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Kubota M108S, Workshop Manual

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Kubota M108S Workshop Manual Download Page 113

1-M18

M108S, WSM

ENGINE

■

Injector Operation

W1017602

The injector controls injection through the fuel pressure in the control chamber. The TWV (Two-Way Valve)

executes leak control of the fuel in the control chamber to control the fuel pressure within the control chamber. The
TWV varies with the injector type.
1) Non-Injection

When the TWV (2) is not energized, the TWV (2) shuts off the leak passage (6) from the control chamber, so the

fuel pressure in the control chamber and the fuel pressure applied to the nozzle needle are both the same rail
pressure. The nozzle needle thus closes due to the difference between the pressure-bearing surface area of the
command piston (4) and the force of the nozzle spring, and fuel is not injected.

For this type, the control chamber outlet orifice (3) is closed directly by the force of the spring.

2) Injection

When TWV energization starts, the TWV valve is pulled up, opening the leak passage (6) from the control chamber.

When this leak passage (6) opens, the fuel in the control chamber leaks out and the pressure drops.

Because of the control chamber internal presusre drops, the pressure on the nozzle needle overcomes the force

pressing down, the nozzle needle is pushed up, and injection starts. When fuel leaks from the control chamber, the
flow quantity is restricted by the orifice, so the nozzle (5) opens gradually. The injection rate rises as the nozzle (5)
opens. As the current continues to apply to the TWV (2), the nozzle needle eventually reaches the maximum amount
of lift, which results in the maximum injection rate. Excess fuel is returned to the fuel tank through the path shown.
3) End of Injection

When TWV energization ends, the valve descends, closing the leak passage (6) from the control chamber. When

the leak passage (6) closes, the fuel pressure within the control chamber instantly returns to the rail pressure, the
nozzle (5) closes suddenly, and injection stops.

(1) Solenoid
(2) TWV (Two-Way Valve)
(3) Outlet Orifice
(4) Command Piston
(5) Nozzle
(6) Leak Passage
(7) Inlet Orifice

A : Non Injection
B : Injection
C : End of Injection
D : From Rail
E : To Fuel Tank

KiSC issued 06, 2007 A

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Summary of Contents for M108S

Page 1: ...M108S WORKSHOP MANUAL TRACTOR KiSC issued 06 2007 A...

Page 2: ...for the one which has not been described to this workshop manual Servicing Information on the troubleshooting servicing specification lists tightening torque checking and adjusting disassembling and...

Page 3: ...l 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 safety regulations before you a...

Page 4: ...lways support the machine by safety stands Do not touch the rotating or hot parts while the engine is running Never remove the radiator cap while the engine is running or immediately after stopping Ot...

Page 5: ...be running to do some work make sure the area is well ventilated Never run the engine in a closed area The exhaust gas contains poisonous carbon monoxide PREVENT ACID BURNS Sulfuric acid in battery el...

Page 6: ...STRUCTIONS PREPARE FOR EMERGENCIES Keep a first aid kit and fire extinguisher handy at all times Keep emergency numbers for doctors ambulance service hospital and fire department near your telephone K...

Page 7: ...UCTIONS The following safety decals 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 SAFETY DECAL...

Page 8: ...6 M108S WSM SAFETY INSTRUCTIONS KiSC issued 06 2007 A...

Page 9: ...7 M108S WSM SAFETY INSTRUCTIONS KiSC issued 06 2007 A...

Page 10: ...8 M108S WSM SAFETY INSTRUCTIONS KiSC issued 06 2007 A...

Page 11: ...9 M108S WSM SAFETY INSTRUCTIONS KiSC issued 06 2007 A...

Page 12: ...26 to 73 42 in Minimum ground clearance 435 mm 17 1 in drawbar bracket Weight 2 3890 kg 8558 lbs Traveling system Standard tire size 3 Front 340 85R24 13 6R24 Rear 460 85R34 18 4R34 Clutch Multiple we...

Page 13: ...0 22 0 30 0 19 2 0 45 0 28 0 38 0 24 3 0 57 0 35 0 47 0 29 4 0 72 0 45 0 60 0 37 1 0 92 0 57 0 76 0 47 2 1 18 0 73 0 97 0 60 3 1 45 0 90 1 20 0 74 4 1 84 1 14 1 52 0 944 L 1 2 02 1 26 1 67 1 04 2 2 57...

Page 14: ...0 0 19 2 0 46 0 29 0 38 0 24 3 0 57 0 35 0 47 0 29 4 0 73 0 45 0 60 0 37 1 0 93 0 58 0 77 0 48 2 1 19 0 74 0 98 0 61 3 1 46 0 91 1 21 0 75 4 1 86 1 16 1 53 0 951 L 1 2 04 1 27 1 68 1 04 2 2 59 1 61 2...

Page 15: ...13 M108S WSM DIMENSIONS DIMENSIONS KiSC issued 06 2007 A...

Page 16: ...G GENERAL KiSC issued 06 2007 A...

Page 17: ...18 4 CHECK POINTS OF EVERY 100 HOURS G 19 5 CHECK POINTS OF EVERY 200 HOURS G 25 6 CHECK POINT OF EVERY 300 HOURS G 29 7 CHECK POINTS OF EVERY 400 HOURS G 30 8 CHECK POINTS OF EVERY 600 HOURS G 30 9...

Page 18: ...ur local KUBOTA distributor always specify engine serial number tractor serial number and hour meter reading W1010602 1 Tractor Identification Plate 2 Tractor Serial Number 3 CABIN Identification Plat...

Page 19: ...y KUBOTA genuine parts for parts replacement to maintain machine performance and to assure safety Gaskets and O rings must be replaced during reassembly Apply grease to new O rings or oil seals before...

Page 20: ...eck for a fee Do not 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 po...

Page 21: ...sag be required W1011587 In installing a part take care not to get wiring caught by it W1011670 After installing wiring check protection of terminals and clamped condition of wiring only connect batte...

Page 22: ...r immediately Before recharging 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 a...

Page 23: ...re is no female connector being too open W1012430 Make certain plastic cover is large enough to cover whole connector W1012519 5 HANDLING OF CIRCUIT TESTER Use tester correctly following manual provid...

Page 24: ...41 lmp qts Engine oil API service classification CF or better EGR type engine Below 0 C 32 F SAE10W 10W 30 or 15W 40 0 to 25 C 32 to 77 F SAE20 10W 30 or 15W 40 Above 25 C 77 F SAE30 10W 30 or 15W 40...

Page 25: ...Exhaust Gas Re circulation type engines The CJ 4 engine oil is intended for DPF Diesel Particulate Filter type engines and cannot be used on this tractor Transmission Oil The oil used to lubricate the...

Page 26: ...1 40 to 44 4 0 to 4 5 29 to 32 61 to 70 6 2 to 7 2 45 to 52 M12 12 mm 0 47 in 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...

Page 27: ...t1 5 49 to 68 5 0 to 7 0 37 to 50 15 t1 6 108 to 117 11 0 to 12 0 79 6 to 86 7 18 t1 6 108 to 117 11 0 to 12 0 79 6 to 86 7 Items Thread size Tightening torque N m kgf m lbf ft POA PF Nipple with O ri...

Page 28: ...100 hrs G 23 8 Air cleaner element Double type Primary element Clean 100 hrs 1 G 20 Replace 1 year 2 G 20 Secondary element Replace 1 year G 20 9 Fuel line Check 100 hrs G 20 Replace 2 years G 20 10...

Page 29: ...nt axle pivot Adjust 600 hrs G 31 27 Engine valve clearance Adjust 800 hrs 1 S14 28 Fuel injection nozzle active test Check 1500 hrs G 32 29 Supply pump Check 3000 hrs G 32 30 Turbo charger Check 3000...

Page 30: ...oad emission regulation As the engine owner you are responsible for the performance of the required maintenance on the engine according to the above instruction Please see the Warranty Statement in de...

Page 31: ...eck and clean the radiator screen and grill 12 Check and clean the air conditioner condenser screen and intercooler screen 13 Check the nuts of tires are tight 14 Check the number plate or SMV emblem...

Page 32: ...fore changing oil filter cartridge Allow engine to cool down sufficiently oil can be hot and can burn 1 Remove the oil filter 1 2 Put a film of clean engine oil on rubber seal of new filter 3 Tighten...

Page 33: ...1 Remove the two oil filters 1 2 Clean off metal filings with clean rags at the magnetic filters 2 3 Put a film of clean transmission oil on rubber seal of new filters 4 Tighten the filter quickly un...

Page 34: ...plugs 2 W1041009 Changing Front Axle Gear Case Oil 1 To drain the used oil remove the right and left drain plugs 2 and filling plugs 1 at the front axle gear case and drain the oil completely into th...

Page 35: ...tch pedal 3 fully 4 Turn the key to START position 5 The engine must not crank W1041704 Checking Wheel Mounting Nuts Tightening Torque CAUTION Never operate tractor with a loose rim wheel or axle Any...

Page 36: ...ad the indicator Check the battery condition by reading the indicator W1042636 Directions for Storage CAUTION When connecting the battery do not reverse the polarities Connection with reverse polariti...

Page 37: ...with the 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...

Page 38: ...ake Pedal Free Travel CAUTION When checking parking the tractor on flat ground and stop the engine 1 Measure the free travel by depressing the brake pedals 2 Slightly depress the brake pedals and meas...

Page 39: ...Gently step on both the right and left pedals at once with your both feet Step on the right pedal all the way the left pedal rises Measure the level difference between the two pedals 2 Next step on t...

Page 40: ...RTANT After adjustment check the parking brake performance according to steps 1 to 5 1 Set the parking brake lever to the 7th notch 2 Start the engine and set at the idling speed 3 Shift the travellin...

Page 41: ...dy condition lubricate grease fittings more often W1045953 1 Grease Fitting Front Axle Support Front 2 Grease Fitting Front Axle Support Rear 3 Grease Fitting Front Wheel Case Support RH LH 4 Grease F...

Page 42: ...alled Overheating 1 Stop the machine operation in a safe place and keep the engine unloaded idling 2 Don t stop the engine suddenly but stop it after about 5 minutes of unloaded idling 3 Keep yourself...

Page 43: ...at rear of tire hub height 6 Front distance should be shorter than rear distance 7 If not adjust tie rod length Toe in Adjustment 1 Detach the snap ring 1 2 Loosen the tie rod joint lock nut 3 3 Turn...

Page 44: ...ch the push rivet assembly Detaching procedure To remove the push rivet of the indoor air filter hold the rivet around its head 3 apply a phillips screwdriver to the recess A and turn the rivet counte...

Page 45: ...lukewarm water with mild dish washing detergent Move it up and down as well as left and right to loosen dirt Rinse the filter with clean water and let it air dry IMPORTANT Do not hit the filter If the...

Page 46: ...before checking air conditioner belt tension 1 Stop the engine and remove the key 2 Apply 98 N 10 kgf 22 lbf pressure to the belt between the pulleys 3 If tension is incorrect loosen the tension pull...

Page 47: ...until it contacts the mounting surface Tighten filter by hand an additional 1 2 turn only 4 Bleed the fuel system Refer to 14 OTHERS in this section W1050132 8 CHECK POINTS OF EVERY 600 HOURS Replacin...

Page 48: ...oil up to the MAX level 2 After installing the vinyl pipes 3 to the bleeder 2 loosen the bleeder a half turn 3 Move the brake pedal up and down Repeat this motion until fresh oil overflows W1050507 Ad...

Page 49: ...GINE section W1052150 10 CHECK POINT EVERY 1500 HOURS Checking Fuel Injection Nozzule Active Test 1 Refer to Diagnosis Manual W1039924 11 CHECK POINTS EVERY 3000 HOURS Checking Turbo Charger 1 Refer t...

Page 50: ...ng Air Conditioner Pipes and Hoses 1 Check to see that all lines and hose clamps are tight and not damaged 2 If hoses and clamps are found worn or damaged replace or repair them at once W1051760 Check...

Page 51: ...he engine Check coolant level and add coolant if necessary IMPORTANT Do not start engine without coolant Use clean fresh water and anti freeze to fill the radiator When the anti freeze is mixed with w...

Page 52: ...or before a long term storage let out coolant 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 se...

Page 53: ...a represents industry standards that necessitate a minimum glycol content in the concentrated anti freeze When the coolant level drops due to evaporation add water only to keep the antifreeze mixing r...

Page 54: ...le 3 Refer to 4 CHECK POINTS OF EVERY 100 HOURS in this section W1054811 Replacing Master Cylinder Kit and Equalizer Kit 1 Refer to 5 BRAKES section W1055146 Replacing Brake Seal 1 and 2 1 Refer to 5...

Page 55: ...er at the mid speed around 1500 min 1 rpm position If engine does not start try it several times at 30 second intervals 5 Accelerate the engine to remove the small portion of air left in the fuel syst...

Page 56: ...ling the vinyl pipe 3 to the bleeder 2 and 4 loosen the bleeder two turns 5 Move the brake pedal up and down Repeat this motion until air bubble in brake oil disappears After bleeding tighten the blee...

Page 57: ...A Work light rear 11 5 A Engine PTO Alternator 12 5 A Meter panel Buzzer 13 10 A Turn signal 14 10 A Transmission control 15 5 A A C Auxiliary power 16 15 A Wiper 17 10 A Beacon 18 5 A Audio radio 19...

Page 58: ...Washer Liquid 1 Add a proper amount of automobile washer liquid when it is necessary W1056398 Light Capacity Head lights 60 55 W Tail light 10 W Turn signal hazard light front 21 W Turn signal hazard...

Page 59: ...speed About 1500 min 1 rpm Temperature control dial Maximum cooling position leftmost Blower switch Highest blow HI Air conditioner switch ON 2 Look into the sight glass to see if the refrigerant is...

Page 60: ...Pressure Tester Code No 07916 32032 Application Use to measure lubricating oil pressure W10243180 Diagnosis Tool Kit Code No 1J574 90010 Application Use to check on the trouble of the common rail die...

Page 61: ...48 in C 150 mm 5 91 in D 44 95 mm dia 1 770 in dia E 48 075 to 48 100 mm dia 1 8928 to 1 8937 in dia F 20 mm dia 0 79 in dia a 6 3 m 250 in b 6 3 m 250 in C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm...

Page 62: ...2 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 3 mm 0 01 in A Rmax 12 5 S B 94 5 to 95 0 mm dia 3 72 to 3 74...

Page 63: ...n F 5 0 mm 0 20 in G 30 mm dia 1 2 in dia H 65 mm dia 2 6 in dia I 6 0 mm 0 24 in J Chamfer 1 0 mm 0 039 in K 53 mm dia 2 1 in dia L 54 70 to 54 90 mm dia 2 154 to 2 161 in dia M 0 26 rad 15 N Chamfer...

Page 64: ...004 in B 1 0 mm 0 039 in C Chamfer 1 0 mm 0 039 in D 54 30 to 54 40 mm dia 2 138 to 2 141 in dia E 34 025 to 34 050 mm dia 1 3396 to 1 3405 in dia F 48 5 mm dia 1 91 in dia G 50 421 to 50 440 mm dia 1...

Page 65: ...Tool Components Parts 1 Bracket W1167794 No Name of Part Q ty 1 Bracket 1 2 Flange Nut 1 3 Washer 1 4 Shaft 1 5 Piece 1 1 6 Clevis 1 7 Washer 1 8 Cotter Pin 1 9 Joint 1 1 10 Piece 2 1 11 Joint 2 1 12...

Page 66: ...2 8 in O 19 5 mm 0 768 in P 12 mm 0 47 in Q 0 8 mm 0 03 in R 6 0 mm 0 24 in A 26 mm 1 0 in B 18 mm 0 71 in C 16 5 to 17 0 mm 0 650 to 0 669 in D 1 5 mm 0 059 in E 54 00 to 54 20 mm dia 2 126 to 2 133...

Page 67: ...n D 1 5 mm 0 059 in E 53 50 to 53 70 mm dia 2 107 to 2 114 in dia F 50 05 to 50 25 mm dia 1 971 to 1 978 in dia G 16 mm 0 63 in H Chamfer 1 0 mm 0 039 in I 8 5 mm dia 0 33 in dia J 0 4 mm 0 02 in K 3...

Page 68: ...dia J 0 4 mm 0 02 in K 3 0 mm 0 12 in L 19 mm 0 75 in M Chamfer 0 5 mm 0 02 in N 36 mm 1 4 in O 45 mm dia 1 8 in dia P 0 78 rad 45 Q 11 5 mm 0 453 in A 10 mm dia 0 39 in dia B M16 Pitch 1 5 C 19 mm 0...

Page 69: ...5 mm 4 272 in D 262 5 mm 10 33 in E 12 5 mm 0 492 in F 237 5 mm 9 350 in G 142 5 mm 5 610 in H 95 mm 3 7 in I 14 mm dia 0 55 in dia J 40 mm radius 1 6 in radius K 210 mm 8 27 in L 190 mm 7 48 in M 10...

Page 70: ...182 to 0 51224 in f 11 mm 0 43 in K 44 mm 1 7 in g 12 9835 to 13 0055 mm 0 511162 to 0 512027 in L 112 6 mm 4 433 in h 5 8 18UNF 2B M 19 84 to 19 95 mm 0 7811 to 0 7854 in i 3 0 mm dia 0 12 in dia thr...

Page 71: ...plication This allows easy testing of hydraulic system W10313180 Adaptor Set for Flow Meter Code No 07916 54031 Application Use for testing the hydraulic system W10313960 1 Gauge 07916 50322 2 Cable 0...

Page 72: ...tion into and removing it from rear tires W10265850 Brake Air Bleeder Code No 07916 54001 Application This allows easy air bleed of the hydraulic brake system W10516480 Relief Valve Setting Pressure A...

Page 73: ...311 Application Use for preventing the shaft from turning when removing the staking nut from the counter shaft and spiral bevel pinion shaft W10445520 A 20 0 mm dia 0 787 in dia B 11 5 mm dia 0 453 in...

Page 74: ...ench 98 Code No 07916 52521 Application Use for removing and installing a rear axle nut Power Steering Adaptor Code No 07916 54021 Application Use for measuring the relief valve setting pressure for p...

Page 75: ...ng the air conditioning system W1013817 Vacuum Pump Code No DENSO CO 95046 00040 AC220V 95046 00050 AC240V Application Use for evacuating the air conditioning system W1013764 1 Manifold Gauge Assembly...

Page 76: ...t clutch W1065437 A 125 mm 4 92 in H 2 09 rad 120 B 40 0 mm dia 1 57 in dia I Radius 27 0 mm Radius 1 06 in C Radius 33 0 mm Radius 1 30 in J Radius 50 0 mm Radius 1 97 in D 16 mm 0 63 in K Weld all a...

Page 77: ...mm dia 1 18 in dia E 90 0 mm 3 54 in F 36 5 mm 1 44 in Top link mounting hole G 30 0 mm 1 18 in H 15 0 mm 0 591 in I 26 0 mm dia 1 02 in dia J Weld all around K Weld all around L 20 0 mm 0 787 in Rig...

Page 78: ...pressure of shuttle valve W1055758 A 24 0 mm 0 945 in B 27 7 mm 1 09 in C G1 4 D 11 0 mm 0 433 in E 15 0 mm 0 591 in F 40 0 mm 1 57 in G 60 0 mm 2 36 in H 15 0 mm 0 591 in I R1 8 J 4 0 mm dia 0 16 in...

Page 79: ...0 mm 13 8 in P 1 0 rad 60 D 23 0 to 23 3 mm 0 906 to 0 917 in Q 3 0 mm dia 0 12 in dia E 16 mm 0 63 in R 36 0 mm 1 42 in F 40 0 mm dia 1 58 in dia S 60 0 mm 2 36 in G 32 40 to 32 70 mm dia 1 276 to 1...

Page 80: ...in D 6 0 mm 0 24 in Q 4 0 mm 0 16 in E 45 0 mm 1 77 in R 72 8 mm 2 87 in F 140 mm 5 51 in S 130 mm 5 12 in G 74 0 mm 2 91 in T 50 0 mm 1 97 in H 12 0 mm 0 472 in U 62 0 mm 2 44 in I 20 0 mm 0 787 in...

Page 81: ...1 42 in I 64 0 mm 2 52 in J 45 0 mm 1 77 in K 20 0 mm 0 787 in 1 Screw M10 P1 25 L50 0 mm 1 97 in 2 Screw M16 P1 5 L50 0 mm 1 97 in 3 Rocking Restrictor A 70 0 mm 2 76 in B 67 5 mm 2 66 in C 56 0 mm 2...

Page 82: ...mm 4 72 in C M18 P1 5 screw D 45 0 mm 1 77 in E 115 mm 4 53 in F 12 0 mm 0 472 in G 32 5 mm 1 28 in H 65 0 mm 2 56 in I 25 0 mm 0 984 in J 110 mm dia 4 33 in dia K 98 0 mm dia 3 86 in dia L 90 0 mm di...

Page 83: ...e the position of the rim and disk right and left to the desired position and tighten the bolts 3 Adjust the toe in Refer to 5 CHECK POINTS OF EVERY 200 HOURS in this section IMPORTANT Always attach w...

Page 84: ...st turning angle with the stopper bolts table of the below 3 The right side is similarly adjusted IMPORTANT Always check if tires contact with tractor or loader frame assemblies W1057295 A 5 mm 0 2 in...

Page 85: ...as illustrated transmission parts may be damaged When re fitting or adjusting a wheel tighten the bolts to the following torques then recheck after driving the tractor 200 m 200 yards and thereafter...

Page 86: ...on 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 W1027488 Front...

Page 87: ...ll the front tires with liquid Preparation of Calcium Chloride Solution CAUTION When making a calcium chloride solution do not pour water over calcium chloride since this results in chemical reaction...

Page 88: ...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 attach the injector Code No 07916 52501 W1033331 1 Injector 2 Ho...

Page 89: ...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 W1033435 Tire sizes 16 9 34 18 4R30 18 4 30 18 4R34 1...

Page 90: ...air valve and drain liquid liquid can only be drained to the level of the valve and liquid under that level remains inside 4 To drain liquid completely use the injector 1 Code No 07916 52501 and direc...

Page 91: ...ay vary depending on soil operating conditions Tread max width Operating condition Lower link max lifting capacity W0 Front Rear IMPORTANT Tractor with front spacer option is not approved for use with...

Page 92: ...1360 kg 3000 lbs Sickle Bar Max Cutting Width 3050 mm 120 in 4 Sprayer Max Tank capacity Mid 1000 L 260 U S gals 220 Imp gals Rear 3P 1000 L 260 U S gals 220 Imp gals Drawbar 5500 L 1450 U S gals 121...

Page 93: ...11 Front Blade 1 2 Max Cutting Width 2600 mm 102 in Max Oil Pressure 19 6 MPa 200 kgf cm2 2842 psi 12 Rear Blade Max Cutting Width 2600 mm 102 in Max Oil Pressure 19 6 MPa 200 kgf cm2 2842 psi 13 Fro...

Page 94: ...1 ENGINE KiSC issued 06 2007 A...

Page 95: ...2 BOTTOM BYPASS SYSTEM 1 M7 5 FUEL SYSTEM 1 M8 1 GENERAL 1 M8 6 INTAKE AND EXHAUST SYSTEM 1 M9 1 INTAKE AIR HEATER 1 M9 2 TURBOCHARGER 1 M9 3 INTERCOOLER 1 M10 7 COMMON RAIL SYSTEM CRS 1 M11 1 GENERAL...

Page 96: ...es a type of accumulation chamber called a rail to store pressurized fuel and injectors that contain electronically controlled solenoid valves to inject the pressurized fuel into the cylinders Because...

Page 97: ...y assemble disassemble it The cylinder is a linerless type which enables good cooling operation less strain and good abrasion resistance W1013119 2 HALF FLOATING HEAD COVER The rubber packing is fitte...

Page 98: ...er By so doing injected fuel and suction air can be mixed more uniformly leading to more stable higher combustion performance In other words cleaner emission higher power output lower fuel consumption...

Page 99: ...en tapered and the stress concentration has been leveled for the countermeasure of fatigue due to enhancement of high power Accordingly its reliability has been further improved W1013438 6 BUILT IN DY...

Page 100: ...also warms the cool engine oil shoftly after start up As shown in the figure the oil flows inside the connected cooler plate whereas coolant is kept circulating outside the cooler plate thereby coolin...

Page 101: ...water cooled by the radiator flows through the water passage which suddenly closes the valve below the thermostat s preset valve closing temperature A repeated cycle of such overshoot and undershoot p...

Page 102: ...is held closed and the coolant is allowed to flow through the bypass pipe and to circulate in the engine When the temperature exceeds the thermostat valve opening level the thermostat fully opens itse...

Page 103: ...d fuel filter 7 where any foreign matter is removed The fuel sent from the electromagnetic fuel feed pump 8 has the required discharge quantity adjusted by the SCV Suction Control Valve 4 and enters o...

Page 104: ...he turbine is located between the exhaust manifold and the muffler The prime job of the turbocharger is by compressing the air to force more air into the engine cylinders This allows the engine to eff...

Page 105: ...d that is due to heat expansion less air is forced into the engine To overcome this condition some turbocharged engines are equipped with an intercooler This is installed between the turbocharger and...

Page 106: ...timally by storing ultra high pressure fuel in the rail and performing ultra high pressure injection by the diesel engine It has excellent combustion efficiency and realizes clean exhaust gas as well...

Page 107: ...tion quantity and injection timing for optimal engine operation and sends the appropriate signals to the actuators ECU enables the injectors to be actuated at high speeds Refer to 5 ENGINE CONTROL SYS...

Page 108: ...h the suction valve 3 The fuel pumped by the pump unit is pumped through the delivery valve 1 to the rail Feed Pump The trochoid type feed pump 6 which is integrated in the supply pump draws fuel from...

Page 109: ...actuated by duty ratio control Fuel is supplied in an amount corresponding to the open surface area of the passage which depends on the duty ratio and then is discharged by the plungers 4 2 Duty Ratio...

Page 110: ...The delivery valve has an integrated element 1 and is made up of the check ball 2 spring 3 and holder 4 When the pressure at the plunger 5 exceeds the pressure in the rail the check ball 2 opens to di...

Page 111: ...ses after the pressure falls to a certain level A Fuel released by the pressure limiter 1 returns to the fuel tank The operating pressures for the pressure limiter 1 are approximately 200 MPa 2040 kgf...

Page 112: ...omizes the fuel and injects it Injector Construction and Features The injector consists of a nozzle 10 similar to the conventional nozzle and nozzle holder an orifice 6 that controls the injection rat...

Page 113: ...When this leak passage 6 opens the fuel in the control chamber leaks out and the pressure drops Because of the control chamber internal presusre drops the pressure on the nozzle needle overcomes the f...

Page 114: ...data the QR code 1 contains the part number and the product number which can be read at extremely high speeds W1018198 Handling Injectors with QR Codes Reference Injectors with QR codes have the engi...

Page 115: ...Pressure Limiter 9 Engine Warning Light 10 Glow Lamp 11 Glow Relay 12 Supply Pump 13 Fuel Temperature Sensor 14 Suction Control Valve 15 Injector 16 EGR Valve DC Motor 17 EGR Valve Lift Sensor 18 Inta...

Page 116: ...he engine and the tractor Then the engine ECU controls the timing and duration of the current that is applied to the injectors in order to obtain optimal injection timing and injection quantity Variou...

Page 117: ...construction consists of the MRE type which is the same as for the crankshaft position sensor The number of pulses for the pulsar gear is 5 W1019369 This figure shows the pulse chart of the crankshaf...

Page 118: ...d with the accelerator pedal and the rotation of this shaft changes the magnetic field of the hall element 2 5 The voltage generated by this change in the magnetic field is amplified by an amplifier 3...

Page 119: ...perature sensor C is installed on the fuel intake side of supply pump and utilizes the characteristics of a thermistor 1 in which the electric resistance changes with the temperature in order to detec...

Page 120: ...idation of nitrogen in the air due to rise of the combustion temperature in engine combustion chambers The EGR is a system in which the exhaust gas with lean oxygen is cooled and returned to engine co...

Page 121: ...the movement of the motor shaft by means of the contact type position sensor The motor shaft engages with the female screw inside the rotating magnet and it performs amplification of motor torque and...

Page 122: ...e pressure difference between inside of the crankcase and the atmosphere and prevents backflow of the mixture of exhaust gas and intake air generated by the piston and valves It is used as the seconda...

Page 123: ...m Clutch Housing 1 S23 3 DISASSEMBLING AND ASSEMBLING V3800 CR TI 1 S25 1 External Components 1 S25 2 Turbocharger 1 S25 3 Exhaust Gas Recirculation EGR 1 S26 4 Common Rail System CRS 1 S27 5 Cylinder...

Page 124: ...oil at low temperature Use specified fuel or engine oil G 7 Fuel with low cetane number Use specified fuel G 7 Fuel leak due to loose injection pipe retaining nut Tighten retaining nut 1 S29 Injector...

Page 125: ...ocharger fin or other part damaged due to foreign matter Replace the turbocharger assembly 1 S26 Either White or Blue Exhaust Gas Is Observed Excessive engine oil Reduce to specified level G 15 Piston...

Page 126: ...ce piston 1 S60 Valve stem and valve guide worn Replace 1 S52 Crankshaft bearing and crank pin bearing worn Replace 1 S62 Oil leaking due to defective seals or packing Replace Fuel Mixed into Engine O...

Page 127: ...ish G 15 Fan belt broken or elongated Replace or adjust 1 S15 16 Coolant level insufficient Replenish G 7 Radiator net and radiator fin clogged with dust Clean Inside of radiator corroded Clean or rep...

Page 128: ...9 to 477 psi 200 min 1 rpm 2 41 MPa 200 min 1 rpm 24 6 kgf cm2 200 min 1 rpm 350 psi 200 min 1 rpm Variance Among Cylinders 10 or less Valve Seat Angle Intake Angle Exhaust Width Intake Width Exhaust...

Page 129: ...004 in 0 1 mm 0 004 in Valve Clearance Cold 0 23 to 0 27 mm 0 0091 to 0 010 in Intake Valve Timing Open Close 0 24 rad 14 before T D C 0 63 rad 36 after B D C Exhaust Valve Timing Open Close 0 79 rad...

Page 130: ...m 0 3553 to 0 3555 in 0 15 mm 0 0059 in Push Rod Alignment 0 25 mm 0 0098 in Tappet to Tappet Guide Tappet Guide Bore Tappet Clearance I D O D 0 020 to 0 062 mm 0 00079 to 0 0024 in 24 000 to 24 021 m...

Page 131: ...Gear 1 2 Shaft Oil Clearance I D O D 0 050 to 0 091 mm 0 0020 to 0 0035 in 45 025 to 45 050 mm 1 7727 to 1 7736 in 44 959 to 44 975 mm 1 7701 to 1 7706 in 0 10 mm 0 0039 in Idle Gear Side Clearance 0...

Page 132: ...1815 in 30 031 to 30 046 mm 1 1824 to 1 1829 in 0 15 mm 0 0059 in Crankshaft Side Clearance Alignment 0 15 to 0 31 mm 0 0059 to 0 012 in 0 50 mm 0 020 in 0 02 mm 0 0008 in Crankshaft Journal to Cranks...

Page 133: ...mm 0 01 in Outer Rotor to Pump Body Clearance 0 100 to 0 184 mm 0 00394 to 0 00724 in 0 3 mm 0 01 in Inner Rotor to Cover Clearance 0 025 to 0 075 mm 0 00099 to 0 0029 in 0 225 mm 0 00886 in Relief Va...

Page 134: ...to 20 Oil cooler pipe nut 49 to 68 5 0 to 7 0 37 to 50 Oil cooler hose retaining nut 46 to 52 4 6 to 5 4 34 to 39 Front axle support mounting screw M14 UBS 167 to 196 17 0 to 20 0 123 to 144 Delivery...

Page 135: ...4 5 29 to 32 Oil pump cover screw 7 9 to 9 3 0 80 to 0 95 5 8 to 6 8 Starter s terminal B mounting nut 9 8 to 11 1 0 to 1 2 7 3 to 8 6 Intake air heater terminal nut 3 5 to 5 3 0 35 to 0 55 2 6 to 3...

Page 136: ...ged battery for performing this test Variances in cylinder compression values should be under 10 W1048776 Compression Factory spec 3 09 to 3 29 MPa 200 min 1 rpm 31 5 to 33 5 kgf cm2 200 min 1 rpm 449...

Page 137: ...ickness gauge between the rocker arm and the bridge head Set the adjusting screw to the specified value then tighten the lock nut NOTE After adjusting tighten the lock nut 4 securely W1047000 Valve cl...

Page 138: ...ine oil pressure switch to the specified torque W10349520 3 Cooling System Fan Belt Tension 1 Measure the deflection A depressing the belt halfway between the fan drive pulley and alternator pulley at...

Page 139: ...iator tester on the radiator cap 2 Set a radiator tester Apply the specified pressure of 80 kPa 0 9 kgf cm2 10 psi 3 Check if the pressure drops to less than 60 kPa 0 6 kgf cm2 9 psi in 10 seconds 4 I...

Page 140: ...eck the exhaust port 3 and inlet port 5 side of turbine housing 1 to see if there is no exhaust gas leak 2 If any gas leak is found retighten the bolts and nuts or replace the gasket 2 4 6 with new on...

Page 141: ...W1030568 Draining Engine Oil 1 Start and warm up the engine for approx 5 minutes 2 Place an oil pan underneath the engine 3 Remove the drain plugs 1 to drain oil 4 After draining screw in the drain pl...

Page 142: ...e bonnet 4 Remove the bonnet 2 and muffler 1 5 Remove the side cover LH and RH IMPORTANT When disconnecting the battery cables disconnect the grounding cable first When connecting positive cable first...

Page 143: ...ve the oil cooler pipe 2 and hose 3 3 Disconnect the radiator hose 5 4 Disconnect the fuel hoses 4 When reassembling W1012041 Tightening torque Starter s terminal B mounting nut 9 8 to 11 N m 1 0 to 1...

Page 144: ...t Tap in the spring pins 2 as shown in figure W1032390 Differential Lock Spring 1 Loosen the lock nut 1 and disconnect spring 2 from differential lock lever 3 When reassembling Be sure to fix the fron...

Page 145: ...ve the hose clamps 7 18 10 Remove the compressor bracket mounting screws 11 Remove the compressor 4 and condenser 2 with hoses When reassembling Take care not to damage the air condenser fin After rea...

Page 146: ...position W1013854 Joint Shaft Hose Brake Oil Tank and Connector 1 Disconnect the power steering delivery hose 3 2 Remove the joint shaft 2 and power steering controller 4 3 Disconnect the connectors...

Page 147: ...h disc boss Apply liquid gasket Three Bond 1141 1211 or equivalent to joint face of the engine and clutch housing W1035075 Tightening torque Engine and clutch housing mounting screw nut standard type...

Page 148: ...not to touch the turbocharger NOTE When detaching and attaching the turbocharger assembly be very careful not to allow dust dirt and other foreign matter in the oil pipes When the turbocharger assembl...

Page 149: ...ipe 1 2 Remove the EGR cooler 2 When reassembling Replace the gaskets with new ones W1052198 EGR Valve 1 Remove the EGR valve 1 NOTE Do not overhaul the EGR valve When reassembling Replace the gaskets...

Page 150: ...ark is very useful to align the timing between the supply pump gear and idle gear 2 when reassembling 3 Fix the flywheel 4 Remove the supply pump gear mounting nut 5 5 Remove the supply pump gear 4 wi...

Page 151: ...new supply pump with connecting K consultant Refer to Diagnosis Manual W1055931 Tightening torque Supply pump mounting nut 24 to 27 N m 2 4 to 2 8 kgf m 18 to 20 lbf ft Supply pump gear mounting nut...

Page 152: ...t Temperature Sensor 1 Remove the coolant temperature sensor When reassembling Replace the gasket with new one W1089291 Camshaft Position Sensor 1 Remove the camshaft position sensor mounting screw 2...

Page 153: ...ake air pressure hose is damage replace the hose with new one W1090756 Coupler of Injector Harness 1 Remove the screw 1 2 Draw out the coupler of injector harness 2 from the cylinder head cover 2 3 3...

Page 154: ...ensor 1 When reassembling Replace the O ring with new one IMPORTANT Do not reuse the crankshaft position sensor if you drop the sensor W1092411 Tightening torque Crankshaft position sensor mounting sc...

Page 155: ...mps 9 8 Remove the injectors 10 and the injector s gaskets IMPORTANT Do not disassemble the injector 10 Do not damage the injector s QR code tag 6 Do not lose the steel ball s on the rocker arm bracke...

Page 156: ...2 3 gasket with new one NOTE If you replace the injector s with new one s you must rewrite new injector s QR code s 11 to ECU Please see the diagnosis manual Common Rail System Engine W1061254 Tighte...

Page 157: ...IMPORTANT After reassembling the rocker arm be sure to adjust the valve clearance W1050212 Injector Oil Seal if necessary 1 Remove the injector oil seal 2 from cylinder head cover 1 1 When reassemblin...

Page 158: ...dust Take care for handling the gasket not to damage it Install the cylinder head Tighten the cylinder head screw gradually in the order of 1 to 18 after applying engine oil Be sure to adjust the valv...

Page 159: ...downward at the head side Wash the valve stem and valve guide hole and apply engine oil sufficiently After installing the valve spring collets lightly tap the stem to assure proper fit with a plastic...

Page 160: ...he gasket 2 Attach the thermostat with its hole facing toward the air suction side W1072747 7 Injection Pump Unit Fan Drive Pulley 1 Set the stopper to the flywheel 2 Remove the crankshaft screw 2 3 D...

Page 161: ...ing the O ring and not to let it out of position W1187742 Oil Cooler 1 Remove the water pipe 1 2 Remove the oil filter cartridge 2 and the oil cooler joint screw 3 3 Remove the oil cooler 4 W1032266 1...

Page 162: ...ing 3 and the packing 4 W1081251 Idle Gear 1 and Idle Gear 2 1 Remove the idle gear mounting screw 1 2 Draw out the idle gear 2 and 3 When reassembling When install the idle gear 2 and 3 be sure to pl...

Page 163: ...sure to place the 4th cylinder piston at the top dead center in compression then align all mating marks on each gear to assemble the timing gears set the idle gear last W1191037 Tightening torque Cam...

Page 164: ...d gasket Three Bond 1217D to the oil pan as shown in the figure Confirm that the liquid gasket coating surface is free of water dust and oil in order to maintain sealing effect Carefully apply the adh...

Page 165: ...cylinder apply enough engine oil to the cylinder When inserting the piston into the cylinder face the mark 3 on the connecting rod to the injection pump IMPORTANT Do not change the combination of cyl...

Page 166: ...pin to the piston Assemble the piston to the connecting rod with the mark 5 and the connecting rod numbering mark 9 facing same side The end faces of the oil ring are plated with hard chrome In putti...

Page 167: ...he flywheel and the crankshaft fit together in just one position Make sure they are securely fit and tighten the screws Replace the O ring of crankshaft position sensor with new one Set the crankshaft...

Page 168: ...oint with turning flywheel counterclockwise 7 Stop to turn the flywheel at the valve stem s highest point 8 Draw straight lines 9 on the flywheel housing 7 and the flywheel with square ruler 6 IMPORTA...

Page 169: ...t line on the flywheel 18 Measure the distance between crankshaft mechanical top dead center 16 and crankshaft position sensor s electrical top dead center 17 19 Calculate the actual gap of angles Dis...

Page 170: ...964 Crankcase 2 1 Remove the crankcase 2 1 When reassembling IMPORTANT Make sure the crankcase 1 and 2 are clean Apply liquid gasket Three Bond 1217D to the crankcase 2 as shown in the figure Tighten...

Page 171: ...ue This helps to minimize the level difference between the crankcase 1 and the crankcase 2 at the flywheel side Possible gap must be 0 05 mm 0 002 in or smaller W1111351 Tightening torque Crankcase 2...

Page 172: ...on the main bearing case facing towards the flywheel side Reassemble the thrust bearing 2 with the oil groove facing outside into both side of the fourth main bearing case 1 Apply oil to the bearing c...

Page 173: ...measure squeezed fuse wires for thickness 6 If the measurement is not within the specified value check the oil clearance of the crankpin journal and the piston pin W1049122 Cylinder Head Surface Flatn...

Page 174: ...g the valve replace the cylinder head W1061543 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 valve flapp...

Page 175: ...apply engine oil to it 2 Using a valve guide replacing tool press in a new valve guide until it is flush with the cylinder head as shown in the figure 3 Ream precisely the I D of the valve guide to t...

Page 176: ...ust valve seat so that the width is close to specified valve seat width 3 After resurfacing the seat inspect for even valve seating apply a thin film of compound between the valve face and valve seat...

Page 177: ...de micrometer and then calculate the oil clearance 3 If the clearance exceeds the allowable limit replace the rocker arm and measure the oil clearance again If it still exceeds the allowable limit rep...

Page 178: ...pet guide 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 W1063847 Push rod alignment Allowabl...

Page 179: ...klash between crank gear and idle gear 1 Factory spec 0 0490 to 0 193 mm 0 00193 to 0 00759 in Allowable limit 0 22 mm 0 0087 in Backlash between idle gear 1 and cam gear Factory spec 0 0490 to 0 189...

Page 180: ...ournal 1 Measure the camshaft journal O D with an outside micrometer 2 Measure the cylinder block bore I D for camshaft with an inside micrometer 3 If the clearance exceeds the allowable limit replace...

Page 181: ...e balancer shaft to the front and rear 3 If the measurement exceeds the allowable limit replace the balancer shaft W1065273 Balance Shaft Alignment 1 Support the balancer shaft with V blocks on the su...

Page 182: ...with a cylinder gauge Calculate the oil clearance 3 If the clearance exceeds the allowable limit replace the connecting rod If it still exceeds the allowable limit replace the piston pin W1065897 Oil...

Page 183: ...exceeds the allowable limit replace the piston ring W1066430 Clearance between Piston Ring and Groove 1 Remove carbon from the ring grooves 2 Measure the clearance between the ring and the groove with...

Page 184: ...ith its tip on the intermediate journal at right angle 2 Rotate the crankshaft on the V block and get the misalignment half of the measurement 3 If the misalignment exceeds the allowable limit replace...

Page 185: ...size dimensions of crankpin W1067389 Crankpin O D Factory spec 52 977 to 52 990 mm 2 0857 to 2 0862 in Oil clearance between crankpin and crankpin bearing Factory spec 0 018 to 0 051 mm 0 00071 to 0 0...

Page 186: ...crankshaft as shown in figure 4 Press fit the sleeve using the auxiliary socket for pushing 4 NOTE Mount the sleeve with its largely chamfered surface facing outward W1069911 Crankshaft journal O D F...

Page 187: ...TE When the oversize cylinder is worn beyond the allowable limit replace the cylinder block with a new one W10344480 6 Oil Pump Rotor Lobe Clearance 1 Measure the clearance between lobes of the inner...

Page 188: ...specified torque 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 allowable limit replace oil pump rotor assem...

Page 189: ...2 CLUTCH KiSC issued 06 2007 A...

Page 190: ...CONTENTS MECHANISM 1 TRAVELING CLUTCH 2 M1 1 STRUCTURE 2 M1 2 OIL FLOW 2 M2 2 PTO CLUTCH 2 M3 1 STRUCTURE 2 M3 2 OPERATION 2 M4 KiSC issued 06 2007 A...

Page 191: ...utch When the clutch pedal 1 is depressed the clutch spool of shuttle valve 3 moves via the clutch cable 2 As for the oil it does not flow to both the forward side 6 and reverse side 5 of the clutch p...

Page 192: ...forward or reverse clutch 5 6 During the oil is feeding in the clutch pack depress the clutch pedal 4 The feeding oil returns to the tank through the spool 7 and the clutch becomes at Disengage condi...

Page 193: ...h valve 3 is set at Engaged position Then the oil flows to clutch pack 4 through the clutch valve 3 and the clutch pack 4 is engaged and the PTO drive shaft 5 and PTO shaft 6 rotate When the shift lev...

Page 194: ...O clutch support 1 When PTO clutch shift lever is set at the Engaged position oil flows through the rotary valve into the accumulator and the clutch pack The accumulating action absorbs shock accordin...

Page 195: ...ERVICING 2 S4 1 CHECKING AND ADJUSTING 2 S4 1 Traveling Clutch 2 S4 2 PTO Clutch 2 S6 2 DISASSEMBLING AND ASSEMBLING 2 S8 1 Removing Damper Disc 2 S8 2 Removing Shuttle Clutch Valve 2 S14 3 Removing P...

Page 196: ...eplace 2 S14 Tractor Does Not Keep in Neutral Shuttle linkage defective or deformed Adjust or replace 3 S6 PTO Clutch Slip Operating pressure is low Adjust 2 S7 PTO clutch valve malfunctioning Repair...

Page 197: ...55 mm 0 0610 in Brake Ring Thickness 4 40 to 4 60 mm 0 174 to 0 181 in 4 2 mm 0 17 in Return Plate Thickness 2 92 to 3 05 mm 0 115 to 0 120 in 2 5 mm 0 098 in Driven Plate Flatness 1 54 to 1 56 mm 0...

Page 198: ...w 48 to 55 4 9 to 5 7 36 to 41 HI LO pipe retaining nut 30 to 39 3 0 to 4 0 22 to 28 Delivery pipe retaining nut 49 to 68 5 0 to 7 0 37 to 50 Shuttle valve mounting screw 24 to 27 2 4 to 2 8 18 to 20...

Page 199: ...end of cable as shown in figure 3 Measure the clutch pedal stroke A 4 If the measurement is not within the factory specifications adjust with stopper bolt 3 NOTE Be sure to fix the coil spring 4 in or...

Page 200: ...e pedal stroke 1 Measure the clutch pedal free travel 2 If adjustment is needed loosen the lock nuts 1 and adjust the cable length within acceptable limits 3 Retighten the lock nut 1 W1012725 Proper c...

Page 201: ...o not connect the universal joint of the implement to the tractor PTO shaft while testing NOTE The clutch control cable 2 is fixed at center of the screw with lock nut 3 at PTO clutch lever side Insta...

Page 202: ...IMPORTANT Do not connect the universal joint of the implement to the tractor PTO shaft while testing NOTE The supply oil to a shuttle clutch a PTO clutch and a swing shift has distributed the oil fro...

Page 203: ...ined reinstall the radiator drain plug W1012714 Muffler and Bonnet 1 Open the bonnet 2 and disconnect the battery 3 negative terminal and head light 4P connector 7 2 Remove the bonnet dampers 4 and cl...

Page 204: ...eller shaft cover 3 after removing the screw 5 2 Tap out the spring pins 2 and then slide the coupling 1 to the rear When reassembling Apply grease to the splines of the propeller shaft 6 and pinion s...

Page 205: ...k nut 1 and disconnect spring 2 from differential lock lever 3 When reassembling Be sure to fix the front edge of differential lock cable at the center of thread W1013256 1 Lock Nut 2 Spring 3 Differe...

Page 206: ...ve the hose clamps 7 18 10 Remove the compressor bracket mounting screws 11 Remove the compressor 4 and condenser 2 with hoses When reassembling Take care not to damage the air condenser fin After rea...

Page 207: ...pe and Connectors 1 Disconnect the connector 1 2 Disconnect the heater hoses 3 and fuel hose 4 3 Remove the throttle cable 2 4 Disconnect the connectors 5 W1014081 Tightening torque Power steering tur...

Page 208: ...denum disulphide Three Bond 1901 or equivalent to the splines of damper disc boss Apply liquid gasket Three Bond 1141 1211 or equivalent to joint face of the engine and clutch housing W1015695 Tighten...

Page 209: ...huttle Clutch Valve Shuttle Clutch Valve 1 Remove the floor mat 1 and inspection plate 2 2 Remove the shuttle valve 3 When reassembling W1016768 Tightening torque Damper disc mounting screw 48 to 55 N...

Page 210: ...d 1206C or equivalent to joint face of transmission case and valve assembly Replace the oil pipes 10 with new ones Be sure to check the PTO clutch lever movement Refer to 1 CHECKING AND ADJUSTING in t...

Page 211: ...embling Hook the return spring 12 of the rotary valve to the spring stopper screw 10 Apply transmission fluid to PTO rotary valve 11 and bearings Apply liquid gasket Three Bond 1206C or equivalent to...

Page 212: ...1011383 Draining Fuel 1 Place oil pans under the right side fuel tank 2 Remove the drain cover 2 at the bottom of side fuel tank 1 3 Drain the fuel 4 Reinstall the drain cover 2 on the fuel tank 1 Whe...

Page 213: ...pipes with new ones and apply oil to them Apply liquid gasket Three Bond 1206C or equivalent to joint face of pump base and transmission case W1021905 Tightening torque Tank stay mounting screw 197 t...

Page 214: ...the hydraulic cylinder gasket to new one W1022741 Rear Axle Case and Parking Brake Case 1 Remove the rear axle case mounting screws and nuts 2 Support the rear axle case with nylon lift strap and hois...

Page 215: ...fluid to the seal rings When reassembling the PTO clutch assembly 5 direct the projection part of brake ring 6 to left side in view of the back Confirm the moving of the piston smoothly when pressure...

Page 216: ...the thickness is less than the allowable limit replace it W1030468 Displacement around disc edge Allowable limit 2 0 mm 0 079 in Thickness of clutch disc Factory spec 1 70 to 1 90 mm 0 0670 to 0 0750...

Page 217: ...ess it to 23 1 mm 0 909 in 2 Read the compression load on the gauge 3 If the measurement is less than the allowable limit replace it W1031235 Flatness of PTO piston Allowable limit 0 15 mm 0 0059 in F...

Page 218: ...3 TRANSMISSION KiSC issued 06 2007 A...

Page 219: ...ECHANISM 3 M15 1 SELECTING THE TRAVELING SPEED 3 M15 2 MAIN GEAR SHIFT LEVER 3 M16 3 SWING SHIFT 3 M18 4 DUAL SPEED 3 M21 4 DUAL SPEED VALVE 3 M22 5 POWER TRAIN FOR TRAVELING GEAR 3 M23 1 MAIN GEAR SH...

Page 220: ...URE 1 Shuttle Shift Section 2 Main Gear Shift Section 3 Swing Shift Hi Lo Section 4 Dual Speed Section Hi Lo 5 PTO Clutch Section 6 PTO Gear Section 7 Range Gear Shift Section 8 4WD Clutch Section 1 8...

Page 221: ...gear 6 Reverse Shift Input shaft 3 clutch body 11 reverse clutch pack 4 27T gear 10 26T gear 9 24T gear 8 26T gear shaft 7 29T gear 6 W1015037 1 Flywheel 2 Damper Disc 3 Input Shaft 4 Reverse Clutch...

Page 222: ...th pressure feeding to the power steering system The regulator valve setting pressure is 2 69 to 2 79 MPa 27 4 to 28 5 kgf cm2 390 to 405 psi 3 Pressure reducing valve 2 This valve controls the operat...

Page 223: ...nching Valve Spool 8 Modulating Valve a Clutch Pedal Released Position b Clutch Pedal Depressed Position c Shuttle Forward Position d Shuttle Neutral Position e Shuttle Reverse Position f Oil from Reg...

Page 224: ...3 M5 M108S WSM TRANSMISSION 2 Operation Shuttle Lever at Neutral Position KiSC issued 06 2007 A...

Page 225: ...lve 2 Proportionally Reducing Valve 3 Shuttle Shift Spool Forward Reverse 4 Accumulate Valve 5 Shuttle Valve 6 Inching Valve 7 Shuttle Lever 8 Clutch Pedal A Check Port Modulation B Check Port Reverse...

Page 226: ...3 M7 M108S WSM TRANSMISSION When Shuttle Lever is Shifting Neutral to Reverse or Forward Position Clutch Pedal is Released KiSC issued 06 2007 A...

Page 227: ...n of modulating valve 1 to reduce a shock 1 Modulating Valve 2 Proportionally Reducing Valve 3 Shuttle Shift Spool Forward Reverse 4 Accumulate Valve 5 Shuttle Valve 6 Inching Valve 7 Shuttle Lever 8...

Page 228: ...3 M9 M108S WSM TRANSMISSION Shuttle Lever at Reverse Position Clutch Pedal is Released KiSC issued 06 2007 A...

Page 229: ...t spool 3 1 Modulating Valve 2 Proportionally Reducing Valve 3 Shuttle Shift Spool Forward Reverse 4 Accumulate Valve 5 Shuttle Valve 6 Inching Valve 7 Shuttle Lever 8 Clutch Pedal A Check Port Modula...

Page 230: ...3 M11 M108S WSM TRANSMISSION Shuttle Lever at Forward Position Clutch Pedal is Released KiSC issued 06 2007 A...

Page 231: ...t spool 3 1 Modulating Valve 2 Proportionally Reducing Valve 3 Shuttle Shift Spool Forward Reverse 4 Accumulate Valve 5 Shuttle Valve 6 Inching Valve 7 Shuttle Lever 8 Clutch Pedal A Check Port Modula...

Page 232: ...3 M13 M108S WSM TRANSMISSION When Clutch Pedal is Depressed with Shuttle Lever at Reverse or Forward Position KiSC issued 06 2007 A...

Page 233: ...ime as the hole e and passage f are connected oil passage among the hole g hole e and T2 port are connected As a result even when the proportionally reducing valve 2 does not move the oil passage from...

Page 234: ...own in the table below are obtained 1 Hydraulic Shuttle Shift Lever 2 Main Gear Shaft Lever 3 Range Gear Shift Lever 4 Pilot Lamp LOW 5 Pilot Lamp HIGH 6 Dual Speed Shift Switch 7 Creep Lever If Equip...

Page 235: ...e 1st 2nd shift fork or 3rd 4th shift fork 4 When the main gear shift lever 1 is moved to the left 3rd 4th speed range side on the NEUTRAL position the select lever 7 is pulled by select cable 3 and w...

Page 236: ...rod at the same time As a result double engagement of the gear is prevented 2 Detent ball prevents the self disengagement of the gears 1 3rd 4th Shift Fork Rod 2 1st 2nd Shift Fork Rod 3 Shaft 4 3rd 4...

Page 237: ...red with both the lamps 2 3 off 5 When moving the main gear shift lever 4 against the left side at Neutral the swing shift switch 6 is turned each time between rabbit HI and turtle LO Battery current...

Page 238: ...Swing Shift Switch 2 LO Solenoid Valve 3 HI Solenoid Valve 4 LO Motion Switch 5 HI Motion Switch 6 Buzzer Relay 7 Buzzer A To Meter Panel 10A Fuse B To OPC Unit C To Meter Panel Swing Shift HI D To M...

Page 239: ...the right or left by switching the solenoid valve 2 3 and flowing oil into A chamber 4 or B chamber 5 3 The HI or LO speed is charged by the shift fork 6 with the shift fork rod 1 W1014355 1 Shift Fo...

Page 240: ...ift switch 1 can be operated when the tractor is travelling without using the clutch Tractor travel speed change by about 17 LO speed and HI speed change at each time by the switch is pushed Dual Spee...

Page 241: ...ed clutch with DS spool 3 By energizing the solenoid valve 7 the oil flows to the 4WD clutch and the 4WD clutch is engaged W1017062 1 Valve Body 2 Line Filter 3 DS Spool 4 Pilot Valve HI 5 Pilot Valve...

Page 242: ...nd Position Main shaft 1 hub 10 shifter 3 22T gear 3 30T gear 11 counter shaft 7 3rd Position Main shaft 1 hub 13 shifter 8 28T gear 4 31T gear 12 counter shaft 7 4th Position Main shaft 1 hub 13 shif...

Page 243: ...utch 2 Clutch Body 3 Range Shift Gear Shaft 6 W1017027 3 RANGE GEAR SHIFT SECTION Besides neutral two ways of power flow from range shift gear shaft 1 to spiral bevel pinion shaft 4 are available by o...

Page 244: ...ft center in the clutch housing Power is transmitted as follows Spiral bevel pinion shaft 2 32T gear 1 30T gear 3 Transmitting shaft rear 4 Transmitting shaft center 5 4WD clutch 6 Transmitting shaft...

Page 245: ...ts own clutch controls completely separated from the travelling clutch and transmission Therefore the PTO can operate while the tractor is stopped and also the PTO can be disengaged and engaged while...

Page 246: ...H BLOCK CLUTCH HOUSING CASE AND TRANSMISSION CASE 3 S14 2 DISASSEMBLING SHUTTLE CASE 3 S19 3 DISASSEMBLING SPEED CHANGE COVER 3 S21 4 DISASSEMBLING CLUTCH HOUSING 3 S24 5 DISASSEMBLING MID CASE 3 S28...

Page 247: ...damaged Repair or replace 3 S38 Shuttle clutch lever linkage cable improperly adjusted Adjust 3 S6 Main gear shift lever linkage improperly adjusted Adjust 3 S9 Range gear shift linkage improperly ad...

Page 248: ...erential lock shift fork damage Replace 3 S33 Differential lock shift fork mounting spring pin damaged Replace 3 S33 Movement of differential lock shifter improperly adjusted Adjust 3 S48 Differential...

Page 249: ...s 2 30 to 2 40 mm 0 0906 to 0 0944 in Shuttle Clutch Piston Thickness 10 9 to 11 1 mm 0 430 to 0 437 in Main Shaft Thrust Bearing to Bearing Washer Side Clearance 0 1 to 0 3 mm 0 004 to 0 01 in Counte...

Page 250: ...mm 0 016 in Differential Case Bore Differential Case Cover Bore to Differential Side Gear Boss Clearance 0 0700 to 0 169 mm 0 00276 to 0 00665 in 0 35 mm 0 014 in Differential Case Bore I D 49 070 to...

Page 251: ...raulic cylinder assembly mounting screw and nut 78 to 90 7 9 to 9 2 58 to 66 Rear axle case mounting screw 118 to 147 12 0 to 15 0 86 8 to 108 Rear cover PTO cover mounting screw 78 to 90 7 9 to 9 2 5...

Page 252: ...e lever 1 and slowly move it to the F and R directions until you feel the lever clicking at the ball detents 3 The shuttle lever guide 3 also has the f n and r grooves for the shuttle lever 4 In this...

Page 253: ...and slowly lower the shuttle lever 1 as shown in the figure And visually inspect the clearance Y 9 Make sure the two clearance X and Y are just the same with shuttle cable retaining nut 5 NOTE The fi...

Page 254: ...Check the engine start condition as follows NOTE Do not touch the shuttle lever 1 when the shuttle lever 1 is at specified position as shown in figure Reference Position A Engine start Position B Engi...

Page 255: ...ck the length of main shift rod 1 1 main shift rod 2 2 and the installation of the select cable 3 Length of rod Check and adjust points of the select cable 3 A Tighten until the bottoms up thread 7 B...

Page 256: ...n of the range gear shift Hi and Lo position 2 If feeling abnormal shifting check the length of range gear shift rod 2 W1016929 Length of range gear shift rod L Initial adjustment 275 mm 10 8 in 1 Ran...

Page 257: ...PECIAL TOOLS at G GENERAL section to inspect the port F and R Pressure gauge is 4 9 MPa 50 kgf cm2 710 psi full scale Apply Three Bond 1324N or equivalent to the plugs F R and M when install them The...

Page 258: ...e assembly 1 to adjust IMPORTANT Do not steer the steering wheel while checking the charge relief valve setting pressure Condition Engine speed Maximum Oil temperature 45 to 55 C 113 to 131 F Referenc...

Page 259: ...d Maximum Oil temperature 45 to 55 C 113 to 131 F Reference Turn the screw 2 to clockwise direction Pressure increase Turn the screw 2 to counterclockwise direction Pressure decrease NOTE The supply o...

Page 260: ...ed different brands fluid together W1011383 Draining Fuel 1 Place oil pans under the right side fuel tank 2 Remove the drain cover 2 at the bottom of side fuel tank 1 3 Drain the fuel 4 Reinstall the...

Page 261: ...haft Tap in the spring pins 2 as shown in figure W1018710 Differential Lock Spring 1 Loosen the lock nut 1 and disconnect spring 2 from differential lock lever 3 When reassembling Be sure to fix the f...

Page 262: ...ngine from the clutch housing When reassembling Apply molybdenum disulphide Three Bond 1901 or equivalent to the splines of damper disc boss Apply liquid gasket Three Bond 1141 1211 or equivalent to j...

Page 263: ...ase mounting screws and nuts 7 Separate the transmission case from the mid case 8 When reassembling Apply liquid gasket Three Bond 1206C or equivalent to joint face of transmission case and mid case W...

Page 264: ...lon lift strap and hoist 2 Separate the rear axle case 1 from brake case 2 3 Remove the brake case 2 4 Remove the rear cover 3 When reassembling Replace the O ring with new one Apply liquid gasket Thr...

Page 265: ...8 2 Top out the input shaft 2 with shuttle clutch and 26T gear shaft 3 together When reassembling Replace the seal rings 5 oil seal 6 sleeve 7 external snap rings 8 with new ones Be sure to install sl...

Page 266: ...fluid to the clutch discs 5 Do not confuse the two types of drive plates The drive plate with plug rubbers 16 and without plug rubbers Three drive plates match the position of plug rubber from the pi...

Page 267: ...e shift valve connector 7 2 Remove the shift valve mounting screws 8 3 Remove the plate 5 and spring disc 6 4 Remove the Hi shift valve 1 and Lo shift valve 2 When reassembling The shift valve with a...

Page 268: ...sing M6 x Pitch 1 screw into the thread 10 NOTE Pay attention so as not to lose the detent ball 7 and spring 8 When reassembling Apply grease to the detent ball 7 Apply transmission fluid to the seal...

Page 269: ...r removing oil seal 1 then remove the select arm 3 2 Remove the positioning screw 4 and ball 5 3 Remove the oil seal 6 and internal snap ring 7 4 Remove the shaft 8 and cam 9 NOTE Pay attention so as...

Page 270: ...hrust collar Apply transmission fluid to the bearing Be sure to change the external snap ring Be sure to check the main shaft rotation smoothly after assembling the support After assembling support be...

Page 271: ...id to the external snap ring Be sure to change the external snap ring with new one Be sure to check the counter shaft rotation smoothly after assembling the support After assembling support be sure to...

Page 272: ...pply transmission fluid to the thrust collars and needle bearings Apply transmission fluid to the inner periphery of the support 18 Take care not to damage the seal rings 17 when installing the suppor...

Page 273: ...ion tool 4 Take out the piston 9 5 Remove the parts for other side as above When reassembling When installing the internal snap ring 1 to the clutch body 13 align its split portion to the notched port...

Page 274: ...49 to 0 98 MPa 5 0 to 10 kgf cm2 72 to 140 psi is sent to clutch pack from oil supply port on mid case side W1029698 Bearing Support 1 Remove the external snap ring 1 2 Remove the feather key 2 and ta...

Page 275: ...ap ring 7 5 Take out the piston 9 D ring 10 and square ring 11 by compression air 6 Remove the parts for other side as above When reassembling Apply transmission fluid to D ring 10 and square ring 11...

Page 276: ...gear shaft 3 W1033034 Disassembling Creep Gear Optional 1 Remove the plug 1 and tap out the spring pin 2 2 Remove the internal snap ring 3 3 Tap out the gear shaft 4 4 Draw out the shift rod 7 5 Remov...

Page 277: ...side 5 Pull out the gear shaft 7 as a unit When reassembling Replace the PTO shaft staking nut 4 with new one and stake it firmly after tightening Apply grease to the oil seal 8 W1034001 Tightening t...

Page 278: ...quivalent to joint face of transmission case and HI LO shift case Apply grease to the ball Align the alignment mark 8 of the range shift shaft 5 and range shift cam 1 When installing the range shift s...

Page 279: ...oving of the piston smoothly when pressure air at 0 30 to 0 39 MPa 3 0 to 4 0 kgf cm2 43 to 56 psi is sent to clutch pack W1036548 Differential Lock Fork 1 Remove the clevis pin 3 and plug 6 2 Draw ou...

Page 280: ...this section W1037396 Spiral Bevel Gear 1 Remove the spiral bevel gear 1 When reassembling Check the spiral bevel gear for wear or damage If it is no longer serviceable replace it Then also replace th...

Page 281: ...excessively worn replace their parts they are in mesh with or they sliding on Apply molybdenum disulfide Three Bond 1901 or equivalent to the inner circumferential surface of the differential pinions...

Page 282: ...turning torque of spiral bevel pinion shaft only Refer to 6 SERVICING in this section There staking groove 4 and lubrication groove 5 on the pinion shaft 3 be sure to stake the nut on right side groo...

Page 283: ...t When reassembling Apply liquid gasket Three Bond 1206C or equivalent to joint face of transmission case and parking brake case W1040231 Tightening torque Parking brake case mounting screw 78 to 90 N...

Page 284: ...em W1041518 Checking Contact between Coupling and Shifter 1 Check to see if there is flaw or wear on the spline of the coupling and shifter and the key groove on the coupling 2 Engage the shifter with...

Page 285: ...clearance NOTE Clearance between internal snap ring and pressure plate is adjusted by two kinds of clutch discs with different thickness Therefore use the one of the same thickness when you change clu...

Page 286: ...nce on Counter Shaft 1 Measure the side clearance between 33T gear 1 and collar 2 2 If the measurement is not within the factory specifications adjust the clearance with shim on the front end of count...

Page 287: ...clearance NOTE Clearance between internal snap ring and pressure plate is adjusted by two kinds of steel plates with different thickness Therefore use the one of the same thickness when you change st...

Page 288: ...e limit replace it W1031318 Clearance between internal snap ring and pressure plate Factory spec 1 5 to 2 0 mm 0 059 to 0 079 in Allowable limit 3 5 mm 0 138 in Item Thickness Number Drive plate 1 7 t...

Page 289: ...actory specifications adjust the tightening torque of staking nut 2 When reassembling Reference Thickness of adjusting collar 1 1 0 mm 0 0394 in Code No 33251 32450 1 5 mm 0 0591 in Code No 33251 3246...

Page 290: ...e spiral bevel pinion shaft 5 and then add a shim to the bearing support R 4 if the turning torque exceeds the factory specifications or add a shim to there if the turning torque is less than the fact...

Page 291: ...lly spaced on the spiral bevel gear 6 Turn the spiral bevel pinion shaft while pressing a wooden piece against the periphery on the spiral bevel gear 7 Check the tooth contact If not proper adjust acc...

Page 292: ...rightward Repeat above until the proper tooth contact and backlash are achieved W1049426 Deep or Toe contact Replace the adjusting collar 5 with a thinner one to move the spiral bevel pinion shaft fo...

Page 293: ...mm 0 00276 to 0 00665 in Allowable limit 0 35 mm 0 014 in Differential case bore I D Factory spec 49 070 to 49 150 mm 1 9319 to 1 9350 in Differential side gear boss O D Factory spec 48 961 to 49 000...

Page 294: ...in W1050323 Clearance of Differential Lock Shifter 1 Measure the clearance A between differential lock shifter and differential case when the differential lock pedal does not operate 2 If the measure...

Page 295: ...4 REAR AXLE KiSC issued 06 2007 A...

Page 296: ...CONTENTS MECHANISM 1 STRUCTURE 4 M1 KiSC issued 06 2007 A...

Page 297: ...axle 1 and rear axle case 2 which support the rear wheel load as well as transmitting power to the rear wheel They withstand all the forces caused by tire rotation and side skidding NOTE Refer to 4 RE...

Page 298: ...SPECIFICATIONS 4 S2 3 TIGHTENING TORQUES 4 S3 4 CHECKING DISASSEMBLING AND SERVICING 4 S4 1 DISASSEMBLING AND ASSEMBLING 4 S4 1 Separating Rear Axle Case from Transmission 4 S4 2 Disassembling Rear A...

Page 299: ...ear and planetary gear Replace Improper backlash between planetary gear and internal gear Replace 4 S7 9 Bearings worn Replace 4 S7 9 Insufficient or improper type of transmission fluid used Replace G...

Page 300: ...in Planetary Gear Thrust Collar Thickness 1 55 to 1 65 mm 0 0611 to 0 0649 in 1 2 mm 0 047 in Planetary Gear to Planetary Gear Shaft Clearance 0 0090 to 0 048 mm 0 00036 to 0 0018 in 0 30 mm 0 012 in...

Page 301: ...ounting nut 344 to 402 35 0 to 41 0 254 to 296 Cabin mounting bolt and nut 124 to 147 12 6 to 15 0 91 2 to 108 Rear bracket mounting bolt and nut 197 to 225 20 0 to 23 0 145 to 166 Rear axle case moun...

Page 302: ...t level IMPORTANT Use only KUBOTA SUPER UDT fluid Use of other oil may damage the transmission or hydraulic system Refer to 4 LUBRICANTS FUEL AND COOLANT at G GENERAL section Do not mixed different br...

Page 303: ...lifting rod 3 and lower link 4 with stabilizer 5 When reassembling W1011956 Fuel Tank When removing the brake case LH 1 Remove the hose cover 1 and hose 2 2 Remove the fuel tank band 3 3 Remove the ta...

Page 304: ...When reassembling Apply liquid gasket Three Bond 1206C or equivalent to the seam of brake case and transmission case Apply grease to the O ring W1013184 Tightening torque Cabin mounting bolt and nut...

Page 305: ...transmission fluid to the inner surface of planetary gear 2 and bearing Tap in the spring pin 1 as shown in the figure W1013638 Rear Axle 1 Remove the rear axle cover mounting screw 2 Hammer out the...

Page 306: ...t wrench 98 Code No 07916 52521 When reassembling W1014181 Rear Axle Cover 1 Remove the rear axle cover 2 with a rear axle cover puller 1 Code No 07916 51041 When reassembling Apply grease to the oil...

Page 307: ...sure the O D of the two needles installed diagonally in the needle bearing 4 Calculate the clearance 5 Clearance Planetary gear I D 2 x Needle O D Planetary gear shaft O D 6 If the clearance exceeds t...

Page 308: ...5 BRAKES KiSC issued 06 2007 A...

Page 309: ...CONTENTS MECHANISM 1 TRAVELLING BRAKE 5 M1 2 HYDRAULIC TRAILER BRAKE VALVE 5 M2 1 STRUCTURE 5 M2 2 OPERATION 5 M3 KiSC issued 06 2007 A...

Page 310: ...ure rise in the brake case 6 is perceived to the trailer brake valve 1 through the pilot pipe 7 Then the trailer brake valve 1 feeds pressurized oil to the trailer through the coupler 2 corresponding...

Page 311: ...ief element 3 with pre loaded spring 4 for limiting the trailer braking pressure Control head 6 with piston 7 and bleed valve 5 for operating the trailer brake valve through the tractor brake line W10...

Page 312: ...through restrictor 11 throttle 9 bore 8 control spool 2 and port R Thus the pressure drop at throttle 9 holds the flow control valve 10 in the open flow position a The flow control valve 10 has no re...

Page 313: ...11 bore 12 check valve 13 and port B The restrictor 11 is designed for the constant flow Qk A residual flow Qp Qk bypasses the flow control valve 10 and then passes to the tractor hydraulic through p...

Page 314: ...is thus switched into position a and has no regulating function As in the case of the released trailer brake the delivery flow Qp from the pump passes through port N and flows as Qp Qx to the tractor...

Page 315: ...factor control spool 2 momentarily opens brake line B to the reservoir and avoids further increasing of the braking pressure In all control positions of the trailer brake valve the tractor hydraulics...

Page 316: ...5 S3 4 CHECKING DISASSEMBLING AND SERVICING 5 S4 1 CHECKING AND ADJUSTING 5 S4 2 DISASSEMBLING AND ASSEMBLING 5 S8 1 Removing Brake Pedal 5 S8 2 Removing Master Cylinder and Equalizer 5 S9 3 Removing...

Page 317: ...r equalizer Repair or replace Master cylinder or equalizer malfunctioning Repair or replace 5 S9 S10 Brake Drags Brake pedal free travel too small Adjust 5 S4 Master cylinder return spring weaken or b...

Page 318: ...1 in Brake Disc Thickness 4 15 to 4 35 mm 0 164 to 0 171 in 3 3 mm 0 13 in Plate Thickness 2 25 to 2 35 mm 0 0886 to 0 0925 in 1 5 mm 0 059 in Master Cylinder Return Spring Free Length 78 4 mm 3 09 in...

Page 319: ...12 58 to 86 Rear wheel mounting nut 344 to 402 35 0 to 41 0 254 to 296 Cabin mounting bolt and nut 124 to 147 12 6 to 15 0 91 2 to 108 Rear bracket mounting bolt and nut M16 197 to 225 20 0 to 23 0 14...

Page 320: ...ake Pedal Stroke and Difference between Right and Left Pedal Strokes CAUTION When checking park the tractor on flat ground and stop the engine 1 Disengage the brake pedal lock 2 Step on either side br...

Page 321: ...cautions for Brake Oil Handling Do not mix brake oils of different brands If brake oils of different brands are mixed chemical reaction may occur causing the boiling point to drop remarkably The boili...

Page 322: ...within P x 0 1 MPa P x 0 1 kgf cm2 P x 0 1 psi 5 If the pressure drop is too big attach the pressure gauge to equalizer brake pipe rear end and master cylinder brake pipe front end to find out the pro...

Page 323: ...reassembling W1014373 Adjusting Parking Brake Lever Free Play 1 Release the parking brake lever 2 Pull the parking brake lever with a force of 30 0 kg 66 1 lbs for checking the free play and check th...

Page 324: ...cylinder 4 Remove the circlip 4 and spring pin 5 and draw out the brake pedal shaft 1 then remove the left and right brake pedal 2 3 When reassembling Apply small amount grease to the brake pedal bear...

Page 325: ...atigue and rust If any defect is found replace 1 Open the bonnet 1 and disconnect the battery negative terminal and head light 4P connector 5 2 Remove the bonnet dampers 2 and close the bonnet 1 3 Clo...

Page 326: ...izer in a vise remove the plug 1 to pull out the piston sub assembly When reassembling Install the piston sub assembly and plug noting the O ring Reference W1017215 Master cylinder return spring Free...

Page 327: ...d Use of other oil may damage the transmission or hydraulic system Refer to 4 LUBRICANTS FUEL AND COOLANT at G GENERAL section Do not mixed different brands fluid together W1018368 Draining Fuel When...

Page 328: ...ifting rod 3 and lower link 4 with stabilizer 5 When reassembling W1021392 Fuel Tank When removing the brake case LH 1 Remove the hose cover 1 and hose 2 2 Remove the fuel tank band 3 3 Remove the tan...

Page 329: ...oint 9 When reassembling Install the brake seal 4 5 noting its direction and distortion Take care not to enter the foreign matter into the seal groove inside brake case Install the plates noting its d...

Page 330: ...6 Remove the return spring 5 7 Loosen the rock nut 6 and disconnect the parking brake wire 7 8 Remove the parking brake assembly 4 When reassembling Apply liquid gasket Three Bond 1206C or equivalent...

Page 331: ...ASSEMBLING at 3 TRANSMISSION section W1020830 3 SERVICING Brake Piston Flatness 1 Place the brake piston on flat surface surface plate and determine if a 0 3 mm 0 01 in feeler gauge will fit underneat...

Page 332: ...If the thickness is less than the allowable limit replace it W1021315 Brake disc wear Factory spec 4 15 to 4 35 mm 0 164 to 0 171 in Allowable limit 3 3 mm 0 13 in Brake plate wear Factory spec 2 25...

Page 333: ...6 FRONT AXLE KiSC issued 06 2007 A...

Page 334: ...CONTENTS MECHANISM 1 STRUCTURE 6 M1 1 4 WHEEL DRIVE TYPE 6 M1 KiSC issued 06 2007 A...

Page 335: ...s transmitted to the differential yoke shaft 16 and to the bevel gear shaft 14 in the front axle case 12 The revolution is greatly reduced by the 13T bevel gear 13 and 34T bevel gear 9 and planetary g...

Page 336: ...3 TIGHTENING TORQUES 6 S3 4 CHECKING DISASSEMBLING AND SERVICING 6 S4 1 CHECKING AND ADJUSTING 6 S4 2 DISASSEMBLING AND ASSEMBLING 6 S6 1 Separating Front Axle 4WD Type 6 S6 2 Disassembling Front Axl...

Page 337: ...rew Adjust 6 S5 Tie rod end loose Tighten 6 S10 Air sucked in power steering circuit Bleed Poor tightening torque of king pin pivot adjusting screw Adjust 6 S5 Front Wheels Can Not Be Driven Propeller...

Page 338: ...fferential Pinion Shaft O D 12 966 to 12 984 mm 0 51048 to 0 51118 in Differential Pinion Gear I D 13 032 to 13 050 mm 0 51307 to 0 51377 in Pinion Bearing Case O D 64 970 to 65 000 mm 2 5579 to 2 559...

Page 339: ...o 147 12 6 to 15 0 91 2 to 108 Bracket mounting screw 167 to 196 17 0 to 20 0 123 to 144 Knuckle arm mounting screw 124 to 147 12 6 to 15 0 91 2 to 108 Tie rod end slotted nut 157 to 196 16 0 to 20 0...

Page 340: ...2 to adjust the rod length until the proper toe in measurement is obtained 4 Retighten the tie rod joint lock nut 3 5 Attach the snap ring 1 of the tie rod joint W1018163 Axial Sway of Front Wheel 1 J...

Page 341: ...easure the adjusting screw 1 tightening torque 3 If tightening torque is not within the factory specifications adjust the adjusting screw 1 4 After adjustment tighten the lock nut 2 firmly W1013116 Ti...

Page 342: ...n and filling plug 1 2 at the front differential case and drain the oil completely into the oil pan 2 After draining reinstall the drain plug 1 3 Remove the oil level check plug 3 4 Fill with the new...

Page 343: ...n 4 After filling reinstall the filling plugs 1 W1013799 Propeller Shaft 1 Slide the propeller shaft cover 3 after removing the screw 5 2 Tap out the spring pins 2 and then slide the coupling 1 to the...

Page 344: ...t wheels 4 Remove the cylinder cover 2 5 Disconnect the both power steering hoses 1 When reassembling W1013932 Tightening torque Power steering hose retaining nut 22 to 27 N m 2 2 to 2 8 kgf m 16 to 2...

Page 345: ...ntial lock cable 4 at the center of thread IMPORTANT Be sure to check the front differential lock pedal free play If the pedal free play is not within the factory specifications adjust at pedal side o...

Page 346: ...grease to the O ring Install the bevel gear case to the front differential case noting the O ring W1016047 Tightening torque Tie rod slotted nut 157 to 196 N m 16 0 to 20 0 kgf m 116 to 144 lbf ft Ti...

Page 347: ...s the outward Apply gear oil to the bearing IMPORTANT Be sure to adjust the kingpin pivot Refer to 1 CHECKING AND ADJUSTING in this section W1016334 Front Wheel Case Cover 1 Remove the front wheel cas...

Page 348: ...ing 2 Apply grease to the oil seal Install the oil seal 1 to the front wheel case so that its lips faces the inward Install the internal snap ring 11 as shown in the figure left side so that align the...

Page 349: ...y gear shaft 5 When reassembling Apply gear oil to the needle bearing 4 Tap in the spring pin 6 as shown in the figure left W1018079 Front Axle 1 Tap out the front axle from front wheel case cover Whe...

Page 350: ...quivalent to the front differential case 1 W1018729 Pinion Bearing Case 1 Remove the pinion bearing case mounting screws 2 Remove the pinion bearing case When reassembling Apply liquid gasket Three Bo...

Page 351: ...case if necessary When reassembling Apply grease to the oil seal 3 Apply gear oil to the bearing Be sure to direct the chamfer side of the shim to the pinion bearing case Install the oil seal 3 to th...

Page 352: ...ond 1324B or equivalent to the spiral bevel gear UBS screws W1020208 Tightening torque Spiral bevel gear UBS screw 30 to 34 N m 3 0 to 3 5 kgf m 22 to 25 lbf ft 1 Bearing 2 27T Spiral Bevel Gear 3 Dif...

Page 353: ...both side in the standard Thickness of adjusting shims 6 The 0 4 mm 0 012 in shim is built in the standard Backlash changes per 0 1 mm 0 004 in shim Approx 0 05 mm 0 002 in IMPORTANT Adjust the tooth...

Page 354: ...earance between differential case and differential side gear Factory spec 0 050 to 0 091 mm 0 0020 to 0 0035 in Allowable limit 0 35 mm 0 014 in Differential case bore I D Factory spec 32 025 to 32 05...

Page 355: ...gns of wear or damage The DX bushing tends to show concentrated wear 2 If the DX bushing is worn beyond the alloy portion A replace it W1022243 Front bracket and rear bracket bushing Alloy thickness A...

Page 356: ...of the shaft diameter to the gear diameter 4 If the backlash exceeds the allowable limit adjust with the shims 1 Reference Thickness of adjusting shim 1 The 1 0 mm 0 039 in shim is built in the standa...

Page 357: ...the allowable limit replace them W1023313 Thrust Collar Thickness 1 Measure the thickness of the thrust collar 2 If the measurement is less than the allowable limit replace it W1023552 Backlash betwee...

Page 358: ...ter 4 If the backlash exceeds the allowable limit adjust with the shims 1 Reference Thickness of adjusting shim 1 The 2 0 mm 0 078 in shim is built in the standard W1023691 Backlash Play x 2 Backlash...

Page 359: ...7 STEERING KiSC issued 06 2007 A...

Page 360: ...CONTENTS MECHANISM 1 STRUCTURE 7 M1 1 STEERING MECHANISM 7 M1 KiSC issued 06 2007 A...

Page 361: ...e divided into two types non load reaction type and load reaction type They are distinguished by whether the cylinder port is blocked or not with the controller in neutral In this models load reaction...

Page 362: ...7 S4 1 Hydraulic Pump for Power Steering 7 S4 2 Power Steering Relief Valve 7 S5 2 DISASSEMBLING AND ASSEMBLING 7 S6 1 Hydraulic Pump 7 S6 2 Removing Steering Controller 7 S8 3 Removing Steering Cyli...

Page 363: ...ing Repair or replace 7 S10 to 12 Steering Wheel Turns SpontaneouslyWhen Released Control valve malfunctioning Repair or replace 7 S10 to 12 Front Wheels Wander to Right and Left Control valve malfunc...

Page 364: ...s min 39 1 L min 10 3 U S gals min 8 6 Imp gals min Housing Bore Depth of Scratch 0 090 mm 0 0035 in Bushing to Gear Shaft Clearance 0 15 mm 0 0059 in Relief Valve Setting Pressure at PTO Clutch Valve...

Page 365: ...raulic pump mounting screw 78 to 90 7 9 to 9 2 58 to 66 Housing cover mounting screw 89 to 93 9 0 to 9 5 65 to 68 Gerotor assembly mounting screw 26 to 28 2 6 to 2 9 19 to 20 Guide assembly 98 1 to 11...

Page 366: ...loading valve completely Turn counterclockwise 6 Start the engine and set the engine speed at 2000 to 2200 min 1 rpm 7 Slowly close the loading valve to generate pressure approx 9 81 MPa 100 kgf cm2 1...

Page 367: ...the measurement is not within the factory specifications adjust the relief pressure by the adjusting plug 4 IMPORTANT Air Bleeding Start the engine then turn the steering wheel slowly in both directio...

Page 368: ...C or equivalent to joint face of transmission case and pump base and pump base and hydraulic pump Replace the oil pipes 10 with new ones Apply oil to oil pipes 10 Be sure to check the PTO clutch lever...

Page 369: ...ransmission fluid to the assemble When installing the driven gear 10 be sure to reassembling it to the original position After reassembly check the smooth rotation of the hydraulic pump for example mo...

Page 370: ...ller 4 When reassembling W1012259 1 Maffler Pipe 2 Bonnet Tightening torque Main delivery pipe and return pipe retaining nut 47 to 50 N m 4 8 to 5 2 kgf m 35 to 37 lbf ft Turning delivery hose retaini...

Page 371: ...5 4 Take out the cylinder When reassembling W1013465 Tightening torque Tie rod end slotted nut 157 to 176 N m 16 0 to 18 0 kgf m 116 to 130 lbf ft Tie rod joint lock nut 167 to 196 N m 17 0 to 20 0 kg...

Page 372: ...it on the end cap with the O ring upward 3 Apply clean transmission fluid specified fluid to the rotor 9 fit an O ring 8 into the groove of the rotor and put the spacer on it Keeping the spacer on the...

Page 373: ...needle bearing from valve assembly When reassembling Apply transmission oil to the bearing races and needle bearing 10 Draw out the sleeve 9 and spool 11 assembly from the gerotor side with the port...

Page 374: ...with the sleeve notch W1036839 5 Steering Cylinder Disassembling Steering Cylinder 1 Carefully clamp the cylinder in a vise 2 Remove the guide assembly 1 and draw out the piston rod 4 When reassemblin...

Page 375: ...D with an outside micrometer 2 Measure the bushing I D with an inside micrometer and calculate the clearance 3 If the clearance exceeds the allowable limit replace the gear shaft and the bushing as a...

Page 376: ...8 HYDRAULIC SYSTEM KiSC issued 06 2007 A...

Page 377: ...CONTENTS MECHANISM 1 STRUCTURE 8 M1 2 HYDRUALIC CIRCUIT 8 M3 1 HYDRAULIC CIRCUIT 8 M4 2 CONTROL VALVE 8 M5 3 POSITION CONTROL 8 M7 KiSC issued 06 2007 A...

Page 378: ...is 65 L min 17 2 U S gal min 14 3 Imp gal min Operating pressure is 19 2 MPa 195 kgf cm2 2780 psi 4 Maximum installation of remote valve is four valves 3 valves with a flow control valve 3 To operate...

Page 379: ...w speed range and high speed range of travelling speed 7 To operate dual speed HI LO The dual speed HI LO is controlled by combination of solenoid valve and hydraulic flow Two way of power train are a...

Page 380: ...ic Pump for 3P 10 Hydraulic Pump PTO Clutch Shuttle Clutch Swing Shift Dual Speed 11 Cylinder Safety Valve 12 Relief Valve for 3P 13 Hydraulic Cylinder 14 Regulator Valve 15 Swing Shift 16 Steering Cy...

Page 381: ...s the maximum pressure in the circuit The hydraulic cylinder 8 has a cylinder safety valve 9 to relieve shock pressure due to heavy implement bounce 5 The control valve 5 is actuated by the mechanical...

Page 382: ...the control lever is moved to UP position spool 3 is pulled by the spool operating lever forming a circuit with the P port and chamber A The pressurized oil thus flows into the chamber A and closes un...

Page 383: ...moves to arrow mark direction and pushes the poppet 2 2 If forms a circuit with the C port and T3 port The oil in the hydraulic cylinder is forced out by the weight of the implement and returns to th...

Page 384: ...does not press the spool retainer 1 the spool 5 is forced out by the return spring in the control valve feedback mechanism 4 When the spool 5 returns to the neutral position the lift arms stop rising...

Page 385: ...stem 8 S6 3 Three Point Hitch Control Linkage 8 S7 4 Auxiliary Control Valve Wire 8 S10 2 DISASSEMBLING AND ASSEMBLING 8 S11 1 Hydraulic Pump 8 S11 2 Relief Valve for Three Point Hitch 8 S13 3 Safety...

Page 386: ...Draft rod and draft control rod improperly adjusted Adjust 8 S9 10 Lever stopper position improper Adjust Implement Does Not Lower Control valve malfunctioning Repair or replace 8 S14 Spool damaged R...

Page 387: ...ls min 14 6 Imp gals min 53 2 L min 14 1 U S gals min 11 7 Imp gals min Housing Bore Depth of Scratch 0 09 mm 0 004 in Bushing to Gear Shaft Clearance 0 15 mm 0 0059 in Position Rod Length Approx 369...

Page 388: ...earance Right 0 140 to 0 250 mm 0 00552 to 0 00984 in 0 50 mm 0 020 in Clearance Left 0 140 to 0 250 mm 0 00552 to 0 00984 in 0 50 mm 0 020 in Hydraulic Arm Shaft O D Right 59 970 to 60 000 mm 2 3611...

Page 389: ...to 93 9 0 to 9 5 65 to 68 Relief valve for three point hydraulic system 35 to 39 3 5 to 4 0 26 to 28 Hydraulic cylinder assembly mounting screw and nut 78 to 90 7 9 to 9 2 58 to 66 Control valve mount...

Page 390: ...lowly close the loading valve to generate pressure approx 9 8 MPa 100 kgf cm2 1422 psi Hold this condition until oil temperature reaches approx 50 C 122 F 8 Open the loading valve completely 9 Set the...

Page 391: ...ing adaptor Refer to 8 SPECIAL TOOLS at G GENERAL section 3 Measure the operating pressure of the cylinder safety valve 4 If the operating pressure is not within the factory specifications adjust by t...

Page 392: ...lbf to the end of the lower links 4 Start the engine and set the speed at 1000 min 1 rpm 5 Move the draft control lever all the way up and measure the offset which is the distance between S1 and S2 6...

Page 393: ...e factory specifications Refer to 1 CHECKING AND ADJUSTING in this section Tighten the lock nut 4 securely 5 Secure the position control lever 1 all the way down position to check that the floating ra...

Page 394: ...90 N 50 kgf 110 lbf to the end of the lower links 2 Attach the test bar 2 to the top link bracket 3 3 Start the engine and set the speed at 1000 min 1 rpm 4 Move the position control lever all the way...

Page 395: ...until the lift arms begin to down measure the travel distance L of the draft control lever 4 on the lever guide 5 7 If L is shorter than 15 0 mm 0 591 in shorten the draft control rod W1031315 4 Auxi...

Page 396: ...nd 1206C or equivalent to joint face of transmission case and pump base and pump base and hydraulic pump Replace the oil pipes 10 with new ones Apply oil to oil pipes 10 Be sure to check the PTO clutc...

Page 397: ...ean transmission fluid to the assemble When installing the driven gear 10 be sure to reassembling it to the original position After reassembly check the smooth rotation of the hydraulic pump for examp...

Page 398: ...3 Loosen the lock nut 2 and remove the adjusting screw 1 4 Draw out the spring 3 seat 4 and ball 5 When reassembling Install the cylinder safety valve to the hydraulic cylinder block taking care not...

Page 399: ...ly to the tractor be sure to adjust the position control lever draft control lever and auxiliary control wire cable W1039812 5 Control Valve for Three Point Hitch Removing Control Valve 1 Remove the c...

Page 400: ...stall the poppet valve noting O ring and backup ring W1041830 Check Valve 1 Remove the seat plug 3 2 Draw out the spring 2 and check valve 1 When reassembling Install the plug noting O ring W1042131 T...

Page 401: ...sition of O ring 22 go to the outside of the hydraulic cylinder body 25 with the process alternately and O ring 24 is assembled into the rod As shown in figure When assemble the position connector 10...

Page 402: ...c arm setting screw to the specified torque insert a wire through the holes of the screw head and hydraulic arm W1044235 Hydraulic Arm and Hydraulic Rod 1 Remove the spring pin 2 and separate the hydr...

Page 403: ...aulic piston bottom contacts with hydraulic rod W1045626 Lowering Speed Adjusting Valve 1 Remove the internal snap ring 1 and adjusting screw 3 2 Remove the internal snap ring 6 and draw out the poppe...

Page 404: ...utside micrometer 2 Measure the bushing I D with an inside micrometer and calculate the clearance 3 If the clearance exceeds the allowable limit replace the gear shaft and the bushing as a unit W10467...

Page 405: ...ec 0 140 to 0 250 mm 0 00552 to 0 00984 in Allowable limit 0 50 mm 0 020 in Hydraulic arm shaft O D Right side Factory spec 59 970 to 60 000 mm 2 3611 to 2 3622 in Bushing I D After press fitted Right...

Page 406: ...9 ELECTRICAL SYSTEM KiSC issued 06 2007 A...

Page 407: ...ECTRICAL CIRCUIT 9 M6 1 FUSE STARTING SYSTEM AND CHARGING SYSTEM 9 M6 2 METER SYSTEM 9 M7 3 SWING SHIFT AND DUAL SPEED SYSTEM 9 M8 4 COMMON RAIL SYSTEM CRS 9 M9 5 LIGHTING SYSTEM 9 M10 6 WORK LIGHT RA...

Page 408: ...0 P B 0 50 P G 8 5 4 3 2 1 Auxiliary Power Connector Seat Suspension 2 00 R W 2 00 R W 1 25 B 1 25 B 2 00 R W 0 85 R 0 85 B 15A Seat Suspension Auxiliary Power Connector Trailer Socket Assembly 0 85 G...

Page 409: ...F 5 00 R B 5 00 W Slow Blow Fuse Box 1 M5 M5 120A M6 60A 60A 120A 0 50 Y L 0 50 B Y Earth Front 2 00 B 0 50 B M6 Compressor Magnetic Clutch Diode Compressor 0 85 Y L 0 85 B 2 1 Assy 0 50 W M4 Engine...

Page 410: ...Engine Coolant Temperature Sensor 2 1 Intake Air Pressure Sensor 0 50 B W 0 50 W G 0 50 P G 2 1 3 Rail Pressure Sensor 0 50 P B 0 50 B W 0 50 W B 3 2 1 Accelerator Sensor 0 50 B W 0 50 OR 0 50 OR B 0...

Page 411: ...L B 1 25 OR 1 25 BR 1 25 B To Bonnet Harness Dual Shift Solenoid Valve Fuel Sensor Traveling Speed Sensor Engine Rotation Sensor Hi Lo Solenoid Valve Shift Hi Switch Shift Lo Switch Shift Transmissio...

Page 412: ...omotor 4 2 8 7 1 Blower Switch A C Control Panel 0 50 L OR 0 50 Y B 0 50 Y 0 50 B 0 50 G 0 50 W B 0 50 B Y 0 50 G Y 0 50 Y L 0 50 L G 0 50 W Y 0 50 G B 0 50 B 0 50 B Y 2 00 B F 2 00 Y G 2 00 L Y p o n...

Page 413: ...5B Y 0 5B L 0 5B L 0 85P L 0 5P B 0 5P G 5A 5A 0 5P G 5R B 5W 60B Y 3R L 3W To Main Key IG 5A Fuse 0 5Y B To Flasher Hazard To Meter Backup 3W 5W 0 5P G To Wiper 0 5P G 0 5P B 0 5P G 0 85P G 3Y 3Y 3W...

Page 414: ...0 5L B Buzzer 2 1 BZ 0 5GY W 0 5GY 2 1 0 5R Y 0 5R Y 0 5R Y 0 5R Y 0 5R Y 0 5R Y 0 5R Y 0 5R Y 1 2 0 5W G To Alternator Brake System Engine System LCD Display Tacho Meter Temperature Meter Fuel Meter...

Page 415: ...W 0 5R L 0 5R W To Meter Panel To Meter Panel 14V1 4W LOCK FREE e d c b a 0 85B CABIN DS 0 5Y V 0 5R Y 2 1 BZ Buzzer 3 2 1 2 3 1 0 5Y V 0 5L B To Meter Panel 0 5L B 0 5R W 0 5R L Shift Lo Switch 0 5BR...

Page 416: ...or 0 5B W 0 5W G 0 5P G 0 5B W 0 5P B 0 5W B Intake Air Pressure Sensor Rail Pressure Sensor Intake Air Pressure Sensor Return Intake Air Pressure Sensor Sensor Power Supply 6 71 52 64 Rail Pressure S...

Page 417: ...25OR 1 25OR 1 25BR 1 25BR 1 25BR 0 5BR To Meter Panel Hi Beem 0 85R G 0 85R G 0 85R 12V10W M5 D B Door Switch LH Dome Room Light To Radio Back Up DOOR OFF ON Brake Switch E H L E H L Head Light RH H4...

Page 418: ...Light To Compressor Relay Work Light Relay 0 5B 4 5 3 2 1 12V20W Speaker LH 12V20W Speaker RH 6 2 SR SL 9 5 8 4 7 SR SL E 0 85B 0 85B 0 85W L 0 85B E OFF ON R B 14V1 12W 0 85W L 12V55W 12V55W Rear Wor...

Page 419: ...r Switch M M Rear Wiper Motor 0 85L 0 85LG B 0 85LG W B S 1 M 0 85L R 0 85L R 0 85L G 0 85L B 0 85LG B 0 85B 0 85L W A E D B C Intermittent Wiper Relay Circuit Timer 0 85L B 0 85L G 0 85L Front Wiper...

Page 420: ...wer Relay 2 3 1 5 4 Compressor Relay Thermostat 0 5W Dual Pressure Switch 0 5B Y 0 5B Y 0 85Y L 0 5B Y 0 85B 0 85Y L 0 5B 0 5B 0 5Y B 0 5L G 0 5G Y 0 5W Y 0 5G B 0 5Y L 0 5W Y 0 5G Y 0 5L OR 0 5Y 0 5Y...

Page 421: ...Y B Yellow Black Lg Light Green L Or Blue Orange Y G Yellow Green Or Orange L R Blue Red Y L Yellow Blue Sb Sky Blue L W Blue White Y R Yellow Red Gy Gray L Y Blue Yellow Y V Yellow Violet B G Black...

Page 422: ...warning indicator This indicator serves the following two functions If the indicator lights up pinpoint the cause and take a proper measure 1 Error with the engine control system If during operation...

Page 423: ...er TM will come on If this should happen during operation check to see that there is no oil leak in the brake system and then add oil Fuel level If the fuel in the tank goes below the prescribed level...

Page 424: ...peed Coefficient 9 S18 7 LIGHTING SWITCH AND FLASHER UNIT 9 S21 1 Lever Combination Switch 9 S21 2 Hazard Switch 9 S22 3 Flasher Unit 9 S23 4 Work Light Switch 9 S24 8 RELAYS 9 S25 1 Starter Relay and...

Page 425: ...ery positive terminal and alternator B terminal Repair or replace Cooling fan belt slipping Adjust tension G 21 Starter Motor Does Not Operate Battery discharged or defective Recharge or replace 9 S9...

Page 426: ...lead and chassis Repair or replace Alternator defective Repair or replace 9 S17 Hi Lo Shift Monitor Not Indicate Fuse blown Replace 9 S11 Monitor switch defective Replace 9 S30 Solenoid valve defecti...

Page 427: ...r replace Tail Light Does Not Light Fuse blown Replace 9 S11 Wiring harness disconnected or improperly connected between combination switch T terminal and tail light Repair or replace Hazard Light Doe...

Page 428: ...een engine oil pressure switch lead and chassis Repair 9 S37 Circuit in panel board defective Replace Engine Oil Pressure Lamp Does Not Light When Main Switch Is Turned ON and Engine Is Not Running Bu...

Page 429: ...operly connected between panel board and fuel level sensor Repair or replace Circuit in panel board defective Replace Coolant Temperature Gauge Does Not Function Coolant temperature gauge defective Re...

Page 430: ...ength 18 0 mm 0 7086 in 11 0 mm 0 4331 in Brush Length 18 5 mm 0 728 in 5 0 mm 0 20 in Slip Ring O D 22 7 mm 0 894 in 22 1 mm 0 870 in Float at Uppermost Position Resistance 1 0 to 5 0 Float at Lowerm...

Page 431: ...ews bolts and nuts Refer to 5 TIGHTENING TORQUES at G GENERAL section W1012736 Item N m kgf m lbf ft Pulley nut Alternator 58 4 to 78 9 5 95 to 8 05 43 1 to 58 2 Air heater lead terminal nut 3 5 to 5...

Page 432: ...e battery specific gravity and recharge the battery W1015899 Battery Terminal Connection 1 Turn the main switch on and turn on the head light 2 Measure the voltage with a voltmeter across the battery...

Page 433: ...battery positive terminal 3 to the charge positive terminal and the negative 2 to the negative then recharge in the standard fashion 2 A boost charge is only for emergencies It will partially charge t...

Page 434: ...ght 2 Since the battery self discharges by approx 0 5 per day even in storage it must be once every two months in cold season 3 When storaging the battery mounted on the tractor disconnect the ground...

Page 435: ...lectrical 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 necessary repairs Failur...

Page 436: ...ator 12 5 A Meter panel OPC Buzzer 13 10 A Turn signal 14 10 A Transmission control 15 5 A Aircon Auxiliary power Defogger control 16 15 A Wiper 17 15 A Auxiliary power Seat suspension 18 5 A Audio ra...

Page 437: ...B terminal and the ACC terminal 3 If 0 ohm is not indicated renew the main switch W1014824 Main Switch at Key ON Position 1 Turn and hold the main switch at the ON position 2 Measure the resistances...

Page 438: ...osition 6 Measure the voltage a voltmeter across 2P connector s 4 1 terminal and chassis 7 If the voltage differs from the battery voltage the wiring harness or slow blow fuse is faulty W1019485 Funct...

Page 439: ...ntinuity across the lead 1 2 and the ground and the lead 2 3 and the ground with an ohmmeter 3 If these do not conduct replace the air heater 1 When reassembling W1021112 4 STARTER MOTOR Starter Motor...

Page 440: ...t 7 If the motor does not run check the motor W1022645 Magnet Switch Test 1 Disconnect the battery negative cable from the battery 2 Disconnect the battery positive cable and the leads from the starte...

Page 441: ...ble 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 R...

Page 442: ...n be done by using the LCD monitor 1 PTO Hour meter select switch 3 and traveling speed select switch 2 1 Setting Mode Input the various dates PTO speed display mode switching entering the traveling s...

Page 443: ...he PTO Hour meter select switch 1 longer than 2 seconds The setting is put in memory and the LCD monitor 2 goes back to the PTO speed display mode 4 Turn the key switch to OFF position to exit NOTE Th...

Page 444: ...ress the PTO Hour meter select switch 1 to select 9 5 Enter 5 and 3 for the remaining digits in the same procedure 6 Make sure the entry is 4953 Press and hold the traveling speed select switch 2 long...

Page 445: ...Light Switch and Turn Signal Switch 1 Test the continuity through the switch with an ohmmeter 2 If the continuity specified below is not indicated the switch is faulty W1032505 Voltage Main switch at...

Page 446: ...y 1 Measure the resistance with ohmmeter across the terminal a and terminal c and across the terminal d and terminal e 2 If the measurement is not following below the hazard switch or the bulb are fau...

Page 447: ...f blinking 3 If the factory specification is not indicated replace the flusher unit W1037638 Voltage Terminal 5 Chassis Approx battery voltage Terminal Color Terminal Connector 1 0 5 B GND 2 0 85 G R...

Page 448: ...harness fuse or main switch is faulty W1038200 Working Light Switch 1 Check the continuity through the switch with an ohmmeter 2 If continuity specified below is not indicated replace it W1038414 1 W...

Page 449: ...is faulty W1043116 Functional Check NOTE The relays described here are used same ones so that these are interchangeable 1 Apply battery voltage across the terminals c and d and check for continuity a...

Page 450: ...ck for continuity across the terminals d and e 2 If continuity is not established across terminals d and e replace it W1037072 b d e At 0 voltage between terminal a and c At battery voltage between te...

Page 451: ...e between terminal and W1040466 Intake Air Pressure Sensor 1 Refer to Diagnosis Manual W1041247 Coolant temperature sensor resistance Factory spec 15 04 k at 20 C 4 F 2 45 k at 20 C 68 F 0 318 k at 80...

Page 452: ...is Manual W1043463 Air Gap of Crankshaft Position Sensor 1 Measure the air gap between crankshaft position sensor 1 and crankshaft position pulsar gear 2 with feeler gauge W1043772 1 Common Rail 2 Rai...

Page 453: ...eck B 1 Dismount the EGR valve from the engine 2 Confirm that EGR valve is opened after EGR valve connector terminal 5 is connected to power terminal 4 and EGR valve connector terminal 4 is connected...

Page 454: ...the switch is faulty 4 If infinity is not indicated when the switch is pushed the switch is faulty W1027086 Resistance Across switch terminals When switch is pushed P 0 When switch is released R Infi...

Page 455: ...terminals and 2 3 terminals repeatedly 4 If the connection does not change shift switch is faulty W1027541 Buzzer 1 Remove the buzzer 1 2 Connect the jumper lead across the battery positive terminal...

Page 456: ...across the 1 terminal to the chassis and the 2 terminal to the chassis 3 If infinity is indicated the solenoid valve is faulty W1028218 Resistance HI solenoid valve 1 terminal to chassis 10 to 12 LO...

Page 457: ...rning ON and turning OFF 4 If infinity is not indicated when switch is pushed on the turning OFF position the switch is faulty W1029124 Connector Voltage 1 Disconnect the dual speed valve wire harness...

Page 458: ...rness 1 Disconnect the leads from the parking brake switch 1 2 Connect the wiring harness lead terminals to each other and turn on the main switch 3 If the indicator do not light the fuse wiring harne...

Page 459: ...ake brake oil level indicator lamp does not light on the panel board circuit or the wiring harness is faulty W1042861 Brake Oil Level Switch Continuity 1 Check the continuity between the 1 and 2 termi...

Page 460: ...mmeter across the terminal a and terminal b 3 If the measurement is not indicated the sensor is faulty W1190488 Resistance Sensor terminal a terminal b Factory spec Float at uppermost position 3 0 to...

Page 461: ...d circuit or the wiring harness is faulty W1040320 Engine Oil Pressure Switch Continuity 1 Measure the resistance with an ohmmeter across the switch terminal and the chassis 2 If 0 ohm is not indicate...

Page 462: ...the switch is released the switch is faulty W1025931 9 PTO Change Switch PTO Change Switch 1 PTO Change Switch Continuity 1 Check the continuity with an ohmmeter across the switch terminals 2 If it d...

Page 463: ...10 CABIN KiSC issued 06 2007 A...

Page 464: ...R CONDITIONING SYSTEM 10 M1 1 STRUCTURE 10 M1 2 COMPRESSOR 10 M3 3 AIR FLOW 10 M4 4 AIR CONTROL VENT 10 M4 5 CONTROL PANEL 10 M6 6 OPERATION 10 M7 7 ELECTRICAL SYSTEM 10 M10 1 Electrical Circuit 10 M1...

Page 465: ...ITIONING SYSTEM 1 STRUCTURE 1 Heater Hose 2 Air Conditioner Unit 3 Control Unit 4 Outer Roof 5 Inner Air Filter 6 Fresh Air Filter 7 High Pressure Pipe and Low Pressure Pipe 8 Receiver 9 Condenser 10...

Page 466: ...oning cycle and functions to lubricate the compressor But the conventional compressor oil for R12 doesn t dissolve in R134a so it doesn t circulate through the cycle and the lifespan of the compressor...

Page 467: ...ylinder chamber separated with the cylinder 1 and the vanes 4 decreases and the refrigerant gas is compressed As the rotor 3 rotates even further the refrigerant gas is highly compressed and then pres...

Page 468: ...tlets can be independently adjusted as required To defrost the windshield rotate the outlets toward the windshield W1013733 Face air outlet The face air outlets can be adjusted to direct air on to the...

Page 469: ...figure position and the in CAB air will be recirculated This is useful for cooling or heating the CAB quickly or keeping it extra cool or warm NOTE When heating do not keep the lever at the RECIRCULAT...

Page 470: ...ion to obtain warmer air Turn it in the Cool direction to obtain cooler air Blower Switch 4 Air volume can be changed in three steps At the 3 position the largest air volume is obtained Air Conditione...

Page 471: ...the temperature in the CAB quickly set this lever to the RECIRCULATION position 3 Adjust the blower 1 2 3 switch 3 and the temperature control dial 1 to achieve a comfortable temperature level W101480...

Page 472: ...end of counterclockwise position Otherwise hot air will raise the temperature in the CAB W1014533 Foot warming and head cooling 1 Set the mode switch 2 to the b position 2 In the cooling or dehumidify...

Page 473: ...tion fresh air selection lever to the FRESH AIR position 4 Set the blower switch 4 and the temperature control dial to the 3 and max Warm end of clockwise position respectively NOTE If you set the tem...

Page 474: ...Mode Switch 3 Thermostat 4 Pressure Switch 5 Compressor Relay 6 Blower Relay 7 Blower Motor 8 Blower Resistor 9 Blower Motor Switch 10 Compressor Magnet Clutch 11 A C Control Panel 12 A C Switch 13 M...

Page 475: ...10 S18 3 Charging the Refrigerant 10 S19 4 Checking Charge Refrigerant Amount 10 S21 6 CHECKING DISASSEMBLING AND SERVICING 10 S22 1 CHECKING AND ADJUSTING 10 S22 1 Compressor 10 S22 2 Air Conditioner...

Page 476: ...oes Not Cool Compressor Does Not Rotate Fuse blown Replace Magnetic clutch defective Repair or replace 10 S22 A C switch defective Replace 10 S26 Pressure switch defective Replace 10 S29 Belt slipping...

Page 477: ...k and repair Too Low Air Flow Rate Flow Rate Does Not Change in 4 Steps Blower resistor defective Replace 10 S25 Relay defective Replace 9 S26 Blower fan switch defective Replace 10 S24 Too Low Air Fl...

Page 478: ...Both Hi pressure and Low pressure Level is Too High Refrigerant overcharged Check with manifold gauge 10 S21 Insufficient Cooling Both Hi pressure and Low pressure Level is Too Low Refrigerant too sh...

Page 479: ...nt of link mechanism Repair 10 S46 Wiper arm seized or rusted Lubricate or replace 10 S46 Windshield Wiper Operating Speed Is Too Low Wiper motor defective Short circuit of motor armature worn motor b...

Page 480: ...20 MPa 1 5 to 2 0 kgf cm2 22 to 28 psi Pressure HI Pressure Side 1 28 to 1 66 MPa 13 0 to 17 0 kgf cm2 185 to 241 psi Pressure Switch Dual Type When pressure switch is turned OFF Setting Pressure LO P...

Page 481: ...to 8 5 High pressure pipe 2 retaining nut receiver side 12 to 14 1 2 to 1 5 8 7 to 10 Compressor mounting screw 24 5 to 29 4 2 5 to 3 0 18 1 to 21 7 Compressor bracket mounting screw M8 to aluminum p...

Page 482: ...n unless necessary When it has to be heated use warm water of 40 C 104 F or lower Do not heat using boiling water IMPORTANT If the refrigerant O rings etc for R12 are used in the R134a air conditioner...

Page 483: ...Side Valve are Closed Two circuits are established Port C LO pressure gauge 1 Port A HI pressure gauge 2 NOTE Schrader valve D must be opened W1013376 When LO Valve is Opened and HI Valve is Closed Tw...

Page 484: ...rt D Schrader valve must be opened Port A LO pressure gauge 1 NOTE Schrader valve D must be opened W1013304 When LO and HI Valve is Opened Two circuits are established Port A HI pressure gauge 2 LO pr...

Page 485: ...nnector should the sleeve 7 move before the quick link connector can be connected to the charging valve move the quick sleeve to its original position and try again When some refrigerant remains in th...

Page 486: ...valve the valve closes to keep out the outside air and allow the vacuum to build up but when the current stops the valve opens to allow in air and end the vacuum 2 Attaching this adaptor to the R12 va...

Page 487: ...turn the handle 1 counterclockwise To stop charging turn it clockwise W1015014 6 T joint T joint 2 is used to increase efficiency of gas charging using two refrigerant containers 4 at a time 1 Install...

Page 488: ...oses at the manifold gauge connection end by utilizing the refrigerant pressure in the refrigerating cycle 3 Start the engine and set at approx 1500 min 1 rpm 4 Turn on the A C switch and set the temp...

Page 489: ...Insufficient Condenser Cooling 1 Symptoms seen in refrigerating cycle Both LO and HI pressure side 1 2 pressures too high LO pressure side 1 0 20 to 0 35 MPa 2 0 to 3 5 kgf cm2 28 4 to 49 8 psi HI pre...

Page 490: ...Moisture Entered in the Cycle 1 Symptoms seen in refrigerating cycle The air conditioner operates normally at the beginning but over time LO pressure side 1 pressure is vacuum and HI pressure side 2...

Page 491: ...e Replace the receiver Evacuate and charge in proper amount of new refrigerant Refer to 3 Charging the Refrigerant in this section If caused by gas leakage in heat sensitizing tube replace the expansi...

Page 492: ...this section 1 Discharging the Refrigerant Prepare for the R134a refrigerant recovery and recycling machine 1 Connect low pressure side hose blue 6 from the recovery and recycling machine to LO pressu...

Page 493: ...p 7 to evacuate the refrigerant cycle For approx 15 minutes 5 When LO pressure gauge 1 reading is more than 750 mmHg 299 in Hg stop the vacuum pump 7 and close both valves 3 9 of manifold gauge fully...

Page 494: ...ated completely 2 Connect the center charging hose 5 to the can tap valve 7 fitting and then loosen the center charging hose at the center fitting of manifold gauge until hiss can be heard Allow the a...

Page 495: ...Set the temperature control lever to maximum cooling position and the blower switch to HI position 4 Open the LO pressure side valve 5 of manifold gauge and the can tap valve 1 on refrigerant contain...

Page 496: ...ecomes as stated below depending on refrigerant charged amount Insufficient refrigerant charge Air bubbles pass continuously the sight glass when pressure on the LO pressure side is over 99 0 kPa 1 01...

Page 497: ...ation 4 If anything abnormal is found repair or replace W1014211 Stator Coil 1 Measure the resistance of the stator coil with an ohmmeter across the 1P connector 1 of magnetic clutch and compressor bo...

Page 498: ...wer Relay Compressor Relay NOTE The relays described here are used same ones so that these are interchangeable 1 Apply battery voltage across the terminals a and c and check for continuity across the...

Page 499: ...ery voltage the wiring harness A C relay fuse or main switch is faulty W1019240 Blower Switch Test 1 Check the continuity through the switch with an ohmmeter 2 If the continuity specified below are no...

Page 500: ...nal momentarily 6 If the blower motor does not run check the motor W1020120 5 Blower Resistor Blower Resistor Check 1 Disconnect the 4P connector for blower resistor 1 2 Measure each resistance from B...

Page 501: ...ness A C relay or fuse is faulty W1020794 A C Switch Check 1 Check the continuity through the switch with an ohmmeter 2 If the continuity specified below are not indicated check the switch 1 Push the...

Page 502: ...1 Disconnect the temperature control dial 3P connector 2 Check the continuity through the dial with an ohmmeter 3 If the continuity specified below is not indicated check the dial W1022044 Terminal Po...

Page 503: ...otor Check 1 Confirm whether the mode switch 3 is defective Refer to 7 Mode Switch in this section 2 Turn the main switch ACC position 3 Turn the blower switch at 1 position 4 Turn the mode switch eac...

Page 504: ...then set the blower switch to HI position 3 Raise pressure on the HI pressure side of the refrigerant cycle by covering the condenser front with a corrugated carboard and the pressure switch 8 is act...

Page 505: ...Voltage 1 Turn on the main switch 2 Disconnect the wiper motor connector 1 3 Measure the voltage with a voltmeter across the connector 4 terminal and chassis 4 If the voltage differs from the battery...

Page 506: ...up the front wiper arm 1 2 Turn on the main switch 3 Push the front wiper switch to ON position 4 Count the number of wiper arm moving per minutes 5 If the number differs from the factory specificatio...

Page 507: ...is drained reinstall the radiator drain plug W1024819 Preparation 1 1 Open the bonnet 2 and disconnect the battery 3 negative terminal and head light 4P connector 7 2 Remove the bonnet dampers 4 and...

Page 508: ...S WSM CABIN Preparation 2 1 Remove the battery 1 2 Remove the ECU cover 2 3 Remove the ECU mounting screws and ECU 3 NOTE Take care not to damage to ECU W1030348 1 Battery 2 ECU Cover 3 ECU KiSC issue...

Page 509: ...e hose clamps 7 18 10 Remove the compressor bracket mounting screws 11 Remove the compressor 4 and condenser 2 with hoses When reassembling Take care not to damage the air condenser fin After reassemb...

Page 510: ...the connector 1 2 Disconnect the heater hoses 3 and fuel hose 4 3 Remove the throttle cable 2 4 Disconnect the connectors 5 W1031471 Tightening torque Power steering turning hose retaining nut 22 to...

Page 511: ...part Refer to 4 CHECKING AND ADJUSTING at 3 TRANSMISSION section Be sure to adjust the shuttle cable the shuttle lever neutral position at B part Refer to 4 CHECKING AND ADJUSTING at 3 TRANSMISSION s...

Page 512: ...ge gear shift rod 8 Refer to 4 CHECKING AND ADJUSTING at 3 TRANSMISSION section Be sure to adjust the parking brake lever free play by parking brake wire 6 Refer to 1 CHECKING AND ADJUSTING at 5 BRAKE...

Page 513: ...ve the cabin mounting bolts and nuts 1 3 Dismounting the cabin from tractor body When reassembling W1062418 Tightening torque Cabin mounting screws and nuts 123 6 to 147 1 N m 12 6 to 15 0 kgf m 91 1...

Page 514: ...not to damage them S letter is marked on the compressor for connecting the low pressure pipe suction side D letter is marked on the compressor for connecting the high pressure pipe discharge side When...

Page 515: ...mbling Do not use the external circlip again Assemble the external circlip for the tapered side to become outside of rotor The width of expanding of external circlip is set in boss of shaft as a minim...

Page 516: ...rant 1 Refer to 1 Discharging the Refrigerant in this section W1029483 Muffler and Bonnet 1 Disconnect the battery s cable 4 2 Remove the muffler 1 3 Remove the bonnet 2 4 Remove the side cover 3 W106...

Page 517: ...sor oil DENSO CO ND OIL8 to the O rings and take care not to damage them W1033365 Inner Covers 1 Remove the inner covers 1 2 2 Remove the seat 3 W1067892 Tightening torque Low pressure pipe mounting s...

Page 518: ...tor cap until coolant temperature is well below its boiling point Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely 1 Stop the engine and let cool down...

Page 519: ...nect the heater hoses 1 2 3 Pull out the heater hoses 1 2 from the bottom of the cabin 4 Take out the heater hoses 1 2 When reassembling When connecting the heater hose with A C unit hose should be pu...

Page 520: ...ternately to cut the adhered part NOTE Do not let the piano wire make sliding contact with the edge of glass plate forcibly In case of using cutter knife When glass is totally crushed finely 1 Insert...

Page 521: ...nect the front wiper motor 4P connector 2 5 Remove the wiper arm mounting nut 4 and wiper arm 5 6 Remove the wiper link cap 3 7 Disconnect the earth lead setting screw 8 Remove the front wiper motor b...

Page 522: ...nce W1060178 Tightening torque Wiper arm mounting nut 7 8 to 9 3 N m 0 8 to 0 95 kgf m 5 79 to 6 87 lbf ft Wiper motor mounting screw 7 8 to 9 3 N m 0 8 to 0 95 kgf m 5 79 to 6 87 lbf ft 1 Rear Wiper...

Page 523: ...I E I e Code No 9Y111 00720 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...

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