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Kubota M5040, Workshop Manual

The Kubota M5040 Workshop Manual is available for free download at manualshive.com. This comprehensive manual provides detailed instructions for maintaining and repairing the Kubota M5040 tractor. With step-by-step guidance, users can easily troubleshoot issues and perform routine maintenance tasks to keep their equipment running smoothly.

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1-S40

M5040, M6040, M7040, WSM

ENGINE

Replacing Injection Pump Assembly (If necessary)

•

The injection pump can be replaced with the crankshaft in
whatever position.

1. Disconnect all injection pipes (2).
2. Disconnect the fuel hose (3) and fuel overflow pipe (1).
3. Disconnect the connector from the stop solenoid (4).  Then

remove the stop solenoid.

4. Detach the sight cover (5) from the injection pump unit.
5. Unhook the start spring (9), and remove the lock nut (8).
6. Slide off the governor connecting rod (6) from the rack pin of

injection pump assembly (7).

7. Remove the injection pump mounting screws and nuts, and take

out the injection pump assembly (10).

NOTE

Q

• Be careful not to drop the lock nut (8).
• Be careful not to deform the start spring (9).
• When taking out the injection pump assembly, be careful not

to hit it against the governor connecting rod (6).

(When reassembling)

• Install the new injection pump according to the installing

procedure.

W1182379

(1) Fuel Overflow Pipe
(2) Injection Pipe
(3) Fuel Hose
(4) Stop Solenoid
(5) Sight Cover

(6) Governor Connecting Rod
(7) Rack Pin
(8) Lock Nut
(9) Start Spring

(10) Injection Pump Assembly

KiSC issued 06, 2008 A

Summary of Contents for M5040

Page 1: ...M5040 M6040 M7040 WORKSHOP MANUAL TRACTOR KiSC issued 06 2008 A...

Page 2: ...actor Mechanism Workshop Manual Code No 9Y021 01874 9Y021 18201 for the one which has not been described to this workshop manual Q Servicing Information on the troubleshooting servicing specification...

Page 3: ...anual 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 y...

Page 4: ...jack Always 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 stop...

Page 5: ...yes Keep electrolyte away from eyes hands and clothing If you spill electrolyte on yourself flush with water and get medical attention immediately DISPOSE OF FLUIDS PROPERLY Do not pour fluids into th...

Page 6: ...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 Q ROPS Model...

Page 7: ...5 M5040 M6040 M7040 WSM SAFETY INSTRUCTIONS KiSC issued 06 2008 A...

Page 8: ...6 M5040 M6040 M7040 WSM SAFETY INSTRUCTIONS KiSC issued 06 2008 A...

Page 9: ...7 M5040 M6040 M7040 WSM SAFETY INSTRUCTIONS KiSC issued 06 2008 A...

Page 10: ...8 M5040 M6040 M7040 WSM SAFETY INSTRUCTIONS Q CABIN Model KiSC issued 06 2008 A...

Page 11: ...9 M5040 M6040 M7040 WSM SAFETY INSTRUCTIONS KiSC issued 06 2008 A...

Page 12: ...10 M5040 M6040 M7040 WSM SAFETY INSTRUCTIONS KiSC issued 06 2008 A...

Page 13: ...11 M5040 M6040 M7040 WSM SAFETY INSTRUCTIONS KiSC issued 06 2008 A...

Page 14: ...U S gals 15 4 Imp gals Engine oil capacity 11 L 11 6 U S qts 9 7 Imp qts Coolant capacity 8 L 8 5 U S qts 7 0 Imp qts Dimensions Overall length 3565 mm 140 in 3445 mm 136 in 3565 mm 140 in 3445 mm 13...

Page 15: ...ol Pump capacity 41 6 L 11 0 U S gals 9 2 Imp gals min 3 point hitch SAE Category 1 and 2 Max lifting force At lift points 3 1900 kg 4189 lbs At lower link end with links horizontal 24 in behind lift...

Page 16: ...gals Engine oil capacity 11 L 11 6 U S qts 9 7 Imp qts Coolant capacity 8 L 8 5 U S qts 7 0 Imp qts Dimensions Overall length 3625 mm 142 7 in 3505 mm 138 in 3625 mm 142 7 in 3505 mm 138 in 3625 mm 1...

Page 17: ...ol Pump capacity 41 6 L 11 0 U S gals 9 2 Imp gals min 3 point hitch SAE Category 1 and 2 Max lifting force At lift points 3 1900 kg 4189 lbs At lower link end with links horizontal 24 in behind lift...

Page 18: ...65 1 1 0 68 L 1 2 3 1 4 2 4 1 5 2 5 1 5 2 3 3 2 0 3 4 2 1 3 5 2 2 3 4 4 2 7 4 5 2 8 4 7 2 9 4 7 1 4 4 7 4 4 6 7 7 4 8 H 1 8 9 5 6 9 3 5 8 9 6 6 0 2 12 7 7 9 13 1 8 2 13 6 8 5 3 17 0 10 5 17 6 10 9 18...

Page 19: ...17 M5040 M6040 M7040 WSM DIMENSIONS DIMENSIONS ROPS Model KiSC issued 06 2008 A...

Page 20: ...18 M5040 M6040 M7040 WSM DIMENSIONS CABIN Model KiSC issued 06 2008 A...

Page 21: ...G GENERAL KiSC issued 06 2008 A...

Page 22: ...G 21 4 CHECK POINTS OF EVERY 100 HOURS G 23 5 CHECK POINTS OF EVERY 200 HOURS G 28 6 CHECK POINTS OF EVERY 300 HOURS G 31 7 CHECK POINTS OF EVERY 400 HOURS G 31 8 CHECK POINTS OF EVERY 600 HOURS G 32...

Page 23: ...ROPS Model When contacting your local KUBOTA distributor always specify engine serial number tractor serial number and hourmeter reading W1030262 1 Tractor Identification Plate 2 Tractor Serial Numbe...

Page 24: ...our local KUBOTA distributor always specify engine serial number tractor serial number and hourmeter reading W1030474 1 Tractor Identification Plate 2 CABIN Identification Plate CABIN Serial Number 3...

Page 25: ...Alphabet or Number Year 1 2001 F 2015 2 2002 G 2016 3 2003 H 2017 4 2004 J 2018 5 2005 K 2019 6 2006 L 2020 7 2007 M 2021 8 2008 N 2022 9 2009 P 2023 A 2010 R 2024 B 2011 S 2025 C 2012 T 2026 D 2013...

Page 26: ...2 CYLINDER NUMBER The cylinder numbers of KUBOTA diesel engine is designated as shown in the figure The sequence of cylinder numbers is given as No 1 No 2 No 3 and No 4 starting from the front cover...

Page 27: ...se only 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...

Page 28: ...odic check 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...

Page 29: ...where 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...

Page 30: ...ely 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 and oxygen...

Page 31: ...at there 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...

Page 32: ...L 1 1 U S qts 0 9 Imp qts 3 Washer liquid 1 3 L 1 4 U S qts 1 1 Imp qts Automobil washer liquid 4 Engine crankcase with filter 11 L 11 6 U S qts 9 7 Imp qts API Service Classification CD CE or CF Bel...

Page 33: ...smission Oil The oil used to lubricate the transmission is also used as hydraulic fluid To insure proper operation of the hydraulic system and complete lubrication of the transmission it is important...

Page 34: ...41 2 39 2 to 44 1 4 0 to 4 5 28 9 to 32 5 60 8 to 70 5 6 2 to 7 2 44 9 to 52 1 M12 12 mm 0 47 in 62 8 to 72 5 6 4 to 7 4 46 3 to 53 5 77 5 to 90 1 7 9 to 9 2 57 2 to 66 5 62 8 to 72 5 6 4 to 7 4 46 3...

Page 35: ...5 0 to 7 0 36 1 to 50 6 15 t1 6 107 9 to 117 7 11 0 to 12 0 79 6 to 86 8 18 t1 6 107 9 to 117 7 11 0 to 12 0 79 6 to 86 8 Items Thread size Tightening torque N m kgf m lbf ft POA PF Nipple with O rin...

Page 36: ...e model Adjust every 100 Hr G 18 9 Air cleaner element Double type Primary element Clean every 100 Hr 1 G 24 Replace every 1 year 2 G 24 Secondary element Replace every 1 year G 24 10 Fuel line Check...

Page 37: ...ferential case oil Change every 600 Hr G 20 24 Front axle case oil Change every 600 Hr G 20 25 Front axle pivot Adjust every 600 Hr G 32 26 Engine valve clearance Adjust every 800 Hr G 32 27 Fuel inje...

Page 38: ...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 detail W1025390...

Page 39: ...oil cooler 11 Check and clean the radiator screen grill oil cooler and condenser CABIN model 12 Check and clean the air conditioner condenser screen CABIN model 13 Check the nuts of tires are tight 14...

Page 40: ...ging oil be sure to stop the engine Allow engine to cool down sufficiently oil can be hot and can burn 1 To drain the used oil remove the drain plugs 2 at the bottom of the engine and drain the oil co...

Page 41: ...hot and can burn 1 Remove the drain plug 1 at the bottom of the transmission case and drain the oil completely into the oil pan 2 After draining reinstall the drain plug 1 3 Remove the two oil filter...

Page 42: ...ifferential Case Oil and Front Axle Case Oil 1 To drain the used oil remove the drain plugs at the both front axle gear cases and filling plugs and drain the oil completely into the oil pan 2 After dr...

Page 43: ...ounted 1 Sit on operator s seat 2 Engage the PTO clutch control lever 3 3 Depress the clutch pedal 2 fully 4 Shift the shuttle shift lever 1 to the neutral position 5 Turn the key to START position 6...

Page 44: ...to 304 0 N m 26 5 to 31 0 kgf m 191 7 to 224 2 lbf ft Rear wheel mounting nut M16 259 9 to 304 0 N m 26 5 to 31 0 kgf m 191 7 to 224 2 lbf ft Tightening torque Front disc mounting nut waffle wheel 4W...

Page 45: ...d coated with petroleum jelly 3 Check the battery condition by reading the indicator W1024321 Directions for Storage CAUTION When connecting the battery do not reverse the polarities Connection with r...

Page 46: ...if it is damaged or not 3 Replace the primary element 2 Once a year or after every six times of cleaning whichever comes first IMPORTANT Q The air cleaner uses a dry element never apply oil Do not ru...

Page 47: ...t Tension CAUTION Be sure to stop the engine before checking belt tension 1 Stop the engine and remove the key 2 Apply moderate thumb pressure to belt between pulleys 3 If tension is incorrect loosen...

Page 48: ...ting for clutch pedal refer to 2 CHECK POINTS OF INITIAL 50 HOURS in this section W1109219 Checking Fuel Line 1 Check to see that all lines and hose clamps are tight and not damaged 2 If hoses and cla...

Page 49: ...fittings more often W1025259 1 Battery Terminals 2 Grease Fitting Front Axle Support 3 Grease Fitting Front Axle Support 4 Grease Fitting Knuckle Shaft RH LH 5 Grease Fitting Front Axle Gear Case Sup...

Page 50: ...tion in a safe place and keep the engine unloaded idling 2 Do not stop the engine suddenly but stop it after about 5 minutes of unloaded idling 3 Keep yourself well away from the machine for further 1...

Page 51: ...the bottom of the fuel tank 1 to let sediments impurities and water out of the tank Finally tighten up the plug IMPORTANT Q If the fuel contains poor qualities with much water in it drain the fuel ta...

Page 52: ...eformed dust may enter into the air conditioner which may cause damage and malfunction W1019336 Checking Air Conditioner Condenser CABIN Model 1 Release the air conditioner hoses off the hook 1 2 Loos...

Page 53: ...ten the filter 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 W1026760 Cleaning Water Separator Th...

Page 54: ...pivot pin adjustment is not correct front wheel vibration can occur causing vibration in the steering wheel Q Adjusting Procedure 1 Loosen the lock nut 1 tighten the adjusting screw 2 with specified t...

Page 55: ...r to 4 CHECK POINTS OF EVERY 100 HOURS in this section W1028012 Checking Air Conditioner Pipe and Hose CABIN Model 1 Check to see that all lines and hose clamps are tight and not damaged 2 If hoses an...

Page 56: ...r and anti freeze until the coolant level is just below the radiator cap Install the radiator cap 3 securely 7 Fill with clean water and anti freeze up to the upper line of recovery tank 4 8 Start and...

Page 57: ...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 sever...

Page 58: ...t in the concentrated anti freeze When the coolant level drops due to evaporation add water only to keep the antifreeze mixing ratio less than 50 In case of leakage add antifreeze and water in the spe...

Page 59: ...um speed position turn the key switch to start the engine and then reset the throttle lever at the mid speed around 1500 min 1 rpm position If engine does not start try it several times at 30 second i...

Page 60: ...t with a new one of the same capacity Q Protected Circuit W1054191 Fuse I D Capacity A Protected circuit a 15 Work light R b 15 Work light L c 5 Alternator Engine glow plug d 5 Meter panel OPC e 10 Tu...

Page 61: ...cuit a 5 Starter relay b 15 Auxiliary power c 15 Work light front side d 10 Air conditioner compressor e 30 Air conditioner fan motor f 15 Cigarette lighter g 15 Work light front h 15 Work light rear...

Page 62: ...ake out the bulb 5 4 Replace with a new bulb and reinstall the head lamp assembly in the reverse order Q Other lights 1 Detach the lens and replace the bulb IMPORTANT Q Be sure to use a new bulb of th...

Page 63: ...mount of refrigerant is extremely low inspect and charge Refer to 4 Checking Charge Refrigerant Amount at 10 CABIN section Q Checking Procedure 1 Run the air conditioner in the following conditions En...

Page 64: ...ation Use to measure diesel engine compression and diagnostics of need for major overhaul W1024200 Oil Pressure Tester Code No 07916 32032 Application Use to measure lubricating oil pressure W1024318...

Page 65: ...ge Material Steel E Hex nut 27 mm 1 06 in across the plat F Adhesive application G Fillet welding on the enter circumference H Retaining nut I 17 mm dia 0 67 in dia J 8 mm dia 0 31 in dia K 1 0 mm 0 0...

Page 66: ...0 7874 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 0 079 in A 157 mm 6 181 in B 14 0 mm 0 5512 in C 120 mm 4 7244 in D 27 4 mm dia 1 0787 in dia E 42 000 mm dia...

Page 67: ...787 in dia K 12 5 to 12 8 mm dia 0 492 to 0 504 in dia L 8 5 to 8 9 mm 0 3346 to 0 3504 in C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in C0 3 Chamfer 0 3 mm 0 012 in A 30 mm 1 1811 in B 30 mm...

Page 68: ...m dia 3 7402 in dia H 78 9 to 79 1 mm dia 3 1063 to 3 1142 in dia I 57 971 to 57 990 mm dia 2 2823 to 2 2831 in dia J 50 mm dia 1 9685 in dia K 15 mm dia 0 5906 in dia L 30 mm dia 1 1811 in dia M 15 m...

Page 69: ...in dia H 100 9 to 101 1 mm dia 3 9724 to 3 9803 in dia I 86 966 to 86 988 mm dia 3 4239 to 3 4247 in dia J 79 mm dia 3 1102 in dia K 15 mm dia 0 5906 in dia L 30 mm dia 1 1811 in dia M 13 mm 0 5118 i...

Page 70: ...n dia through hole B 19 mm 0 7480 in C 23 2 mm 0 9134 in D 42 0 to 42 4 mm 1 6535 to 1 6693 in E 12 5 mm dia 0 4921 in dia through hole F 61 mm 2 4016 in G 18 7 mm 0 7362 in H 30 9 to 31 7 mm 1 2165 t...

Page 71: ...173 in F 6 mm 0 2362 in V 8 mm dia 0 315 in dia G 23 5 mm 0 9252 in W 33 475 to 33 525 mm 1 3180 to 1 3198 in H 29 5 mm 1 1614 in a Ra 1 6 a I 58 mm 2 2835 in b 0 5 mm radius 0 0197 in radius J 95 mm...

Page 72: ...m 4 016 in F 15 mm 0 591 in G 59 mm 2 323 in H 14 mm dia 0 551 in dia I 80 mm radius 3 150 in radius J 70 mm 2 756 in K 460 mm 18 110 in L 270 mm 10 630 in M 6 mm 0 236 in N 70 mm 2 756 in C10 Chamfer...

Page 73: ...3 2311 in dia G 77 mm dia 3 0315 in dia H 57 mm dia 2 2441 in dia I 35 mm dia 1 3780 in dia J 30 mm dia 1 1811 in dia K 84 mm dia 3 3071 in dia L 3 5 mm 0 1378 in M 3 mm 0 1181 in N 6 6 to 6 8 mm 0 2...

Page 74: ...m dia 0 630 in dia P0 5 N 17 mm 0 669 in D 13 mm dia 0 512 in dia O 61 5 mm 2 421 in E 9 5 mm dia 0 374 in dia P 15 mm 0 591 in F M8 x 1 0 Q 10 mm 0 394 in G 6 5 to 6 7 mm dia 0 256 to 0 264 in dia R...

Page 75: ...depth D 40 0 to 40 2 mm dia 1 5748 to 1 5827 in dia E 35 9 to 36 1 mm dia 1 4134 to 1 4213 in dia F 2 256 rad 120 G M8 H 9 mm dia 0 3543 in dia I 19 mm dia 0 7480 in dia J 12 mm 0 4724 in K 15 mm 0 59...

Page 76: ...radius 0 0394 in radius G 0 5 mm radius 0 0197 in radius H 7 mm dia 0 276 in dia I 13 mm 0 512 in J 13 mm 0 512 in C0 5 Chamfer 0 5 mm 0 0197 in C1 Chamfer 1 0 mm 0 0394 in C2 Chamfer 2 0 mm 0 0787 i...

Page 77: ...in S Ra 1 6 a F 7 mm 0 2756 in AA Governor housing side G 6 mm 0 2362 in BB Press in side H 80 mm 3 1496 in a 0 6 mm radius 0 0236 in radius I 27 95 to 28 05 mm 1 1004 to 1 1043 in b 1 mm radius 0 039...

Page 78: ...WSM G GENERAL Pin for Balancer Shaft Bearing Replacing Tool W1020662 A 7 2 to 7 4 mm 0 283 to 0 291 in B 4 0 mm dia 0 158 in dia C Ra 0 8 a C0 1 Chamfer 0 1 mm 0 0039 in C0 5 Chamfer 0 5 mm 0 0197 in...

Page 79: ...8 8 to 48 9 mm dia 1 9213 to 1 9252 in dia a 3 mm 0 1181 in I 0 523 rad 30 b 35 mm 1 3780 in J 40 mm dia 1 5748 in dia c 53 mm 2 0866 in K 20 mm dia 0 7874 in dia d 3 mm 0 1181 in L 34 9 to 35 0 mm di...

Page 80: ...mm dia 0 7874 in dia c 12 mm 0 4724 in I 46 mm dia 1 8110 in dia d 12 mm 0 4724 in J 34 mm 1 3386 in e 4 mm 0 1575 in K 99 mm 3 8976 in f 35 mm 1 3780 in L 34 9 to 35 0 mm 1 3740 to 1 3780 in g 53 mm...

Page 81: ...46 mm dia 1 8110 in dia c 4 mm 0 1575 in I 34 mm 1 3386 in d 3 mm 0 1181 in J 99 mm 3 8976 in e 35 mm 1 3780 in K 34 9 to 35 0 mm 1 3740 to 1 3780 in f 53 mm 2 0866 in L 5 mm 0 1969 in g 3 mm 0 1181...

Page 82: ...48 9 mm dia 1 9213 to 1 9252 in dia V 50 mm 1 9685 in G 40 mm dia 1 5748 in dia W 0 698 rad 40 H 0 523 rad 30 X 2 mm 0 0787 in I 1 5 mm 0 0591 in Y 3 mm 0 1181 in J 20 mm dia 0 7874 in dia a 0 8 mm ra...

Page 83: ...dia 0 2756 in depth c 18 mm 0 7087 in I 20 mm dia 0 7874 in dia d 4 mm 0 1575 in J 46 mm dia 1 8110 in dia e 12 mm 0 4724 in K 34 9 to 35 0 mm dia 1 3740 to 1 3780 in dia f 15 mm 0 5906 in L 8 mm 0 3...

Page 84: ...35 0 mm dia 1 3740 to 1 3780 in dia a 50 mm 1 9685 in I 4 000 to 4 018 mm dia 7 mm depth 0 1575 to 0 1582 in dia 0 2756 in depth b 0 698 rad 40 J 1 2 mm 0 0472 in c 2 mm 0 0787 in K 5 mm 0 1969 in d 3...

Page 85: ...ose Application 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 C...

Page 86: ...ing Pressure Adaptor G Code No 07916 52751 Application This offers easy measurement of relief valve setting pressure from the hydraulic coupler This is available with the relief valve setting pressure...

Page 87: ...following special tools are not provided make them referring to the figure Front Axle Rocking Restrictor W10545380 A 120 mm 4 72 in B 12 mm 0 72 in C M10 P1 25 D 30 mm 1 18 in E M16 P1 5 F 10 mm 0 39...

Page 88: ...4 5 mm dia 0 57 in dia C 60 mm dia 2 36 in dia D Chamfer 5 mm 0 20 in E M14 x P1 5 F 25 mm 0 98 in G 40 mm 1 57 in H 450 mm 17 72 in I 14 mm dia 0 55 in dia J 50 mm dia 1 97 in dia K M14 x P1 5 L 10 m...

Page 89: ...t M6 x P1 0 Stud Bolt M8 x P1 25 A 24 65 to 24 80 mm dia 0 970 to 0 976 in dia B 131 85 to 132 15 mm 5 19 to 5 20 in C 99 25 to 100 75 mm 3 91 to 3 97 in D 54 to 60 mm full spline 2 12 to 2 36 in full...

Page 90: ...2 76 in B 67 5 mm 2 66 in 67 5 mm 2 66 in C 10 mm 0 39 in 10 mm 0 39 in D 55 mm dia 2 17 in dia 80 mm dia 3 15 in dia E 60 35 to 60 40 mm dia 2 376 to 2 378 in dia 85 35 to 85 40 mm dia 3 360 to 3 362...

Page 91: ...mm dia 0 961 to 0 969 in dia D 34 5 to 34 95 mm dia 1 36 to 1 37 in dia E Chamfer 1 0 mm 0 039 in F Chamfer 2 0 mm 0 078 in A 170 mm 6 69 in B 130 mm 5 12 in C 63 5 mm 2 5 in D 40 mm radius 1 57 in r...

Page 92: ...52 rad 30 E 26 0 mm dia 1 02 in dia 32 6 to 33 0 mm dia 1 28 to 1 29 in dia F Involute spline refer to below Involute spline refer to below G Chamfer 1 0 mm 0 039 in Chamfer 1 0 mm 0 039 in H 30 mm 1...

Page 93: ...the cylinder W1045740 A 1045 mm 41 14 in B 1000 mm 29 37 in C 20 mm dia 0 79 in dia D 30 mm dia 1 18 in dia E 100 mm 3 94 in F 35 5 mm 1 4 in G 30 mm 1 18 in H 15 mm 0 59 in I 20 mm dia 0 79 in dia J...

Page 94: ...3 in dia C 35 mm 13 8 in P 1 05 rad 60 D 23 to 23 3 mm 0 9055 to 0 9713 in Q 3 mm dia 1 18 in dia E 16 mm 0 63 in R 36 mm 1 18 in F 40 mm dia 1 58 in dia S 60 mm 2 36 in G 32 4 to 32 7 mm dia 1 2756 t...

Page 95: ...ation Use for gas leak testing 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 W10137...

Page 96: ...h the stopper magnet clutch W1065437 A 125 mm 4 92 in H 4 52 rad 120 B 40 mm dia 1 57 in dia I Radius 27 mm Radius 1 06 in C Radius 33 mm Radius 1 30 in J Radius 50 mm Radius 1 97 in D 16 mm 0 63 in K...

Page 97: ...st be changed Otherwise the travel speed will not get correctly displayed Such mode switching is also needed when the original tires are back on the machine Refer to 4 CHECKING AND ADJUSTING at 9 ELEC...

Page 98: ...ted as shown with the standard equipped tires To change the tread width 1 Remove the front axle mounting bolts 1 and the tie rod mounting bolt 2 2 Move the front axles right and left to the desired po...

Page 99: ...cording to service interval Refer to 5 CHECK POINTS OF EVERY 50 HOURS at 7 CHECK AND MAINTENANCE in this section NOTE Q Wheels with beveled or tapered holes use the tapered side of lug nut Disc Manufa...

Page 100: ...EVERY 50 HOURS at 7 CHECK AND MAINTENANCE in this section Disc Manufactured by TITAN INTERNATIONAL INC Disc Other manufactured W1082792 Tightening torque Rear wheel mounting nut M16 259 9 to 304 0 N m...

Page 101: ...a front loader of when equipped with lots of front weight W1027488 Front wheel hub Rear wheel hub 2WD 4WD Screw circle diameter A 152 4 mm 6 in 203 2 mm 8 in 203 2 mm 8 in Number of screws 6 8 8 Scre...

Page 102: ...alcium chloride solution do not pour water over calcium chloride since this results in chemical reaction which will cause high temperature Instead add a small amount of calcium chloride to the water a...

Page 103: ...into the tire to the specified pressure Weight of Calcium Chloride Solution Filling 75 of Full Capacity of a Tire W1033435 Tire sizes 14 9 28 16 9 28 16 9 30 Slush free at 10 C 14 F Solid at 30 C 22 F...

Page 104: ...om 3 Remove the 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 and direct co...

Page 105: ...t covered by the warranty NOTE Q Implement size may vary depending on soil operating conditions Tread max width with farm tires Lower link end max loading weight W0 Front Rear 2WD 4WD 1820 mm 71 7 in...

Page 106: ...L 180 U S gals 150 Imp gals Rear 3 point Hitch 680 L 180 U S gals 150 Imp gals Draw bar 3000 L 800 U S gals 660 Imp gals 3500 L 920 U S gals 770 Imp gals 4000 L 1030 U S gals 880 Imp gals 5 Rotary Til...

Page 107: ...000 lbs 550 kg 1200 lbs 11 Front Blade 1 2 Max Cutting Width 1820 mm 72 in 2130 mm 84 in Max Oil Pressure 19 6 MPa 200 kgf cm2 2844 psi 12 Rear Blade Max Cutting Width 1820 mm 72 in 2130 mm 84 in Max...

Page 108: ...1 ENGINE KiSC issued 06 2008 A...

Page 109: ...E 1 M5 6 CENTER DIRECT INJECTION SYSTEM E CDIS 1 M6 7 GEAR TRAIN CONFIGURATION 1 M7 8 PISTON 1 M7 9 BUILT IN DYNAMIC BALANCER 1 M7 3 LUBRICATING SYSTEM 1 M8 1 OIL COOLER 1 M8 4 COOLING SYSTEM 1 M9 1 T...

Page 110: ...with the new E CDIS The 07 series DI engine newly adopted ladder frame crankshaft support structure gear train located at flywheel side and coolant evenness distribution type cooling jacket Thus this...

Page 111: ...which supports the crankcase 1 1 The following benefits are in the ladder frame structure 1 Minimizing parts 2 Noise reduction 3 Reduction of loss and dispersion on friction thanks to accuracy of axi...

Page 112: ...der through the main gallery in the jacket mold core W1013000 3 HALF FLOATING HEAD COVER The rubber packing is fitted in to maintain the head cover 0 5 mm 0 02 in or so off the cylinder head This arra...

Page 113: ...E 4 CYLINDER HEAD This engine employs four valve system the cylinder head is provided with double intake passenge in order to ensure appropriate air suction and give an optimum swirl W1013336 1 Intake...

Page 114: ...sembled from the top and bottom to the crankcase 1 3 with each of 10 screws The following objectives are in the 4 screws per each cylinder assembling structure 1 Reduce the load share rate of combusti...

Page 115: ...g to more stable higher combustion performance In other words cleaner emission higher power output lower fuel consumption lower operating noise and higher start up performance W11094950 The 07 series...

Page 116: ...s a solid lubricant like a Graphite or Teflon This material helps resist metal wears even with little lube oil W1015665 9 BUILT IN DYNAMIC BALANCER Engine are sure to vibrate by piston s reciprocation...

Page 117: ...oil but also warms the cool engine oil shortly 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 there...

Page 118: ...o much 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 under...

Page 119: ...ermostat 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 o...

Page 120: ...mechanical governor that controls the fuel injection rate at all speed ranges from idling to maximum speed by utilizing the balance between the flyweight s centrifugal force and spring tension A gover...

Page 121: ...to compress the torque spring and move the fork lever 1 in the direction of the arrow A The fork lever 2 moves until it reaches the output limiting bolt to keep rated rotation and rated output When th...

Page 122: ...is turned off the spring tension of the solenoid is released the rod extrudes and the stop lever moves the control rack in the direction of the arrow B which stops the engine To stop the engine manual...

Page 123: ...fficiently to move the needle valve through its full lift This gives the following features Improved engine stability at low and intermediate speeds Decreased engine hunting and surge Decreased noise...

Page 124: ...the needle valve is again lifted and main injection can begin Second opening pressure is represemented by point F in the bottom left hand figure and B C in the above figure 3 INJECTION PUMP WITH F S P...

Page 125: ...surface 2 opens when the fuel pressure becomes more than the delivery valve set pressure Q At after injection The delivery valve 1 the steel ball 4 and the snapper valve 5 are moved down and the deli...

Page 126: ...e as a Unit 1 S22 2 Separating Engine 1 S25 3 DISASSEMBLING AND ASSEMBLING 1 S28 1 External Components 1 S28 2 Cylinder Head and Valves 1 S28 3 Thermostat 1 S32 4 Injection Pump Unit 1 S33 5 Water Pum...

Page 127: ...Incorrect injection timing Adjust 1 S19 Fuel camshaft worn Replace 1 S38 Injection nozzle clogged Repair or replace 1 S21 28 Injection pump malfunctioning Repair or replace 1 S20 40 41 42 Seizure of c...

Page 128: ...erload Reduce the load Low grade fuel used Use specified fuel G 10 Fuel filter clogged Replace G 30 Air cleaner clogged Clean or replace G 23 Deficient nozzle injection Repair or replace nozzle 1 S21...

Page 129: ...t type of oil Use specified type of oil G 10 Oil pump defective Replace 1 S15 71 72 High Oil Pressure Different type of oil Use specified type of oil G 10 Relief valve defective Replace 1 S44 Engine O...

Page 130: ...ust 0 65 to 0 85 mm 0 0256 to 0 0335 in 1 2 mm 0 0472 in Valve Stem to Valve Guide Intake and Exhaust Valve Stem Valve Guide Clearance O D I D 0 055 to 0 085 mm 0 0022 to 0 0033 in 6 960 to 6 975 mm 0...

Page 131: ...23 to 9 032 mm 0 3552 to 0 3556 in 9 050 to 9 065 mm 0 3563 to 0 3569 in 0 15 mm 0 0059 in Push Rod Alignment 0 25 mm 0 0098 in Tappet to Tappet Bore Tappet Tappet Bore Oil Clearance O D I D 0 020 to...

Page 132: ...am Height Intake Exhaust 37 50 mm 1 4764 in 37 90 mm 1 4921 in 37 00 mm 1 4567 in 37 40 mm 1 4724 in Camshaft Camshaft Journal 1 Camshaft Block Bore 1 Camshaft Journal 2 Camshaft Block Bore 2 Oil Clea...

Page 133: ...28 013 mm 1 1024 to 1 1029 in 28 05 mm 1 1043 in Piston Pin to Small End Bushing Piston Pin Small End Bushing Oil Clearance O D I D 0 020 to 0 040 mm 0 0008 to 0 0016 in 28 006 to 28 011 mm 1 1026 to...

Page 134: ...20 mm 0 0079 in Cylinder Bore I D 94 000 to 94 022 mm 3 7008 to 3 7017 in 94 15 mm 3 7067 in Cylinder Bore Oversize I D 94 500 to 94 522 mm 3 7205 to 3 7213 in 94 65 mm 3 7264 in Engine Oil Pressure...

Page 135: ...to 12 mm 98 N 0 44 to 0 47 in 98 N 10 kgf 22 lbf Alternator Belt Tension 10 0 to 12 0 mm 98 N 0 394 to 0 472 in 98 N 10 kgf 22 lbf Radiator Cap Air Leakage 10 seconds or more 88 59 kPa 0 9 0 6 kgf cm2...

Page 136: ...t Fuel Tightness 18 63 MPa 190 kgf cm2 2702 psi Delivery Valve Fuel Tightness 10 seconds 18 63 17 65 MPa 190 180 kgf cm2 2702 2560 psi 5 seconds 18 63 17 65 MPa 190 180 kgf cm2 2702 2560 psi Fuel Inje...

Page 137: ...ew 23 5 to 27 5 2 4 to 2 8 17 3 to 20 3 Overflow pipe assembly retaining screw 9 8 to 11 3 1 0 to 1 15 7 23 to 8 32 Rocker arm bracket screw 49 0 to 55 9 5 0 to 5 7 36 2 to 41 2 Cylinder head mounting...

Page 138: ...6 Item N m kgf m lbf ft Balancer shaft set screw 23 5 to 27 5 2 4 to 2 8 17 3 to 20 3 Connecting rod screw 68 6 to 73 5 7 0 to 7 5 50 6 to 54 2 Crankcase 2 mounting screw 137 3 to 147 1 14 0 to 15 0 1...

Page 139: ...at 200 to 300 min 1 rpm with the starter 4 Read the maximum pressure Measure the pressure more than twice NOTE Q Check the compression pressure with the specified valve clearance Always use a fully ch...

Page 140: ...ouch the top of valve stem then tighten the lock nut 6 Loosen the lock nut 4 of adjusting screw 3 push rod side and insert the feeler gauge between the rocker arm and the bridge head Set the adjusting...

Page 141: ...iner clogged Oil filter cartridge clogged Oil gallery clogged Excessive oil clearance Foreign matter in the relief valve When reassembling After checking the engine oil pressure tighten the engine oil...

Page 142: ...o increase the belt tension W1021011 Alternator Belt Tension 1 Measure the deflection L depressing the belt halfway between the pulleys at specified force 98 N 10 kgf 22 lbf 2 If the measurement is no...

Page 143: ...Wear 1 Check the belt for damage 2 If the belt is damaged replace it 3 Check if the belt is worn and sunk in the pulley groove 4 If the belt is nearly worn out and deeply sunk in the pulley groove rep...

Page 144: ...n water leakage is excessive replace the radiator If water leakage is caused by a small pinhole correct the radiator with radiator sealant W1072497 Thermostat Valve Opening Temperature 1 Push down the...

Page 145: ...ing 9 Check to see the degree on flywheel The flywheel has mark 1TC and 10 for the crank angle before the top dead center of No 1 piston 10 If the injection timing is not within the specification rota...

Page 146: ...tarter when the fuel jets from the injection nozzle After that turn the flywheel by the hand and raise the pressure to approx 18 63 MPa 190 kgf cm2 2702 psi 7 Now turn the flywheel back about half a t...

Page 147: ...lowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle 3 If the measurement is not within the factory specifications replace the injection nozzle assembl...

Page 148: ...ers 4 4 Remove the bonnet 1 and side cover 3 R H L H IMPORTANT Q When disconnecting the battery cables disconnect the grounding cable first When connecting positive cable first When reassembling For c...

Page 149: ...tape 3 to the R H W1055187 Radiator Hose and Oil Cooler Pipe 1 Disconnect the radiator hoses 1 and 3 2 Disconnect the oil cooler pipe retaining nuts 2 3 Remove the power steering hose clamp 4 When rea...

Page 150: ...denser 4 without removing the air conditioner hoses 3 Disconnect the heater hoses 1 When reassembling Take care not to damage the air condenser fin After reassembling the compressor be sure to adjust...

Page 151: ...wire 4 and fuel hose 2 2 Disconnect the wire harness from water temperature sensor 3 engine speed sensor 5 and glow plug 1 3 Disconnect the fuel hose 9 from fuel filter 4 Disconnect the 2P connector...

Page 152: ...oler Pipe CABIN Model 1 Remove the power steering pipe 1 2 Remove the oil cooler pipe 2 3 Remove the steering joint shaft 3 When reassembling W1058442 1 Steering Support Under Cover 2 Panel Guide 3 Re...

Page 153: ...del 1 Remove the floor cover and duct retainer 1 2 Remove the seat under cover 3 3 Remove the duct 2 4 Hoist the engine with a the hoist and chain 5 Remove the engine mounting screws and nuts and sepa...

Page 154: ...emove the injection pipes 5 4 Remove the cylinder head cover 4 When reassembling Check to see that the cylinder head cover gasket is not detective Tighten the head cover mounting screws to specified t...

Page 155: ...rly engaged with the grooves When installing the bridge arm apply engine oil to the bridge arm shaft sufficiently and check whether to move smoothly IMPORTANT Q After reassembling the rocker arm be su...

Page 156: ...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 10 after applying engine oil Be sure to adjust the valve cle...

Page 157: ...ial gauge as shown in figure 2 Select the suitable cylinder head gasket refer to the table below W1022965 Notch of Cylinder Head Gasket Thickness of cylinder head gasket Part Code Piston Head s protru...

Page 158: ...mmer W1053044 3 Thermostat Thermostat Assembly 1 Remove the thermostat cover mounting screws and remove the thermostat cover 1 2 Remove the thermostat assembly 3 When reassembling Apply a liquid gaske...

Page 159: ...t comes into contact with the fuel camshaft Make sure the camshaft does not move any longer 5 Tighten the lower fuel camshaft lock screw 7 until it comes into contact with the fuel camshaft NOTE Q Nev...

Page 160: ...crankcase 1 6 Tighten the injection pump unit mounting nut 5 to the specified torque 7 Reconnect the lubricating oil pipe 7 and place the injection pump unit support 8 and the window cover of the inje...

Page 161: ...rack pin tighten the nut with the specified torque with using the jig for keeping the governor connecting rod horizontal See the Replacing Injection Pump Assembly After tightening the nut hook the st...

Page 162: ...the governor housing 5 When reassembling After reassembling the governor housing assembly check the movement of the governor fork lever assembly the speed control lever and the stop lever NOTE Q When...

Page 163: ...the governor housing 4 Remove the start spring 6 W1142375 Stop Lever 1 Remove the spring pin 3 2 Remove the stop lever 2 and the return spring 1 3 Remove the stop lever shaft 4 W1143531 1 Return Sprin...

Page 164: ...when removing the governor weight mounting nut Otherwise the lock screws or injection pump housing might get damage IMPORTANT Q This injection pump gear mounting nut 3 has left handed screw To loose...

Page 165: ...s with the specified torque Install the injection pump gear and mounting nut to the fuel camshaft and temporarily tighten nut Install the injection pump unit to the crankcase 1 and temporarily tighten...

Page 166: ...governor connecting rod 6 from the rack pin of injection pump assembly 7 7 Remove the injection pump mounting screws and nuts and take out the injection pump assembly 10 NOTE Q Be careful not to drop...

Page 167: ...fuel injection pump unit 1 Refer to 8 SPECIAL TOOLS at G GENERAL section 5 Make sure the permanent magnet at the tip of the service jig is attracted to the governor connecting rod 4 6 Slightly tighten...

Page 168: ...nto place W1069772 Fan Drive Pulley 1 Set the stopper to the flywheel 2 Remove the crankshaft screw 2 3 Draw out the fan drive pulley 1 When reassembling Tighten the crankshaft screw to specified torq...

Page 169: ...n Confirm that the liquid gasket coating surface is free of water dust and oil in order to maintain sealing effect NOTE Q Assemble the adhesive applied parts within ten minutes Apply a liquid gasket T...

Page 170: ...flywheel using jack up screws 3 When reassembling Apply engine oil to the flywheel screws Before fitting the flywheel and the crankshaft gear together wipe oil dust and other foreign substances off th...

Page 171: ...kshaft gear 4 Refer to 8 SPECIAL TOOLS at G GENERAL section Apply a liquid gasket Three Bond 1217D to the seam between crankcase 1 and crankcase 2 Assemble the adhesive applied parts within ten minute...

Page 172: ...ousing W1189797 Balancer Shaft 1 Remove the balancer shaft 1 set screws 1 and draw out the balancer shaft 1 3 2 Remove the balancer shaft 2 set screws 2 and draw out the balancer shaft 2 4 When reasse...

Page 173: ...ake care to fit them to the mating parts Assemble the adhesive applied parts within ten minutes To avoid uneven tightening tighten mounting screws in diagonal order from the center After cleaning the...

Page 174: ...he cylinder apply enough engine oil to the cylinder When inserting the piston into the cylinder face the mark 2 on the connecting rod to the injection pump IMPORTANT Q Do not change the combination of...

Page 175: ...piston pin to the piston Assemble the piston to the connecting rod with the mark 2 and the connecting rod numbering mark 9 facing same side The end faces of the oil ring are plated with hard chrome I...

Page 176: ...ng screw and crankcase 2 flange screw in the order of Z to A 2 Remove the crankcase 2 1 from the crankcase 1 2 3 Remove the crankshaft 3 W1037243 1 Crankcase 2 2 Crankcase 1 3 Crankshaft a Front Cover...

Page 177: ...fied torque same as the flywheel housing screw Refer to 8 SPECIAL TOOLS at G GENERAL section This helps to minimize the level difference between the crankcase 1 and the crankcase 2 at the flywheel sid...

Page 178: ...and 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...

Page 179: ...allowable limit after replacing 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 o...

Page 180: ...section When installing 1 Clean a new valve guide and 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 fi...

Page 181: ...ay around W10283500 Free Length and Tilt of Valve Spring 1 Measure the free length B with vernier calipers If the measurement is less than the allowable limit replace it 2 Put the spring on a surface...

Page 182: ...shaft O D with an outside micrometer and then calculate the oil clearance 3 If the clearance exceeds the allowable limit replace the bridge arm 1 and measure the oil clearance again If it still exceed...

Page 183: ...et O D with an outside micrometer 2 Measure the I D of the tappet bore at the most wear part with a small hole gauge 3 If the oil clearance exceeds the allowable limit or the tappet is damaged replace...

Page 184: ...1 to 0 139 mm 0 0016 to 0 0055 in Allowable limit 0 22 mm 0 0087 in Backlash between cam gear and balancer 1 gear Factory spec 0 041 to 0 134 mm 0 0016 to 0 0053 in Allowable limit 0 22 mm 0 0087 in B...

Page 185: ...e the side clearance by moving the cam gear to the front and rear 3 If the measurement exceeds the allowable limit replace the camshaft bearing W1064307 Camshaft Alignment 1 Support the camshaft 1 wit...

Page 186: ...g camshaft cover replacing tool Refer to 8 SPECIAL TOOLS at G GENERAL section W1048526 Intake and exhaust cam height Factory spec Intake valve 37 50 mm 1 4764 in Exhaust valve 37 90 mm 1 4921 in Allow...

Page 187: ...al at high angle 2 Rotate the balancer shaft on the V block and get the misalignment half of the measurement value 3 If the misalignment exceeds the allowable limit replace the balancer shaft W1065448...

Page 188: ...060 to 0 146 mm 0 0024 to 0 0057 in Allowable limit 0 2 mm 0 0079 in Balancer shaft 1 journal O D Factory spec 48 934 to 48 950 mm 1 9265 to 1 9272 in Balancer shaft 1 bearing I D A Factory spec 49 0...

Page 189: ...kcase Otherwise the balancer shaft may be seized and engine may get damaged Apply engine oil to the bearing surface Reference W1010756 Bearing Code No Quantity Bearing A 1G772 26960 1 Bearing B 1G772...

Page 190: ...in bushing at the connecting rod small end with a cylinder gauge Calculate the oil clearance 3 If the clearance exceeds the allowable limit replace the bushing If it still exceeds the allowable limit...

Page 191: ...I D of the connecting rod small end bushing is the basis of this check check the bushing for wear beforehand 1 Remove the piston pin from the piston 2 Install the piston pin in the connecting rod 3 I...

Page 192: ...new ring 4 If clearance still exceeds the allowable limit after replacing the ring replace the piston W1066183 Top ring Factory spec 0 25 to 0 40 mm 0 0098 to 0 0157 in Allowable limit 1 25 mm 0 0492...

Page 193: ...on the intermediate journal at right angle 2 Rotate the crankshaft on the V block and get the misalignment half of the measurement value 3 If the misalignment exceeds the allowable limit replace the...

Page 194: ...f crankpin W1067389 Crankpin O D Factory spec 49 980 to 49 991 mm 1 9677 to 1 9682 in Oil clearance between crankpin and crankpin bearing Factory spec 0 017 to 0 048 mm 0 0007 to 0 0019 in Allowable l...

Page 195: ...nal W1069159 Crankshaft journal O D Factory spec 79 977 to 79 990 mm 3 1487 to 3 1492 in Oil clearance between crankshaft journal and crankshaft bearing Factory spec 0 030 to 0 073 mm 0 0012 to 0 0029...

Page 196: ...Housing Oil Seal 1 Remove the used oil seal 2 Clean the new flywheel housing oil seal 2 and apply engine oil to it 3 Install the new oil seal 2 to the specific position using replacing tool 1 Refer to...

Page 197: ...es NOTE Q 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...

Page 198: ...h the 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...

Page 199: ...2 CLUTCH KiSC issued 06 2008 A...

Page 200: ...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 OIL FLOW 2 M5 3 PTO CLUTCH VALVE 2 M5 KiSC issued 06 2008 A...

Page 201: ...e traveling clutch When the clutch pedal 2 is depressed the clutch spool of shuttle valve 8 moves via the clutch cable 9 As for the oil it does not flow to both the forward side 5 and reverse side 6 o...

Page 202: ...ng in the clutch pack and the clutch is depressed The feeding oil returns to the tank through the spool 6 and the clutch is in a Disengage condition NOTE Q Refer to 2 HYDRAULIC SHUTTLE VALVE at 3 TRAN...

Page 203: ...photo When the PTO shift lever 1 is moved to the B side the PTO clutch valve 3 is set at Engaged position Then the oil flows to clutch pack through the clutch valve 3 When the shift lever is moved to...

Page 204: ...clutch valve tightly presses the clutch discs 6 and drive plates 7 toward the pressure plate 5 As a result the rotation of the PTO propeller shaft 1 is transmitted to the PTO propeller shaft 2 3 throu...

Page 205: ...lic pack and PTO brake W1013531 3 PTO CLUTCH VALVE PTO clutch valve is composed of the following parts A Main Relief Valve PTO clutch inner pressure is kept in approx 2157 5 kPa 22 0 kgf cm2 313 1 psi...

Page 206: ...ing ROPS Model 2 S10 2 Separating Engine from Clutch Housing CABIN Model 2 S14 3 Separating Clutch Housing from Transmission Case 2 S19 4 Removing PTO Clutch Valve 2 S22 2 DAMPER DISC HYDRAULIC SHUTTL...

Page 207: ...vely worn Replace 3 S28 47 Deformation of piston or steel plate Replace Shuttle Clutch Operating Pressure Is Low Transmission oil improper or insufficient Replenish or change G 10 Relief valve malfunc...

Page 208: ...oil on clutch disc facing Replace 2 S23 Clutch disc or pressure plate warped Replace 2 S23 27 Pressure plate worn Replace Pressure plate assembly 2 S23 27 Chattering Grease or oil on clutch disc facin...

Page 209: ...n or return plate Replace 2 S25 29 PTO Shaft Does Not Rotate PTO clutch malfunctioning Repair or replace 2 S9 PTO propeller shaft coupling disengaged Engage PTO Clutch Operating Pressure Is Low Transm...

Page 210: ...Gear Shaft Backlash Displacement Around Disc Edge 2 0 mm 0 079 in Clutch Pedal ROPS Model Free Travel Total Stroke 40 to 45 mm 1 57 to 1 77 in 155 to 165 mm 6 10 to 6 50 in Clutch Pedal CABIN Model F...

Page 211: ...MPa 22 to 23 kgf cm2 312 91 to 327 14 psi PTO Clutch Disc Thickness 2 5 to 2 7 mm 0 098 to 0 106 in 2 1 mm 0 083 in PTO Steel Plate Thickness 1 93 to 2 07 mm 0 076 to 0 081 in 1 80 mm 0 071 in PTO Pi...

Page 212: ...ng pipe retaining nut 49 0 to 68 6 5 0 to 7 0 36 2 to 50 6 ROPS under frame mounting screw M16 9T 259 9 to 304 0 26 5 to 31 0 191 7 to 224 2 Rear wheel mounting nut 260 to 304 26 5 to 31 0 191 8 to 22...

Page 213: ...33 Clutch Pedal Free Travel Synchro Shuttle Model 1 Measure the clutch pedal free travel L 2 If adjustment is needed change the clutch rod length with turnbuckle so that the free travel becomes 40 to...

Page 214: ...lever 5 to ON position 2 If not making contact between the PTO valve lever 2 with stopper pin 1 adjust the PTO wire 4 retaining position with nuts 3 IMPORTANT Q Do not connect the universal joint of t...

Page 215: ...peed to maximum 9 Engage the PTO clutch lever to the ON position and measure the pressure 10 If only the pressure in the PTO clutch engaged position is low check the hydraulic PTO clutch system 11 If...

Page 216: ...COOLANT at G GENERAL section W1039800 Bonnet 1 Open the bonnet 1 and disconnect the negative battery terminal 2 Disconnect the connectors 2 for head lights 3 Disconnect the dampers 4 4 Remove the bon...

Page 217: ...2 as shown in figure W1044966 Power Steering Hose 1 Disconnect both power steering hoses 2 from power steering cylinder 1 When reassembling Connect the power steering hose with blue tape 3 to the R H...

Page 218: ...pipe 1 2 Remove the pipe clamp 2 When reassembling W1040843 Steering Support Under Cover and Rear Bonnet 1 Remove the steering support under cover 1 2 Loosen the rear bonnet mounting screws 4 3 Remove...

Page 219: ...olybdenum 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 W1030352 Tig...

Page 220: ...isconnect the dampers 3 4 Remove the bonnet 1 and side cover 2 R H L H IMPORTANT Q When disconnecting the battery cables disconnect the grounding cable first When connecting positive cable first When...

Page 221: ...2 as shown in figure W1042088 Power Steering Hose 1 Disconnect both power steering hoses 2 from power steering cylinder 1 When reassembling Connect the power steering hose with blue tape 3 to the R H...

Page 222: ...e speed sensor 13 and glow plug 3 3 Disconnect the fuel hose 10 from fuel filter 4 Disconnect the 2P connector 5 from alternator 8 and wire harness from alternator B terminal 4 5 Disconnect the wire h...

Page 223: ...oses 4 5 Disconnect the breather hose 5 and grounding wire 6 When reassembling W1043207 Tightening torque Power steering pipe retaining nut 49 0 to 68 6 N m 5 0 to 7 0 kgf m 36 2 to 50 6 lbf ft Oil Co...

Page 224: ...over 4 and duct 3 5 Remove the engine mounting screws and nuts 6 Separate the engine from the clutch housing When reassembling Apply molybdenum disulphide Three Bond 1901 or equivalent to the splines...

Page 225: ...O clutch cable 5 6 Remove the rear fender 1 R H L H When reassembling W1044376 ROPS Under Fuel Tank and Seat 1 Disconnect the wire harness from seat and remove the seat 1 2 Disconnect the wire harness...

Page 226: ...Hydraulic Pipes and Brake Rods 1 Remove the PTO delivery pipe 1 2 Remove the power steering pipe 2 3 Remove the 3 point hitch delivery pipe 1 4 and 3 point hitch delivery pipe 2 5 with outlet block 7...

Page 227: ...pipe ends with the PTO clutch holder holes assemble the PTO clutch valve 1 to the transmission case W1023008 Removing PTO Clutch Pack and Holder 1 Draw out the pin 2 with sliding hammer 3 2 Take out t...

Page 228: ...PTO clutch wire 1 from PTO clutch valve 3 2 Remove the PTO delivery pipe 2 from PTO clutch valve 3 3 Remove the PTO clutch valve assembly 3 When reassembling Replace the PTO pipe 4 with new ones and a...

Page 229: ...W1047775 Release Holder and Clutch Lever 1 Draw out the clutch release holder 2 and the release bearing 1 as a unit 2 Remove the release fork setting screws 5 3 Draw out the clutch lever 4 to remove...

Page 230: ...0 5 Draw out the relief sleeve 6 and relief poppet 7 6 Draw out the spring seat 9 and spring 14 When reassembling When assembling the PTO clutch valve adjust the PTO relief valve setting pressure refe...

Page 231: ...r to figure below Apply enough transmission fluid to the discs 3 Confirm the moving of the piston 13 smoothly when pressure air at 0 29 to 0 39 MPa 3 to 4 kgf cm2 42 to 57 psi is sent to clutch pack R...

Page 232: ...the washer 4 lightly by the hand press using the hydraulic clutch spring compressor Refer to 8 SPECIAL TOOLS at G GENERAL section 2 Remove the external circlip 3 3 Draw out the piston 6 When reassembl...

Page 233: ...shaft 2 Hold the shaft so that it does not turn 3 Rotate disc lightly and measure the displacement around the disc edge 4 If the measurement exceeds the allowable limit replace it W1024559 Pressure Pl...

Page 234: ...g pressure to it 3 If the bearing rotation is rough or noisy replace the release bearing 1 NOTE Q Do not depress bearing outer race when replacing release bearing Do not wash the release bearing with...

Page 235: ...her cupped spring washer 2 If the back plate has deformed or is scratched and or scared replace it W1026255 Piston Return Spring Free Length 1 Measure the free length of spring with vernier calipers 2...

Page 236: ...the thickness of seal rings 1 with an outside micrometer 2 If the measurement is less than the allowable limit replace it W1025453 Thickness of seal ring Factory spec 2 45 to 2 50 mm 0 096 to 0 098 i...

Page 237: ...3 TRANSMISSION KiSC issued 06 2008 A...

Page 238: ...M2 2 SHUTTLE SHIFT 3 M3 1 HYDRAULIC SHUTTLE 3 M3 2 SYNCHRO SHUTTLE DISC TYPE 3 M4 3 HYDRAULIC SHUTTLE VALVE HYDRAULIC SHUTTLE MODEL 3 M7 1 Structure 3 M7 2 Operation 3 M8 3 LUBRICATION FOR TRANSMISSI...

Page 239: ...TTLE MODEL 3 M1 M5040 M6040 M7040 WSM TRANSMISSION 1 STRUCTURE 1 Damper 2 Hydraulic Shuttle Clutch 3 Main Gear Shift 4 Front Wheel Drive Shift 5 Range Gear Shift 6 PTO Clutch 7 PTO Gear Case 1 2 3 7 4...

Page 240: ...SHUTTLE MODEL 3 M2 M5040 M6040 M7040 WSM TRANSMISSION 1 Traveling Clutch 2 Shuttle Gear Shift 3 Main Gear Shift 4 Front Wheel Drive Shift 5 Range Gear Shift 6 PTO Clutch 7 PTO Gear Case 1 2 3 4 5 7 6...

Page 241: ...clutch shifting It also operaates as a reduction when shifting from forward to reverse When the shuttle lever is move to the F or R position clutch is engaged to the front or rear by the hydraulic W1...

Page 242: ...10 hold the synchronizer keys 4 out against the shifter 5 The holder 2 3 each have three slots into which the ends of the synchronizer keys 4 fit The holder 2 3 fixed plates 9 The gear 1 is splined to...

Page 243: ...gaged from the shifter 5 The synchronizer keys 4 fixed in the grooves provided on the holder 2 3 however since the width of the grooves are wider than that of the keys the synchronizer keys begin rota...

Page 244: ...force of the holder 2 3 in its rotating direction is not applied to the shifter 5 and the holder 2 3 rotation is no longer transmitted to the shifter 5 Therefore the shifter 5 engages with the holder...

Page 245: ...Reverse 2 Inching Valve Spool 3 Line Filter 4 Modulating Valve 5 Proportionally Reducing Valve 6 Shuttle Valve 7 Line Filter 8 Accumulate Valve a Shuttle Forward Position b Shuttle Neutral Position c...

Page 246: ...ort flows to the T3 port Thus the shuttle clutch is not engaged 1 Proportionally Reducing Valve 2 Shuttle Valve 3 Shuttle Shift Spool Forward Reverse 4 Inching Valve 5 Modulating Valve 6 Accumulate Va...

Page 247: ...ly by modulating valve 5 When the shuttle clutch is engaging the accumulate valve 6 assists the operation of modulating valve 5 to reduce a shock 1 Proportionally Reducing Valve 2 Shuttle Valve 3 Shut...

Page 248: ...n the R side of shuttle clutch returns to T2 port through R port and shuttle shift spool 3 1 Proportionally Reducing Valve 2 Shuttle Valve 3 Shuttle Shift Spool Forward Reverse 4 Inching Valve 5 Modul...

Page 249: ...in the F side of shuttle clutch returns to T2 through F port and shuttle shift spool 3 1 Proportionally Reducing Valve 2 Shuttle Valve 3 Shuttle Shift Spool Forward Reverse 4 Inching Valve 5 Modulati...

Page 250: ...nsmission case via R port of F port through the proportionally reducing valve 1 and T2 port This cause the shuttle clutch to be set to off As a result even when the proportionally reducing valve 1 doe...

Page 251: ...aulic shuttle section main shift change synchromesh gears hydraulic pump drive driven gear PTO hydraulic pack and PTO brake are forcedly lubricated The lubrication oil from the PTO valve to PTO clutch...

Page 252: ...ump drive driven gear PTO hydraulic pack and PTO brake are forcedly lubricated The lubrication oil from the PTO valve to PTO clutch holder and lubricate the each section through PTO propeller shaft an...

Page 253: ...Housing Case ROPS Model 3 S14 2 Separating Engine from Clutch Housing CABIN Model 3 S18 3 Separating Clutch Housing from Transmission Case 3 S23 4 Removing Shuttle Valve Assembly 3 S25 2 HYDRAULIC SHU...

Page 254: ...ck ball fallen Reassemble Synchronizer unit damaged Repair or replace 3 S48 Hard Shifting Shifter or shift fork worn or damaged Replace 3 S48 Shift fork rod bent Replace Synchronizer unit damaged Repa...

Page 255: ...ear Synchro Shuttle Model Clearance 1 8 to 2 0 mm 0 071 to 0 078 in Shift Fork to Shift Groove for Main Change Section and Range Section Clearance 0 15 to 0 40 mm 0 0059 to 0 0157 in 0 80 mm 0 031 in...

Page 256: ...to 0 122 mm 0 004 to 0 0048 in 20 06 to 20 081 mm 0 7898 to 0 79059 in 19 959 to 19 980 mm 0 78579 to 0 7866 in 0 25 mm 0 010 in Differential Pinion to Differential SIde Gear Backlash 0 15 to 0 30 mm...

Page 257: ...utch housing mounting screw and nut M10 9T 60 8 to 70 5 6 2 to 7 2 44 9 to 52 1 Transmission case and clutch housing mounting screw and nut M14 9T 166 7 to 196 1 17 0 to 20 0 123 0 to 144 6 Shuttle va...

Page 258: ...shuttle 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...

Page 259: ...wly 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 Q The figure C...

Page 260: ...eutral Stop the engine and remove the key before checking and adjusting Steering Post Cover 1 Remove the steering post cover 2 W1010703 Shuttle Cable 1 1 The movement of shuttle lever is adjusted shut...

Page 261: ...il you feel the lever clicking at the ball detents 2 The steering column also has the f n and r grooves for the shuttle lever 3 In this adjustment procedure make alignment between the shuttle valve ne...

Page 262: ...art condition as follows NOTE Q 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 Engine does not start...

Page 263: ...shift rod 1 1 and main shift rod 2 3 Adjust the select cable 2 so that the lever end 4 has contact with stopper 5 when main gear shift lever operates to 1st 2nd direction and the main gear shift leve...

Page 264: ...d 2 1 and main shift rod 1 3 Adjust the select cable 2 so that the lever end 4 has contact with stopper 5 when main gear shift lever operates to 1st 2nd direction and the main gear shift lever is posi...

Page 265: ...feels abnormal check the length of range gear shift rod 1 3 and 2 1 W1102254 Length of range gear shift rod 2 L1 Factory spec 193 mm 7 6 in Length of range gear shift rod 1 L2 Initial adjustment 368 m...

Page 266: ...nd set the brake pedals to parking brake position when check the shuttle valve system pressure NOTE Q Pressure gauge is 5 MPa 50 kgf cm2 700 psi full scale Apply Three Bond 1324N or equivalent to the...

Page 267: ...L AND COOLANT at G GENERAL section W1012355 Bonnet 1 Open the bonnet 1 and disconnect the negative battery terminal 2 Disconnect the connectors 2 for head lights 3 Disconnect the dampers 4 4 Remove th...

Page 268: ...ins 2 as shown in figure W1012547 Power Steering Hose 1 Disconnect both power steering hoses 2 from power steering cylinder 1 When reassembling Connect the power steering hose with blue tape 3 to the...

Page 269: ...er pipe 1 2 Remove the pipe clamp 2 When reassembling W1013005 Steering Support Under Cover and Rear Bonnet 1 Remove the steering support under cover 1 2 Loosen the rear bonnet mounting screws 4 3 Rem...

Page 270: ...y molybdenum 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 W1013389...

Page 271: ...3 Disconnect the dampers 3 4 Remove the bonnet 1 and side cover 2 R H L H IMPORTANT Q When disconnecting the battery cables disconnect the grounding cable first When connecting positive cable first Wh...

Page 272: ...ins 2 as shown in figure W1013821 Power Steering Hose 1 Disconnect both power steering hoses 2 from power steering cylinder 1 When reassembling Connect the power steering hose with blue tape 3 to the...

Page 273: ...gine speed sensor 13 and glow plug 3 3 Disconnect the fuel hose 10 from fuel filter 4 Disconnect the 2P connector 5 from alternator 8 and wire harness from alternator B terminal 4 5 Disconnect the wir...

Page 274: ...r hoses 4 5 Disconnect the breather hose 5 and grounding wire 6 When reassembling W1014474 Tightening torque Power steering pipe retaining nut 49 0 to 68 6 N m 5 0 to 7 0 kgf m 36 2 to 50 6 lbf ft Oil...

Page 275: ...r cover 4 and duct 3 5 Remove the engine mounting screws and nuts 6 Separate the engine from the clutch housing When reassembling Apply molybdenum disulphide Three Bond 1901 or equivalent to the splin...

Page 276: ...PTO clutch cable 5 6 Remove the rear fender 1 R H L H When reassembling W1015170 ROPS Under Fuel Tank and Seat 1 Disconnect the wire harness from seat and remove the seat 1 2 Disconnect the wire harn...

Page 277: ...move the PTO delivery pipe 2 2 Remove the power steering pipe 3 3 Remove the brake rod 1 4 R H L H and brake rod 2 6 R H L H 4 Remove the wire harness 1 and steering support unit 7 as shown photo 5 Di...

Page 278: ...Rear Wheel L H and Fender L H 1 Place the disassembling stand under the transmission case 2 Remove the rear wheel 2 3 Place the disassembling stand under the rear axle case 4 Remove the fender 1 When...

Page 279: ...fix the O rings 11 in position as shown photo and apply transmission fluid Adjust the clutch pedal free travel refer to 4 CHECKING AND ADJUSTING in this section W1030797 Tightening torque Shuttle val...

Page 280: ...embling Be sure to fit the O rings 3 and apply transmission fluid The passage hole of oil b is not closed with liquid gaskets Apply liquid gaskets Three Bond 1206C or equivalent to joint face of the s...

Page 281: ...e When installing the internal circlip 16 to the clutch body 6 align its split portion to the notched portion of clutch body as shown in photo When assembling the input shaft 8 with 27T gear 17 for re...

Page 282: ...circlip 3 2 Remove the springs 7 3 Draw out the piston 5 using a air pressure NOTE Q Ten springs for one side The passage holes for the piston are beside the feather key groove When reassembling Apply...

Page 283: ...ft Lever 1 Disconnect the 1P connectors 4 from neutral switch 1 and remove the neutral switch 1 2 Draw out the roll pin 6 and ball 5 using a magnetic tool 3 Remove the shuttle lever retaining screw an...

Page 284: ...ction when reassembling the shuttle gear case unit to prevent the oil seal 4 damaged IMPORTANT Q Use four guide screws 2 and PTO propeller shaft guide 3 otherwise it may give a damage the oil seal NOT...

Page 285: ...2 Tap out the input shaft 6 and remove the input shaft assembly with shift fork 4 and rod 5 When reassembling Assemble the input shaft assembly shuttle shift assembly and shift fork with rod together...

Page 286: ...hen reassembling Replace the external circlips with new one Apply enough transmission fluid to the discs 11 Check the clearance between holder 2 and coupling both forward and reverse side with a feele...

Page 287: ...holder 2 5 NOTE Q Apply enough transmission fluid to the clutch disc Five steel plates and six clutch discs for one side There is two different thickness steel plate check and adjust the clearance bet...

Page 288: ...in a M12 x 1 25 mm screw into threaded hole a to remove the shift cover 1 4 Remove the shift change cover 1 gently When reassembling Apply liquid gasket Three Bond 1206C or equivalent to joint face W...

Page 289: ...en external circlip 1 and adjusting collar 5 If the measurement is not within the factory specification adjust with shim Reference Thickness of adjusting collar 5 3 00 mm 0 118 in 3 2 mm 0 126 in 3 4...

Page 290: ...s with gears together 2 Take out the three shafts from clutch housing case IMPORTANT Q Do not fall down the shaft when removing the shafts with gears Do not tap the bearing stop part a of clutch housi...

Page 291: ...The coupling for 1 2 speed 31 turn the longer boss side D to the rearward R The coupling for 3 4 speed 32 turn the longer boss side D to the forward F Apply transmission fluid to synchronizer unit Ap...

Page 292: ...0 19T Gear 21 Needle Bearing 22 Needle Bearing 23 Inner Race 24 Collar 25 Bearing 26 1st Shaft 27 Without Teeth 28 Teeth 29 Coupling 1 2 Speed for Hydraulic Shuttle Model 30 Coupling 3 4 speed for Hyd...

Page 293: ...tside 4 Remove the oil seal 1 and internal circlip 7 5 Tap out the DT shaft 8 to forward When reassembling Be sure to insert the DT shift arm 6 groove of shifter 5 as shown photo Replace the oil seal...

Page 294: ...not to damage the hydraulic pipes IMPORTANT Q After assembling the PTO clutch assembly be sure to check the piston operation by air pressure W1025105 Removing 3 point Hitch Hydraulic Block 1 Disconne...

Page 295: ...ply grease to the brake ball seats Do not grease excessively W1026106 Differential Lock Fork 1 Remove the clevis pin 3 and plug 1 2 Draw out the differential lock shaft 5 3 Take out the differential l...

Page 296: ...t with a new one and be sure to adjust the turning torque of spiral bevel pinion shaft itself refer to 6 SERVICING in this section Stake the staking nut after installing the differential gear assembly...

Page 297: ...liding on Apply molybdenum disulfide Three Bond 1901 or equivalent to the inner circumferential surface of the differential pinions Install the parts to their original position Install the differentia...

Page 298: ...g nut 1 2 Tap out the PTO shaft 2 to the rear side When reassembling Replace the PTO shaft staking nut 1 with new one and stake it firmly after tightening Apply grease to the oil seal 3 W1021609 1 Sta...

Page 299: ...ng 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 the coupling and...

Page 300: ...place them 5 Remeasure to confirm the correct clearance NOTE Q Clearance between internal circlip and belleville washer cupped spring washer is adjusted by two kinds of clutch discs with different thi...

Page 301: ...fter and the key groove on the coupling 2 Engage the shifter with the coupling and check that they slide smoothly 3 Similarly check that there is any flaw or wear on the gear splines 4 If there is any...

Page 302: ...d by two kinds of steel plates with different thickness Therefore use the one of the same thickness when you change steel plates Reference There are two kinds of thickness steel plates Thickness of cl...

Page 303: ...6 in 1 9 mm 0 075 in 2 1 mm 0 082 in W1029017 Side Clearance of 1st 2nd Gear and 3rd 4th Gear on 1st Shaft Synchro Shuttle Model 1 Measure the side clearance L between external circlip 1 and adjusting...

Page 304: ...with locking wrench and turning wrench 2 After tapping the bevel pinion shaft to the front and rear retighten the staking nut 1 to specified torque 3 Measure the turning torque of spiral bevel pinion...

Page 305: ...three positions equally 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...

Page 306: ...backward And reduce the shim 4 to move the spiral bevel gear rightward Repeat above until the proper tooth contact and backlash are achieved Deep or Toe Contact Replace the adjusting collar 2 with a t...

Page 307: ...c 0 08 to 0 181 mm 0 004 to 0 00712 in Allowable limit 0 35 mm 0 014 in Differential case bore I D Factory spec 40 53 to 40 592 mm 1 5960 to 1 5981 in Differential side gear boss O D Factory spec 40 4...

Page 308: ...n 1 8 mm 0 071 in 2 0 mm 0 078 in W1030074 Clearance of Differential Lock Shifter 1 Measure the clearance L between differential lock shifter and differential case when the differential lock pedal OFF...

Page 309: ...4 REAR AXLE KiSC issued 06 2008 A...

Page 310: ...CONTENTS MECHANISM 1 STRUCTURE 4 M1 KiSC issued 06 2008 A...

Page 311: ...aring between the rear 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 skid...

Page 312: ...SPECIFICATIONS 4 S2 3 TIGHTENING TORQUES 4 S3 4 DISASSEMBLING AND SERVICING 4 S4 1 PREPARATION 4 S4 1 Separating Rear Axle Case from Transmission Case 4 S4 2 DISASSEMBLING AND ASSEMBLING 4 S5 1 Rear...

Page 313: ...Probable Cause Solution Reference Page Excessive or Unusual Nose at All Time Improper backlash between planetary gear and internal gear Replace 4 S5 7 Bearing worn Replace 4 S5 7 Insufficient or impr...

Page 314: ...5 mm 0 020 in Thrust Collar Thickness 1 55 to 1 65 mm 0 0610 to 0 0650 in 1 2 mm 0 047 in Planetary Gear to Planetary Gear Shaft Planetary Gear Shaft Planetary Gear Needle Clearance O D I D O D 0 009...

Page 315: ...RAL section W1012736 Item N m kgf m lbf ft ROPS under frame mounting screw M16 9T 259 9 to 304 6 26 5 to 31 0 191 7 to 224 2 Rear wheel mounting nut 260 to 304 26 5 to 31 0 191 8 to 224 2 Cylinder hos...

Page 316: ...2 Remove the lift rod 3 and lower link 4 3 Remove the rear wheel 2 L H 4 Remove the rear fender 1 When reassembling W1011448 Fuel Tank and ROPS Under L H 1 Remove the ROPS under 1 L H 2 Disconnect the...

Page 317: ...1 2 Remove the external circlip 3 3 Carefully remove the planetary gear support 4 4 Remove the internal gear 6 and pins 5 When reassembling Be sure to insert the retainer plate 1 W1012424 Tightening t...

Page 318: ...Tap out the rear axle 3 from the rear axle case 2 Remove the bearing 2 and oil seal 1 Assembling Procedure for Rear Axle 1 Assemble the ball bearing 2 to the rear axle case 2 Assemble the oil seal 1 1...

Page 319: ...tween Internal Gear and Planetary Gear 1 Set a dial indicator lever type on the tooth of the planetary gear 2 Hold the planetary gear support and move only the planetary gear to measure the backlash 3...

Page 320: ...ance Planetary gear I D 2 Needle O D Planetary gear shaft O D 6 If the clearance exceeds the allowable limit replace them W1013795 Clearance between planetary gear and planetary gear shaft Factory spe...

Page 321: ...5 BRAKES KiSC issued 06 2008 A...

Page 322: ...CONTENTS MECHANISM 1 STRUCTURE 5 M1 KiSC issued 06 2008 A...

Page 323: ...wet disc brakes are used for the right and left traveling brakes They are operated by the brake pedals through the mechanical linkages The parking brake is a mechanical type which is designed to actu...

Page 324: ...TENING TORQUES 5 S3 4 CHECKING DISASSEMBLING AND SERVICING 5 S4 1 CHECKING AND ADJUSTING 5 S4 1 Brake Pedal 5 S4 2 DISASSEMBLING AND ASSEMBLING 5 S4 1 Separating Rear Axle Case from Transmission Case...

Page 325: ...place 5 S6 7 Brake Drags Brake pedal free travel too small Adjust 5 S4 Ball holes of cam plate for uneven wear Replace 5 S5 Brake pedal return spring weaken or broken Replace Brake cam rusted Repair 5...

Page 326: ...to 45 mm 1 6 to 1 8 in Cam Plate Flatness 0 3 mm 0 012 in Cam Plate and Ball Height 25 45 to 25 55 mm 1 002 to 1 0059 in 25 00 mm 0 9843 in Brake Disc Thickness 4 15 to 4 35 mm 0 1634 to 0 1713 in 3 3...

Page 327: ...o 5 TIGHTENING TORQUES at G GENERAL section W1012736 Item N m kgf m lbf ft ROPS under frame mounting screw M16 9T 259 9 to 304 0 26 5 to 31 0 191 7 to 224 2 Rear wheel mounting nut 260 to 304 26 5 to...

Page 328: ...ransmission Fluid 1 Refer to 7 CHECK AND MAINTENANCE and 4 LUBRICANTS FUEL AND COOLANT at G GENERAL section W1011874 ROPS Upper 1 Loosen the ROPS under frame 4 mounting screws Do not remove screws 2 R...

Page 329: ...liquid gaskets Three Bond 1206C or equivalent to joint face W1012475 Brake Cam Plate 1 Remove the return spring 1 2 Remove the brake cam plate 2 When reassembling Apply grease to the brake ball seats...

Page 330: ...d disc should be overlapped W1012102 Brake Cam and Brake Cam Lever 1 Remove the external circlip 1 2 Remove the brake cam 2 and brake cam lever 3 When reassembling Apply grease to the O ring 4 and tak...

Page 331: ...n the allowable limit replace it W1012945 Brake Plate Wear 1 Measure the brake plate thickness with vernier calipers 2 If the measurement is less than the allowable limit replace it W1014676 Brake Pla...

Page 332: ...6 FRONT AXLE KiSC issued 06 2008 A...

Page 333: ...CONTENTS MECHANISM 1 STRUCTURE 6 M1 1 2 WHEEL DRIVE 6 M1 2 4 WHEEL DRIVE 6 M2 3 LIMITED SLIP DIFFERENTIAL LSD M7040 6 M3 KiSC issued 06 2008 A...

Page 334: ...y the RUMOAN method With this method the shape of the front axle is relatively simple and front axle is supported at its center with the front axle support 12 on the front axle bracket 13 so that stee...

Page 335: ...l Gear 3 51T Bevel Gear 4 Front Axle Case Cover 5 Front Axle 6 10T Bevel GEar 7 Bevel Gear Shaft 8 10T Bevel Gear 9 Differential Yoke Shaft 10 Differential Gear Assembly LSD 11 Bracket Rear 12 Propell...

Page 336: ...ock condition and the right and left wheels rotate at the same speed allowing stable running in a straight line When the tractor takes a turn the right and left wheels are forced to rotate in differen...

Page 337: ...ION 6 S8 1 Separating Front Axle 2WD Model 6 S8 2 Separating Front Axle 4WD Model 6 S8 3 DISASSEMBLING AND ASSEMBLING 6 S10 1 Disassembling Front Axle 2WD Model 6 S10 2 Disassembling Front Axle 4WD Mo...

Page 338: ...just 6 S7 Front wheel sway excessive Replace 6 S6 Tie rod end loose Tighten 6 S6 Aeration of the hydraulic fluid in power steering circuit Bleed Knuckle shaft bushings worn 2WD model Replace 6 S18 Fro...

Page 339: ...urning Torque 2 94 to 4 90 N m 0 3 to 0 5 kgf m 2 17 to 3 62 lbf ft Front Axle Middle Boss to Bracket Bushing Front Axle Middle Boss Bracket Bushing Clearance O D I D 0 050 to 0 150 mm 0 00197 to 0 00...

Page 340: ...886 in 0 35 mm 0 0138 in Differential Pinion Shaft to Pinion Gear Differential Pinion Shaft Differential Pinion Gear Clearance O D I D 0 016 to 0 052 mm 0 00063 to 0 00205 in 15 966 to 15 984 mm 0 628...

Page 341: ...0224 in 59 97 to 60 00 mm 2 36102 to 2 36220 in Front Wheel Case Bushing Bevel Gear Case Alloy Thickness O D 0 57 mm 0 0224 in 54 97 to 55 00 mm 2 1642 to 2 1653 in Bevel Gear in Bevel Gear Case Backl...

Page 342: ...Tie rod end slotted nut 77 5 to 90 2 7 9 to 9 2 57 1 to 66 5 Knuckle arm mounting screw and nut 123 6 to 147 1 12 6 to 15 0 91 1 to 108 5 Tie rod end lock nut 167 7 to 196 1 17 1 to 20 0 123 7 to 144...

Page 343: ...Turn the rod end 4 to adjust until the proper toe in measurement is obtained 4WD model 5 Retighten the tie rod nut 3 6 Attach the snap ring 1 of the tie rod joint W1022542 Axial Sway of Front Wheel 1...

Page 344: ...ear case 2 shorten the length of stopper 3 4 Keeping the knuckle arm 1 contact with the bevel gear case 2 make a specified length as shown in the table 5 After adjustment secure the stopper with the l...

Page 345: ...axle from front axle bracket When reassembling IMPORTANT Q Be sure to adjust the front axle pivot W1012918 2 Separating Front Axle 4WD Model Draining Front Axle Gear Case Right and Left and Front Dif...

Page 346: ...ounted on the disassembly stand 2 Remove the front wheel 3 Lift the front axle and remove the front wheels 4 Disconnect the power steering hoses 1 2 When reassembling Connect the power steering hose w...

Page 347: ...Apply grease to the oil seal and bearing in the front wheel hub IMPORTANT Q After tightening the slotted nut to the specified torque measure the front wheel hub turning torque If the measurement is n...

Page 348: ...en reassembling Assemble the knuckle shaft making sure that the hole of the thrust collars 5 6 at properly fitted to the knuckle shaft dowel pins 3 When lift the knuckle shaft the knuckle arms must be...

Page 349: ...ase support 8 3 Draw out the bevel gear shaft 5 When reassembling Apply grease to the front wheel case support DX bushing and front wheel case DX bushing Install the oil seal to the front wheel case s...

Page 350: ...adjusting shims 8 3 Tap the bevel gear to downward and take out the 10T bevel gear 6 with bearing When reassembling Apply grease to the front wheel case DX bushing 2 Apply grease to the oil seal Repla...

Page 351: ...own in the figure below End play of axle shaft adjusts with shim 3 to 0 1 mm 0 004 in or less while front wheel case and front wheel case cover were assembled Install the shims 3 to their original pos...

Page 352: ...1 2 Be sure to adjust the spiral bevel pinon shaft turning torque with lock nut 9 after assemble the spiral bevel pinion shaft assembly Refer to 4 SERVICING in this section Reference Adaptor for slide...

Page 353: ...or excessively worn replace there parts they mesh with or are sliding on Apply molybdenum disulfide Three Bond 1901 or equivalent to inner circumferential surface of differential pinions side gear an...

Page 354: ...to the LSD discs Apply molybdenum disulfide Three Bond 1901 or equivalent to side gear and shim Assemble the belleville washers cupped spring washer as shown in the figure Check the slip torque of LS...

Page 355: ...e 3 If the clearance exceeds the allowable limit replace the bushing When replacing bushing Remove the bushing with a bushing puller set Code No 07916 51011 W1018596 Taper Roller Bearing 1 Check the b...

Page 356: ...n Code No 3C011 43040 6 2 mm 0 245 in Code No 3C011 43050 6 4 mm 0 252 in Code No 3C011 43070 Thickness of adjusting shims 4 0 7 mm 0 028 in Code No 3A151 32180 0 8 mm 0 032 in Code No 3A151 32130 1 0...

Page 357: ...allowable limit replace W1020024 Clearance between differential case and differential side gear Factory spec 0 050 to 0 091 mm 0 00197 to 0 00358 in Allowable limit 0 35 mm 0 0138 in Differential case...

Page 358: ...im 3 5 Adjust the backlash properly by repeated above procedure Reference Thickness of adjusting shim 0 8 mm 0 032 in Code No 67211 15170 1 0 mm 0 039 in Code No 67211 15160 1 2 mm 0 047 in Code No 67...

Page 359: ...asure the thickness of fuse 7 If the backlash exceeds the allowable limit adjust with shim 10 8 Adjust the backlash properly by repeated above procedure Reference Thickness of adjusting shim 0 8 mm 0...

Page 360: ...2 Measure the turning torque of spiral bevel pinion shaft 3 If the turning torque is not within the factory specifications adjust with the lock nut 1 NOTE Q After turning torque adjustment be sure to...

Page 361: ...e photo is Spline from yoke shaft and welded with box wrench Refer to 8 SPECIAL TOOLS at G GENERAL section Thickness of LSD shim 0 1 mm 0 004 in Code No 35533 43010 0 2 mm 0 008 in Code No 35533 43020...

Page 362: ...signs of wear or damage The DX bushing tends to show concentrated wear 2 If the DX bushing is worn beyond the alloy portion L replace it W1020339 Front bracket and rear bracket bushing Alloy thickness...

Page 363: ...backlash exceeds the allowable limit adjust with the shims 1 Reference Thickness of adjusting shims 1 0 1 mm 0 004 in Code No 35533 44081 0 4 mm 0 016 in Code No 3A021 44021 0 6 mm 0 024 in Code No 3...

Page 364: ...cklash Play x 2 4 If the backlash exceeds the allowable limit adjust with the shims 1 Reference Thickness of adjusting shims 1 0 4 mm 0 016 in Code No 3C011 44130 0 6 mm 0 024 in Code No 3C011 44140 0...

Page 365: ...7 STEERING KiSC issued 06 2008 A...

Page 366: ...CONTENTS MECHANISM 1 STEERING MECHANISM 7 M1 2 STEERING CYLINDER 7 M2 KiSC issued 06 2008 A...

Page 367: ...vided into two types non load reaction type and load reaction type They are distinguished by wether the cylinder port is blocked or not with the controller in neutral In these models load reaction typ...

Page 368: ...ntees equal steering movement to both front wheels The steering cylinder provide force in both directions Depending upon direction the steering wheel is turned pressure oil enters at one end of the cy...

Page 369: ...REPARATION 7 S6 1 Removing Power Steering Hydraulic Pump 7 S6 2 Removing Power Steering Controller ROPS Model 7 S7 3 Removing Steering Controller CABIN Model 7 S8 4 Removing Power Steering Cylinder 2W...

Page 370: ...or replace 7 S7 8 14 Steering Wheel Turns SpontaneouslyWhen Released Controller malfunctioning Repair or replace 7 S7 8 14 Front Wheels Wander to Right and Left Controller malfunctioning Repair or re...

Page 371: ...ve 4 71 Imp gals min 18 0 L min 4 76 U S gals min 3 96 Imp gals min Relief Valve Setting Pressure At Idling Engine Speed At Maximum Engine Speed Above 12 3 MPa 125 kgf cm2 1777 9 psi Below 18 1 MPa 18...

Page 372: ...2 to 50 6 Power steering joint shaft mounting screw 23 5 to 27 4 2 4 to 2 8 17 4 to 20 3 Tie rod end slotted nut 2WD 77 5 to 90 2 7 9 to 9 2 57 1 to 66 5 Tie rod joint lock nut 2WD 166 7 to 196 1 17 0...

Page 373: ...maximum engine speed 3 If the measurement is not within the factory specifications adjust the relief pressure by the adjust plug 4 Q IMPORTANT Air Bleeding Start the engine then turn the steering whee...

Page 374: ...8 Connect the other hydraulic test hose 1 to the flowmeter outlet insert the hydraulic test hose other end to transmission oil filling port at PTO case 9 Open the flowmeter loading valve completely T...

Page 375: ...n pipe 5 6 Disconnect the power steering delivery pipe 2 7 Remove the hydraulic pump 4 When reassembling W1016819 Hydraulic pump delivery at no pressure Factory spec Above 21 8 L min 5 76 U S gals min...

Page 376: ...ttery cables disconnect the grounding cable first When connecting positive cable first W1017878 Steering Support Under Cover and Rear Bonnet 1 Remove the steering support under cover 1 2 Loosen the re...

Page 377: ...ery cables disconnect the grounding cable first When connecting positive cable first When reassembling Connect the engine harness 6 connector and head light harness 5 connector within the space of con...

Page 378: ...the toe in and adjust it if necessary W1022966 Tightening torque Power steering pipe retaining nut 49 0 to 68 6 N m 5 0 to 7 0 kgf m 36 2 to 50 6 lbf ft Oil cooler pipe retaining nut 49 0 to 68 6 N m...

Page 379: ...rque Cylinder clamp nut 34 3 to 39 2 N m 3 5 to 4 0 kgf m 25 3 to 28 9 lbf ft Cylinder clamp lock nut 39 2 to 45 1 N m 4 0 to 4 6 kgf m 28 9 to 33 3 lbf ft Cylinder cover mounting screw 48 1 to 55 9 N...

Page 380: ...with blue tape to the R H Replace cotter pin with a new one After tightening the tie rod end nut to the specified torque install a cotter pin as shown in the figure left After assembling the power ste...

Page 381: ...g Apply liquid lock Three Bond 1372 or equivalent to the tie rod joint When reassembling internal circlip 3 should be positioned so that sharp edge face to outward as shown in the figure W1011578 Tigh...

Page 382: ...the each original position Seal element on the backup plate 8 does not face to the gear side Take care not to damage the seal elements and O rings After reassembly check the smooth rotation of the hy...

Page 383: ...he rotor and put the spacer on it Keeping the spacer on the rotor fit it into the stator 6 with the spline bevelled side upward 4 After putting the spacer into the rotor 9 insert the splines of driven...

Page 384: ...es and 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...

Page 385: ...the guide assembly to the specified torque stake the cylinder firmly W1017601 Steering Cylinder 4WD Model 1 Draw out the cylinder head 4 2 Draw out the cylinder rod 1 When reassembling Apply transmis...

Page 386: ...f the clearance exceeds the allowable limit replace as a unit W1017904 Steering cylinder I D 2WD Factory spec 50 000 to 50 062 mm 1 9686 to 1 9709 in Allowable limit 50 100 mm 1 9725 in Steering cylin...

Page 387: ...8 HYDRAULIC SYSTEM KiSC issued 06 2008 A...

Page 388: ...M2 1 Hydraulic Shuttle Model 8 M2 2 Synchro Shuttle Model 8 M3 3 THREE POINT HITCH HYDRAULIC SYSTEM 8 M4 1 THREE POINT HITCH HYDRAULIC CIRCUIT 8 M4 2 HYDRAULIC BLOCK 8 M5 3 LINKAGE MECHANISM 8 M6 1 Po...

Page 389: ...t hydraulic cylinders Implements with double acting cylinders can easily receive hydraulic power drawn from the quick coupler Auxiliary control permits simultaneous operation of implements powered by...

Page 390: ...der 7 Oil Cooler 8 PTO Clutch Pack 9 Relief Valve for Lubricating Line 10 PTO Valve 11 Oil Cooler Check Valve 12 Exterior Hydraulic Cylinder 13 Shuttle Clutch Pack 14 Relief Valve for 3 point Hitch 15...

Page 391: ...Clutch Pack 9 PTO Valve 10 Relief Valve for Lubricating Line 11 Orifice 6 Steering Cylinder 12 Oil Cooler Check Valve 13 Exterior Hydraulic Cylinder 14 Relief Valve for 3 point Hitch 15 Hydraulic Pum...

Page 392: ...f valve 6 which restricts the maximum pressure in the circuit The hydraulic cylinders 5 have a cylinder safety valve 3 to relieve shock pressure due to heavy implement bounce 5 The control valve 2 is...

Page 393: ...mechanism Code No 97897 18200 2 To operate the relief valve operation refer to 8 HYDRAULIC SYSTEM 4 RELIEF VALVE 2 PILOT OPERATED TYPE in the workshop manual of tractor mechanism Code No 97897 18200...

Page 394: ...tion Lever Shaft 1 2 Position Link 1 3 Position Link 2 4 Position Lever Shaft 2 5 Draft Link 6 Draft Link Shaft 7 Spool Drive Lever Draft 8 Spool Drive Lever Position 9 Position Feedback Shaft 10 Draf...

Page 395: ...hen the spool 6 returns to the neutral position Q Down 1 When the position control lever 12 is moved to the DOWN position the position link 2 3 is free The spool 6 of control valve moves by spool spri...

Page 396: ...l point 2 When the traction load decreases the torsion bar is restored and its displacement is transmitted to the draft feedback link shaft 5 via the draft feedback rod 13 and draft feedback lever 6 A...

Page 397: ...linder is single acting type and it is installed directly between hydraulic lift arms The main components of the hydraulic cylinder are shown in the figure W1015282 1 Dust Seal 2 Circlip 3 Head 4 O ri...

Page 398: ...BLING 8 S13 1 HYDRAULIC PUMP 8 S13 2 THREE POINT HITCH HYDRAULIC BLOCK ASSEMBLY 8 S14 1 Removing 3 point Hitch Hydraulic Block ROPS Model 8 S14 2 Removing 3 point Hitch Hydraulic Block CABIN Model 8 S...

Page 399: ...r replace 8 S13 Implement Does Not Reach Maximum Height Position rod and feedback rod improperly adjusted Adjust 8 S8 Draft rod and feedback rod improperly adjusted Adjust 8 S8 Implement Does Not Lowe...

Page 400: ...ve Opening Pressure 23 1 to 24 5 MPa 235 to 250 kgf cm2 3342 to 3556 psi Position Control Rod ROPS Length Approx 159 mm 6 26 in Draft Control Rod ROPS Length Approx 146 mm 5 75 in Position Control Rod...

Page 401: ...C SYSTEM CONTROL VALVE W1013874 LIFT ARM AND TOP LINK BRACKET W1013874 Item Factory Specification Allowable Limit Spool Joint Length 24 5 to 25 0 mm 0 9646 to 0 9842 in Bushing Press fit Location 11 0...

Page 402: ...ch delivery pipe retaining nut 107 9 to 117 7 11 0 to 12 0 79 6 to 86 8 Housing cover mounting screw 39 2 to 44 1 4 0 to 4 5 28 9 to 32 5 Cylinder hose rataining nut 45 1 to 53 0 4 6 to 5 4 33 3 to 39...

Page 403: ...ic pump 2 and flowmeter 4 inlet port 8 Connect the other hydraulic test hose 1 to the flowmeter outlet insert the hydraulic test hose other end to transmission oil filling port at PTO case 9 Open the...

Page 404: ...on and read the pressure gauge when the relief valve is actuated 4 If the pressure is not within the factory specification adjust the relief valve adjuster 3 Condition Engine speed Approx 2600 min 1 r...

Page 405: ...rmly When reassembling Install the safety valve to the hydraulic cylinder block taking care not to damage the O ring and apply transmission fluid NOTE Q Use specified transmission fluid refer to 4 LUB...

Page 406: ...t the position control rod 1 length L1 and or draft control rod 3 length L2 ROPS Model CABIN Model W1013598 Position control rod length L1 Factory spec Approx 159 mm 6 26 in Draft control rod length L...

Page 407: ...ition turn the turnbuckle 5 1 5 turns to shorten the position feedback rod 3 7 Tighten the lock nut 4 8 Move the position control lever 2 to the lowest position to check the cylinder goes to lowest po...

Page 408: ...Start the engine and set the engine speed at 1000 min 1 rpm 3 Move the position control lever 1 and draft control lever 2 all the way down 4 Move the draft control lever 2 to uppermost position then...

Page 409: ...bracket 3 comes in contact with the body 6 Slowly shift the draft control lever 5 upward until the lift arms begin to rise C1 Then slowly shift the draft control lever 5 downward until the lift arms b...

Page 410: ...t arms begin to down measure the floating range L of the draft control lever 5 from the end of the lever guide 4 7 If floating range L is not within the factory specification adjust the draft control...

Page 411: ...seal element 11 be sure to reassemble them to the each original position Seal element on the backup plate 8 does not face to the gear side Take care not to damage the seal elements and O rings After r...

Page 412: ...ples Take care not to damage the grease nipples when reassemble the hydraulic cylinder To assemble the auxiliary control valve wire refer to 4 CHECKING AND ADJUSTING in this section Be sure to fit the...

Page 413: ...d gasket Three Bond 1206C or equivalent to joint face of transmission case and cylinder block NOTE Q After reassembling the cylinder block assembly to the tractor be sure to adjust the position and dr...

Page 414: ...c cylinder To assemble the auxiliary control valve wire refer to 4 CHECKING AND ADJUSTING in this section Be sure to fit the O rings for auxiliary control valve Be sure to adjust the position control...

Page 415: ...n draw out the spring plates 6 springs 5 and plate 4 3 Tap out the roll pin then draw out the friction plates 3 draft lever 1 1 and position lever 1 7 When reassembling Be sure to assemble the frictio...

Page 416: ...Rod and Position Lever Rod 1 Tap out the roll pin 1 and 2 2 Draw out the rod 3 and 4 When reassembling Apply grease to the bushes W1021505 Draft Lever 3 and Position Lever 3 1 Tap out the roll pin 3 2...

Page 417: ...nd apply grease to them NOTE Q Do not disassemble the spool joint 1 4 from the spool 5 unless necessary If disassembled due to unavoidable reasons record the installation length L of the spool joint 3...

Page 418: ...the factory specification neutral state with operate the draft feedback lever 10 and position link lever 11 3 Check the gap G between the lowering poppet and adjusting screw 7 4 If the gap G is not w...

Page 419: ...late 4 5 Draw out the spool 12 6 Remove the sleeve 8 and spring 9 7 Remove the seat plug 2 11 When reassembling Install the plug noting O ring W1020079 Tightening torque Seat plug 1 39 2 to 58 8 N m 4...

Page 420: ...n A just over the internal circlip 5 as shown in figure Use a small screwdriver and remove the internal circlip 5 Simultaneously support this action by pushing from the outside of the cylinder tube wi...

Page 421: ...n seal 1 to the piston using the slide jig Refer to SPECIAL TOOLS section 3 Compress the piston seal to the correct size by installing the piston into the correcting jig 5 NOTE Q Do not turn roll the...

Page 422: ...Remove the safety valve assembly 1 2 Secure the safety valve assembly in a vise 3 Loosen the lock nut 3 and remove the adjust screw 2 4 Draw out the spring 4 seat 5 and ball 6 When reassembling Instal...

Page 423: ...care not to damage the O rings W1022677 9 LOWERING SPEED ADJUSTING VALVE Disassembling Lowering Speed Adjusting Valve 1 Remove the plate 1 2 Tap out the roll pin 2 using a vice grip pliers 3 Remove th...

Page 424: ...8 SPECIAL TOOLS at G GENERAL section When press fitting a new bushing apply transmission fluid to the lift arm support liner boss When press fitting a new bushing Lift arm support bushing s seam face...

Page 425: ...portion A replace it When installing When press fitting a new bushing apply transmission fluid to the bushing press in position When press fitting a new bushing of top link bracket the seam of bushing...

Page 426: ...9 ELECTRICAL SYSTEM KiSC issued 06 2008 A...

Page 427: ...Lighting System 9 M9 3 Working Light Radio and Defogger 9 M10 4 Air Conditioner 9 M11 5 Wiper System 9 M12 4 WIRING COLOR 9 M13 3 STARTING SYSTEM 9 M14 1 SYSTEM OUTLINE AND ELECTRICAL CIRCUIT 9 M14 1...

Page 428: ...VSS 0 5 R W 3 R G 3 R B 0 5 B 0 85 R L 0 85 B 0 85 R 0 85 B 3 B W AVX 5 W AVSX 60 B Y EB 60 B Y EB 0 5 B 0 85 W R 0 85 R 0 85 W R 0 85 G W 0 85 B 0 85 R B 0 85 G W 0 85 G B 1 25 Y B 1 25 B 1 25 Y 1 25...

Page 429: ...0 5 Or 0 5 L Y 1 25 Y R 0 5 B 1 25 Y R 1 25 R G 1 25 Y G 0 5 L Y 0 5 Or 0 5 B 0 85 B 0 85 G W 5 R B 3 R B 3 R L 3 R B 2 R B 3 R B 3 R W 2 B R 0 85 L 1 25 Y G 1 25 Y R 3 W R 3 R W 3 B 36 16 23 3 21 22...

Page 430: ...Y G 0 5 B Y 0 5 G B 2 Y L 0 5 W L 0 5 L G 0 5 Y L 0 5 G Y 0 5 L 0 5 W B 0 5 L Or 0 5 G 0 5 P L 0 5 Y 0 5 P W 0 85 R Y 0 85 B 0 85 B 0 5 B 0 5 B 1 25 B 0 85 B 0 85 B 0 85 B 0 85 B 0 85 B 0 85 B 0 85 B...

Page 431: ...0 5 W 0 85 Y L AVS 0 5 B 0 85 Br Y 60 B Y 60 B Y 15 W 3 B W 0 85 Br 0 85 W R 0 85 Or 0 85 L W 0 85 Br Y 0 5 Y 0 5 Y R 0 5 W R 0 5 W G 0 85 B L 0 85 Y L AVS 0 5 W 0 5 Sb 0 5 B W 0 5 P W 0 5 R G 0 5 Y L...

Page 432: ...tart b To PTO Switch c To Heater Relay d To Engine Stop Relay e To Flasher Unit Output L f To Flasher Unit Output R g To Light Switch h To Alternator 25 11 10 13 19 24 26 0 5L Y 0 5Lg B 0 5L 0 5B W 0...

Page 433: ...A Fuel Work Light B Key Light C Key IG a To Meter Panel b To Meter Panel OPC c To Turn Signal d To Meter Back Up e To Head Light Tail Lamp f To Flasher Hazard M B S 3R B 5 1 0 5B 3B W 5W 60B Y 60B Y 3...

Page 434: ...anel 0 85B FREE 20A 0 85G 0 85G a b c d e LOCK 0 85G 0 5B 0 85G R 0 85G R 0 85G R B2 R L 2 1 OFF 10A 0 5R Y 0 5R Y 0 85Lg B 15A 0 5Br 0 5Or 4 5 1 0 85Lg B 0 85Lg B 2 OFF 1 0 85G W 2 3 0 85Or 0 5B 0 85...

Page 435: ...ogger j To Quarter Window Defogger k To Radio Fuse 5A l To Working Light Front Side m To Air Conditioner Compressor n To Air Conditioner Fan Motor o To Working Light Rear p To Working Light Front q To...

Page 436: ...ntrol Panel d To Meter Panel Back Up e To Radio Back Up 0 5L W 0 85G W 0 85R B 0 85G B 0 5L W 0 85G W 0 85Lg B 0 85Lg B 0 5R Y 0 85G 0 85G R 0 5B 0 85G 0 85G 0 85G R 0 85L W 0 5G L 0 5G Y 10A 20A 20A...

Page 437: ...Window Defogger Relay 22 Rear Window Defogger 12V 98W 23 Quarter Window Defogger L H 12V 70W 24 Quarter Window Defogger R H 12V 70W A Light DEF B Blower Motor C ACC D Key ACC a To Dome Light 5A 0 5B...

Page 438: ...High Relay A Blower Motor B Key ACC a To Light Switch k 2B 2Y G 2Y L 0 5B Y L M1 M2 H 0 5L 2Y G 2Y L 0 5B Y 0 5Y L 0 5B Y 3B 0 5L 3Y B 0 5Y B 3 2 1 5 4 m 2B HI MH ML LO d f e c b a OFF 0 5B 0 85Y L 0...

Page 439: ...tch 7 Rear Wiper Motor A Key ACC 0 85B S 0 85L W 0 85B 0 85Lg B 0 85L Y 0 85L 0 85L 0 85L 1 2 3 1 5 4 M 15A 0 85Lg Y 0 85B 0 85L R 0 85L G 0 85L B 0 85B 0 85L W A E D B C 0 85L 0 85L R F WASH INT OFF...

Page 440: ...ck Br Brown G Y Green Yellow W G White Green Lg Light Green L B Blue Black W L White Blue Or Orange L G Blue Green W R White Red Sb Sky Blue L Or Blue Orange W Y White Yellow B G Black Green L R Blue...

Page 441: ...OFF position PTO switch 10 is pushed to ON Terminal AM of the main switch is connected to terminal M and terminal ST Consequently battery current flows to safety switches 7 10 coil of starter relay 3...

Page 442: ...the safety switch 7 is turned on the PTO lever is in OFF position PTO switch 10 is pushed to ON Terminal AM of the main switch is connected to terminal M and terminal ST Consequently battery current f...

Page 443: ...ignal Indicator 2 PTO Clutch Indicator 3 Liquid Crystal Display 4 Electrical Charge Indicator 5 Engine Oil Pressure Indicator 6 Tachometer 7 4WD Indicator 8 Heater Indicator 9 Fuel Level Indicator 10...

Page 444: ...hen the engine is accelerated to more than 1000 min 1 rpm check level of engine oil Q Fuel Level If the fuel in the tank goes below the prescribed level the warning lamp in the Easy Checker TM will co...

Page 445: ...he following automatic display modes PTO clutch control lever ON traveling speed and PTO speed are displayed PTO clutch control lever OFF traveling speed and hour meter are displayed Q Switching Hour...

Page 446: ...fferent setting modes PTO speed display mode switching entering the traveling speed coefficient and model select mode Q PTO Speed Display Mode Switching The PTO speed display mode switching is set at...

Page 447: ...our items as below W1016259 No Contents Condition Displayed unit 1 Fuel sensor voltage F to E V 2 Coolant temperature sensor voltage 30 to 120 C 4 to 248 F V 3 Battery voltage V 4 Engine revolution Id...

Page 448: ...PTO switch 4 and buzzer 5 Q Electric Circuit 1 When sitting on the seat in the state at engine running the battery voltage passes the seat switch 3 and the CPU 2 2 The CPU 2 detect the seat switch 3 P...

Page 449: ...requency as a only one side of lamp blinking of turn signal and both right and left side lamps blinking of hazard signal The blinking frequency is 60 to 80 times per minutes W1015651 1 Flasher Unit 2...

Page 450: ...minal Function Color of wire harness ROPS Model CABIN Model 1 Ground Black White 2 Tail light Sidemarker light Parking light Yellow Black Black 3 Turn signal light L H Green White Yellow 4 Brake stop...

Page 451: ...ing Mode 9 S22 3 Checking Meter Panel PTO Hour Meter Select Switch and Traveling Speed Select Switch 9 S23 4 Switch and Sensor 9 S25 8 LIGHTING SWITCHES AND FLASHER UNIT 9 S29 1 Combination Switch ROP...

Page 452: ...or replace Cooling fan belt slipping Adjust tension G 24 Starter Motor Does Not Operate Battery discharged or defective Recharge or replace 9 S8 9 Slow blow fuse blown Replace G 37 38 Starter relay d...

Page 453: ...harness disconnected or improperly connected Repair or replace 9 S29 30 Hazard Light Does Not Light Fuse blown Replace G 37 38 Bulb blown Replace G 39 Flasher unit defective Replace 9 S32 Hazard swit...

Page 454: ...ctive Repair or replace 9 S17 Short circuit between alternator terminal L and chassis Repair Circuit in meter panel defective Replace Charge Lamp Does Not Light When Main Switch Is Turned ON Wiring ha...

Page 455: ...ween meter panel and fuel unit Repair or replace Circuit in meter panel defective Replace Coolant Temperature Gauge Does Not Function Coolant temperature gauge defective Replace 9 S23 Coolant temperat...

Page 456: ...1 0 mm 0 4331 in Glow Plug Resistance Approx 0 95 Brush Length 18 5 mm 0 728 in 5 0 mm 0 197 in Slip Ring O D 22 7 mm 0 894 in 22 1 mm 0 870 in Float at Uppermost Position Resistance 3 0 to 5 0 Float...

Page 457: ...orques of screws bolts and nuts on the table below are especially specified For general use screws bolts and nuts Refer to 5 TIGHTENING TORQUES at G GENERAL section W1012736 Item N m kgf m lbf ft Pull...

Page 458: ...d damage to alternator and regulator may result 1 BATTERY FUSE GROUNDING AND CONNECTOR 1 Battery Battery Voltage 1 Stop the engine and turn the main switch off 2 Connect the COM lead of the voltmeter...

Page 459: ...ct the 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 c...

Page 460: ...spect the circuit line check the related fuses 2 If any of the fuse is blown replace with a new one of the same capacity IMPORTANT Q If a fuse is blown check the cause and be sure to replace it with a...

Page 461: ...de d 10 Air conditioner compressor e 30 Air conditioner fan motor f 15 Cigarette lighter g 15 Work light front h 15 Work light rear i 20 Spare fuse j 20 Flasher hazard k 20 Head light tail lamp l 10 M...

Page 462: ...tor Checking Connector 1 When inspect the circuit line check the related connectors 2 Disconnect the connectors and check their terminals for contamination and deformation 3 Check to see that cable do...

Page 463: ...e main switch to ON position 2 Measure the resistance with an ohmmeter across the terminal B and the terminal M 3 If 0 ohm is not indicated the B M contacts of the main switch are faulty W1014494 Main...

Page 464: ...e the air outlet 3 and 4 3 Remove the panel under cover R H 5 and disconnect the connector 4 Perform the following checking W1018558 Connector Voltage 1 Measure the voltage with a voltmeter across the...

Page 465: ...old the main switch key at the PREHEAT position 2 Measure the resistances with an ohmmeter across the terminal 3 and terminal 2 and the terminal 3 and the terminal 6 3 If 0 ohm is not indicated these...

Page 466: ...e cable is faulty W1022522 Motor Test CAUTION Secure the starter to prevent it from jumping up and down while testing the motor 1 Disconnect the battery negative cable from the battery 2 Disconnect th...

Page 467: ...shown in the figure Connect the jumper leads from terminal P through the switch 4 to the battery positive terminal Connect the jumper leads from terminal H through the switch 3 to the battery positive...

Page 468: ...ive cable from the battery 5 Measure the voltage between the terminal B 2 and the chassis 6 If the measurement is less than the factory specifications disassemble the alternator and check the IC regul...

Page 469: ...e 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 speed coe...

Page 470: ...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 Q The setting...

Page 471: ...same procedure 6 Make sure the entry is 179 0 Press and hold the traveling speed select switch 2 longer than 2 seconds The setting is put in memory and the LCD monitor 3 goes back to the hour meter m...

Page 472: ...d hold the traveling speed select switch 2 longer than 2 seconds The setting is put in memory and the LCD monitor 3 goes back to the PTO speed display or hour meter display mode 4 Turn the key switch...

Page 473: ...position to exit NOTE Q To check the engine revolution enter the checking mode under running the engine When enter the checking mode under running the engine code 3 display the generating voltage of...

Page 474: ...of checking be sure to turn OFF the main switch before hand Moreover pay attention not to allow the terminal to come in contact with other terminal or chassis while checking When applying the test pi...

Page 475: ...tch L H Battery voltage and 0 V alternately Main switch at ON and turn signal switch L H ON T17 W R Coolant temperature switch Approx 117 at 120 C 248 F to 5 88 k at 0 C 32 F Main switch at OFF T18 Y...

Page 476: ...ty is not indicated at pressure over 4 9 kPa 0 5 kgf cm2 7 psi the switch is faulty W1106807 Checking Coolant Temperature Sensor 1 Disconnect the connector from the coolant temperature sensor 1 2 Meas...

Page 477: ...s released the switch is faulty W1025931 Shuttle Neutral Switch 1 Shuttle Neutral Switch Continuity 1 Check the continuity with an ohmmeter across the switch terminals 2 If it does not conduct or any...

Page 478: ...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 5 0 Float at lower...

Page 479: ...is pushed the switch is faulty 3 If infinity is not indicated when the switch is released the switch is faulty 2 Setting 4WD Switch 1 Be sure to set the DT lever 2 at 2WD position 2 Measure the setti...

Page 480: ...Checking Light Switch and Turn Signal Switch 1 Test the continuity through the switch with an ohmmeter W1031103 Voltage Main switch at ON Terminal B1 Chassis Approx battery voltage Main switch at OFF...

Page 481: ...d 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 OFF Terminal B1...

Page 482: ...ure 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 faulty W104...

Page 483: ...the wiring harness or fuse is faulty Reference W1036747 Voltage Terminal 5 Chassis Approx battery voltage Terminal Color Terminal Connector 1 0 5 B GND 2 0 85 G R Hazard Input 3 Vacancy 4 0 5 L Turni...

Page 484: ...ulty W1035385 Checking Hazard Switch Continuity 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 followi...

Page 485: ...ty NOTE Q The terminal b of 3P connector for front work light switch is white black color wire for rear light switch is white blue color wire W1036008 Checking Switch Continuity 1 Test the continuity...

Page 486: ...are used same ones so that these are interchangeable 1 Apply battery voltage across the terminals c and d and check for continuity across the terminals a and b 2 If continuity is not established acro...

Page 487: ...ssis Approx battery voltage Head light relay high main switch at OFF position ROPS Terminal d Chassis Approx battery voltage A C compressor relay main switch at OFF position CABIN Terminal d Chassis A...

Page 488: ...zzer does not whistle 4 Stand up from the seat 5 The warning buzzer whistles about one second after standing up It whistles for 10 seconds W1097537 Checking Seat Switch 1 Disconnect the connector from...

Page 489: ...the jumper lead across the battery positive terminal and terminal 1 of connector 3 Connect the jumper lead across the battery negative terminal and terminal 2 of connector 4 If the buzzer does not wh...

Page 490: ...he front bracket Take note of the positions of the set of packings and the setup bolt Apply grease to the gears bearings shaft s sliding part and ball NOTE Q Do not damage to the brush and commutator...

Page 491: ...Rotor 1 Remove the 4 screws and detach the bearing retainer 2 Temporarily install the nut on the pulley screw and detach the rotor W1018685 Brush 1 When the rotor is detached the 2 brushes are found...

Page 492: ...position Use a 4 mm hex wrench to push the brushes into place Using a pin pointed 2 mm punch keep the brushes from popping out 2 Match the tally line of the front section with that of the rear sectio...

Page 493: ...ttery negative cable 2 Remove the top cover 1 and protect tape 3 3 Draw out the fuse stay 5 from the fuse box 2 4 Open the cover 4 and remove the screw 6 to draw out the fuse 100 A 7 When reassembling...

Page 494: ...ca undercut 6 If the undercut is less than the allowable limit correct it with a saw blade and chamfer the segment edges W1017092 Brush Wear 1 If the contact face of the brush is dirty or dusty clean...

Page 495: ...e is any defect replace the overrunning clutch assembly 3 Check that the pinion turns freely and smoothly in the overrunning direction and does not slip in the cranking direction 4 If the pinion slips...

Page 496: ...ad of the stator coil with an ohmmeter 2 If the measurement is not within factory specification replace it 3 Check the continuity across each stator coil lead and core with an ohmmeter 4 If infinity i...

Page 497: ...e measurement is less than allowable limit replace it 3 Make sure that the brush moves smoothly 4 If the brush is defective replace it W1020329 Rectifier 1 Check the continuity across each diode of re...

Page 498: ...10 CABIN KiSC issued 06 2008 A...

Page 499: ...RE 10 M1 2 COMPRESSOR 10 M2 3 AIR CONDITIONER UNIT 10 M3 4 SYSTEM CONTROL 10 M4 5 AIR FLOW 10 M5 6 AIR CONTROL VENT 10 M5 7 ELECTRICAL SYSTEM 10 M6 1 Electrical Circuit 10 M6 2 Blower Relay and Compre...

Page 500: ...onditioner unit 7 The comfortable air warmed moderately with the heater comes from the air duct with low humidity The six dashboard air outlets allow opening and closing and adjusting direction of win...

Page 501: ...the cylinder 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 the...

Page 502: ...eed of the blower motor 1 can be adjusted in 4 steps by the resistor 3 The blower fan 2 is centrifugal type The air being sucked in parallel with the rotary shaft is blown in the centrifugal direction...

Page 503: ...osition the door D3 6 is moved to establish the air passages to outlets O1 and O2 Air comes out from both outlets O DASHBOARD Moving the mode dial 14 to e position the door D3 6 is moved to set up the...

Page 504: ...ir port while washing the vehicle W1014867 6 AIR CONTROL VENT Q Dashboard Air Outlet The dashboard air outlet can be independently adjusted as required W1015170 1 Defroster Air Outlet 2 Dashboard Air...

Page 505: ...emperature is more than 3 C 37 4 F Pressure Switch 6 ON if refrigerant pressure is between 0 21 MPa 2 1 kgf cm2 30 psi and 265 MPa 27 kgf cm2 384 psi Magnetic Clutch of Compressor Engaged 1 Battery 2...

Page 506: ...directly from the battery 1 forgetting to turn off the blower motor 6 could result in a discharged battery 1 To protect against such trouble relays have been provided These relays have been made so t...

Page 507: ...r 5 Blower Resistor 7 a b and c Blower Switch 8 Ground O Medium 1 Position Battery 1 Slow Blow Fuse 2 Main Switch 3 Fuse Blower Relay 4 Blower Motor 5 Blower Resistor 7 a and b Blower Switch 8 Ground...

Page 508: ...NG 10 S22 1 CHECKING AND ADJUSTING 10 S22 1 Compressor 10 S22 2 Relay A C Compressor Front Working Light Front Wiper Blower Blower Hi ACC Auxiliary Power 10 S22 3 Wiper Relay 10 S23 4 Control Panel Bl...

Page 509: ...d Repair Does Not Cool Compressor Does Not Rotate Fuse blown Replace Magnetic clutch defective Repair or replace 10 S22 A C switch defective Replace 10 S25 Pressure switch defective Replace 10 S29 Bel...

Page 510: ...ck and repair Too Low Air Flow Rate Flow Rate Does Not Change in 4 Steps Blower resistor defective Replace 10 S27 Relay defective Replace 9 S36 Blower fan switch defective Replace 10 S24 Too Low Air F...

Page 511: ...9 Expansion valve clogged Replace Insufficient Cooling Both Hi pressure and Low pressure Level is Too High Refrigerant overcharged Check with manifold gauge 10 S21 Insufficient Cooling Both Hi pressur...

Page 512: ...nt of link mechanism Repair 10 S49 50 Wiper arm seized or rusted Lubricate or replace 10 S49 50 Windshield Wiper Operating Speed Is Too Low Wiper motor defective Short circuit of motor armature worn m...

Page 513: ...to 2 0 kgf cm2 21 to 28 psi Pressure HI Pressure Side 1 27 to 1 66 MPa 13 to 17 kgf cm2 185 to 242 psi Pressure Switch Dual Type When pressure switch is turned OFF Setting Pressure LO Pressure Side Le...

Page 514: ...8 7 Compressor mounting screw 24 5 to 29 4 2 5 to 3 0 18 1 to 21 7 Magnetic clutch mounting screw 15 0 to 21 0 1 5 to 2 1 11 1 to 15 5 A C unit mounting screw M8 9 8 to 15 7 1 0 to 1 6 7 2 to 11 6 Pre...

Page 515: ...T Q If the refrigerant O rings etc for R12 are used in the R134a air conditioner system problems such as refrigerant leakage or cloudiness in the sight glass may occur Therefore in order to prevent ch...

Page 516: ...Closed Two circuits are established Port C LO pressure gauge 1 Port A HI pressure gauge 2 NOTE Q Schrader valve D must be opened W1013376 Q When LO Valve is Opened and HI Valve is Closed Two circuits...

Page 517: ...B Port D Schrader valve must be opened Port A HI pressure gauge 2 NOTE Q Schrader valve D must be opened W1013304 Q When LO and HI Valve is Opened Two circuits are established Port A HI pressure gauge...

Page 518: ...ect connector 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...

Page 519: ...enoid 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...

Page 520: ...stem 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 In...

Page 521: ...e charging hoses 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...

Page 522: ...t or 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 H...

Page 523: ...1016771 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...

Page 524: ...n valve 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 e...

Page 525: ...nt Prepare for the R134a refrigerant recovery and recycling machine 9 1 Connect low pressure side hose blue 4 from the recovery and recycling machine 9 to LO pressure side charging valve 1 Connect hig...

Page 526: ...ump 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 full...

Page 527: ...completely 2 Connect the center charging hose green 5 to the can tap valve 7 fitting and then loosen the center charging hose green 5 at the center fitting of manifold gauge until hiss can be heard A...

Page 528: ...t 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 container...

Page 529: ...glass 7 becomes as stated below depending on refrigerant charged amount Q Insufficient refrigerant charge Air bubbles pass continuously the sight glass when pressure on the LO pressure side is over 99...

Page 530: ...meter across the 1P connector 1 of magnetic clutch and compressor body 2 If the measurement is not within the factory specifications replace the stator coil W1014331 Air Gap 1 Check the air gap with f...

Page 531: ...wiper relay 2 Connect jumper leads across the wiper relay bulb 2 and 12 V battery 3 as shown in the figure left 3 When the jumper lead 4 is connected with terminal a the bulb 2 should light up When i...

Page 532: ...4 If the voltage differs from the battery 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 I...

Page 533: ...itch to set it at ON position indicator ON and then measure a voltage using a circuit tester 6 If a measured voltage does not comply with the values in the table below the control panel wiring harness...

Page 534: ...ltmeter across the terminal c and chassis Make the following measurement with the terminals connected 2 Turn the main switch to ON position 3 Press the recirculation fresh air selection switch to set...

Page 535: ...tor 2 of blower motor 1 3 Connect a jumper lead from battery 3 positive terminal to connector terminal b 4 Connect a jumper lead from battery negative terminal to connector terminal e momentarily 5 If...

Page 536: ...Checking 1 Confirm whether the mode switch 2 is defective Refer to 4 Control Panel in this section 2 Turn the main switch to ON position 3 Turn the blower switch at 1 position 4 Turn the mode switch...

Page 537: ...is defective Refer to 4 Control Panel in this section 2 Turn the main switch to ON position 3 Turn the blower switch at 1 position 4 Push the recirculation fresh air selection switch to Recirculation...

Page 538: ...clutch is turned off At this time read the HI pressure gauge of the manifold gauge If this pressure reading differs largely with the setting pressure replace the pressure switch with a new one 2 LO Pr...

Page 539: ...switch is faulty W1021874 12 Front Wiper Motor Front Wiper Motor 1 Raise up the front wiper arm 3 2 Turn the main switch to ON position 3 Push the front wiper switch to ON position 4 Count the number...

Page 540: ...ow is not indicated the switch is faulty W1023782 14 Rear Wiper Motor If Equipped Rear Wiper Motor 1 Raise up the rear wiper arm 3 2 Turn the main switch to ON position 3 Push the front wiper switch t...

Page 541: ...olant is drained reinstall the radiator drain plug W1024819 Preparation 1 1 Open the bonnet 2 and disconnect the battery 3 negative terminal and 6P connector 5 for head light 2 Remove the bonnet dampe...

Page 542: ...the air condenser belt tension Refer to 7 CHECK AND MAINTENANCE at G GENERAL section W1029723 Preparation 3 1 Remove the steering joint shaft 1 2 Remove the hose clamp 2 3 Disconnect the accelerator w...

Page 543: ...mat 1 3 and mat 2 4 3 Remove the floor cover 5 4 Disconnect the connectors 6 and pull out them from cabin 5 Disconnect the connector 7 and pull out them from cabin W1027792 1 Fuel Filling Port 2 Fuel...

Page 544: ...rod 4 When reassembling Be sure to adjust the clutch cable for the clutch pedal free travel Refer to 4 CHECKING AND ADJUSTING at 2 CLUTCH section Be sure to adjust the shuttle cable for the shuttle le...

Page 545: ...control wire 6 7 Disconnect the lowering speed adjusting rod 5 8 Disconnect the ground cable 7 When reassembling Be sure to adjust the PTO clutch lever movement by the PTO clutch cable 4 Refer to 4 CH...

Page 546: ...sembling W1035187 Dismounting Cabin 1 Remove the cabin mounting all screws and nut 1 2 Set the cabin dismounting tool 2 to the cabin 3 Dismounting the cabin from tractor body When reassembling W102997...

Page 547: ...etter 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 replacing the compres...

Page 548: ...reassembling 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...

Page 549: ...er to 1 Discharging the Refrigerant in this section W1031483 Seat Floor Mats and Floor Cover 1 Disconnect the battery negative cable from battery 2 Disconnect the 2P connector 1 for OPC buzzer 3 Remov...

Page 550: ...resistor 4 Disconnect the 5P connector 7 for recirculation fresh air selection motor 5 Disconnect the 7P connector 3 for air mix control motor 6 Disconnect the 1P connector 5 for thermistor 7 Disconn...

Page 551: ...L8 or equivalent to O rings W1025169 4 Removing Air Conditioner Pipes Discharging Refrigerant Gas 1 Refer to 1 Discharging the Refrigerant in this section W1033151 Cover and Guide 1 Remove the both si...

Page 552: ...Remove the pressure pipes joint 3 Disconnect the high pressure pipe 2 3 and low pressure pipe 2 then cap the open fitting immediately to keep moisture out of the system 4 Pull out the high pressure pi...

Page 553: ...sconnect the heater hoses 2 and 3 from the engine 3 Remove the clamps 4 When reassembling Note the inlet hose and outlet hose W1034358 Seat Mats and Floor Cover 1 Refer to 3 Removing Air Conditioner U...

Page 554: ...d remove the inner cover 1 R H 6 W1034733 Removing Heater Hoses 1 Disconnect the heater hoses 1 and 2 2 Pull out the heater hoses 1 and 2 from the bottom of the cabin 3 Take out the heater hoses 1 and...

Page 555: ...ard alternately to cut the adhered part NOTE Q 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...

Page 556: ...Ultrafast or equivalent on the glasses as shown in figure left NOTE Q Apply the Sika Tack Ultrafast or equivalent with the jig having the specified tip shape as shown in the figure left Apply it with...

Page 557: ...nting nut 11 and wiper arm 7 8 Remove the wiper link cap 10 and nut 9 9 Disconnect the earth lead setting screw 10 Remove the front wiper motor bracket 13 mounting screws 15 then take out the front wi...

Page 558: ...is added or deleted Reference W1060178 Tightening torque Wiper arm mounting nut 7 9 to 9 3 N m 0 8 to 1 0 kgf m 5 8 to 6 9 lbf ft Wiper motor mounting screw 7 9 to 9 3 N m 0 8 to 1 0 kgf m 5 8 to 6 9...

Page 559: ...de No 9Y011 13746 2006 05 S EI EI e KUBOTA Corporation EDITOR KUBOTA FARM INDUSTRIAL MACHINERY SERVICE LTD 64 ISHIZU KITAMACHI SAKAI KU SAKAI CITY OSAKA 590 0823 JAPAN PHONE 81 72 241 1129 FAX 81 72 2...

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