G Fillet welding on the enter circumference H Retaining nut I 17 mm dia 0 67 in dia J 8 0 mm dia 0 31 in dia K 1 0 mm 0 039 in L 17 mm dia 0 67 in dia M 6 10 to 6 20 mm dia 0 241 to 0 244 in dia N 8 0 mm 0 31 in O 4 0 mm 0 16 in P 11 97 to 11 99 mm dia 0 4713 to 0 4720 in dia Q PF 1 2 R 23 mm 0 91 in S 17 ...

Page 57: ... 12 5 to 12 8 mm dia 0 493 to 0 503 in dia L 8 90 to 9 10 mm 0 351 to 0 358 in C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in C0 3 Chamfer 0 30 mm 0 012 in A 135 mm 5 31 in B 72 mm 2 8 in C 40 mm radius 1 6 in radius D 10 mm 0 39 in E 24 mm 0 94 in F 20 mm dia 0 79 in dia G 51 20 to 51 40 mm dia 2 016 to 2 023 in dia H 47 30 to 47 50 mm dia 1 863 to 1 870 in dia C1 Chamfer 1 0 mm 0 039 in C...

Page 58: ...000001GEG0030US0 Pitman Arm Puller Code No 07909 39051 Application Use for removing the tie rod end with ease WSM000001GEG0050US0 Toe in Gauge Code No 07909 31681 Application This allows easy measurement of toe in for all machine models WSM000001GEG0034US0 Clutch Center Tool For B and L Series Tractors Application The clutch center tool can be used for all B and L series tractors with a diaphragm ...

Page 59: ...erring to the figure 9Y1210272GEG0064US0 1 Gauge 07916 50322 2 Cable 07916 50331 3 Threaded Joint 07916 50401 4 Threaded Joint 07916 50341 5 Adaptor B M18 P1 5 07916 50361 6 Adaptor C PS3 8 07916 50371 7 Adaptor D PT1 8 07916 50381 8 Adaptor E PS3 8 07916 50392 9 Adaptor F PF1 2 07916 62601 10 Adaptor 58 PT1 4 07916 52391 1 Flow Meter 2 Hydraulic Test Hose 1 Adaptor 52 2 Adaptor 53 3 Adaptor 54 4 ...

Page 60: ... mm 0 94 in C 120 mm 4 72 in D 21 8 to 21 9 mm dia 0 859 to 0 862 in dia E 24 8 to 24 9 mm dia 0 977 to 0 980 in dia F 20 mm dia 0 79 in dia a 6 3 µm 250 µin b 6 3 µm 250 µin A 196 mm 7 72 in B 26 mm 1 0 in C 150 mm 5 91 in D 25 80 to 25 90 mm dia 1 016 to 1 019 in dia E 28 80 to 28 90 mm dia 1 134 to 1 137 in dia F 20 mm dia 0 79 in dia a 6 3 µm 250 µin b 6 3 µm 250 µin A 20 mm 0 79 in B 15 mm 0 ...

Page 61: ...ng to figure 9Y1210272GEG0065US0 A 75 mm 3 0 in G 95 mm 3 7 in M 9 mm 0 4 in B 37 5 mm 1 48 in H 208 mm 8 19 in N 100 mm 3 94 in C 16 5 mm 0 650 in I 200 mm 7 87 in O 50 mm 2 0 in D 16 mm dia 0 63b in dia J 150 mm 5 91 in P 174 mm 6 85 in E 9 mm 0 4 in K 75 mm 3 0 in C1 Chamfer 1 mm 0 04 in F 190 mm 7 48 in L 12 mm dia 0 47 in dia KiSC issued 07 2011 A ...

Page 62: ... 425 to 1 429 in N 3 mm dia 0 12 in dia D 8 mm 0 31 in O 12 mm 0 47 in E 13 mm 0 55 in P 3 mm 0 12 in F 8 mm 0 31 in Q Pin 6 mm dia 15 mm length 0 24 in dia 0 59 in length G 33 mm 1 30 in R C3 Chamfer 3 mm 0 12 in H 45 mm 1 77 in S C3 Chamfer 3 mm 0 12 in I 16 mm 0 63 in T R10 10 mm radius 0 39 in radius J 6 mm 0 24 in U C12 Chamfer 12 mm 0 47 in K 12 0 to 12 1 mm dia 0 472 to 0 476 in dia V C1 Ch...

Page 63: ... an air compressor or hand pump Q Recommended inflation pressure Maintain the pressure shown below for normal use NOTE Maintain the maximum pressure in front tires if using a front loader of when equipped with a full load of front weights Q Dual Tires Dual tires are not approved 9Y1210272GEG0045US0 Tire Sizes Inflation Pressure Rear 7 16 4PR 180 kPa 1 8 kgf cm2 26 psi 8 16 4PR 160 kPa 1 6 kgf cm2 ...

Page 64: ...nsmission parts may be damaged Do not use tires larger than specified 9Y1210272GEG0046US0 1 Front Wheels Front wheel cannot be adjusted IMPORTANT Do not turn front discs to obtain wider tread In setting up the front wheels make sure that the inflation valve stem of the tires face outward 9Y1210272GEG0047US0 4 5 10 Farm 5 12 Farm 6 12B Farm 20 8 00 10 Turf 20 5 8 00 10 Turf 778 mm 30 6 in 767 mm 30...

Page 65: ...ollowing torques then recheck after driving the tractor 200 m 200 yards and there after daily check service Remove the wheel hub and reinstall it on the other side of the wheel disk then set the wheel as shown NOTE Insert the bolt 2 from the recessed side of both cotters and tighten the nut 4 with flat side of cotter as shown in figure 9Y1210272GEG0049US0 1 Nut 2 Spring Washer 3 Bolt 4 Wheel Hub P...

Page 66: ... chloride solution do not pour water over calcium chloride since this results in chemical reaction which will cause high temperature Instead add a small amount of calcium chloride to the water at a time until the desired solution is achieved 9Y1210272GEG0051US0 Attaching Injector 1 Lift the rear tires off the ground 2 Turn the tire so that the air valve is at the top 3 Remove the air valve and att...

Page 67: ...ction is completed reset the air valve and pump air into the tire to the specified pressure Weight of calcium chloride solution filling 75 of full capacity of a tire 9Y1210272GEG0053US0 Tire sizes 8 16 9 5 16 11 2 16 Slush free at 10 C 14 F Solid at 30 C 22 F Approx 1 kg 2 lbs CaCl2 per 4 L 1 gal of water 35 kg 77 lbs 54 kg 119 lbs 70 kg 155 lbs Slush free at 24 C 11 F Solid at 47 C 53 F Approx 1 ...

Page 68: ...1 ENGINE KiSC issued 07 2011 A ...

Page 69: ...l System 1 S15 2 PREPARATION 1 S19 1 Separating Engine from Tractor 1 S19 3 DISASSEMBLING AND ASSEMBLING 1 S26 1 Cylinder Head Valves and Oil Pan 1 S26 2 Gear Case and Timing Gears 1 S31 3 Piston and Connecting Rod 1 S34 4 Flywheel and Crankshaft 1 S36 4 SERVICING 1 S39 1 Cylinder Head and Valves 1 S39 2 Timing Gears 1 S45 3 Piston and Connecting Rod 1 S48 4 Crankshaft 1 S50 5 Cylinder 1 S55 6 Oil...

Page 70: ... leak from cylinder Replace head gasket tighten cylinder head screw glow plug and nozzle holder 1 S10 Improper valve timing Correct or replace timing gear 1 S32 Piston ring and cylinder worn Replace 1 S35 Excessive valve clearance Adjust 1 S11 Stop solenoid malfunctioning Replace Starter Does Not Run Battery discharged Charge G 23 Starter malfunctioning Repair or replace 9 S26 Wiring disconnected ...

Page 71: ... S29 Crankshaft bearing and crank pin bearing worn Replace 1 S38 Oil leaking due to defective seals or packing Replace Fuel Mixed into Lubricant Oil Injection pump s plunger worn Repair or replace 1 S31 Deficient nozzle injection Repair or replace nozzle 1 S18 Injection pump broken Replace 1 S31 Water Mixed into Lubricant Oil Head gasket defective Replace 1 S28 Cylinder block or cylinder head flaw...

Page 72: ...ator net and radiator fin clogged with dust Clean Inside of radiator corroded Clean or replace G 29 Coolant flow route corroded Clean or replace G 29 Radiator cap defective Replace 1 S13 Overload running Reduce the load Head gasket defective Replace 1 S28 Incorrect injection timing Adjust 1 S15 Unsuitable fuel used Use specified fuel G 9 Symptom Probable Cause Solution Reference Page KiSC issued 0...

Page 73: ...ve Guide Clearance O D I D 0 030 to 0 057 mm 0 00118 to 0 00224 in 5 968 to 5 980 mm 0 23496 to 0 23543 in 6 010 to 6 025 mm 0 23661 to 0 23720 in 0 10 mm 0 0039 in Valve Face Angle 0 785 rad 45 Valve Seat Angle Width 0 785 rad 45 2 12 mm 0 0835 in Valve Spring Free Length Tilt Setting Load Setting Length 31 3 to 31 8 mm 1 232 to 1 252 in 64 7 N 27 0 mm 6 6 kgf 27 0 mm 14 6 lbf 1 063 in 28 4 mm 1 ...

Page 74: ... 0059 to 0 0122 in 0 50 mm 0 0197 in 0 01 mm 0 0004 in Cam Height Intake and Exhaust 26 88 mm 1 0583 in 26 83 mm 1 0563 in Camshaft Journal to Cylinder Block Bore Camshaft Journal Cylinder Block Bore Oil Clearance O D I D 0 050 to 0 091 mm 0 00197 to 0 00358 in 32 934 to 32 950 mm 1 29661 to 1 29724 in 33 000 to 33 025 mm 1 29921 to 1 30020 in 0 15 mm 0 0059 in Idle Gear Shaft to Idle Gear Bushing...

Page 75: ...ance Alignment 0 15 to 0 31 mm 0 0059 to 0 0122 in 0 50 mm 0 0197 in 0 02 mm 0 0008 in Crankpin to Crankpin Bearing Crankpin Crankpin Bearing Oil Clearance O D I D 0 020 to 0 051 mm 0 00079 to 0 00201 in 33 959 to 33 975 mm 1 33697 to 1 33760 in 33 995 to 34 010 mm 1 33839 to 1 33898 in 0 15 mm 0 0059 in Crankshaft Journal to Crankshaft Bearing 1 Crankshaft Journal Crankshaft Bearing 1 Oil Clearan...

Page 76: ...peed More than 49 kPa 0 50 kgf cm2 7 psi 197 to 441 kPa 2 00 to 4 50 kgf cm2 28 5 to 64 0 psi 147 kPa 1 50 kgf cm2 21 3 psi Inner Rotor to Outer Rotor Clearance 0 03 to 0 14 mm 0 0012 to 0 0055 in Outer Rotor to Pump Body Clearance 0 07 to 0 15 mm 0 0028 to 0 0059 in Inner Rotor to Cover Clearance 0 075 to 0 135 mm 0 00295 to 0 00531 in Item Factory Specification Allowable Limit Fan Belt Tension 7...

Page 77: ...re T D C Pump Element Fuel Tightness 13 73 kPa 140 kgf cm2 1991 psi Delivery Valve Fuel Tightness 10 seconds 13 73 12 75 kPa 140 130 kgf cm2 1991 1849 psi 5 seconds 13 73 12 75 kPa 140 130 kgf cm2 1991 1849 psi Injection Nozzle Injection Pressure 13 73 to 14 71 kPa 140 to 150 kgf cm2 1991 to 2134 psi Injection Nozzle Valve Seat Valve Seat Tightness When the pressure is 12 75 kPa 130 kgf cm2 1849 p...

Page 78: ...jection pipe retaining nut M12 1 5 25 to 34 2 5 to 3 5 18 to 25 Overflow pipe retaining nut M12 1 5 20 to 24 2 0 to 2 5 15 to 18 Nozzle holder assembly M20 1 5 49 to 68 5 0 to 7 0 37 to 50 Glow plug M8 1 7 9 to 14 0 80 to 1 5 5 8 to 10 Rocker arm bracket nut M6 1 9 81 to 11 2 1 00 to 1 15 7 24 to 8 31 Cylinder head screw M8 1 25 38 to 42 3 8 to 4 3 28 to 31 Fan drive pulley screw M12 1 5 118 to 12...

Page 79: ... and 7 for each cylinder 9 If the measurement is below the allowable limit apply a small amount of oil to the cylinder wall through the nozzle hole and measure the compression pressure again 10 If the compression pressure is still less than the allowable limit check the top clearance valve clearance and cylinder head 11 If the compression pressure increases after applying oil check the cylinder wa...

Page 80: ...ton comes to the T D C position when the TC marking line is aligned with center of timing window on clutch housing Turn the flywheel 0 26 rad 15 clockwise and counterclockwise to see if the piston is at the compression top dead center or the overlap position The piston is at the compression top dead center when both the IN and EX valves do not move it is at the overlap position when both the valve...

Page 81: ... Oil strainer clogged Oil filter cartridge clogged Oil gallery clogged Excessive oil clearance Foreign matter in the relief valve When reassembling After checking the engine oil pressure tighten the engine oil pressure switch to the specified torque 9Y1210272ENS0016US0 Engine oil pressure Factory specifica tion At idle speed More than 49 kPa 0 50 kgf cm2 7 1 psi At rated speed 197 to 441 kPa 2 00 ...

Page 82: ...replace it 9Y1210272ENS0018US0 Radiator Cap Air Leakage CAUTION When removing the radiator cap wait at least ten minutes after the engine has stopped and cooled down Otherwise hot water way gush out scalding nearby people 1 Set a radiator tester 1 and adaptor 2 on the radiator cap 2 Apply the specified pressure 88 kPa 0 90 kgf cm2 13 psi and measure the time for the pressure to fall to 59 kPa 0 60...

Page 83: ...f water into the radiator 2 Set a radiator tester 1 adaptor 2 and raise the water pressure to the specified pressure 3 Check the radiator for water leaks 4 If the water leak from the pinhole replace the radiator or repair with the radiator cement When water leak is excessive replace the radiator 9Y1210272ENS0020US0 Radiator water leakage test pressure Factory specification 137 kPa 1 40 kgf cm2 19 ...

Page 84: ...0 175 mm 0 00689 in Combine these shims for adjustments Addition or reduction of shim 0 025 mm 0 00098 in delays or advances the injection timing by approx 0 0044 rad 0 25 In disassembling and replacing the injection pump be sure to use the same number of new shims with the same thickness The 0 175 mm 0 00689 in thick shim is coated only on the lower face Therefore do not use the 0 175 mm 0 00689 ...

Page 85: ...p the starter when the fuel jets from the injection nozzle After that turn the flywheel by the hand and raise the pressure to approx 13 73 MPa 140 0 kgf cm2 1991 psi 7 Now turn the flywheel back about half a turn to keep the plunger free Maintain the flywheel at this position and clock the time taken for the pressure to drop from 13 73 to 12 75 MPa from 140 0 to 130 0 kgf cm2 from 1991 to 1849 psi...

Page 86: ...ure at which fuel begins jetting out from the nozzle 3 If the measurement is not within the factory specifications replace the adjusting washer 1 in the nozzle holder to adjust it Reference Pressure variation with 0 01 mm 0 0004 in difference of adjusting washer thickness Approx 235 kPa 2 41 kgf cm2 34 1 psi 9Y1210272ENS0026US0 Valve Seat Tightness 1 Set the injection nozzle to a nozzle tester Cod...

Page 87: ...ction After assembling the nozzle be sure to adjust the fuel injection pressure 9Y1210272ENS0028US0 Tightening torque Nozzle holder 35 to 39 N m 3 5 to 4 0 kgf m 26 to 28 lbf ft Overflow pipe nut 20 to 24 N m 2 0 to 2 50 kgf m 15 to 18 lbf ft Nozzle holder assembly 49 to 68 N m 5 0 to 7 0 kgf m 37 to 50 lbf ft 1 Nozzle Holder 2 Adjusting Washer 3 Nozzle Spring 4 Push Rod 5 Distance Piece 6 Nozzle ...

Page 88: ...n connecting positive cable first 9Y1210272ENS0001US0 Draining Coolant CAUTION Never open the radiator cap while operating or immediately after stopping Otherwise hot water will spout out from the radiator Wait for more than ten minutes to cool the radiator before opening the cap 1 Loosen the drain cock 3 from the radiator hose to drain coolant 2 Remove the radiator cap 1 to drain coolant complete...

Page 89: ...1 When refilling Fill with the new oil up to the upper notch on the dipstick IMPORTANT Never mix two different types of oil Use the proper SAE Engine Oil according to ambient temperatures Refer to LUBRICANTS FUEL AND COOLANT See page G 9 9Y1210272ENS0003US0 Engine oil capacity B1220 1 6 L 1 7 U S qts 1 4 Imp qts B1620 B1820 2 4 L 2 5 U S qts 2 1 Imp qts 1 Drain Plug 2 Oil Inlet 3 Dipstick A Proper...

Page 90: ...CANTS FUEL AND COOLANT See page G 9 Never work the tractor immediately after changing the transmission oil Keep the engine at medium speed for a few minutes to prevent damage to the transmission Do not mix different brands oil together 9Y1210272ENS0004US0 Steering Wheel 1 Remove the steering wheel cap 2 Remove the steering wheel mounting nut and remove the steering wheel 1 with a steering wheel pu...

Page 91: ...ctor 6 combination switch connector 4 and hazard switch connector 7 Except B1220 Then remove the meter panel 3 3 Disconnect the main switch connector 8 and remove the panel under cover 5 9Y1210272ENS0006US0 1 Hand Accelerator Lever 2 Spring Pin 3 Meter Panel 4 Combination Switch Connector 5 Panel Under Cover 6 Meter Panel Connector 7 Hazard Switch Connector Except B1220 8 Main Switch Connector KiS...

Page 92: ...e tank frame stay 1 6 and the tank frame stay 2 12 9 Disconnect the fuse box 8 from the fuel tank 14 10 Remove the fuel tank 14 with tank frame 13 11 Disconnect the drag link 9 When reassembling IMPORTANT Do not loosen the slotted nut 10 to align the hole Install the cotter pins as shown in the figure 9Y1210272ENS0007US0 Tightening torque Slotted nut 18 to 35 N m 1 9 to 3 5 kgf m 14 to 25 lbf ft 1...

Page 93: ...2 and slide the universal joint cover 1 to the rear 2 Tap out the spring pin 4 3 Slide the universal joint 3 to the rear When reassembling Apply grease to the splines of the propeller shaft and universal joint When inserting the spring pin 4 face the split in the direction parallel to the universal joint cover 1 so that the water drain hole may become downward Replace the spring pin 4 with new one...

Page 94: ...g screws and separate the engine from the front axle frame When reassembling Direct the shorter end of the clutch disc boss toward the flywheel Apply molybdenum disulphide Three Bond 1901 or equivalent to the splines of clutch boss Insert the pressure plate noting the position of straight pins IMPORTANT Be sure to align the center of disc and flywheel by inserting the clutch center tool 10 NOTE Do...

Page 95: ...le holder assemblies 4 3 Remove the copper gasket 5 and heat seal 6 4 Remove the lead 2 from the glow plugs 3 5 Remove the glow plugs 3 When reassembling Replace the copper gasket and heat seal with new one 9Y1210272ENS0032US0 Tightening torque Cylinder head cover screw 9 81 to 11 2 N m 1 00 to 1 15 kgf m 7 24 to 8 31 lbf ft 1 Breather Hose 2 Cylinder Head Cover Screws 3 Cylinder Head Cover Tighte...

Page 96: ...asket must be changed when the injection nozzle is removed for cleaning or for service 9Y1210272ENS0033US0 Rocker Arm and Push Rod 1 Remove the rocker arm bracket screws 2 2 Detach the rocker arm assembly 1 3 Remove the push rods 3 When reassembling When putting the push rods 3 onto the tappets 4 check to see if their ends are properly engaged with the dimples IMPORTANT After installing the rocker...

Page 97: ...steps and specified sequence a to n or j NOTE Do not use O ring on the pin pipe It is not necessary to retighten the cylinder head screw and to readjust valve clearance after engine warmed up 9Y1210272ENS0035US0 Tappets 1 Remove the tappets 1 from the crankcase When reassembling Visually check the contact between tappets and cams for proper rotation If defect is found replace tappets Before instal...

Page 98: ...t Assembly 1 Remove the thermostat cover mounting screws 1 and remove the thermostat cover 2 2 Remove the thermostat assembly 4 When reassembling Replace the gasket 3 with a new one 9Y1210272ENS0038US0 Water Pump Assembly 1 Loosen the alternator mounting screws and remove the fan belt 2 Remove the fan and fan pulley 3 Remove the water pump assembly 1 from the gear case cover 3 When reassembling Re...

Page 99: ...ered 3 install the oil strainer by mounting screw IMPORTANT Scrape off the old adhesive completely Wipe the sealing surface clean using waste cloth soaked with gasoline Now apply new adhesive 3 0 to 5 0 mm 0 12 to 0 19 in thick all over the contact surface Apply the adhesive also on the center of the flange as well as on the inner wall of each bolt hole Cut the nozzle of the liquid gasket Three Bo...

Page 100: ...e slot 7 on the fork lever as shown in the photo NOTE The sealant is applied to both sides of the soft metal gasket shim The liquid gasket is not required for assembling Addition or reduction of shim 0 05 mm 0 002 in delays or advances the injection timing by approx 0 009 rad 0 5 In disassembling and replacing be sure to use the same number of new gasket shims with the same thickness 9Y1210272ENS0...

Page 101: ...r assembly 1 2 Remove the idle gear shaft mounting screws 3 3 Remove the idle gear shaft 4 if necessary When reassembling Apply engine oil to the idle gear shaft mounting screw 3 And tighten them Install the idle gear aligning the mark 5 on the gears referring to the photo 9Y1210272ENS0099US0 1 Screw Inside 2 Start Spring 3 Fork Lever 1 4 Gear Case Tightening torque Nut 79 to 88 N m 8 to 9 kgf m 5...

Page 102: ...1210272ENS0047US0 Oil Pump and Crankshaft Gear 1 Remove the oil pump gear 7 2 Remove the oil pump mounting screw 6 and the oil pump 5 3 Remove the collar 4 O ring 3 and crankshaft oil slinger 2 For Z482 D722 and D782 4 Remove the crankshaft gear 1 with a puller When reassembling Install the collar 4 after aligning the marks on the gears See the photo at Idle Gear 9Y1210272ENS0048US0 1 Camshaft Mou...

Page 103: ...d as above When reassembling Before inserting the piston into the cylinder apply enough engine oil to the cylinder When inserting the piston into the cylinder face the mark on the connecting rod to the injection pump NOTE Do not change the combination of cylinder and piston Make sure of the position of each piston by marking For example mark 1 on the No 1 piston When installing the piston into the...

Page 104: ...il ring gap 11 Apply engine oil to the piston pin When installing the connecting rod to the piston immerse the piston in 80 C 176 F oil for 10 to 15 minutes and insert the piston pin to the piston When installing the connecting rod to the piston align the mark 9 on the connecting rod to the fan shaped concave 8 IMPORTANT Mark the same number on the connecting rod and the piston so as not to change...

Page 105: ...g case cover 5 When reassembling Fit the bearing case gasket 3 and the bearing case cover gasket 4 with correct directions Install the bearing case cover 5 to position the casting mark UP a on it upward Apply engine oil to the oil seal 6 lip and take care that it is not rolled when installing Tighten the bearing case cover mounting screws with even force on the diagonal line 9Y1210272ENS0053US0 Ti...

Page 106: ...inder comes to the center of the third cylinder 4 Repeat the above steps to draw out all the crankshaft When reassembling Clean the oil passage of the crankshaft with compressed air Install the crankshaft assembly aligning the screw hole of main bearing case screw 2 with the screw hole of crankcase When tightening the main bearing case 2 apply oil to the main bearing case screw 2 1 and screw by ha...

Page 107: ...or Z482 and 1 2 for D722 D782 from the gear case side Refer to the figure Match the alignment numbers a on the main bearing case assembly 1 1 Do the same for the main bearing case assembly 2 2 and the main bearing case assembly 3 too When installing the main bearing case 1 and 2 face the mark FLYWHEEL to the flywheel Install the thrust bearing 7 with its oil groove facing outward Confirm that the ...

Page 108: ... the oil clearance between the crankpin and crankpin bearing and between the piston pin and small end bushing NOTE After checking the top clearance be sure to assemble the cylinder head with a new cylinder head gasket 9Y1210272ENS0056US0 Cylinder Head Surface Flatness 1 Clean the cylinder head surface 2 Place a straightedge on the cylinder head s four sides and two diagonal as shown in the figure ...

Page 109: ...9Y1210272ENS0059US0 Clearance between Valve Stem and Valve Guide 1 Remove carbon from the valve guide section 2 Measure the valve stem O D with an outside micrometer 3 Measure the valve guide I D with a small hole gauge and calculate the clearance 4 If the clearance exceeds the allowable limit replace the valves If it still exceeds the allowable limit replace the valve guide 9Y1210272ENS0060US0 1 ...

Page 110: ...ment 9Y1210272ENS0061US0 Valve Seating 1 Coat the valve face lightly with prussian blue and put the valve on its seat to check the contact 2 If the valve does not seat all the way around the valve seat or the valve contact is less than 70 correct the valve seating as follows 3 If the valve contact does not comply with the reference value replace the valve or correct the contact of valve seating 9Y...

Page 111: ...5 valve seat cutter again and visually recheck the contact between the valve and seat 5 Repeat steps 3 and 4 until the correct contact is achieved 6 Continue lapping until the seated rate becomes more than 70 of the total contact area 9Y1210272ENS0063US0 Valve Lapping 1 Apply compound evenly to the valve lapping surface 2 Insert the valve into the valve guide Lap the valve onto its seat with a val...

Page 112: ...earance between Rocker Arm and Rocker Arm Shaft 1 Measure the rocker arm shaft O D with an outside micrometer 2 Measure the rocker arm I D with an inside micrometer and then calculate the oil clearance 3 If the oil clearance exceeds the allowable limit replace the rocker arm and measure the oil clearance again If it still exceeds the allowable limit replace also the rocker arm shaft 9Y1210272ENS00...

Page 113: ...bore with a cylinder gauge and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit or the tappet is damaged replace the tappet 9Y1210272ENS0069US0 Push rod alignment Allowable limit 0 25 mm 0 0098 in Oil clearance between tappet and tappet guide bore Factory specification 0 016 to 0 052 mm 0 00063 to 0 0020 in Allowable limit 0 10 mm 0 0039 in Tappet O D Factory specific...

Page 114: ...e cam gear to the font and rear 3 If the measurement exceeds the allowable limit replace the camshaft stopper 9Y1210272ENS0072US0 Backlash between idle gear and crank gear Factory specification 0 0430 to 0 124 mm 0 00170 to 0 00488 in Allowable limit 0 15 mm 0 0059 in Backlash between idle gear and cam gear Factory specification 0 0470 to 0 123 mm 0 00185 to 0 00484 in Allowable limit 0 15 mm 0 00...

Page 115: ...e the camshaft journal O D with an outside micrometer 2 Measure the cylinder block bore I D for camshaft with a inside micrometer and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit replace the camshaft 9Y1210272ENS0075US0 Camshaft alignment Allowable limit 0 01 mm 0 0004 in Cam height of intake and exhaust Factory specification 26 88 mm 1 058 in Allowable limit 26 8...

Page 116: ...r bushing using an idle gear bushing replacing tool Refer to SPECIAL TOOLS B When installing 1 Clean a new idle gear bushing and idle gear bore and apply engine oil to them 2 Press in a new brushing using an idle gear bushing replacing tool until it is flush with the end of the idle gear 9Y1210272ENS0077US0 Oil clearance between idle gear shaft and idle gear bushing Factory specification 0 020 to ...

Page 117: ...ushing and small end hole and apply engine oil to them 2 Using a small end bushing replacing tool press in a new bushing service parts taking due care to see that the position of the connecting rod oil hole matches the bushing hole Servicing parts dimension 9Y1210272ENS0080US0 Piston pin bore I D Factory specification 20 000 to 20 013 mm 0 78741 to 0 78791 in Allowable limit 20 05 mm 0 7894 in Oil...

Page 118: ...le limit replace the connecting rod 9Y1210272ENS0081US0 Piston Ring Gap 1 Insert the piston ring into the lower part of the cylinder the least worn out part with a piston ring compressor and piston 2 Measure the ring gap with a feeler gauge 3 If the measurement exceeds the allowable limit replace the piston ring 9Y1210272ENS0082US0 Connecting rod alignment Allowable limit 0 05 mm 0 002 in Piston r...

Page 119: ...rence Oversize thrust bearing 9Y1210272ENS0084US0 Piston ring gap Second ring Factory specifica tion 0 0900 to 0 120 mm 0 00355 to 0 00472 in Allowable limit 0 15 mm 0 0059 in Oil ring Factory specifica tion 0 040 to 0 080 mm 0 0016 to 0 0031 in Allowable limit 0 15 mm 0 0059 in Crankshaft side clearance Factory specification 0 15 to 0 31 mm 0 0059 to 0 012 in Allowable limit 0 50 mm 0 020 in Over...

Page 120: ... to move the crankshaft while the connecting rod screws are tightened Reference Undersize crankpin bearing 9Y1210272ENS0086US0 Crankshaft alignment Allowable limit 0 02 mm 0 0008 in Oil clearance between crankpin and crankpin bearing Factory specification 0 020 to 0 051 mm 0 00079 to 0 0020 in Allowable limit 0 15 mm 0 0059 in Crankpin O D Factory specification 33 959 to 33 975 mm 1 3370 to 1 3375...

Page 121: ...side See figure 9Y1210272ENS0088US0 Oil Clearance between crankshaft journal and crankshaft bearing 1 Factory specification 0 0340 to 0 106 mm 0 00134 to 0 00417 in Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Factory specification 39 934 to 39 950 mm 1 5722 to 1 5728 in Crankshaft bearing 1 I D Factory specification 39 984 to 40 040 mm 1 5742 to 1 5763 in Undersize Bearing Code Number...

Page 122: ...Flywheel side Factory specification 43 934 to 43 950 mm 1 7297 to 1 7303 in Crankshaft bearing 2 I D Factory specification 43 978 to 43 993 mm 1 7315 to 1 7320 in Crankshaft journal O D Intermediate Factory specification 39 934 to 39 950 mm 1 5722 to 1 5728 in Crankshaft bearing 3 I D Factory specification 39 978 to 39 993 mm 1 5740 to 1 5745 in Undersize Bearing Code Number Marking 0 20 mm 0 0079...

Page 123: ...and 392 F and fix the sleeve to the crankshaft as shown in figure 4 Press fit the sleeve using the auxiliary socket for pushing 4 Refer to SPECIAL TOOLS NOTE Mount the sleeve with its largely chamfered surface facing outward Should heating is not enough a sleeve might stop halfway so careful 9Y1210272ENS0091US0 1 Crankshaft 2 Crankshaft Sleeve 3 Sleeve Guide 4 Auxiliary Socket for Pushing KiSC iss...

Page 124: ... the cylinder is worn beyond the allowable limit bore and hone it to the specified dimension 2 Replace the piston and piston rings with oversize ones Oversize 0 25 mm 0 0098 in Marking 025 NOTE When the oversize cylinder is worn beyond the allowable limit replace the cylinder block with a new one 9Y1210272ENS0093US0 Cylinder liner I D Factory specification 67 000 to 67 019 mm 2 6378 to 2 6385 in A...

Page 125: ...p rotor assembly 9Y1210272ENS0096US0 Clearance between Rotor and Cover 1 Put a strip of plastigage onto the rotor face with grease 2 Install the cover and tighten the screws 3 Remove the cover carefully and measure the amount of the flattening with the scale and get the clearance 4 If the clearance exceeds the factory specifications replace oil pump rotor assembly 9Y1210272ENS0095US0 Rotor lobe cl...

Page 126: ...2 CLUTCH KiSC issued 07 2011 A ...

Page 127: ...CONTENTS 1 LINKAGE MECHANISM 2 M1 MECHANISM KiSC issued 07 2011 A ...

Page 128: ... installed in pressure plate assembly Then the torque is transmitted to the transmission via the clutch shaft 11 When the clutch pedal 8 is depressed the clutch release hub 9 and the clutch release bearing 10 move towards the flywheel and push the fingers of the diaphragm spring 5 In other words this movement pulls the pressure plate 4 up and disengages the clutch 9Y1210272CLM0001US0 1 Engine Flyw...

Page 129: ...ONS 2 S2 3 TIGHTENING TORQUES 2 S3 4 CHECKING DISASSEMBLING AND SERVICING 2 S4 1 CHECKING AND ADJUSTING 2 S4 2 PREPARATION 2 S4 1 Separating Engine from Clutch Housing 2 S4 2 Separating Clutch Assembly 2 S10 3 SERVICING 2 S11 SERVICING KiSC issued 07 2011 A ...

Page 130: ...phragm spring weaken or broken Replace 2 S11 Wiring of the pressure plate worn or broken Replace Pressure plate assembly 2 S11 Chattering Grease or oil on clutch disc facing Replace 2 S10 Clutch disc or pressure plate warped Replace 2 S11 Clutch disc boss spline worn or rusted Replace or remove rest 2 S11 Clutch shaft bent or spline worn Replace 2 S11 Pressure plate or flywheel face cracked or sco...

Page 131: ...imit Hydraulic Pump Free Travel on Clutch Pedal 15 to 25 mm 0 59 to 0 98 in Distance A 10 to 15 mm 0 40 to 0 59 in Clutch Disc Boss to Gear Shaft Backlash Displacement around Disc Edge 2 0 mm 0 079 in Clutch Disc Disc Surface to Rivet Top Depth 0 30 mm 0 012 in Pressure Plate Flatness 0 2 mm 0 008 in KiSC issued 07 2011 A ...

Page 132: ...nd nuts See page G 11 9Y1210272CLS0003US0 Item N m kgf m lbf ft Steering wheel mounting nut 30 to 49 3 0 to 5 0 22 to 36 Slotted nut 18 to 35 1 9 to 3 5 14 to 25 Power steering delivery pipe nut If equipped 35 to 45 3 6 to 4 5 26 to 33 Clutch housing and engine mounting screw 18 to 20 1 8 to 2 1 13 to 15 Clutch mounting screw 24 to 27 2 4 to 2 8 18 to 20 KiSC issued 07 2011 A ...

Page 133: ...ith the clutch pedal stopper bolt 5 NOTE After adjustment fix the stopper bolt with the lock nut 6 9Y1210272CLS0004US0 2 PREPARATION 1 Separating Engine from Clutch Housing Bonnet Front Grille Side Cover and Battery Negative Cable 1 Open the bonnet 3 and remove the front grille 1 2 Disconnect the negative cable 2 3 Disconnect the head light connectors horn connectors and remove the bonnet 3 4 Remo...

Page 134: ...To drain the used oil remove the drain plug 1 at the bottom of the engine and drain the oil completely 3 Screw in the drain plug 1 When refilling Fill with the new oil up to the upper notch on the dipstick IMPORTANT Never mix two different types of oil Use the proper SAE Engine Oil according to ambient temperatures Refer to LUBRICANTS FUEL AND COOLANT See page G 9 9Y1210272ENS0003US0 Coolant with ...

Page 135: ...CANTS FUEL AND COOLANT See page G 9 Never work the tractor immediately after changing the transmission oil Keep the engine at medium speed for a few minutes to prevent damage to the transmission Do not mix different brands oil together 9Y1210272ENS0004US0 Steering Wheel 1 Remove the steering wheel cap 2 Remove the steering wheel mounting nut and remove the steering wheel 1 with a steering wheel pu...

Page 136: ...tor 6 combination switch connector 4 and hazard switch connector 7 Except B1220 Then remove the meter panel 3 3 Disconnect the main switch connector 8 and remove the panel under cover 5 9Y1210272ENS0006US0 1 Hand Accelerator Lever 2 Spring Pin 3 Meter Panel 4 Combination Switch Connector 5 Panel Under Cover 6 Meter Panel Connector 7 Hazard Switch Connector Except B1220 8 Main Switch Connector KiSC...

Page 137: ...e tank frame stay 1 6 and the tank frame stay 2 12 9 Disconnect the fuse box 8 from the fuel tank 14 10 Remove the fuel tank 14 with tank frame 13 11 Disconnect the drag link 9 When reassembling IMPORTANT Do not loosen the slotted nut 10 to align the hole Install the cotter pins as shown in the figure 9Y1210272ENS0007US0 Tightening torque Slotted nut 18 to 35 N m 1 9 to 3 5 kgf m 14 to 25 lbf ft 1...

Page 138: ... and slide the universal joint cover 1 to the rear 2 Tap out the spring pin 4 3 Slide the universal joint 3 to the rear When reassembling Apply grease to the splines of the propeller shaft and universal joint When inserting the spring pin 4 face the split in the direction parallel to the universal joint cover 1 so that the water drain hole may become downward Replace the spring pin 4 with new one ...

Page 139: ...late noting the position of straight pins IMPORTANT Align the center of clutch disc and flywheel by inserting the clutch center tool 3 NOTE Do not allow grease and oil on the clutch disc facing 9Y1210272CLS0005US0 Clutch Rod and Clutch Release Fork 1 Remove the clutch pedal rod 2 Remove the external snap ring 2 at the end of clutch rod 4 and remove the clutch release fork 3 and release bearing 5 w...

Page 140: ... measure clearance with a feeler gauge at several points 2 If the clearance exceeds the allowable limit replace it 3 When the pressure plate is worn around its outside and its inside surface only is in contact with the straightedge replace even if the clearance is within allowable limit 9Y1210272CLS0009US0 Checking Pressure Plate and Diaphragm 1 Check the pressure plate and if scratched on its sur...

Page 141: ...3 TRANSMISSION KiSC issued 07 2011 A ...

Page 142: ... GEAR SHIFT SECTION 3 M3 2 HI LO GEAR SHIFT SECTION 3 M4 3 FRONT WHEEL DRIVE SHIFT SECTION 3 M4 3 POWER TRAIN FOR PTO GEAR 3 M5 1 REAR PTO SHIFT SECTION 3 M5 1 B1220 3 M5 2 B1620 and B1820 3 M6 2 MID PTO SHIFT SECTION IF EQUIPPED 3 M7 1 B1620 and B1820 3 M7 4 SHIFT LINKAGE 3 M8 MECHANISM KiSC issued 07 2011 A ...

Page 143: ...B1820 WSM 3 M1 EU 1 STRUCTURE 1 B1220 1 Front Wheel Drive Section 2 Main Gear Shift Section 3 Lo Hi Gear Shift Section 4 Differential Gear Section 5 One Way Clutch Section Rear PTO 6 PTO Gear Shift Section KiSC issued 07 2011 A ...

Page 144: ... 2 B1620 AND B1820 1 Front Wheel Drive Section 2 Main Gear Shift Section 3 Lo Hi Gear Shift Section 4 Differential Gear Section 5 One Way Clutch Section Rear PTO 6 Mid PTO Shift Section If Equipped 7 PTO Gear Shift Section KiSC issued 07 2011 A ...

Page 145: ...haft 2 28T gear Spline boss 2nd gear shaft 13T gear 15T gear 17T gear 26T gear Spline boss 4th gear shaft 1 B1620 and B1820 Q 1 1st Speed 1st gear shaft 16T gear Spline boss 2nd gear shaft 2 26T gear Spline boss 2nd gear shaft 11T gear 26T gear Spline boss 4th gear shaft 1 Q 2 2nd Speed 1st gear shaft 16T gear Spline boss 2nd gear shaft 2 26T gear Spline boss 2nd gear shaft 13T gear 17T gear Splin...

Page 146: ...3T gear Spline boss 12T gear Spline boss Spiral bevel pinion shaft 2 9Y1210272TRM0004US0 3 FRONT WHEEL DRIVE SHIFT SECTION Q Front Wheel Drive Spiral bevel pinion shaft 2 Spline boss 13T gear 20T gear Spline boss Front wheel drive shaft 1 9Y1210272TRM0005US0 1 4th Gear Shaft with 11T Gear 2 Spiral Bevel Pinion Shaft 1 Front Wheel Drive Shaft 2 Spiral Bevel Pinion Shaft KiSC issued 07 2011 A ...

Page 147: ...ine boss 5th gear shaft 11T gear 24T gear Spline boss PTO shaft 4 Q H High Range 1st gear shaft 1 14T gear 28T gear Spline boss 2nd gear shaft 5 18T gear 13T gear Spline boss 3rd gear shaft Spline boss One way clutch 2 Spline boss 5th gear shaft 11T gear 24T gear Spline boss PTO shaft 4 9Y1210272TRM0006US0 1 1st Gear Shaft with 14T Gear 2 One Way Clutch 3 5th Gear Shaft with 11T Gear 4 PTO Shaft 5...

Page 148: ...30T gear PTO shaft 4 Q H High Range 1st gear shaft 1 16T gear 26T gear Spline boss 2nd gear shaft 5 18T gear 13T gear Spline boss 3rd gear shaft Spline boss One way clutch 2 Spline boss 5th gear shaft 12T gear 30T gear PTO shaft 4 9Y1210272TRM0007US0 1 1st Gear Shaft with 16T Gear 2 One Way Clutch 3 5th Gear Shaft with 12T Gear 4 PTO Gear Shaft with 30T Gear 5 2nd Gear Shaft with 11T 13T 18T Gear ...

Page 149: ...620 and B1820 Q Engage 1st gear shaft 1 16T gear 26T gear Spline boss 2nd gear shaft 2 18T gear 13T gear 19T gear 12T gear Mid PTO shaft 3 9Y1210272TRM0008US0 1 1st Gear Shaft with 16T Gear 2 2nd Gear Shaft with 11T 13T 18T Gear 3 Mid PTO Gear Shaft with 12T Gear KiSC issued 07 2011 A ...

Page 150: ...n Gear Shift Lever Shaft 2 Safety Switch for Main Gear Shift 3 Main Gear Shift Fork 4 Front Wheel Drive Shift Lever 5 PTO Gear Shift Lever 6 Hi Lo Gear Shift Lever 7 Hi Lo Gear Shift Fork 8 PTO Gear Shift Fork 9 Safety Switch for PTO Gear Shift KiSC issued 07 2011 A ...

Page 151: ...ine from Clutch Housing 3 S4 2 Separating Center Frame and Transmission 3 S11 2 DISASSEMBLING AND ASSEMBLING 3 S14 1 Disassembling Clutch Housing 3 S14 2 Disassembling Transmission Case 3 S15 3 Disassembling Differential Gear Case 3 S20 3 SERVICING 3 S21 1 Clutch Housing 3 S21 2 Transmission Case 3 S21 3 Differential Gear 3 S23 SERVICING KiSC issued 07 2011 A ...

Page 152: ...nt Replace 3 S18 Symptom Probable Cause Solution Reference Page Excessive or Unusual Noise at All Time Improper backlash between spiral bevel pinion and bevel gear Adjust 3 S24 Improper backlash between differential pinion and differential side gear Adjust 3 S23 Bearing worn Replace 3 S21 Insufficient or improper type of transmission fluid used Replenish or Replace 3 S6 Noise while Turning Differe...

Page 153: ...klash Thickness 0 1 to 0 3 mm 0 004 to 0 01 in 0 2 mm 0 008 in 0 5 mm 0 02 in 0 4 mm 0 02 in Differential Pinion to Differential Side Gear Adjusting Shim Backlash Thickness 0 1 to 0 3 mm 0 004 to 0 01 in 0 8 mm 0 03 in 1 0 mm 0 039 in 1 2 mm 0 047 in 0 4 mm 0 02 in Differential Case to Differential Side Gear Differential Case Spiral Bevel Gear Differential Side Gear Clearance O D I D O D 0 025 to ...

Page 154: ...43 to 47 4 4 to 4 7 32 to 34 Rear wheel mounting nut 145 to 150 14 8 to 15 3 107 to 111 Steering wheel mounting nut 30 to 49 3 0 to 5 0 22 to 36 Joint bolt 3 Point hitch delivery pipe 50 to 60 5 1 to 6 1 37 to 44 Transmission case and center frame mounting screw 63 to 72 6 4 to 7 4 47 to 53 Top link bracket L H mounting screw 78 to 90 7 9 to 9 2 58 to 66 Hydraulic cylinder case mounting screw 40 t...

Page 155: ...ative cable first When connecting positive cable first 9Y1210272ENS0001US0 Draining Coolant CAUTION Never open the radiator cap while operating or immediately after stopping Otherwise hot water will spout out from the radiator Wait for more than ten minutes to cool the radiator before opening the cap 1 Loosen the drain cock 3 from the radiator hose to drain coolant 2 Remove the radiator cap 1 to d...

Page 156: ...g 1 When refilling Fill with the new oil up to the upper notch on the dipstick IMPORTANT Never mix two different types of oil Use the proper SAE Engine Oil according to ambient temperatures Refer to LUBRICANTS FUEL AND COOLANT See page G 9 9Y1210272ENS0003US0 Engine oil capacity B1220 1 6 L 1 7 U S qts 1 4 Imp qts B1620 B1820 2 4 L 2 5 U S qts 2 1 Imp qts 1 Drain Plug 2 Oil Inlet 3 Dipstick A Prop...

Page 157: ...BRICANTS FUEL AND COOLANT See page G 9 Never work the tractor immediately after changing the transmission oil Keep the engine at medium speed for a few minutes to prevent damage to the transmission Do not mix different brands oil together 9Y1210272ENS0004US0 Steering Wheel 1 Remove the steering wheel cap 2 Remove the steering wheel mounting nut and remove the steering wheel 1 with a steering wheel...

Page 158: ...nector 6 combination switch connector 4 and hazard switch connector 7 Except B1220 Then remove the meter panel 3 3 Disconnect the main switch connector 8 and remove the panel under cover 5 9Y1210272ENS0006US0 1 Hand Accelerator Lever 2 Spring Pin 3 Meter Panel 4 Combination Switch Connector 5 Panel Under Cover 6 Meter Panel Connector 7 Hazard Switch Connector Except B1220 8 Main Switch Connector K...

Page 159: ... the tank frame stay 1 6 and the tank frame stay 2 12 9 Disconnect the fuse box 8 from the fuel tank 14 10 Remove the fuel tank 14 with tank frame 13 11 Disconnect the drag link 9 When reassembling IMPORTANT Do not loosen the slotted nut 10 to align the hole Install the cotter pins as shown in the figure 9Y1210272ENS0007US0 Tightening torque Slotted nut 18 to 35 N m 1 9 to 3 5 kgf m 14 to 25 lbf f...

Page 160: ...p 2 and slide the universal joint cover 1 to the rear 2 Tap out the spring pin 4 3 Slide the universal joint 3 to the rear When reassembling Apply grease to the splines of the propeller shaft and universal joint When inserting the spring pin 4 face the split in the direction parallel to the universal joint cover 1 so that the water drain hole may become downward Replace the spring pin 4 with new o...

Page 161: ...ket Three Bond 1206D or equivalent to join face of the engine and clutch housing 9Y1210272ENS0010US0 Separating Clutch Housing from Center Frame 1 Place the disassembling stand under the clutch housing 1 When reassembling 9Y1210272TRS0038US0 Tightening torque Clutch housing and engine mounting screw 18 to 20 N m 1 8 to 2 1 kgf m 13 to 15 lbf ft A Power Steering Model B Manual Steering Model Tighte...

Page 162: ...r hydraulic system Refer to LUBRICANTS FUEL AND COOLANT See page G 9 Never work the tractor immediately after changing the transmission oil Keep the engine at medium speed for a few minutes to prevent damage to the transmission Do not mix different brands oil together 9Y1210272ENS0004US0 Battery Negative Cable 1 Open the bonnet 1 and remove the front grille 3 2 Disconnect the battery negative cabl...

Page 163: ...over 1 Place the disassembling jack under the transmission case 2 Remove the seat 2 3 Remove the rear wheels 5 4 Disconnect the lever guides 3 and remove the fenders 1 5 Remove the seat under cover 4 9Y1210272TRS0008US0 Tightening torque ROPS mounting bolt M12 90 to 95 N m 9 2 to 9 6 kgf m 67 to 70 lbf ft 3 Point hitch shaft setting screw 15 to 20 N m 1 6 to 2 0 kgf m 11 to 14 lbf ft 3 Point hitch...

Page 164: ...he brake rod R H 3 2 Disconnect the hydraulic control lever 1 3 Remove the pipe clamps and disconnect the 3 Points hitch delivery pipe 2 from hydraulic cylinder case 4 Disconnect the suction pipe 4 at the transmission case side 9Y1210272TRS0010US0 Seat Stay and Others 1 Disconnect the wire harness from the front seat stay and 1 and remove the front seat stay 1 and rear seat stay 3 2 Disconnect the...

Page 165: ...ith release hub When reassembling Set the clutch release fork 3 and release hub with set spring 1 in the correct direction 9Y1210272TRS0040US0 Clutch Shaft 1 Remove the oil seal 1 2 Remove the internal snap ring 2 3 Pull out the clutch shaft assembly 3 When reassembling Apply small amount of the grease to the oil seal 1 9Y1210272TRS0039US0 Tightening torque Transmission case and center frame mount...

Page 166: ...rallel the universal joint as shown in the figure below Apply grease to the spline of the front wheel drive propeller shaft universal joint and ball coupling Replace the spring pin with new one 9Y1210272TRS0013US0 Main Gear Shift Cover and Hydraulic Filter 1 Remove the main gear shift cover 1 2 Remove the hydraulic filter 2 When reassembling 9Y1210272TRS0014US0 Tightening torque Top link bracket L...

Page 167: ... reassembling the front cover to the transmission case be sure to wrap the 1st gear shaft with vinyl tape And then insert the 1st gear shaft to the front cover take care not to damage the oil seal of the front cover with 1st gear shaft 9Y1210272TRS0016US0 2nd Gear Shaft 1 Remove the bearing 5 then 26T gear 3 2 Remove the 26T gear 2 3 Remove the bearing 6 then external snap ring and 17T 15T gear 1 ...

Page 168: ...nap ring 2 and one way clutch cum 1 2 Separate the transmission case 4 and differential case 3 When reassembling Apply liquid gasket Three Bond 1206D or equivalent to join face of the transmission case and differential case 9Y1210272TRS0019US0 1 3rd Shaft 2 17T 13T Gear 3 Shift Fork 4 Shift Rod 5 19T Gear If equipped 6 Middle Shaft If equipped a Front b Rear Tightening torque Transmission case and...

Page 169: ... install the shims 8 Install the shift fork 4 so that the groove 7 of the shift rod 6 faces rearward When reassembling the shift fork attach it making the shift fork arm fit the rear shift groove of the shift fork 9Y1210272TRS0020US0 Front Wheel Drive Shaft 1 Draw out the front wheel drive shaft 1 with 20T gear 2 9Y1210272TRS0021US0 1 4th Gear Shaft 2 Spiral Bevel Pinion Shaft 3 12T 32T Shift Gear...

Page 170: ...shift rod 6 and remove the 1st reverse gear shift fork 2 3 Remove the 2nd 3rd gear shift fork 1 in the same way as the 1st reverse shift fork removing procedure 4 Take out the interlocker 10 and slide the shift arm stopper 9 and then remove the shift arm 7 5 Remove the shift shaft 8 9Y1210272TRS0023US0 1 Oil Seal 2 Mid PTO Shaft 3 Internal Snap Ring 4 Bearing 1 2nd 3rd Gear Shift Fork 2 1st Revers...

Page 171: ...g 0 2 mm 0 008 in shim 0 5 mm 0 020 in shim 9Y1210272TRS0025US0 Differential Gear Assembly 1 Remove the internal snap ring 1 from the differential case 2 Remove the shims 2 3 Remove the differential gear assembly 3 from the differential case When reassembling 0 2 mm 0 008 in shim 0 5 mm 0 020 in shim 9Y1210272TRS0026US0 Tightening torque Rear PTO cover mounting screw 40 to 44 N m 4 0 to 4 5 kgf m ...

Page 172: ...Clutch Housing Checking Bearing 1 Hold the inner race and push and pull the outer race in all directions to check for wear and roughness 2 Apply transmission fluid to the bearing and hold the inner race Then turn the outer race to check rotation 3 If there is any defect replace it 9Y1210272TRS0029US0 2 Transmission Case Checking Bearing 1 Hold the inner race and push and pull the outer race in all...

Page 173: ... O D and two needles O D 4 If the clearance exceeds the allowable limit replace it 9Y1210272TRS0033US0 Clearance between shift fork and shift gear groove Factory specification 0 03 to 0 4 mm 0 002 to 0 1 in Allowable limit 0 5 mm 0 02 in Clearance between shift fork and shift groove Factory specification 0 03 to 0 3 mm 0 002 to 0 1 in Allowable limit 0 5 mm 0 02 in Clearance between F W D shaft an...

Page 174: ...case 4 Hold the differential pinion and move the differential side gear to measure the backlash 5 If the backlash exceeds the allowable limit adjust with differential side gear shims NOTE Thickness of shims 0 8 mm 0 3 in 1 0 mm 0 039 in 1 2 mm 0 047 in 9Y1210272TRS0036US0 Clearance between differential case spiral bevel gear and differential side gear Factory specification 0 025 to 0 066 mm 0 0009...

Page 175: ...he backlash by fixing the spiral bevel pinion 4 and moving bevel gear 2 by hand 6 If the backlash exceeds the factory specifications adjust with the shims 1 5 at bearing holder 6 and differential case 7 Adjust the backlash properly by repeating the above procedures Reference Thickness of shims 1 5 0 2 mm 0 008 in 0 5 mm 0 020 in Thickness of shims 3 0 2 mm 0 008 in 0 3 mm 0 01 in 1 0 mm 0 039 in 1...

Page 176: ...TRANSMISSION B1220 B1620 B1820 WSM 3 S25 EU Continued 9Y1210272TRS0037US0 1 Shim 2 Bevel Gear 3 Shim 4 Spiral Bevel Pinion 5 Shim 6 Bearing Holder KiSC issued 07 2011 A ...

Page 177: ...4 REAR AXLE KiSC issued 07 2011 A ...

Page 178: ...CONTENTS 1 STRUCTURE 4 M1 MECHANISM KiSC issued 07 2011 A ...

Page 179: ...oad as well as transmitting power to the rear wheels The differential gears 6 automatically control the revolution of right and left wheels when the rear wheels encounter unequal road resistance during turning 9Y1210272RAM0001US0 1 9T Differential Gear Shaft Brake Shaft 2 58T Spur Gear 3 Ball Bearing 4 Rear Axle Case 5 Rear Axle 6 Differential Gear 7 37T Spiral Bevel Gear KiSC issued 07 2011 A ...

Page 180: ...CONTENTS 1 TROUBLESHOOTING 4 S1 2 TIGHTENING TORQUES 4 S2 3 DISASSEMBLING AND SERVICING 4 S3 1 DISASSEMBLING AND ASSEMBLING 4 S3 2 SERVICING 4 S5 SERVICING KiSC issued 07 2011 A ...

Page 181: ...r Unusual Noise at All Time Improper backlash between differential gear shaft and final reduction gear Replace Bearing worn Replace 4 S5 Insufficient or improper type of transmission fluid used Replenish or change 4 S3 Noise while Turning Brake shaft and 58T gear and internal gear worn or damaged Replace 4 S5 5 S10 KiSC issued 07 2011 A ...

Page 182: ...especially specified For general use screws bolts and nuts See page G 11 9Y1210272RAS0003US0 Item N m kgf m lbf ft Rear wheel cotter setting bolt and nut 123 to 147 12 6 to 15 0 91 to 108 Rear wheel hub mounting nut 108 to 125 11 0 to 12 8 80 to 93 Rear axle case mounting screw 40 to 45 4 0 to 4 6 29 to 33 KiSC issued 07 2011 A ...

Page 183: ...ssion or hydraulic system Refer to LUBRICANTS FUEL AND COOLANT See page G 9 Never work the tractor immediately after changing the transmission oil Keep the engine at medium speed for a few minutes to prevent damage to the transmission Do not mix different brands oil together 9Y1210272ENS0004US0 Battery Negative Cable 1 Open the bonnet 1 and remove the front grille 3 2 Disconnect the battery negati...

Page 184: ...5 and parking brake arm 6 Except B1220 4 Remove the rear axle case L H 4 When reassembling Apply liquid gasket Three Bond 1206D or equivalent to joint face of the rear axle case and differential gear case after eliminating the water and oil 9Y1210272RAS0005US0 Tightening torque Rear wheel cotter setting bolt and nut 123 to 147 N m 12 6 to 15 0 kgf m 91 to 108 lbf ft Rear wheel hub mounting nut 108...

Page 185: ... the external snap ring 6 and remove the bearing 5 4 Draw out the 58T gear 4 from the rear axle 7 5 Tap out the rear axle 7 to the outside of the rear axle case 9Y1210272RAS0007US0 2 SERVICING Checking Ball Bearing 1 Hold the inner race and push and pull the outer race in all directions to check for wear and roughness 2 Apply transmission fluid to the bearing and hold the inner race Then turn the ...

Page 186: ...5 BRAKES KiSC issued 07 2011 A ...

Page 187: ...CONTENTS 1 LINKAGE 5 M1 1 B1220 5 M1 2 B1620 AND B1820 5 M2 2 OPERATION 5 M3 MECHANISM KiSC issued 07 2011 A ...

Page 188: ...ide stable braking and require little adjustment The parking brake is a mechanical type which is designed to actuate the traveling brakes through the linkages Pulling the parking brake lever 7 results in the same state as the obtained when the brake pedals are depressed 9Y1210272BRM0001US0 1 Rear Axle Case 2 Lock Nut 3 Adjusting Nut 4 Brake Cam Lever 5 Brake Rod 6 Brake Pedal 7 Parking Brake Lever...

Page 189: ...uire little adjustment The parking brake is a mechanical type which is designed to actuate the traveling brakes through the linkages Depressing the parking brake pedal 3 results in the same state as the obtained when the brake pedals are pressed 9Y1210272BRM0002US0 1 Brake Pedal 2 Brake Rod 3 Parking Brake Pedal 4 Parking Brake Release Lever 5 Parking Brake Lever Rod 6 Parking Brake Arm 7 Parking ...

Page 190: ...ged between the brake discs Q During Braking When the brake pedal is pressed the linage causes the brake cam lever 8 and brake cam 7 to turn into the direction of arrow shown in the above figure Therefore the cam plate 1 also moves the direction of arrow At this time since the cam plate 1 rides on the steel balls 5 set in the grooves of the rear axle case to press the brake disc 3 the differential...

Page 191: ... 4 CHECKING DISASSEMBLING AND SERVICING 5 S4 1 CHECKING AND ADJUSTING 5 S4 2 DISASSEMBLING AND ASSEMBLING 5 S5 1 Brake Pedal B1220 5 S5 2 Brake Pedal B1620 and B1820 5 S6 3 Separating Rear Axle Case 5 S7 4 Disassembling Rear Axle Case 5 S10 3 SERVICING 5 S11 SERVICING KiSC issued 07 2011 A ...

Page 192: ...Replace 5 S11 Brake Drags Brake pedal free travel too small Adjust 5 S4 Ball holes of cam plate for uneven wear Replace 5 S11 Brake pedal return spring weaken or broken Replace 5 S5 5 S6 Brake cam rusted Repair 5 S11 Poor Braking Force Brake pedal free travel excessive Adjust 5 S4 Brake disc worn Replace 5 S11 Cam plate warped Replace 5 S11 Brake cam or lever damaged Replace 5 S11 Transmission flu...

Page 193: ... to 40 mm 1 2 to 1 5 in Cam Plate and Bearing Holder Flatness Cam Plate and Ball Height 22 89 to 22 99 mm 0 9012 to 0 9051 in 22 40 mm 0 8819 in Brake Disc Thickness 3 30 to 3 50 mm 0 130 to 0 137 in 3 0 mm 0 12 in Friction Plate Thickness 1 92 to 2 08 mm 0 0756 to 0 0818 in 1 52 mm 0 0598 in Parking Brake Pedal Free Travel 1 notch KiSC issued 07 2011 A ...

Page 194: ...specially specified For general use screws bolts and nuts See page G 11 9Y1210272BRS0003US0 Item N m kgf m lbf ft Rear wheel cotter setting bolt and nut 123 to 147 12 6 to 15 0 91 to 108 Rear wheel hub mounting nut 108 to 125 11 0 to 12 8 80 to 93 Rear axle case mounting screw 40 to 45 4 0 to 4 6 29 to 33 KiSC issued 07 2011 A ...

Page 195: ...lease the parking brake pedal 1 2 Be sure to adjust the free travel of right and left brake pedal 3 Check the parking brake performance according to the following steps 4 to 5 4 Set the parking brake pedal 1 to 2 notches 5 Push the tractor by hands 6 If the tractor is moved release the parking brake pedal 1 Loosen the lock nut 4 and the adjusting nut 5 Adjust the adjusting nut 5 to keep no clearan...

Page 196: ...ake pedal L H 11 5 Remove the clutch pedal rod 9 6 Pull the right and left brake pedals from the brake pedal shaft 6 7 Tap out the brake pedal shaft 6 to the left and remove it with the clutch pedal 7 When reassembling Apply grease to the brake pedal shaft 6 9Y1210272BRS0018US0 1 External Snap Ring 2 Return Spring 3 Brake Rod 4 Parking Brake Lever 5 Return Spring 6 Brake Pedal Shaft 7 Clutch Pedal...

Page 197: ...ng brake rods 4 6 and pull out the parking brake rod 4 6 9 Remove the pin 8 of the parking brake lever L H 7 and remove the parking brake rod 2 9 10 Remove the parking brake lever L H 7 and pull out the parking brake lever R H 5 When reassembling Apply grease to the brake pedal shaft 13 and parking brake lever R H 5 9Y1210272BRS0019US0 1 External Snap Ring 2 Return Spring 3 Brake Rod 4 Parking Bra...

Page 198: ... system Refer to LUBRICANTS FUEL AND COOLANT See page G 9 Never work the tractor immediately after changing the transmission oil Keep the engine at medium speed for a few minutes to prevent damage to the transmission Do not mix different brands oil together 9Y1210272ENS0004US0 Battery Negative Cable 1 Open the bonnet 1 and remove the front grille 3 2 Disconnect the battery negative cable 2 NOTE Wh...

Page 199: ... and parking brake arm 6 Except B1220 4 Remove the rear axle case L H 4 When reassembling Apply liquid gasket Three Bond 1206D or equivalent to joint face of the rear axle case and differential gear case after eliminating the water and oil 9Y1210272RAS0005US0 Tightening torque Rear wheel cotter setting bolt and nut 123 to 147 N m 12 6 to 15 0 kgf m 91 to 108 lbf ft Rear wheel hub mounting nut 108 ...

Page 200: ...e case R H 5 When reassembling Apply liquid gasket Three Bond 1206D or equivalent to joint face of the rear axle case and differential gear case after eliminating the water and oil 9Y1210272RAS0006US0 Tightening torque Rear axle case mounting screw 40 to 45 N m 4 0 to 4 6 kgf m 29 to 33 lbf ft 1 Parking Brake Rod R H Except B1220 2 Brake Rod R H 3 Spring 4 Parking Brake Shaft Except B1220 5 Rear A...

Page 201: ...bling When installing the internal snap ring 1 to rear axle case 3 as shown in the figure When installing the bearing holder 4 to the rear axle case 3 do not forget to install the straight pin 5 9Y1210272BRS0007US0 Brake Discs and Friction Plate 1 Remove the external snap ring 1 and remove the brake discs and friction plate Reference 2 brake discs and 1 friction plates When reassembling Install th...

Page 202: ...re the dimensions of the cam plate with the ball installed 2 If the measurement is less than the allowable limit replace the cam plate and balls 3 Inspect the ball holes of cam plate for uneven wear 4 If the uneven wear is found replace it 9Y1210272BRS0016US0 Brake Disc and Friction Plate Wear 1 Measure the brake disc thickness and the friction plate thickness with an outside micrometer 2 If the t...

Page 203: ...6 FRONT AXLE KiSC issued 07 2011 A ...

Page 204: ...CONTENTS 1 STRUCTURE 6 M1 MECHANISM KiSC issued 07 2011 A ...

Page 205: ...evel gear case 6 The revolution is greatly reduced by the bevel gears 18 3 then the power is transmitted to the axle 1 The differential system allows each wheel to rotate at a different speed to make turning easier 9Y1210272FAM0001US0 1 Axle 2 Axle Flange 3 Bevel Gear 4 Bevel Gear 5 Bevel Gear 6 Bevel Gear Case 7 Differential Yoke Shaft L H 8 Front Axle Case 9 Differential Gear Assembly 10 Differe...

Page 206: ...CING SPECIFICATION 6 S2 3 TIGHTENING TORQUES 6 S3 4 CHECKING DISASSEMBLING AND SERVICING 6 S4 1 DISASSEMBLING AND ASSEMBLING 6 S4 1 Separating Front Axle 6 S4 2 Disassembling Front Axle 6 S6 2 SERVICING 6 S10 SERVICING KiSC issued 07 2011 A ...

Page 207: ...oose Tighten Air sucked in power steering circuit Bleed Front Wheels Cam Not Be Driven Front wheel driving gears in front axle gear case broken Replace 6 S7 Universal joint broken Replace 3 S9 3 S15 Front wheel drive gears in transmission broken Replace 3 S18 Front differential gear broken Replace 6 S9 Coupling displaced Reassembling Noise Gear backlash excessive Adjust or replace 6 S11 Oil insuff...

Page 208: ...f m 0 59 to 0 73 lbf ft Spiral Bevel Pinion Shaft to Spiral Bevel Gear Backlash 0 1 to 0 3 mm 0 004 to 0 012 in 9T Bevel Gear to 23T Bevel Gear Backlash 0 1 to 0 3 mm 0 004 to 0 012 in Front Axle Case Boss to Bracket Front Front Axle Case Boss Bracket Clearance O D I D 0 125 to 0 280 mm 0 0049 to 0 0110 in 49 950 to 49 975 mm 1 9665 to 1 9675 in 50 10 to 50 23 mm 1 9722 to 1 9774 in 0 45 mm 0 018 ...

Page 209: ...1 9Y1210272FAS0003US0 Item N m kgf m lbf ft Front wheel mounting nut 78 to 90 7 9 to 9 2 58 to 66 Slotted nut 18 to 35 1 9 to 3 5 14 to 25 Front axle bracket mounting screw 126 to 150 12 9 to 15 2 93 0 to 110 Bevel gear case mounting screw 78 to 90 7 9 to 9 2 58 to 66 Knuckle arm mounting screw 78 to 90 7 9 to 9 2 58 to 66 Axle flange mounting screw 48 to 56 4 9 to 5 7 36 to 41 KiSC issued 07 2011...

Page 210: ...005US0 Universal Joint 1 Loosen the clamp 2 and slide the universal joint cover 1 to the rear 2 Tap out the spring pin 4 3 Slide the universal joint 3 to the rear When reassembling Apply grease to the splines of the propeller shaft and universal joint When inserting the spring pin 4 face the split in the direction parallel to the universal joint cover 1 so that the water drain hole may become down...

Page 211: ...r and place the disassembling stand under the front axle 2 Remove the front axle brackets Front side and rear side mounting screws 3 Separating the front axle from the front axle frame When reassembling Apply grease to the splines of the propeller shaft and coupling 9Y1210272FAS0007US0 Tightening torque Front wheel mounting nut 78 to 90 N m 7 9 to 9 2 kgf m 58 to 66 lbf ft Slotted nut 18 to 35 N m...

Page 212: ... bevel gear case mounting screws 2 Remove the bevel gear case 1 and front gear case 4 as a unit from the front axle case 3 When reassembling Apply grease to the O ring 2 and take care not to damage it Do not interchange right and left bevel gear case assemblies and right and left gear case assemblies 9Y1210272FAS0010US0 1 Front Axle Bracket Front 2 Front Axle Bracket Rear 3 Tie rod 4 O ring 5 O ri...

Page 213: ...ivalent to joint face of the axle flange 2 and front gear case 1 after eliminate the water oil and stuck liquid gasket 2 Tighten the axle flange mounting screws and nuts diagonally in several steps 3 Install the oil seal 5 of bevel gear case noting its direction as shown in the figure 9Y1210272FAS0011US0 Tightening torque Knuckle arm mounting screw 78 to 90 N m 7 9 to 9 2 kgf m 58 to 66 lbf ft Axl...

Page 214: ...e out the collar 3 4 Tap out the axle 4 When reassembling Install the oil seal 7 of axle flange 6 noting its direction as shown in the figure Install the shims 8 9 to their original position Reference Thickness of adjusting shim 8 0 8 mm 0 031 in 1 0 mm 0 039 in 1 2 mm 0 47 in 1 4 mm 0 055 in Thickness of adjusting shim 9 0 8 mm 0 031 in 1 0 mm 0 039 in 1 2 mm 0 47 in 9Y1210272FAS0013US0 1 Interna...

Page 215: ...en pull out the both differential yoke shafts 1 9 2 Remove the differential side gears 4 3 Remove the differential pinions 6 4 Remove the spiral bevel gear 8 and bearings 7 11 NOTE Arrange the parts to know their original position When reassembling Apply molybdenum disulfide Three Bond 1901 or equivalent to the inner circumferential surface of the differential side gears 4 and differential pinions...

Page 216: ...t axle case and measure the thickness of the fuses with an outside micrometer 5 If the backlash is not within the factory specifications adjust with shim 3 Reference Thickness of adjusting shims 3 0 8 mm 0 031 in 1 0 mm 0 039 in 1 2 mm 0 047 in 1 4 mm 0 055 in Tooth contact More than 35 9Y1210272FAS0016US0 Clearance between differential case and differential pinion Factory specification 0 032 to 0...

Page 217: ...peating the above procedures Reference Above factory specification should be measured on the tooth of spiral bevel pinion When measuring the backlash on the spline of its shaft factory specification will be 0 0571 to 0 1714 mm 0 00225 to 0 00675 in Thickness of adjusting shims 3 0 6 mm 0 02 in 0 8 mm 0 03 in 1 0 mm 0 039 in 1 2 mm 0 047 in 1 4 mm 0 055 in 1 6 mm 0 063 in 9Y1210272FAS0017US0 Backla...

Page 218: ...7 STEERING KiSC issued 07 2011 A ...

Page 219: ...CONTENTS 1 STRUCTURE 7 M1 1 STEERING LINKAGE 7 M1 2 POWER STEERING 7 M2 MECHANISM KiSC issued 07 2011 A ...

Page 220: ...STEERING B1220 B1620 B1820 WSM 7 M1 EU 1 STRUCTURE 1 STEERING LINKAGE 9Y1210272STM0001US0 1 Tie rod 2 Knuckle Arm 3 Steering Gear Box 4 Pitman Arm 5 Steering Wheel 6 Drag Link KiSC issued 07 2011 A ...

Page 221: ...tary type control valve with torsion bar Hydraulic oil flow is shown as follows 9Y1210272STM0002US0 1 Valve Housing 2 Gear Case 3 Sector Gear Shaft 4 Rack Piston 5 Worm Shaft 6 Control Valve 7 Relief Valve 8 Steering Wheel 9 Hydraulic Pump 10 Oil Filter 11 Transmission Case A Suction Oil B Low Pressure Oil KiSC issued 07 2011 A ...

Page 222: ...ulic Pump for Power Steering Only B1820 7 S10 2 Separating Manual Steering Controller Box Assembly 7 S11 3 DISASSEMBLING AND ASSEMBLING 7 S14 1 Hydraulic Pump for Power Steering Only B1820 7 S14 2 Manual Steering Controller Body If Equipped 7 S15 3 Power Steering Controller Body Only B1820 7 S17 4 SERVICING 7 S19 1 Hydraulic Pump for Power Steering 7 S19 2 Manual Steering Controller Body If Equipp...

Page 223: ...Steering Wheel Play Backlash between sector gear shaft and ball nut too large Adjust 7 S6 Steering linkage worn Replace Sector gear shaft worn Replace 7 S16 Tractor Pulls to Right or Left Tire pressure uneven Adjust G 49 Steering wheel play too small Adjust 7 S6 Front Wheels Vibration Steering linkage worn Replace KiSC issued 07 2011 A ...

Page 224: ...alfunctioning Replace 7 S18 Seals in the steering gear box damaged Replace 7 S18 Backlash between sector gear shaft and rack piston too small Adjust 7 S7 Air in the hydraulic pipes Air vent Low Operating Pressure Hydraulic pump malfunctioning Replace 7 S10 Improper relief valve adjustment Adjust 7 S8 Relief valve malfunctioning Replace 7 S8 Seals in the steering gear box damaged Replace 7 S18 Rack...

Page 225: ...gf m 37 lbf ft 5 0 to 30 mm 0 20 to 1 1 in Item Factory Specification Allowable Limit Pump Delivery At no pressure Above 9 8 L min 2 6 U S gals min 2 2 Imp gals min Gear to Casing Clearance 0 15 mm 0 0059 in Gear Shaft to Bushing Bushing Clearance I D 0 020 to 0 091 mm 0 00079 to 0 0035 in 15 000 to 15 061 mm 0 59056 to 0 59295 in 0 12 mm 0 0047 in Side Plate Thickness 2 48 to 2 50 mm 0 0977 to 0 ...

Page 226: ...elivery At no load 7 9 L min 2 1 U S gals min 1 7 Imp gals min Steering Gear Box to Rack Piston Gear Box Bore Rack Piston Clearance I D O D 0 030 to 0 079 mm 0 0012 to 0 0031 in 61 000 to 61 030 mm 2 4016 to 2 4027 in 60 951 to 60 970 mm 2 3997 to 2 4003 in 0 14 mm 0 0055 in Rack Piston Assembly Axial Play 0 to 0 02 mm 0 to 0 0007 in 0 004 mm 0 002 in Valve Housing to Sleeve Sleeve Valve Housing C...

Page 227: ...link and slotted nut 18 to 35 1 9 to 3 5 14 to 25 Item N m kgf m lbf ft Drag link and slotted nut 18 to 35 1 9 to 3 5 14 to 25 Steering wheel mounting nut 30 to 49 3 0 to 5 0 22 to 36 Power steering delivery pipe nut 65 to 75 6 7 to 7 6 48 to 55 Return pipe nut 34 to 39 3 5 to 3 9 25 to 28 Power steering controller assembly mounting screw 78 to 90 7 9 to 9 2 58 to 66 Steering column mounting screw...

Page 228: ...el 5 Loosen the lock nut and turn the adjusting screw with a screw driver to adjust the play When the adjusting screw is turned clockwise the play decreases 6 After adjustment fix it with the lock nut while holding the adjusting screw 9Y1210272STS0004US0 Steering Wheel Operating Torque 1 Park the tractor on flat concrete place 2 Set a spring balance to the steering wheel to measure the operating t...

Page 229: ...eases 6 After adjustment fix it with the lock nut while holding the adjusting screw 9Y1210272STS0004US0 Steering Wheel Operating Torque 1 Park the tractor on flat concrete place 2 Start the engine After warming up set the engine speed at approx 2800 min 1 rpm 3 Set a spring balance to the steering wheel to measure the operating torque 4 If the measurement exceeds the factory specification check th...

Page 230: ...speed at approx 2800 min 1 rpm 7 Fully turn the steering wheel to the left end to read the relief pressure After reading stop the engine 8 If the pressure is not factory specification loosen the lock nut and adjust by adjusting screw 2 Reference Replace the hydraulic pump if pressure does not rise in 9 30 to 9 80 MPa 94 9 to 100 kgf cm2 1350 to 1420 psi Condition Engine speed Approx 2800 min 1 rpm...

Page 231: ... the flowmeter loading valve completely Turn counterclockwise 7 Start the engine and set the engine speed at 2800 min 1 rpm 8 Slowly close the loading valve to generate the pressure approx 9 8 MPa 100 kgf cm2 1400 psi 9 Hold in this condition until oil temperature reaches approx 50 C 122 F Reference Adaptor is included in the adaptor set Code No 07916 54031 9Y1210272STS0009US0 Pump Test NOTE Befor...

Page 232: ... 1 then remove the front grille 3 side cover R H and disconnect the battery negative cable 2 2 Disconnect the fuel filter assembly 8 and then remove the lever link assembly 9 3 Disconnect the power steering delivery pipe 4 4 Disconnect the 3 point hitch delivery pipe 7 and suction hose 5 5 Remove the hydraulic pump 6 When reassembling NOTE For fastening hydraulic pipe nut use two wrenches Hold the...

Page 233: ...When reassembling 9Y1210272ENS0005US0 Meter Panel and Panel Under Cover 1 Tap out the spring pin 2 and remove the hand accelerator lever 1 2 Open the meter panel 3 and disconnect the hourmeter cable meter panel connector 6 combination switch connector 4 and hazard switch connector 7 Except B1220 Then remove the meter panel 3 3 Disconnect the main switch connector 8 and remove the panel under cover...

Page 234: ...op timer connector 12 starter relay connector 8 starter relay connector 8 regulator connector and lead wire 13 Only B1220 6 Remove the tank frame stay 1 4 and the tank frame stay 2 9 7 Disconnect the fuse box 6 from the fuel tank 11 8 Remove the fuel tank 11 with tank frame 10 9Y1210272STS0013US0 1 Fuel Hose 2 Lead Wire 3 Over Flow Hose 4 Tank Frame Stay 1 5 Hour Meter Cable 6 Fuse Box 7 Regulator...

Page 235: ...ower steering controller box assembly 2 IMPORTANT Do not loosen the slotted nut 7 to align the hole Install the cotter pin as shown in the figure NOTE For fastening hydraulic pipe nut use two wrenches Hold the fitting with a wrench turn the pipe nut with another wrench to avoid damage at fitting installed part 9Y1210272STS0015US0 Tightening torque Slotted nut 18 to 35 N m 1 9 to 3 5 kgf m 14 to 25...

Page 236: ...late 5 3 Remove the drive gear 4 and driven gear 2 from the casing 1 When reassembling Take care not to damage the O ring Align the holes of the cover and casing Install the side plate noting its location and direction Install the gears noting its direction 9Y1210272STS0016US0 Tightening torque Cover mounting screw 35 to 39 N m 3 5 to 4 0 kgf m 26 to 29 lbf ft 1 Casing 2 Driven Gear 3 Hydraulic Pu...

Page 237: ...09 39011 When reassembling Apply liquid lock Three Bond 1324B or equivalent to the steering column mounting screw When reassembling the pitman arm 3 to the sector gear shaft according to the following steps 1 to 4 1 Install the steering wheel temporary to the steering shaft 2 Turn the steering wheel clockwise to the end 3 Install the pitman arm 3 to the sector gear shaft holding the pitman arm 3 i...

Page 238: ...haft 1 3 Remove the top cover 4 4 Remove the top cover 4 mounting screw 5 Pull the worn shaft 3 with ball nut 1 from the steering gear box When reassembling Apply liquid lock Three Bond 1206D or equivalent to joint face of top cover 4 steering box 2 and shims Turn the worn shaft so that the ball nut 1 is centered in its travel Then install the sector shaft 3 to center tooth engage the center of th...

Page 239: ...11 When reassembling IMPORTANT Install the pitman arm to the sector gear shaft so that their marks align 9Y1210272STS0021US0 Side Cover and Sector Gear Shaft 1 Loosen the lock nut 2 Remove the side cover mounting screws 3 Screw in the adjusting screw 1 to remove the side cover 4 Tap out the sector gear shaft 2 toward the side cover When reassembling Turn the worm shaft so that the rack piston is c...

Page 240: ...lock nut 6 and remove the adjusting screw 5 2 Remove the relief spring 3 and the relief valve poppet 2 When reassembling IMPORTANT Do not disassemble the relief valve needlessly since it has been factory adjusted If the relief valve is disassembled replace the adjusting screw with new one and after reassembly be sure to adjust the setting pressure then stake the adjusting screw with a punch 9Y1210...

Page 241: ... 3 If the clearance exceeds the allowable limit replace it 9Y1210272STS0028US0 Side Plate Thickness 1 Measure the side plate thickness with an outside micrometer 2 If the thickness is less than the allowable limit replace it 9Y1210272STS0026US0 Clearance between tip of gear tooth and casing Allowable limit 0 15 mm 0 0059 in Clearance between busing and shaft Factory spec 0 020 to 0 091 mm 0 00079 ...

Page 242: ... wear or scoring 2 Inspect the teeth area and pitman arm spline for cracks chipping or excessive wear Replace the sector shaft as necessary 3 Check the side cover bush and steering gear box bush cracks or damage Replace the side and steering gear box 9Y1210272STS0030US0 Ball Nut 1 Thoroughly clean the worm shaft 2 and ball nut 3 Turn the ball nut on the shaft feeling for roughness binding or stick...

Page 243: ...indicator with its finger on the worm shaft of the rack piston assembly 3 Move the worm shaft axially and measure the play 4 If the play exceeds the allowable limit replace the rack piston assembly 9Y1210272STS0034US0 Backlash between Sector Gear Shaft and Rack Piston 1 Attach the pitman arm having no play 2 Set a dial indicator with its finger on the pitman arm 3 Move the pitman arm lightly and m...

Page 244: ...8 HYDRAULIC SYSTEM KiSC issued 07 2011 A ...

Page 245: ... B1820 MANUAL STEERING MODEL 8 M4 3 B1820 POWER STEERING MODEL 8 M5 3 HYDRAULIC PUMP 8 M6 1 MANUAL STEERING MODEL 8 M6 2 POWER STEERING MODEL 8 M6 3 HYDRAULIC CONTROL VALVE 8 M7 4 FEEDBACK LINKAGE FOR POSITION CONTROL 8 M8 5 RELIEF VALVE 8 M9 6 HYDRAULIC CYLINDER 8 M10 7 HYDRAULIC BLOCK TYPE OUTLET 8 M11 8 REAR HYDRAULIC OUTLET 8 M11 MECHANISM KiSC issued 07 2011 A ...

Page 246: ...aulic system of B1220 is composed of main components as shown in the figure 9Y1210272HYM0001US0 1 Lowering Speed Adjusting Valve 2 Hydraulic Control Valve 3 Hydraulic Block 4 Relief Valve 5 Hydraulic Pump 6 Oil Filter 7 Transmission Case 8 Hydraulic Cylinder KiSC issued 07 2011 A ...

Page 247: ...and B1820 manual steering model are composed of main components as shown in the figure 9Y1210272HYM0002US0 1 Lowering Speed Adjusting Valve 2 Hydraulic Control Valve 3 Rear Hydraulic Outlet 4 Hydraulic Block 5 Hydraulic Pump 6 Oil Filter 7 Transmission Case 8 Relief Valve 9 Hydraulic Cylinder KiSC issued 07 2011 A ...

Page 248: ...components as shown in the figure 9Y1210272HYM0003US0 1 Lowering Speed Adjusting Valve 2 Hydraulic Control Valve 3 Rear Hydraulic Outlet 4 Power Steering Assembly 5 Hydraulic Pump for Power Steering 6 Oil Filter 7 Transmission Case 8 Hydraulic Pump for 3 Point Hitch 9 Hydraulic Block 10 Relief Valve 11 Hydraulic Cylinder KiSC issued 07 2011 A ...

Page 249: ...2 B1620 AND B1820 MANUAL STEERING MODEL 9Y1210272HYM0005US0 1 Hydraulic Pump 2 Suction Pipe 3 Oil Filter 4 Delivery Pipe A Suction Oil B Low Pressure Oil 1 Hydraulic Pump 2 Suction Pipe 3 Oil Filter 4 Delivery Pipe 5 Hydraulic Block A Suction Oil B Low Pressure Oil KiSC issued 07 2011 A ...

Page 250: ...72HYM0006US0 1 Hydraulic Pump for 3 Point Hitch 2 Power Steering Delivery Pipe 3 Suction Pipe 4 Oil Filter 5 Hydraulic Block 6 3 Point Hitch Delivery Pipe 7 Return Pipe 8 Power Steering Assembly 9 Hydraulic Pump for Power Steering A Suction Oil B Low Pressure Oil KiSC issued 07 2011 A ...

Page 251: ... displacement is as follows Hydraulic Pump for Power Steering Hydraulic Pump for 3P 9Y1210272HYM0008US0 Displacement Engine Speed Condition 8 4 L min 2 2 U S gals min 1 8 Imp gals min Approx 3100 min 1 rpm At no load Displacement Engine Speed Condition 14 1 L min 3 72 U S gals min 3 10 Imp gals min Approx 2800 min 1 rpm At no load 1 Casing 2 Drive Gear 3 Cover 4 Side Plate 5 Driven Gear Displaceme...

Page 252: ...en the control lever is moved to DOWN position the spool 2 is moved to the right Oil in the hydraulic cylinder is forced out to the transmission case through the T3 port by the weight of the implement causing the implement to lower Oil forced into the control valve 1 through the P port and returns to the transmission case through the T1 port NOTE The T0 port is connected to T2 through the relief v...

Page 253: ... feedback arm 7 control lever shaft 6 and control lever arm 8 And after the lift arm 1 moves upward the spool is pushed in and returned to form a neutral circuit by the motions of interlocker 2 feedback rod 3 feedback arm 7 control lever shaft 6 and control lever arm 8 9Y1210272HYM0010US0 1 Lift Arm RH 2 Interlocker 3 Feedback Rod 4 Hydraulic Control Lever 5 Feedback Pin 6 Control Lever Shaft 7 Fe...

Page 254: ...oom A through the clearance a of the valve seat 4 then the poppet 3 is pushed against the spring 2 force This mechanism relieves the shock of this hydraulic system Finally oil flows out to the transmission case through T2 ports preventing any further rise in pressure The poppet closes again when enough oil is released to drop pressure below the valve setting Reference B1220 Relief valve setting pr...

Page 255: ... of the implement At this time the lowering speed of the implement can be controlled by the ball 2 attached to the hydraulic cylinder 3 Turning the lowering speed adjusting knob clockwise decreases the lowering speed and counterclockwise increases lowering speed When the lowering speed adjusting valve 2 is completely closed the lift arm 10 is held at its position since oil in the hydraulic cylinde...

Page 256: ...ed at the right hand side of the hydraulic cylinder body This rear hydraulic outlet is provided to take power out from the tractor to operate the hydraulic cylinder on the implement such as damp trailer so on 9Y1210272HYM0016US0 1 Block Cover 2 Block Outlet Cover Option 3 Hydraulic Block 4 From Hydraulic Pump 5 To Position Control Valve 1 When implement is not attached 2 When implement is attached...

Page 257: ... 8 S5 2 Relief Valve 8 S7 3 Lift Arm 8 S8 2 PREPARATION 8 S9 1 Hydraulic Pump 8 S9 2 Hydraulic Cylinder and Control Valve 8 S9 3 DISASSEMBLING AND ASSEMBLING 8 S11 1 Hydraulic Pump Manual Steering Model 8 S11 2 Hydraulic Pump Power Steering Model 8 S12 3 Hydraulic Cylinder 8 S13 4 Hydraulic Control Valve 8 S14 4 SERVICING 8 S15 1 Hydraulic Pump 8 S15 2 Hydraulic Cylinder 8 S16 SERVICING KiSC issue...

Page 258: ... Suction pipe loosen or broken Repair or Replace Suction pipe connecting hose loosen or broken Repair or Replace Suction pipe O ring broken Replace Insufficient transmission oil Refill G 9 Relief valve setting pressure too low Adjust or Replace 8 S7 Hydraulic pump broken Replace 8 S9 Implement Does Not Reach Maximum Height Feedback rod improperly adjusted Adjust 8 S8 Implement Does Not Lower Contr...

Page 259: ... min 13 1 L min 3 46 U S gals min 2 88 Imp gals min Gear to Casing Clearance 0 15 mm 0 059 in Gear Shaft to Bushing Clearance B1220 B1620 and B1820 0 0050 to 0 0088 mm 0 00020 to 0 0034 in 0 020 to 0 091 mm 0 00079 to 0 0035 in 0 12 mm 0 0047 in 0 12 mm 0 0047 in Bushing I D B1220 B1620 and B1820 12 000 to 12 068 mm 0 47244 to 0 47511 in 15 000 to 15 061 mm 0 59056 to 0 59295 in Side Plate Thickne...

Page 260: ...00 min 1 rpm Oil Temperature 45 to 55 C 113 to 131 F 11 5 to 12 3 MPa 118 to 125 kgf cm2 1670 to 1780 psi Lift Arm 5 0 to 15 mm 0 20 to 0 59 in Hydraulic Cylinder I D 65 05 to 65 10 mm 2 561 to 2 562 in 65 15 mm 2 565 in Hydraulic Arm Shaft to Bushing Hydraulic Arm Shaft Right Hydraulic Arm Shaft Left Bushing Right Bushing Left Clearance O D O D I D I D 0 020 to 0 11 mm 0 00079 to 0 0043 in 31 925...

Page 261: ...ering delivery pipe nut 35 to 45 3 6 to 4 5 26 to 33 Top link bracket mounting screw 78 to 90 7 9 to 9 2 58 to 66 3 point hitch delivery pipe joint bolt 50 to 60 5 1 to 6 1 37 to 44 Hydraulic cylinder assembly mounting screw 40 to 44 4 0 to 4 5 29 to 32 Rear wheel mounting nut 80 0 to 110 8 20 to 11 2 59 0 to 81 1 Hydraulic pimp cover mounting screw 35 to 39 3 5 to 4 0 26 to 29 Control valve mount...

Page 262: ...ort 4 Connect the another hydraulic test hose 3 to flowmeter outlet port and adaptor 69 power beyond port 5 Open the flowmeter loading valve completely Turn counterclockwise 6 Start the engine and set the engine speed at 3100 min 1 rpm Only B1220 7 Start the engine and set the engine speed at 2800 min 1 rpm Except B1220 8 Slowly close the loading valve to generate the pressure approx 9 4 MPa 96 kg...

Page 263: ... MPa 117 kgf cm2 1670 psi Except B1220 7 Read and note the pump flow at rated pressure 8 Open the loading valve and stop the engine Reference Condition B1220 Engine speed Approx 3100 min 1 rpm Rated pressure 9 4 MPa 96 kgf cm2 1400 psi Oil temperature 50 C 122 F B1620 and B1820 Engine speed Approx 2800 min 1 rpm Rated pressure 11 5 MPa 117 kgf cm2 1670 psi Oil temperature 50 C 122 F 9Y1210272HYS00...

Page 264: ...s not within the factory specifications remove the hydraulic cylinder assembly Refer to 8 S9 and adjust with the adjusting plug 2 9 Reinstall the hydraulic cylinder assembly After checking the pressure be sure to stake the adjusting plug and control valve body with a punch and reinstall the feedback rod interlocker correctly Condition B1220 Engine speed Approx 3100 min 1 rpm Oil temperature 45 to ...

Page 265: ...m moves to the uppermost position and relief valve opens 4 Move the lift arm 1 to the upper end by hand and measure the free play 5 If the measurement is not within the factory specifications adjust the free play by changing the set position of feedback rod 2 with bolt 3 and lock nut 4 9Y1210272HYS0008US0 Lift arm free play Factory specification 5 0 to 15 mm 0 20 to 0 59 in 1 Lift Arm 2 Feedback R...

Page 266: ...ect the power steering delivery pipe 4 4 Disconnect the 3 point hitch delivery pipe 7 and suction hose 5 5 Remove the hydraulic pump 6 When reassembling NOTE For fastening hydraulic pipe nut use two wrenches Hold the fitting with a wrench turn the pipe nut another wrench to avoid damage at fitting installed part When disconnecting battery cords disconnect the negative cord first When connecting po...

Page 267: ...isconnect the hydraulic control lever 1 9Y1210272HYS0012US0 3 Point Hitch Delivery Pipe and Hydraulic Cylinder Assembly 1 Disconnect the 3 point hitch delivery pipe 1 2 Remove the hydraulic cylinder assembly 2 When reassembling Apply liquid gasket Three Bond 1206D or equivalent to joint face of the differential case and the hydraulic cylinder 9Y1210272HYS0013US0 Tightening torque Top link bracket ...

Page 268: ...o damage the O ring Align the holes of the cover and casing Install the side plate noting its location and direction Install the gears noting its direction 9Y1210272HYS0014US0 Oil Seal 1 Remove the internal snap ring 2 and remove the oil seal 1 When reassembling If the oil seal is defective worn or scratched replace it 9Y1210272HYS0015US0 Tightening torque Cover mounting screw 35 to 39 N m 3 5 to ...

Page 269: ...ng Align the holes of the cover and casing Install the side plate noting its location and direction Install the gears noting its direction 9Y1210272HYS0016US0 Oil Seal 1 Remove the internal snap ring 2 and remove the oil seal 1 When reassembling If the oil seal is defective worn or scratched replace it 9Y1210272HYS0017US0 Tightening torque Hydraulic pump cover mounting screw 35 to 39 N m 3 5 to 4 ...

Page 270: ...t marks 4 of the lift arm L H and hydraulic arm shaft Apply grease to the right and left bushings and O rings Take care not to damage the O rings 9Y1210272HYS0019US0 Hydraulic Piston 1 Inject the compressed air into the hydraulic cylinder and take out the hydraulic piston 1 When reassembling Take care not to damage the O ring 3 and backup ring 2 Apply transmission fluid to the O ring Replace the O...

Page 271: ...ontrol Valve Spool 1 Remove the spool 1 9Y1210272HYS0022US0 Relief Valve 1 Remove the adjusting plug 1 spring 2 and poppet 3 When reassembling Recutting the threads of adjusting plug and control valve inner thread After adjusting the pressure be sure to stake the adjusting plug and control valve body 9Y1210272HYS0023US0 1 Lowering Speed Adjusting Shaft 2 Lowering Speed Adjusting Valve Body 3 Poppe...

Page 272: ...thickness is less than the allowable limit replace it B1220 B1620 and B1820 9Y1210272HYS0026US0 Clearance between tip of gear tooth and casing Allowable limit 0 15 mm 0 059 in Clearance between busing and shaft Factory specification 0 0050 to 0 088 mm 0 00020 to 0 0034 in Allowable limit 0 12 mm 0 0047 in Bushing I D Factory specification 12 000 to 12 068 mm 0 47244 to 0 47511 in Clearance between...

Page 273: ...ith an outside micrometer 2 Measure the bushing I D with a cylinder gauge and calculate the clearance 3 If the clearance exceeds the allowable limit replace the bushing 9Y1210272HYS0028US0 Cylinder I D Factory specification 65 05 to 65 10 mm 2 561 to 2 562 in Allowable limit 65 15 mm 2 565 in Hydraulic arm shaft O D Factory specifica tion Right 31 925 to 31 950 mm 1 2569 to 1 2578 in Left 29 925 t...

Page 274: ...9 ELECTRICAL SYSTEM KiSC issued 07 2011 A ...

Page 275: ...C Type 9 M9 3 With OPC and PTO Gear Shift Lever Switch Type 9 M10 3 SAFETY SWITCH AND ENGINE CONDITION 9 M11 1 Related Switches 9 M11 2 Engine Starting Conditions 9 M11 3 Related Switches 9 M12 4 Engine Starting Conditions and Automatic Engine Stop 9 M15 3 CHARGING SYSTEM 9 M16 1 B1220 9 M16 2 B1620 AND B1820 9 M17 4 LIGHTING SYSTEM 9 M18 1 B1220 9 M18 1 Head Light 9 M18 2 B1620 AND B1820 9 M19 1 ...

Page 276: ...ELECTRICAL SYSTEM B1220 B1620 B1820 WSM 9 M1 EU 1 WIRING DIAGRAM 1 B1220 WITHOUT OPC TYPE KiSC issued 07 2011 A ...

Page 277: ...ELECTRICAL SYSTEM B1220 B1620 B1820 WSM 9 M2 EU 2 B1220 WITH OPC TYPE KiSC issued 07 2011 A ...

Page 278: ...ELECTRICAL SYSTEM B1220 B1620 B1820 WSM 9 M3 EU 3 B1620 AND B1820 WITHOUT OPC TYPE KiSC issued 07 2011 A ...

Page 279: ...ELECTRICAL SYSTEM B1220 B1620 B1820 WSM 9 M4 EU 4 B1620 AND B1820 WITH OPC TYPE KiSC issued 07 2011 A ...

Page 280: ...ELECTRICAL SYSTEM B1220 B1620 B1820 WSM 9 M5 EU 5 B1620 AND B1820 WITH OPC AND PTO GEAR SHIFT LEVER SWITCH TYPE KiSC issued 07 2011 A ...

Page 281: ...e safety switches on the terminal B is connected to the terminal 50 and AC Consequently battery current flows to the starter motor and start the engine The main switch automatically returns to the ON position the terminal B is connected only to the terminal AC thereby causing the starting circuit to be opened stopping the starter motor 9Y1210272ELM0003US0 1 Joint Connector 2 Glow Plug Indication 3...

Page 282: ... switch is turned to the PREHEAT position the terminal B is connected to the terminals 19 and AC The glow plugs become red hot and at the same time the glow plug indicator also lights on When the main switch is then turned to the START position with the safety switches on the terminal B is connected to the terminal 50 and AC Consequently battery current flows to the starter motor and start the eng...

Page 283: ...the starter motor and start the engine The main switch automatically returns to the ON position the terminal B is connected only to the terminal AC thereby causing the starting circuit to be opened stopping the starter motor When the main switch turned from the ON position to the OFF position the fuel cut off solenoid moves the fuel injection pump control rack to the No Fuel Injection position and...

Page 284: ...plugs become red hot and at the same time the glow plug indicator also lights on When the main switch is then turned to the START position with the safety switches on the terminal B is connected to the terminal 50 and AC Consequently battery current flows to the starter motor and start the engine The main switch automatically returns to the ON position the terminal B is connected only to the termi...

Page 285: ...ically returns to the ON position the terminal B is connected only to the terminal AC thereby causing the starting circuit to be opened stopping the starter motor When the main switch turned from the ON position to the OFF position the fuel cut off solenoid moves the fuel injection pump control rack to the No Fuel Injection position and stop the engine 9Y1210272ELM0026US0 1 Timer Relay 2 2 Relay 3...

Page 286: ...ch is located near the PTO gear shift lever When the PTO gear shift lever is in neutral position the PTO switch is pushed in and electric circuit is closed 9Y1210272ELM0006US0 2 Engine Starting Conditions When the following conditions become complete electric current 12V reaches starter S terminal through starter relay from main switch 50 terminal and the engine can be started 9Y1210272ELM0007US0 ...

Page 287: ...s switch is located near the axle case L H When the parking brake switch is not in neutral position the parking brake switch is pushed in and electric circuit is opened 9Y1210272ELM0029US0 Seat Switch This switch is located under the seat When the seat switch is not in neutral position the seat switch is turned on and electric circuit is opened 9Y1210272ELM0030US0 1 Parking Brake Switch 1 Seat Swi...

Page 288: ...is not in contact with the arm when the parking brake is in the second notch position NOTE In case the seat is vacant or the operator gets up from the seat a When the parking brake is in the released position engine must stop immediately after shifting the PTO gear shift lever b When the parking brake is in the second notch position engine does not stop and the rear PTO rotates after shifting the ...

Page 289: ...ch Type PTO Gear Shift Lever Switch with Mid PTO This switch is located under the left lever guide When the PTO gear shift lever switch is not in neutral position the PTO gear shift lever switch is turned on and electric circuit is opened 9Y1210272ELM0035US0 1 PTO Gear Shift Lever Switch KiSC issued 07 2011 A ...

Page 290: ...ON OFF Cannot Start ON Main Shift Lever Switch PTO Gear Shift Lever Switch PTO Switch REAR Parking Brake Switch Seat Switch Engine Start Key Stop Output Neutral Switch ON Switch ON Neutral Switch ON Lock Switch ON Sit Switch ON Cannot Start ON Engine Stop Engaged Switch OFF Switch OFF Engaged Switch OFF Unlock Switch OFF Stand Switch OFF Start OFF Engine does not Stop 1 Neutral ON ON Neutral ON Lo...

Page 291: ...ic power for various electrical devices and also charges the battery while the engine runs It consists of a AC dynamo and a regulator 9Y1210272ELM0008US0 1 Fuse 2 Joint Connector 3 Charging Lamp 4 Main Switch 5 Frame Earth 6 Slow Blow Fuse 7 Battery 8 Starter 9 AC Dynamo 10 IC Regulator KiSC issued 07 2011 A ...

Page 292: ...ing system supplies electric power for various electrical devices and also charges the battery while the engine runs This alternator has IC regulator 9Y1210272ELM0009US0 1 Charging Lamp 2 Main Switch 3 Fuse 4 Slow Blow Fuse 5 Battery 6 Starter 7 Alternator KiSC issued 07 2011 A ...

Page 293: ...tem consists of light switch head lights etc 9Y1210272ELM0010US0 1 Head Light The light switch has two position OFF and ON Current passes through the light circuit as shown in the figure above 9Y1210272ELM0011US0 Head Light Switch 9Y1210272ELM0012US0 1 Head Light Switch KiSC issued 07 2011 A ...

Page 294: ... has two position OFF and ON Current passes through the light circuit as shown in the figure above 9Y1210272ELM0014US0 2 Turn Signal Light The turn signal light switch which forms a combination switch with the light switch has three position OFF 1 2 When using turn signal light switch blinks only one side light The operation of the turn signal light switch is given to priority when the hazard swit...

Page 295: ...rn switch 9Y1210272ELM0016US0 3 HAZARD LAMP Hazard switch has two positions ON and OFF Blinking the hazard lamp and indicator lamps as shown in the figure above The hazard lamp is operative when the key switch is in either the ON or OFF positions 9Y1210272ELM0017US0 1 Head Light Switch 2 Horn Switch 3 Turn Signal Light Switch KiSC issued 07 2011 A ...

Page 296: ...s low this lamp illuminates 2 Charge Lamp When the charging system is not functioning properly this lamp illuminates 3 Pre heat Indicator Lamp When the key switch is in the Pre heat position the pre heat indicator lamp illuminates 9Y1210272ELM0019US0 2 ENGINE OIL PRESSURE LAMP When the engine oil pressure has dropped the engine oil pressure switch is activated to let the current flow from the main...

Page 297: ...s 9 S17 10 Starter 9 S26 11 AC Dynamo B1220 9 S26 12 Regulator B1220 Without OPC Type 9 S27 13 Regulator B1220 With OPC Type 9 S28 14 Alternator B1620 and B1820 9 S29 15 Head Light Switch B1220 9 S30 16 Combination Switch B1620 and B1820 9 S31 17 Hazard Switch B1620 and B1820 9 S33 18 Brake Switch B1620 and B1820 9 S34 19 Flasher Unit B1620 and B1820 9 S35 20 Easy Checker 9 S36 21 Gauge 9 S38 2 DI...

Page 298: ...ooling fan belt slipping Adjust tension G 27 Symptom Probable Cause Solution Reference Page Starter Motor Does Not Operate Battery discharged or defective Recharge or Replace G 23 9 S9 Slow blow fuse blown Replace G 36 Safety switch improperly adjusted or defective Repair or Replace 9 S17 9 S19 Wiring harness disconnected or improperly connected between main switch 50 terminal and starter relay sa...

Page 299: ... connected between main switch AC terminal and combination switch B1 terminal between combination switch 1 terminal and headlight Repair or Replace Illumination Light Does Not Light Fuse blown 10A Replace G 36 Bulb blown Replace G 37 Wiring harness disconnected or improperly connected between main switch AC terminal and combination switch B1 terminal between combination switch T terminal and panel...

Page 300: ...t in panel board defective Replace 9 S38 Symptom Probable Cause Solution Reference Page Engine Does Not Stop Seat switch defective Replace 9 S20 Key stop solenoid relay defective Replace 9 S13 Key stop solenoid defective Replace 9 S12 Rear PTO switch defective Adjust and Replace 9 S20 Main gear shift switch defective Adjust and Replace 9 S19 Wiring harness disconnected or improperly connected betw...

Page 301: ...G 27 Symptom Probable Cause Solution Reference Page Starter Motor Does Not Operate Battery discharged or defective Recharge or Replace G 23 9 S9 Slow blow fuse blown Replace G 37 Safety switch improperly adjusted or defective Repair or Replace 9 S17 9 S22 Wiring harness disconnected or improperly connected between main switch 50 terminal and starter relay safety switches between safety switches an...

Page 302: ...y and battery positive terminal Adjust and Replace Starter Motor Does Not Operate Seat switch defective Replace 9 S23 Key stop solenoid relay defective Replace 9 S13 Key stop solenoid defective Replace 9 S12 Rear PTO switch defective Replace 9 S23 Main gear shift switch defective Replace 9 S22 Starter defective Replace 9 S26 Wiring harness disconnected or improperly connected between key stop sole...

Page 303: ...main switch AC terminal and combination switch B1 terminal between combination switch T terminal and panel board Repair or Replace Hazard Light Does Not Light Fuse blown 10A Replace G 37 Bulb blown Replace G 38 Wiring harness disconnected or improperly connected Repair or Replace Flasher unit defective Replace 9 S35 Hazard switch defective Replace 9 S33 Hazard Indicator Lamp Does Not Light Bulb bl...

Page 304: ...arness disconnected or improperly connected between panel board and oil pressure switch Repair or Replace Circuit in panel board defective Replace 9 S37 Symptom Probable Cause Solution Reference Page Fuel Gauge Does Not Function Fuel gauge defective Repair 9 S38 Fuel level sensor defective Replace 9 S38 Wiring harness disconnected or improperly connected between panel board and fuel level sensor R...

Page 305: ...cification Allowable Limit Commutator O D Difference of O D s 28 0 mm 1 10 in Less than 0 02 mm 0 0008 in 27 0 mm 1 06 in 0 05 mm 0 002 in Mica Undercut 0 60 mm 0 024 in 0 20 mm 0 0079 in Brush Length 14 0 mm 0 551 in 9 0 mm 0 35 in Item Factory Specification Allowable Limit Glow Plug Resistance Approx 0 9 Ω KiSC issued 07 2011 A ...

Page 306: ...regarded damage to regulator may result 9Y1210272ELS0004US0 1 CHECKING AND ADJUSTING 1 Battery Battery Voltage 1 Stop the engine and turn the main switch off 2 Connect the COM lead of the voltmeter to the battery s negative terminal post and the lead to the positive terminal post and measure the battery voltage 3 If the battery voltage is less than the factory specification check the battery speci...

Page 307: ...rometer at eye level The hydrometer reading must be taken at the highest electrolyte level Reference Specific gravity slightly varies with temperature To be exact the specific gravity decreases by 0 0007 with an increase of 1 C 0 0004 with an increase of 1 F in temperature and increases by 0 0007 with a decreases of 1 C 0 0004 with a decrease of 1 F Therefore using 20 C 68 F as a reference the spe...

Page 308: ...OFF position 2 Measure the resistance with an ohmmeter across the B terminal and the AC terminal B terminal and 50 terminal B terminal and 19 terminal 3 If infinity is not indicated the contacts of the main switch are faulty 9Y1210272ELS0010US0 2 Main Switch Key at ON Position 1 Set the main switch ON position 2 Measure the resistance with an ohmmeter across the B terminal and the AC terminal 3 If...

Page 309: ... of the main switch are faulty 9Y1210272ELS0012US0 3 Key Stop Solenoid Key Stop Solenoid Test 1 Disconnect the 1P connector from the key stop solenoid 2 Remove the key stop solenoid from the engine 3 Connect the jumper leads from the battery positive terminal to the 1P connector and from the battery negative terminal to the key stop solenoid body 4 If the solenoid plunger is not attracted the key ...

Page 310: ...ide down or inclined side ways water may intrude timer solenoid failure 9Y1210272ELS0074US0 Key Stop Solenoid Relay Actuator Test 1 Connect a jumper lead from the terminal 3 and terminal 4 to the battery positive terminal 2 Connect a jumper lead from the terminal 2 to battery negative terminal 3 Connect a jumper lead from the terminal 1 to a lamp 4 The lamp lights when disconnect the jumper lead f...

Page 311: ...s mounted up side down or inclined side ways water may intrude timer solenoid failure 9Y1210272ELS0077US0 Timer Relay 2 Actuator Test 1 Connect a jumper lead from the terminal 1 and terminal 2 to the battery positive terminal 2 Connect a jumper lead from the terminal 3 to battery negative terminal 3 Connect a jumper lead from the terminal 4 to a lamp 4 The lamp lights when disconnect the jumper le...

Page 312: ...erminal 6 and 7 5 If ohm is not indicated renew the relay 2M 9Y1210272ELS0079US0 7 Starter Relay Starter Relay 1 Remove the panel board and starter relay 1 2 Apply battery voltage across 2 terminal and 4 terminal and check for continuity across 1 terminal and 3 terminal 3 If 0 Ω is not indicated renew the starter relay 1 9Y1210272ELS0015US0 1 Relay 2M Resistance 1 terminal 3 terminal Battery volta...

Page 313: ... from the battery voltage the wiring harness or main switch is faulty 9Y1210272ELS0067US0 Glow Plug Continuity 1 Disconnect the lead from the glow plugs 2 Measure the resistance between the glow plug terminal and the chassis 3 If 0 ohm is indicated the screw at the tip of the glow plug and the housing are short circuited 4 If the factory specification is not indicated the glow plug is faulty WSM00...

Page 314: ...als 2 If the continuity is not infinity the switch is faulty replace it When the main gear shift lever is in 2nd or 3rd position 1 Measure the resistance between terminals 2 If the continuity is not infinity the switch is faulty replace it 9Y1210272ELS0018US0 Safety Switch State Resistance Main gear shift switch Main gear shift lever in neutral 0 Ω Main gear shift lever in engage Infinity Rear PTO...

Page 315: ...infinity the switch is faulty replace it When the PTO gear shift lever is in 540 rpm PTO speed position 1 Measure the resistance between terminals 2 If the continuity is not infinity the switch is faulty replace it 9Y1210272ELS0020US0 Resistance When the PTO gear shift lever is in NEUTRAL position 0 Ω When the PTO gear shift lever is in rpm rear PTO speed and 2500 rpm mid PTO Speed If equipped the...

Page 316: ... the continuity is not infinity the switch is faulty replace it When the main gear shift lever is in 2nd or 3rd position 1 Measure the resistance between terminals 2 If the continuity is not infinity the switch is faulty replace it 9Y1210272ELS0073US0 Safety Switch State Resistance Main gear shift switch Main gear shift lever in neutral 0 Ω Main gear shift lever in engage Infinity Rear PTO switch ...

Page 317: ...Seat Switch Continuity Check 1 Disconnect the safety switch leads 2 Connect the circuit tester leads to the seat switch terminals When switch is not pushed 1 Measure the resistance between terminals 2 If the continuity is not infinity the switch is faulty replace it When switch is pushed 1 Measure the resistance between terminals 2 If the continuity is not 0 Ω the switch is faulty replace it 9Y121...

Page 318: ...ushed 1 Measure the resistance between terminals 2 If the continuity is not infinity the switch is faulty replace it When switch is pushed 1 Measure the resistance between terminals 2 If the continuity is not 0 Ω the switch is faulty replace it 9Y1210272ELS0080US0 Resistance When parking brake switch is not pushed Infinity When parking brake switch is pushed 0 Ω 1 Parking Brake Switch KiSC issued ...

Page 319: ... 2 If the continuity is not infinity the switch is faulty replace it When the main gear shift lever is in 2nd or 3rd position 1 Measure the resistance between terminals 2 If the continuity is not infinity the switch is faulty replace it 9Y1210272ELS0018US0 Safety Switch State Resistance Main gear shift switch Main gear shift lever in neutral 0 Ω Main gear shift lever in engage Infinity Rear PTO sw...

Page 320: ...y Check 1 Disconnect the safety switch leads 2 Connect the circuit tester leads to the seat switch terminals When switch is not pushed 1 Measure the resistance between terminals 2 If the continuity is not infinity the switch is faulty replace it When switch is pushed 1 Measure the resistance between terminals 2 If the continuity is not 0 Ω the switch is faulty replace it 9Y1210272ELS0069US0 Resist...

Page 321: ...ushed 1 Measure the resistance between terminals 2 If the continuity is not infinity the switch is faulty replace it When switch is pushed 1 Measure the resistance between terminals 2 If the continuity is not 0 Ω the switch is faulty replace it 9Y1210272ELS0068US0 Resistance When parking brake switch is not pushed Infinity When parking brake switch is pushed 0 Ω 1 Parking Brake Switch KiSC issued ...

Page 322: ...0 PTO Gear Shift Lever Switch Check 1 Disconnect the PTO gear shift lever switch 2 Connect the circuit tester leads to the PTO gear shift lever switch terminals When switch is not pushed 1 Measure the resistance between terminals 2 If the continuity is not infinity the switch is faulty replace it When switch is pushed 1 Measure the resistance between terminals 2 If the continuity is not 0 Ω the sw...

Page 323: ...from the battery 2 Disconnect the battery positive cable and the leads from the starter M terminal 3 Remove the starter from the engine 4 Disconnect the connecting lead 3 from the starter C terminal 2 5 Connect a jumper lead from the starter S terminal 1 to the battery positive terminal post 6 Connect a jumper lead momentarily between the starter C terminal 2 and the battery negative terminal post...

Page 324: ... Check with a tester whether the regulator is in optimum condition or not 3 If the continuity is not measured as show in the table below the contacts of the regulator are faulty Q Check Table NOTE Use a high resistance tester as far as possible 9Y1210272ELS0024US0 1 Regulator 1 Sky Blue 2 Black 3 Sky Blue 4 Green 5 Yellow 6 Red KiSC issued 07 2011 A ...

Page 325: ...heck with a tester whether the regulator is in optimum condition or not 3 If the continuity is not measured as show in the table below the contacts of the regulator are faulty Q Check Table NOTE Use a high resistance tester as far as possible 9Y1210272ELS0087US0 1 Regulator 1 Sky Blue 2 Black 3 Sky Blue 4 Green 5 Yellow 6 Red KiSC issued 07 2011 A ...

Page 326: ...ct the negative cable from the battery 5 Measure the voltage between the B terminal 2 and the chassis 6 If the measurement is less than the factory specifications disassemble the alternator and check the IC regulator Reference Once the engine has started the alternator temperature rises quickly up to an ambient temperature of 70 to 90 C 158 to 194 F As the temperature goes higher than 50 C 122 F t...

Page 327: ...tting Switch at OFF Position 1 Set the light switch to the OFF position 2 Measure the resistance with an ohmmeter across the B1 terminal to the terminal 1 3 If infinity is not indicated the head light switch is faulty 3 Head Light Switch Continuity When Setting Switch at On Position 1 Set the light switch to the ON position 2 Measure the resistance with an ohmmeter across the B1 terminal to the te...

Page 328: ...witch is faulty 3 Head Light Switch Continuity When Setting Switch at On Position 1 Set the light switch to the ON position 2 Measure the resistance with an ohmmeter across the B1 terminal to the T terminal and the B1 terminal to the terminal 1 3 If 0 Ω is not indicated the head light switch is faulty 4 Turn Signal Light Switch Continuity When Setting Switch Knob OFF Position 1 Set the turn signal...

Page 329: ...nuity when Not Pushing Button 1 Set the horn button to the OFF position 2 Measure the resistance with an ohmmeter across the B3 terminal and the H terminal 3 If infinity is not indicated the combination switch is faulty 8 Horn Button at ON Position 1 Set the horn button to the ON position 2 Measure the resistance with an ohmmeter across the B3 terminal and the H terminal 3 If infinity is not indic...

Page 330: ...er from the battery voltage the wiring harness is faulty 9Y1210272ELS0031US0 Hazard Switch continuity 1 Measure the resistance with ohmmeter across the a terminal 3 and c terminal 5 and across the d terminal 6 and e terminal 2 If the measurement is not following below the hazard switch 1 or the bulb 2 are faulty 9Y1210272ELS0032US0 1 Hazard Switch Voltage a terminal Chassis Approx battery voltage ...

Page 331: ... position 9Y1210272ELS0033US0 Brake Switch Distance 1 Depress the brake pedal 2 and set the distance B 2 Check the brake light by operating brake pedal 2 The brake light should come ON when the brake pedal 2 is depressed If not adjust the brake switch 1 distance A Reference Distance B 15 to 25 mm 0 59 to 0 98 in 9Y1210272ELS0034US0 Resistance When brake pedal is depressed 0 Ω When brake pedal is r...

Page 332: ... turn signal switch to the right and make sure the right hand light gives flashes Make sure the same actions as above result 3 If both the hazard switch and the turn signal switch and the turn signal switch function but the above actions do not take place replace the flasher unit with new one 9Y1210272ELS0035US0 Voltage Terminal 12 Chassis Approx battery voltage Terminal 13 Chassis Approx battery ...

Page 333: ...e Oil Pressure Switch Continuity 1 Measure the resistance with an ohmmeter across the switch terminal and the chassis 2 If 0 Ω is not indicated in the normal state the switch is faulty 3 If infinity is not indicated at pressure over 4 9 kPa 0 5 kgf cm2 7 psi the switch is faulty 9Y1210272ELS0039US0 Glow Plug 1 Disconnect the lead from the glow plug 1 2 Connect the tester positive cable to the glow...

Page 334: ...ge Engine Oil Pressure Pre heat Illumination Position and Trailer Indicator B1620 and B1820 1 Remove the meter panel from the tractor 2 Remove the each lamp 3 Measure the lamp resistance 4 If it is infinity replace the lamp with new 9Y1210272ELS0042US0 Lamp spec All lamp 12 V 1 7 W 1 Illumination 2 Pre heat 3 Turn Signal 4 Charge 5 Engine Oil Pressure Lamp spec All lamp 12 V 1 7 W 1 Illumination 2...

Page 335: ...t Temperature Gauge Continuity 1 Remove the meter panel from the tractor 2 Check the continuity with an ohmmeter across the U terminal 1 and IGN terminal 3 and across the U terminal 1 and GND terminal 2 3 If infinity is indicated the coolant temperature sensor is faulty 4 Check the continuity with an ohmmeter across the U terminal 4 and IGN terminal 6 and across the U terminal 4 and GND terminal 5...

Page 336: ...r 14 5 Draw out the armature 13 and yoke 12 6 Remove the gasket 11 gasket 19 and plate 18 7 Draw out the shaft assembly 9 with the drive lever 5 NOTE Do not damage the brush and commutator Do not miss the ball 10 9Y1210272ELS0046US0 1 Screw 2 Front Bracket 3 Magnetic Switch 4 Overrunning Clutch 5 Drive Lever 6 Internal Gear 7 Shaft 8 Planetary Gear 9 Shaft Assembly 10 Ball 11 Gasket 12 Yoke 13 Arm...

Page 337: ...f the pulley shaft with a double ended ratchet wrench as shown in the figure loosen the pulley nut with a socket wrench and remove it When reassembling WSM000001ELS0023US0 Rear End Cover 1 Unscrew the three rear end cover screws and the B terminal nut and remove the rear end cover WSM000001ELS0024US0 Brush Holder 1 Unscrew the two screws holding the brush holder and remove the brush holder 1 WSM00...

Page 338: ... two nuts and two screws holding the drive end frame and the rear end frame 2 Remove the rear end frame 1 WSM000001ELS0028US0 Rotor 1 Press out the rotor 1 from drive end frame 3 IMPORTANT Take special care not to drop the rotor and damage the slip ring or fan etc WSM000001ELS0029US0 Retainer Plate 1 Unscrew the four screws holding the retainer plate and remove the retainer plate 1 WSM000001ELS003...

Page 339: ...ing from drive end frame 3 with a press and jig 1 WSM000001ELS0031US0 Bearing at Slip Ring Side 1 Lightly secure the rotor 1 with a vise to prevent damage and remove the bearing 2 with a puller 3 WSM000001ELS0032US0 1 Jig 2 Block 3 Drive End Frame 1 Rotor 2 Bearing 3 Puller KiSC issued 07 2011 A ...

Page 340: ...ear 1 If the contact face of the brush is dirty or dusty clean it with emery paper 2 Measure the brush length A with vernier calipers 3 If the length is less than the allowable limit replace the yoke assembly and brush holder 9Y1210272ELS0060US0 Brush Holder 1 Check the continuity across the brush holder and the holder support with an ohmmeter 2 If it conducts replace the brush holder WSM000001ELS...

Page 341: ...ss each lead of the stator coil with an ohmmeter 2 If the measurement is not within factory specification replace it 3 Check the continuity across each stator coil lead and core with an ohmmeter 4 If the measurement is not within the factory specifications replace it WSM000001ELS0040US0 Rotor 1 Measure the resistance across the slip rings with an ohmmeter 2 If the resistance is not the factory spe...

Page 342: ...e reverse direction IMPORTANT Do not use a 500 V megger for measuring because it will destroy the rectifier NOTE Do not use an auto digital multimeter Because it s very hard to check the continuity of rectifier by using it WSM000001ELS0044US0 IC Regulator 1 Check the continuity across the B terminal and the F terminal of IC regulator with an analog ohmmeter Conduct the test in the R x 1 setting 2 ...

Page 343: ...ode No 9Y111 02723 2009 02 S EI EI e KUBOTA Corporation EDITOR KUBOTA FARM INDUSTRIAL MACHINERY SERVICE LTD 64 ISHIZU KITAMACHI SAKAI KU SAKAI CITY OSAKA 590 0823 JAPAN PHONE 81 72 241 1129 FAX 81 72 245 2484 E mail ksos pub kubota co jp ...

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