Kubota M9540 Workshop Manual Download Page 505

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9-S4

M8540, M9540, WSM

ELECTRICAL SYSTEM

EASY CHECKER (Continued)

W1013580

ENGINE KEY SWITCH SHUT-OFF SYSTEM

W1011890

Symptom

Probable Cause

Solution

Reference
Page

Coolant Temperature
Indicator Does Not
Light When Water
Temperature Gauge
Points to H (Red
Zone)

Fuse blown

Replace

–

Coolant temperature sensor is defective

Replace

9-S26

Wiring harness disconnected or improperly
connected (between panel and coolant
temperature sensor)

Repair or replace

–

Circuit in panel board is defective

Replace

9-S24

4WD Indicator Lamp
Lights Up When 4WD
Is Not Engaged

4WD switch is defective

Replace

9-S31, 32

4WD Indicator Lamp
Does Not Light When
4WD Is Engaged

4WD switch is defective

Replace

9-S31, 32

Air Cleaner Clogged
Lamp Lights Up

Air cleaner clogged

Clean or replace

G-25

Air cleaner sensor defective

Repair or replace

9-S33

Short circuit between air cleaner sensor lead and
chassis

Replace

9-S33

Circuit panel board defective

Repair or replace

9-S24

Air Cleaner Clogged
Lamp Does Not Light
When Air Cleaner
Clogged

Air Cleaner sensor defective

Replace

9-S33

Wiring harness disconnected or improperly
connected (between panel board and air cleaner
sensor, between air cleaner sensor and ground)

Repair or replace

–

Engine Does Not
Stop When Main
Switch Is Turned
OFF

Fuse blown

Replace

9-S10, 11

Key stop relay defective

Replace

9-S41

Engine stop relay defective

Replace

9-S41

Meter panel defective

Replace

9-S24

Wiring harness disconnected or improperly
connected

Repair or replace

–

Engine Does Not
Start

Fuse or slow blow fuse blown

Replace

9-S10, 11

Engine stop solenoid defective

Replace

9-S17

Engine stop relay defective

Replace

9-S41

Key stop relay defective

Replace

9-S41

PTO switch defective

Replace

9-S27

Shuttle neutral switch defective

Replace

9-S28

KiSC issued 09, 2008 A

Summary of Contents for M9540

Page 1: ...M8540 M9540 WORKSHOP MANUAL TRACTOR KiSC issued 09 2008 A...

Page 2: ...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 lists...

Page 3: ...al and on labels on the machine itself to warn of the possibility of personal injury Read these instructions carefully It is essential that you read the instructions and safety regulations before you...

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

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

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

Page 7: ...lowing safety decals pictorial safety labels are installed on the machine If a decal becomes damaged illegible or is not on the machine replace it The decal part number is listed in the parts list Q R...

Page 8: ...6 M8540 M9540 WSM SAFETY INSTRUCTIONS KiSC issued 09 2008 A...

Page 9: ...7 M8540 M9540 WSM SAFETY INSTRUCTIONS KiSC issued 09 2008 A...

Page 10: ...8 M8540 M9540 WSM SAFETY INSTRUCTIONS Q CABIN Model KiSC issued 09 2008 A...

Page 11: ...9 M8540 M9540 WSM SAFETY INSTRUCTIONS KiSC issued 09 2008 A...

Page 12: ...10 M8540 M9540 WSM SAFETY INSTRUCTIONS KiSC issued 09 2008 A...

Page 13: ...del 2560 mm 100 8 in CABIN Model 2650 mm 104 3 in Wheel base 2250 mm 88 6 in Tread Front 1514 1554 1608 mm 59 61 61 18 63 31 in Rear 1503 1599 1695 mm 59 17 62 95 66 73 in Minimum ground clearance ROP...

Page 14: ...0 43 0 27 0 46 0 29 0 39 0 24 2 0 55 0 34 0 59 0 37 0 50 0 31 3 0 73 0 45 0 78 0 48 0 65 0 40 4 0 94 0 58 0 99 0 62 0 84 0 52 5 1 16 0 721 1 23 0 764 1 04 0 646 6 1 44 0 895 1 48 0 920 1 25 0 777 L 1...

Page 15: ...0 46 0 29 0 39 0 24 2 0 55 0 34 0 60 0 37 0 50 0 31 3 0 73 0 45 0 79 0 49 0 66 0 41 4 0 93 0 58 1 01 0 628 0 85 0 53 5 1 15 0 715 1 25 0 777 1 05 0 652 6 1 43 0 889 1 50 0 932 1 26 0 783 L 1 2 8 1 7...

Page 16: ...14 M8540 M9540 WSM DIMENSIONS DIMENSIONS ROPS Model KiSC issued 09 2008 A...

Page 17: ...15 M8540 M9540 WSM DIMENSIONS CABIN Model KiSC issued 09 2008 A...

Page 18: ...G GENERAL KiSC issued 09 2008 A...

Page 19: ...URS G 22 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 32 8 CHECK POINTS OF EVERY 600 HOURS G...

Page 20: ...ng your local KUBOTA distributor always specify engine serial number tractor serial number and hourmeter reading W1010800 1 Tractor Identification Plate 2 Tractor Serial Number 3 Engine Serial Number...

Page 21: ...Year 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...

Page 22: ...le E2 engines may result in emission levels out of compliance with the original E3 design and EPA or other applicable regulations Please refer to the emission label located on the engine head cover to...

Page 23: ...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 bef...

Page 24: ...c 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 th...

Page 25: ...re 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 ba...

Page 26: ...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 are...

Page 27: ...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 pro...

Page 28: ...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 10 7 L 11 3 U S qts 9 4 Imp qts API Service Classification CF or CI 4 External...

Page 29: ...case support 2 Until grease overflows Multipurpose NLGI 2 or NLGI 1 GC LB grease Front axle support 2 Top link 1 Top link bracket 2 Lift rod 2 Hydraulic lift cylinder pin 4 Steering joint shaft CABIN...

Page 30: ...n 0 5 sulfur content is used reduce the service interval for engine oil and filter by 50 DO NOT use diesel fuel with sulfur content greater than 1 0 Diesel fuels specified to EN 590 or ASTM D975 are r...

Page 31: ...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 to...

Page 32: ...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 ring P...

Page 33: ...every 100 Hr 1 G 25 Replace every 1 year 2 G 25 Secondary element Replace every 1 year G 25 8 Fuel line Check every 100 Hr G 26 Replace every 2 years G 26 9 Parking brake lever Adjust every 100 Hr G...

Page 34: ...every 800 Hr G 33 26 Fuel injection nozzle injection pressure Check every 1500 Hr G 33 27 Turbocharger Check every 3000 Hr G 34 28 Injection pump Check every 3000 Hr G 34 29 Intake air heater Check ev...

Page 35: ...on by reading the indicator annually W1025390 No Item Service Interval Since then Impor tant Refe rence page 50 100 150 200 250 300 350 400 450 500 550 600 650 700 1 Inner air filter Clean every 200 H...

Page 36: ...and clean the radiator screen grill oil cooler and battery mount 12 Check and clean the air conditioner condenser screen CABIN model 13 Check the nuts of tires are tight 14 Check the number plate for...

Page 37: ...ngine before changing oil filter cartridge Allow engine to cool down sufficiently oil can be hot and can burn 1 Remove the oil filter 1 2 Put a film of clean engine oil on rubber seal of new filter 3...

Page 38: ...the filter quickly until it contacts the mounting surface Tighten filter by hand and additional 1 2 turn only 7 After the new filter has been replaced fill with the oil up to the upper notch on the di...

Page 39: ...ely after changing the transmission fluid Run the engine at medium speed for a few minutes to prevent damage to the transmission W1022400 Changing Front Differential Case Oil 1 To drain the used oil r...

Page 40: ...After draining reinstall the drain plugs 3 Fill with the new oil up to the filling plug port Refer to 4 LUBRICANTS FUEL AND COOLANT in this section 4 After filling reinstall the filling plugs 2 NOTE...

Page 41: ...the clutch pedal 2 fully 4 Shift the shuttle shift lever 1 to the neutral position 5 Turn the key to START position 6 The engine must not crank 7 If it cranks inspect the safety switch W1062967 Checki...

Page 42: ...e grease to following points every 100 hours 2 If you operated the machine in extremely wet and muddy condition lubricate grease fittings more often To be continued 1 Battery Terminals 2 Grease Fittin...

Page 43: ...GENERAL Continued W1025259 5 Grease Fitting Top Link Bracket 6 Grease Fitting Lifting Rod 7 Grease Fitting Top Link 8 Grease Fitting Hydraulic Lift Cylinders Pin 9 Steering Joint Shaft A CABIN Model...

Page 44: ...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 run t...

Page 45: ...bleed the fuel system Refer to 14 OTHERS in this section W1067279 Adjusting Brake Pedal 1 To check and adjusting for brake pedal refer to 1 CHECKING AND ADJUSTING at 5 BRAKES section W1025046 Adjustin...

Page 46: ...eum 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 reverse polarities wi...

Page 47: ...n 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 10 m...

Page 48: ...ach the snap ring 1 of the tie rod joint W1026029 Draining Fuel Tank Water 1 Loosen the drain plug 2 at the bottom of the fuel tank 1 to let sediments impurities and water out of the tank Finally tigh...

Page 49: ...flow NOTE Q If the filter is very dirty Dip the filter in lukewarm water with mild dish washing detergent Move it up and down as well as left and right to loosen dirt Rinse the filter with clean wate...

Page 50: ...9 Adjusting Air Conditioner Belt Tension CABIN Model CAUTION Be sure to stop the engine before checking belt tension 1 Push on the belt between the pulleys with a finger under 9 8 N 10 kgf 22 lbf load...

Page 51: ...ction W1026760 Cleaning Water Separator This job should not be done in the field but in a clean place 1 Close the fuel cock 1 2 Unscrew the retainer ring 2 and remove the cup 3 and rinse the inside wi...

Page 52: ...front axle 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 2 screw in the adjusting screw 1 unti...

Page 53: ...NG at 9 ELECTRICAL SYSTEM section W1074973 12 CHECK POINTS OF EVERY 1 YEAR Replacing Air Cleaner Primary Element and Secondary Element 1 Refer to 4 CHECK POINTS OF EVERY 100 HOURS in this section W102...

Page 54: ...nd 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 op...

Page 55: ...ore 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 several...

Page 56: ...ry standards that necessitate a minimum glycol content in the concentrated anti freeze When the coolant level drops due to evaporation add water only to keep the antifreeze mixing ratio less than 50 I...

Page 57: ...HECKING DISASSEMBLING AND SERVICING at 5 BRAKES section W1079117 Replacing Equalizer Kit 1 To check and adjusting for brake pedal refer to 4 CHECKING DISASSEMBLING AND SERVICING at 5 BRAKES section W1...

Page 58: ...ot start try it several times at 30 second intervals 4 Accelerate the engine to remove the small portion of air left in the fuel system 5 If air still remains and the engine stops repeat the above ste...

Page 59: ...lb 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 the specified wa...

Page 60: ...nt 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 Engin...

Page 61: ...n Use to measure diesel engine compression and diagnostics of need for major overhaul W10242000 Oil Pressure Tester Code No 07916 32032 Application Use to measure lubricating oil pressure W10243180 1...

Page 62: ...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 0 039...

Page 63: ...a 6 3 m 0 00025 in b 6 3 m 0 00025 in C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in A 157 mm 6 1811 in B 14 5 mm 0 571 in C 120 mm 4 7244 in D 30 0 mm dia 1 1811 in dia E 42 000 mm dia 1 6535...

Page 64: ...I 57 9 to 58 1 mm dia 2 2795 to 2 2874 in dia J 79 5 mm dia 3 1299 in dia K 87 mm dia 3 452 in dia L 12 mm 0 4724 in M 40 mm 1 5748 in N 120 mm 4 7244 in A 20 mm dia 0 79 in dia B 11 7 to 11 9 mm dia...

Page 65: ...0 4724 in F 7 9 to 8 1 mm 0 3110 to 0 3189 in G 20 mm 0 0787 in H 130 mm dia 5 1181 in dia I 99 4 to 99 6 mm dia 3 9134 to 3 9213 in dia J 95 05 to 95 20 mm dia 3 7421 to 3 7480 in dia K 3 mm dia 0 11...

Page 66: ...1 61 in dia P 32 mm dia 1 26 in dia Q 33 961 to 34 0 mm dia 1 3370 to 1 3386 in dia R 18 mm dia 0 71 in dia S 19 967 to 20 0 mm dia 0 7861 to 0 7874 in dia U 3 mm 0 12 in V 149 1 to 149 4 mm 5 8701 t...

Page 67: ...94 in dia G 50 421 to 50 44 mm dia 1 9851 to 1 9858 in dia H 8 mm 0 31 in I 2 mm 0 08 in J 35 mm 1 38 in K 5 mm 0 20 in L 0 26 rad 15 A 35 mm 1 38 in B 33 mm 1 30 in C Chamfer 0 5 mm 0 02 in D 1 mm 0...

Page 68: ...et W1037894 No Name of Part Q ty 1 Bracket 1 2 Flange Nut 1 3 Washer 1 4 Shaft 1 5 Piece 1 1 6 Clevis 1 7 Washer 1 8 Cotter Pin 1 9 Joint 1 1 10 Piece 2 1 11 Joint 2 1 12 Piece 3 1 a Tool 3 b Tool 4 c...

Page 69: ...m 2 76 in O 19 5 mm 0 77 in P 12 mm 0 47 in Q 0 8 mm 0 03 in R 6 mm 0 24 in A 26 mm 1 02 in B 18 mm 0 71 in C 16 5 to 17 0 mm 0 6496 to 0 6693 in D 1 5 mm 0 06 in E 54 0 to 54 2 mm dia 2 1260 to 2 133...

Page 70: ...693 in D 1 5 mm 0 06 in E 53 5 to 53 7 mm dia 2 1063 to 2 1142 in dia F 50 05 to 50 25 mm dia 1 9705 to 1 9783 in dia G 16 mm 0 63 in H Chamfer 1 mm 0 04 in I 8 5 mm dia 0 33 in dia J 0 4 mm 0 0157 in...

Page 71: ...04 in I 8 5 mm dia 0 33 in dia J 0 4 mm 0 0157 in K 3 mm 0 12 in L 19 mm 0 75 in M Chamfer 0 5 mm 0 02 in N 36 mm 1 42 in O 45 mm dia 1 77 in dia P 0 78 rad 45 Q 11 5 mm 0 45 in A 480 mm 18 90 in B 50...

Page 72: ...ss than 3 mm Less than 0 1 in I M14 x Pitch 1 5 J 0 52 rad 30 K 32 mm 1 3 in L M14 x Pitch 1 5 M 45 mm 1 8 in N 30 mm 1 2 in O 15 mm 0 59 in P 0 8 mm radius 0 03 in radius Q Chamfer 1 mm 0 04 in R Les...

Page 73: ...1 6 to 12 1 mm 0 4567 to 0 4764 in a 14 94 to 15 mm dia 0 5882 to 0 5906 in dia J 6 to 6 1 mm 0 2362 to 0 2402 in b 55 mm 2 1654 in K 13 mm dia 0 5118 in dia c 66 mm 2 5984 in L 11 mm 0 4331 in d 100...

Page 74: ...in H C0 2 mm 0 0079 in I R8 mm 0 3150 in J 1 mm 0 0394 in K 1 mm 0 0394 in L C0 2 mm 0 0079 in M C0 2 mm 0 0079 in N 29 mm 1 1417 in O 6 mm 0 2362 in P 10 7 mm 0 4213 in Q 35 mm 1 3780 in R 99 3 mm 3...

Page 75: ...ion Use for aligning the crankcase 1 and 2 W1047882 A 115 mm 4 53 in B 56 mm 2 2 in C 17 mm 0 67 in D 20 mm 0 79 in E 14 mm dia 0 55 in dia F 11 mm dia 0 43 in dia G 14 mm dia 0 55 in dia H 17 5 mm 0...

Page 76: ...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 Cabl...

Page 77: ...rake Air Bleeder Code No 07916 54001 Application This allows easy air bleed of the hydraulic brake W10516480 Relief Valve Setting Pressure Adaptor G Code No 07916 52751 Application This offers easy me...

Page 78: ...lowing 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 in...

Page 79: ...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 mm 0...

Page 80: ...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 spline E 22 4 to 28 4 mm 0 88 to 1 11 in F 4 to 6 mm 0 16 to 0 2...

Page 81: ...n B 40 mm 1 6 in C 16 mm 0 63 in D 8 mm 0 3 in E 16 mm 0 63 in F 5 2 mm dia 0 20 in dia G 5 70 to 5 90 mm 0 225 to 0 232 in H 80 mm 3 1 in A M5 x P1 0 x 12 mm depth 0 47 in depth B 19 mm 0 75 in C 5 m...

Page 82: ...35 mm 1 4 in M Chamfer 0 5 mm 0 02 in F Radius 5 mm 0 2 in N 7 mm 0 3 in G 10 00 to 10 27 mm 0 3937 to 0 4043 in O 20 mm 0 79 in H 20 mm 0 79 in X X X View direction A 330 mm 13 0 in G 6 00 to 6 58 m...

Page 83: ...0 78 rad 45 L 10 mm 0 39 in M 50 mm 1 97 in N 55 mm 2 17 in O 25 mm 0 97 in P 80 mm 3 15 in A 12 75 to 12 90 mm square 0 50 to 0 51 in square B 32 500 to 32 525 mm dia 1 2795 to 1 2805 in dia C 35 mm...

Page 84: ...l W1062519 A 54 85 to 54 95 mm 2 159 to 2 163 in B 11 mm 0 43 in C 60 mm 2 36 in D 30 mm 1 18 in E 48 85 to 48 95 mm 1 923 to 1 927 in F 78 mm dia 3 07 in dia G 40 mm dia 1 57 in dia H 50 mm 1 97 in I...

Page 85: ...ad 9 0 C 60 18 mm 2 369 in 65 18 mm 2 566 in 75 18 mm 2 960 in D 61 18 mm 2 409 in 66 18 mm 2 606 in 76 18 mm 2 999 in E 42 mm 1 7 in 42 mm 1 7 in 42 mm 1 7 in F 10 mm 0 39 in 10 mm 0 39 in 10 mm 0 39...

Page 86: ...n 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 to 1...

Page 87: ...d dual hi lo valve W1039227 A 50 mm 2 0 in H 16 5 mm 0 650 in N 7 5 mm dia 0 30 in dia B 22 mm 0 87 in I M18 P1 5 O 1 0 rad 60 C 13 mm 0 51 in J 0 79 rad 45 P 5 mm 0 2 in D 15 mm 0 59 in K 2 5 mm 0 03...

Page 88: ...nkage A 18 mm 0 71 in G PS 1 4 M 4 mm 0 16 in B 15 mm 0 59 in H M7 x P1 0 N 2 mm 0 079 in C 15 mm 0 59 in I 0 79 rad 45 O 2 mm dia 0 079 in dia D 3 mm 0 12 in J 0 79 rad 45 P 5 mm dia 0 20 in dia E 0...

Page 89: ...on 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 W1013764...

Page 90: ...he 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 We...

Page 91: ...ANT Q Excessive wear of tires may occur due to improper gear ratio Through the tire pressure is factory set to the prescribed level it naturally drops slowly in the course of time Thus check it every...

Page 92: ...sired position and tighten the bolts 3 Adjust the toe in Refer to 5 CHECK POINTS OF EVERY 200 HOURS at 7 CHECK AND MAINTENANCE in this section IMPORTANT Q Always attach wheels as shown in the figure I...

Page 93: ...in 1656 mm 65 20 in 320 70R24 1515 mm 59 65 in 1555 mm 61 22 in 1609 mm 63 35 in 320 85R24 1566 mm 61 65 in 1652 mm 61 50 in 360 70R24 1514 mm 59 61 in 1554 mm 61 18 in 1608 mm 63 31 in 44 x 18 00 20...

Page 94: ...d thereafter according to service interval Refer to 5 CHECK POINTS OF EVERY 50 HOURS at 7 CHECK AND MAINTENANCE in this section W1082792 Tightening torque Rear wheel mounting nut M18 343 to 401 N m 35...

Page 95: ...ERAL 3 WHEEL HUB W1043392 Front wheel hub Rear wheel hub Screw circle diameter A 203 2 mm 8 in 203 2 mm 8 in Number of screws 8 8 Screws M16 P1 5 M18 P1 5 Hub pilot diameter B 152 4 mm 6 in 152 4 mm 6...

Page 96: ...ium chloride solution do not pour water over calcium chloride since this results in chemical reaction which will cause high temperature Instead add a small amount of calcium chloride to the water at a...

Page 97: ...n is completed reset the air valve and pump air into the tire to the specified pressure Weight of Calcium Chloride Solution Filling 75 of Full Capacity of a Tire W1033435 Tire sizes 480 70R34 Slush fr...

Page 98: ...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 compr...

Page 99: ...improper implements are not 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 Rea...

Page 100: ...Mid 800 L 211 U S gals 176 Imp gals 1000 L 260 U S gals 220 Imp gals Rear 3 point Hitch 800 L 211 U S gals 176 Imp gals 1000 L 260 U S gals 220 Imp gals Draw bar 4500 L 1200 U S gals 990 Imp gals 5000...

Page 101: ...11 Front Blade 1 2 Max Cutting Width 2430 mm 96 in 2600 mm 102 in Max Oil Pressure 19 6 MPa 200 kgf cm2 2844 psi 12 Rear Blade Max Cutting Width 2430 mm 96 in 2600 mm 102 in Max Oil Pressure 19 6 MPa...

Page 102: ...kg 2888 lbs 1320 kg 2910 lbs E 1550 kg 3417 lbs 1500 kg 3307 lbs 1500 kg 3307 lbs 1600 kg 3527 lbs Trailer loading weight max capacity W3 Unbraked towable mass 3000 kg 6614 lbs 3000 kg 6614 lbs 3000 k...

Page 103: ...1 ENGINE KiSC issued 09 2008 A...

Page 104: ...BRICATING SYSTEM 1 M5 1 OIL COOLER 1 M5 4 COOLING SYSTEM 1 M6 1 THERMOSTAT 1 M6 2 BOTTOM BYPASS SYSTEM 1 M7 5 FUEL SYSTEM 1 M8 1 GOVERNOR 1 M8 2 MECHANICAL TIMER WITH COLD START ADVANCE FUNCTION 1 M11...

Page 105: ...s the four valve system two inlet valves with double ports and two exhaust valves with the new E CDIS Thus this engine achieves high combustion efficiency and complies with various regulations of exha...

Page 106: ...sily assemble disassemble it The cylinder is a linerless type which enables good cooling operation less strain and good abrasion resistance W1013119 2 HALF FLOATING HEAD COVER The rubber packing is fi...

Page 107: ...inder By so doing injected fuel and suction air can be mixed more uniformly leading to more stable higher combustion performance In other words cleaner emission higher power output lower fuel consumpt...

Page 108: ...lube oil W1015665 6 BUILT IN DYNAMIC BALANCER Engine are sure to vibrate by piston s reciprocation Theoretically three cylinder engines are much less prone to cause vibration than four cylinder ones...

Page 109: ...ut also warms the cool engine oil shoftly after start up As shown in the figure the oil flows inside the connected cooler plate whereas coolant is kept circulating outside the cooler plate thereby coo...

Page 110: ...uch 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 undersho...

Page 111: ...at is held closed and the coolant is allowed to flow through the bypass pipe and to circulate in the engine When the temperature exceeds the thermostat valve opening level the thermostat fully opens i...

Page 112: ...anical 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 governor...

Page 113: ...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 the engine is over...

Page 114: ...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 manually...

Page 115: ...injection timing is max advanced When the engine rpm is low and engine oil temperature is higher than 70 C the fuel injection timing advance is 0 degree The fuel injection timing advance by engine oi...

Page 116: ...ming is variably changed by centrifugal force of the timer flyweights which meets engine rpm W1017759 1 Timer Flyweight 2 Injection Pump Gear 3 Fuel Camshaft A At Low rpm B At High rpm a No Gap Betwee...

Page 117: ...ciently 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 at...

Page 118: ...e valve is again lifted and main injection can begin Second opening pressure is represented by point F in the bottom left hand figure and B to C in the bottom right hand figure 4 INJECTION PUMP WITH F...

Page 119: ...ance and to reduce the white smoke at cold starting The intake air heater is mounted on the intake manifold In this new construction there is no need to arrange any glow plug on the cylinder head This...

Page 120: ...d valve and thermo valve When the coolant temperature is getting higher thermo valve is open and the boost pressure of intake manifold gets to reach the diaphragm of mechanical EGR valve If the coolan...

Page 121: ...tant to clogging up compact and efficient tubes internally W1175338 B Thermo Valve Thermo valve controls boost pressure ON OFF for the EGR valve If the coolant temperature is low thermo valve is close...

Page 122: ...onfluence of exhaust gas after passing the EGR valve and intake air It operates by the pressure difference between inside of the crankcase and the atmosphere and prevents backflow of the mixture of ex...

Page 123: ...r 1 S28 4 SEPARATING ENGINE CABIN MODEL 1 S29 1 Separating Front Axle and Front Frame as a Unit 1 S29 2 Separating Engine 1 S33 3 Separating Engine from Clutch Housing Case 1 S34 5 REMOVING EXTERNAL C...

Page 124: ...aining nut 1 S39 Incorrect injection timing Adjust 1 S19 Fuel camshaft worn Replace Injection nozzle clogged Repair or replace 1 S21 39 Injection pump malfunctioning Repair or replace 1 S21 52 Seizure...

Page 125: ...he turbocharger assembly 1 S36 Turbocharger fin or other part damaged due to foreign matters Replace the turbocharger assembly 1 S36 Either White or Blue Exhaust Gas Is Observed Excessive engine oil R...

Page 126: ...groove worn Replace piston 1 S60 73 Valve stem and valve guide worn Replace 1 S66 Crankshaft bearing and crank pin bearing worn Replace 1 S75 76 77 Oil leaking due to defective seals or packing Repla...

Page 127: ...with dust Clean Inside of radiator corroded Clean or replace G 35 Coolant flow route corroded Clean or replace G 35 Radiator cap defective Replace 1 S17 Overload running Reduce the load Head gasket de...

Page 128: ...psi 250 min 1 rpm 2 56 MPa 250 min 1 rpm 26 1 kgf cm2 250 min 1 rpm 371 psi 250 min 1 rpm Variance Among Cylinders 10 or less Valve Seat Angle Intake Angle Exhaust Width Intake Width Exhaust 1 0 rad...

Page 129: ...0039 in 0 1 mm 0 0039 in Valve Clearance Cold 0 23 to 0 27 mm 0 0091 to 0 010 in Intake Valve Timing Open Close 0 24 rad 14 before T D C 0 63 rad 36 after B D C Exhaust Valve Timing Open Close 0 79 ra...

Page 130: ...32 mm 0 3552 to 0 3556 in 0 15 mm 0 0059 in Push Rod Alignment 0 25 mm 0 0098 in Tappet to Tappet Guide Tappet Guide Bore Tappet Clearance I D O D 0 020 to 0 062 mm 0 00079 to 0 0024 in 24 000 to 24 0...

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

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

Page 133: ...3 mm 0 01 in Outer Rotor to Pump Body Clearance 0 100 to 0 184 mm 0 00394 to 0 00724 in 0 3 mm 0 01 in Inner Rotor to Cover Clearance 0 025 to 0 075 mm 0 00099 to 0 0029 in 0 225 mm 0 00866 in Relief...

Page 134: ...seconds 18 63 17 65 MPa 190 0 180 0 kgf cm2 2702 2560 psi 5 seconds 18 63 17 65 MPa 190 0 180 0 kgf cm2 2702 2560 psi Fuel Injection Nozzle Injection Pressure 1st stage Injection Pressure 2nd stage Va...

Page 135: ...aster cylinder hose and return hose retaining nut 23 to 27 2 3 to 2 8 17 to 20 Oil cooler return pipe nut 49 to 68 5 0 to 7 0 37 to 50 Delivery pipe retaining nut 49 to 68 5 0 to 7 0 37 to 50 Damper d...

Page 136: ...unting screw Length 25 mm 1 0 in 49 to 55 5 0 to 5 7 37 to 41 Connecting rod screw 79 to 83 8 0 to 8 5 58 to 61 Flywheel screw 98 1 to 107 10 0 to 11 0 73 4 to 79 5 Flywheel housing mounting screw M14...

Page 137: ...re the pressure more than twice NOTE Q Check the compression pressure with the specified valve clearance Always use a fully charged battery for performing this test Variances in cylinder compression v...

Page 138: ...alve stem then tighten the lock nut 6 Loosen the lock nut 4 of adjusting screw 3 push rod side and insert the thickness gauge between the rocker arm and the bridge head Set the adjusting screw to the...

Page 139: ...ine oil pressure switch to the specified torque W10349520 3 Cooling System Fan Belt Tension 1 Measure the deflection A depressing the belt halfway between the fan drive pulley and alternator pulley at...

Page 140: ...radiator tester on the radiator cap 2 Set a radiator tester Apply the specified pressure of 88 kPa 0 9 kgf cm2 13 psi 3 Check if the pressure drop to less than 59 kPa 0 6 kgf cm2 9 psi in 10 seconds...

Page 141: ...en the water temperature rises the thermostat valve will open allowing it to fall down from the string Read the temperature at this moment on the thermometer 4 Continue heating the water and read the...

Page 142: ...ounterclockwise and stop turning when the fuel begins to come up to get the present injection timing 11 Check to see the degree on flywheel The flywheel has mark 1TC 10 and 20 for the crank angle befo...

Page 143: ...o increase the pressure 6 Stop the starter 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 t...

Page 144: ...ve 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 assembly or rep...

Page 145: ...31 F cool down the engine 3 Start the engine and go to check 1 immediately 4 After completing checking 1 arrange the coolant temperature is getting over 70 C 158 F 5 If the coolant temperature is over...

Page 146: ...1 S23 M8540 M9540 WSM ENGINE 2 If the coolant temperature is over 70 C 158 F the surface temperature of EGR pipe must be over 100 C 212 F KiSC issued 09 2008 A...

Page 147: ...ide 1 Check the inlet hose 1 of the compressor cover 3 to see if there is no air leak 2 Check for loose connections or cracks in the suction side of the intake hose 3 If any air leak is found change t...

Page 148: ...eassembling Apply grease to the splines of the propeller shaft 5 and pinion shaft Tap in the roll pins 2 as shown in figure W1027651 Power Steering Hose 1 Disconnect both power steering delivery hoses...

Page 149: ...positive cable first W1052591 Cover Power Steering Hose and Wire Harness for L H Side 1 Remove the side cover 1 both side 2 Remove the power steering hose bands 2 3 Disconnect the wire harness 6 from...

Page 150: ...ffler pipe stay 4 and remove the muffler 3 with muffler pipe 2 Disconnect the air cleaner hose 1 3 Disconnect the radiator upper hose 2 and lower hose 5 4 Disconnect the 1P connectors 7 from the air c...

Page 151: ...ousing 1 Hoist the engine using the hoist and chain 2 Remove the engine mounting screws and nuts and separate the engine from the clutch housing When reassembling Apply molybdenum disulphide Three Bon...

Page 152: ...dampers 4 4 Remove the bonnet 1 5 Remove the both side covers 2 When reassembling The connector 3 should be placed within the space of controller pipe 7 power steering controller 5 and stay 6 IMPORTA...

Page 153: ...delivery hose to original position The power steering hose with blue tape 2 fix to rear joint W1095987 1 Muffler Pipe Tightening torque Power steering delivery hose 1 and 2 retaining nut 23 to 27 N m...

Page 154: ...tor 13 starter 14 and engine oil pressure switch 15 When reassembling Assemble the heater hoses as align the both white mark W1096401 Hydraulic Pipe and U joint 1 Disconnect the delivery pipe retainin...

Page 155: ...NG AND CHARGING at 10 CABIN section W1098475 Muffler Radiator Hoses and Oil Cooler Pipe 1 Remove the muffler 1 2 Disconnect the radiator upper hose 2 and lower hose 3 3 Disconnect the oil cooler pipe...

Page 156: ...1 Remove the clutch wire cable nut 1 2 Loose the cable retaining nut 2 3 Remove the clutch wire cable 3 and draw out the cable to outside of cabin When reassembling Adjust the clutch pedal free travel...

Page 157: ...Hoist the engine using the hoist and chain 2 Remove the engine mounting screws and nut and separate the engine from the clutch housing When reassembling Apply molybdenum disulphide Three Bond 1901 or...

Page 158: ...028793 Fan Starter Alternator and Power Steering Controller CABIN Model 1 Remove the air conditioner drive belt 7 2 Remove the fan 1 and fan belt 6 3 Remove the alternator 2 and starter 5 4 Remove the...

Page 159: ...4 and take off the pipe 1 2 3 Remove the bolts 1 and release the clamp 6 4 Disconnect the oil pipe 2 7 and pipe 4 3 When reassembling Pour fresh engine oil through the oil filler port of the turbocha...

Page 160: ...1185665 EGR Cooler Flange 1 Remove the EGR cooler flange 2 When reassembling Replace the gaskets with new ones W1187006 EGR Valve 1 Remove the EGR valve 1 When reassembling Replace the gaskets with ne...

Page 161: ...ve 3 replace the thermo valve 3 with new one When reassembling Securely connect the hoses 1 2 W1188855 Tightening torque Thermo valve 30 to 39 N m 3 0 to 4 0 kgf m 22 to 28 lbf ft 1 Hose to EGR Valve...

Page 162: ...ward the tank W1049737 Injection Nozzle Oil Seal if necessary 1 Remove the injection nozzle oil seal 1 from cylinder head cover 2 When reassembling When install the injection nozzle oil seal use the n...

Page 163: ...When putting the push rods onto the tappets check to see if their ends are properly engaged with the grooves IMPORTANT Q After reassembling the rocker arm be sure to adjust the valve clearance W105021...

Page 164: ...nd dust Take care for handling the gasket not to damage it Install the cylinder head Tighten the cylinder head screw gradually in the order of 1 to 18 after applying engine oil Be sure to adjust the v...

Page 165: ...tch end downward at the head side Wash the valve stem and valve guide hole and apply engine oil sufficiently After installing the valve spring collets lightly tap the stem to assure proper fit with a...

Page 166: ...ver 1 2 Remove the thermostat assembly 3 When reassembling Apply a liquid gasket Three Bond 1215 or equivalent only at the thermostat cover side of the gasket 2 Attach the thermostat with its hole fac...

Page 167: ...When the already existing align marks align with each other there is no need to put another align mark 5 Unscrew the two plugs 7 of the injection pump unit 6 Tighten the upper fuel camshaft lock screw...

Page 168: ...12 Loosen the three injection pump unit mounting nut 6 13 Remove the injection pump unit support 5 and take out the injection pump unit To be continued 1 Time Lubricating Pipe 2 Gear Cover 3 Timer Ge...

Page 169: ...for aligning the injection timing 9 Moving the injection pump unit clockwise viewed from gear case side align the injection timing marks 6 on the injection pump unit and on the gear case 10 Tighten th...

Page 170: ...en 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 start spring on t...

Page 171: ...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 ass...

Page 172: ...the governor housing 3 Remove the start spring 4 and the stop spring 5 W1142375 Stop Lever 1 Remove the stop lever 1 and the return spring 2 2 Remove the stop lever shaft 3 W1143531 1 Speed Control L...

Page 173: ...weight mounting nut Otherwise the lock bolts or injection pump housing might get damage When reassembling Press the bearings into the fuel camshaft Set the cir clip at the gear side s bearing Install...

Page 174: ...leeve NOTE Q Be careful not to damage the O ring Be careful the direction of the governor sleeve When reassembling the inside parts put the oil on each inside part slightly W1144178 Tightening torque...

Page 175: ...which the injection pump assembly keeps tilted 7 Slide off the governor connecting rod 8 from the rack pin of injection pump assembly 8 Remove the injection pump mounting screws and nuts and take out...

Page 176: ...the fuel injection pump unit 5 Make sure the permanent magnet at the tip of the service jig is attracted to the governor connecting rod 4 To do this turn the jig a little clockwise and counterclockwi...

Page 177: ...e fan drive pulley 2 When reassembling W1185033 4 Water Pump and Oil Cooler Water Pump 1 Remove the pipe band and the water pipe 1 2 Remove the water pump 2 When reassembling When mounting the water p...

Page 178: ...ten minutes Apply a liquid gasket Three Bond 1217D or equivalent to the gear case cover W1189218 Relief Valve 1 Remove the relief valve retaining screw 1 2 Remove the relief valve 2 the spring 3 and...

Page 179: ...2 3 Remove the balancer shaft 2 set screws and draw out the balancer shaft 2 6 When reassembling When install the balancer shaft 1 and 2 be sure to place the 4th cylinders piston at the top dead cente...

Page 180: ...ree Bond 1217D adhesive or equivalent over the shaded zones on both sides of the gasket that will be sandwiched between the crankcase and plate Be sure to fix the O rings 4 W1057656 Tightening torque...

Page 181: ...the adhesive evenly NOTE Q When mounting the adhesive applied parts take care to fit them to the mating parts Assemble the adhesive applied parts within ten minutes To avoid uneven tightening tighten...

Page 182: ...the cylinder apply enough engine oil to the cylinder When inserting the piston into the cylinder face the mark 3 on the connecting rod to the injection pump IMPORTANT Q Do not change the combination...

Page 183: ...ston pin to the piston Assemble the piston to the connecting rod with the mark 8 and the connecting rod numbering mark 9 facing same side The end faces of the oil ring are plated with hard chrome In p...

Page 184: ...equipment to flywheel housing Confirm that the liquid gasket coating surface is free of water dust and oil in order to maintain sealing effect Be careful not to get a damage to the oil seal when insta...

Page 185: ...1 and 2 referring to the flywheel housing s contoured face Tighten the crankcase 2 mounting screws loosely Tighten up the jig to the specified torque same as the flywheel housing screw This helps to m...

Page 186: ...on the main bearing case facing towards the flywheel side Reassemble the thrust bearing 2 with the oil groove facing outside into both side of the fourth main bearing case 4 Apply oil to the main bea...

Page 187: ...d 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 Flatness 1 Clean the...

Page 188: ...the valve replace the cylinder head W1061543 Valve Lapping 1 Apply compound evenly to the valve lapping surface 2 Insert the valve into the valve guide Lap the valve onto its seat with a valve flappe...

Page 189: ...d apply engine oil to it 2 Using a valve guide replacing tool press in a new valve guide until it is flush with the cylinder head as shown in the figure 3 Ream precisely the I D of the valve guide to...

Page 190: ...exhaust valve seat so that the width is close to specified valve seat width 3 After resurfacing the seat inspect for even valve seating apply a thin film of compound between the valve face and valve s...

Page 191: ...th an outside micrometer and then calculate the oil clearance 3 If the clearance exceeds the allowable limit replace the rocker arm and measure the oil clearance again If it still exceeds the allowabl...

Page 192: ...tappet guide bore with a cylinder gauge and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit or the tappet is damaged replace the tappet W1063847 Push rod alignment Allow...

Page 193: ...07 Backlash between crank gear and idle gear 1 Factory spec 0 0490 to 0 193 mm 0 00193 to 0 00759 in Allowable limit 0 22 mm 0 0087 in Backlash between idle gear 1 and cam gear Factory spec 0 0490 to...

Page 194: ...t Journal 1 Measure the camshaft journal O D with an outside micrometer 2 Measure the cylinder block bore I D for camshaft with an inside micrometer 3 If the clearance exceeds the allowable limit repl...

Page 195: ...the balancer shaft to the front and rear 3 If the measurement exceeds the allowable limit replace the balancer shaft W1065273 Balance Shaft Alignment 1 Support the balancer shaft with V blocks on the...

Page 196: ...ce exceeds allowable limit check the new ring since compression leak and oil shortage result 4 If clearance still exceeds the allowable limit after replacing the ring replace the piston W1066183 Oil c...

Page 197: ...en removing 1 Press out the used bushing using a small end bushing replacing tool When installing 1 Clean a new small end bushing and bore and apply engine oil to them 2 Insert a new bushing onto the...

Page 198: ...f the crankshaft journal wear replace it with an oversize one referring to the table and figure Reference Oversize dimensions of crankshaft journal W1066738 Crankshaft Alignment 1 Support the cranksha...

Page 199: ...Undersize dimensions of crankpin W1067389 Crankpin O D Factory spec 52 977 to 52 990 mm 2 0857 to 2 0862 in Oil clearance between crankpin and crankpin bearing Factory spec 0 018 to 0 051 mm 0 00071...

Page 200: ...he crankshaft as shown in figure 4 Press fit the sleeve using the auxiliary socket for pushing 4 NOTE Q Mount the sleeve with its largely chamfered surface facing outward W1069911 Crankshaft journal O...

Page 201: ...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 i...

Page 202: ...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 as...

Page 203: ...2 CLUTCH KiSC issued 09 2008 A...

Page 204: ...CONTENTS MECHANISM 1 PTO CLUTCH 2 M1 1 STRUCTURE 2 M1 2 PTO SOLENOID VALVE RELIEF VALVE AND OIL FLOW 2 M2 KiSC issued 09 2008 A...

Page 205: ...utch valve tightly presses the clutch discs 8 and drive plates 9 toward the pressure plate 7 As a result the rotation of the PTO propeller shaft 1 3 is transmitted to the PTO propeller shaft 2 5 throu...

Page 206: ...valve 2 maintains the hydraulic system pressure and supply the oil to lubricate the shuttle section synchro mesh gears PTO clutch pack and PTO brake section NOTE Q Hydraulic system pressure is a opera...

Page 207: ...IN Model 2 S4 2 PTO CLUTCH 2 S5 5 DISASSEMBLING AND ASSEMBLING 2 S6 1 REMOVING PTO CLUTCH PACK AND HOLDER 2 S6 1 Separating Transmission Case and Clutch Housing Case 2 S6 2 PTO Clutch Pack and Holder...

Page 208: ...ft Does Not Rotate PTO clutch malfunctioning Repair or replace 2 S6 PTO propeller shaft coupling disengaged Engage PTO solenoid valve malfunctioning Replace 9 S43 PTO switch malfunctioning Replace 9 S...

Page 209: ...6 11 to 6 49 in PTO Clutch Valve Condition Engine Speed Maximum Oil temperature 45 to 55 C 113 to 131 F PTO Clutch Operating 2 16 to 2 26 MPa 22 to 23 kgf cm2 312 91 to 327 14 psi PTO Clutch Disc Thi...

Page 210: ...ews 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 PTO clutch holder...

Page 211: ...28233 2 CABIN Model Clutch Pedal Free Travel Hydraulic Shuttle Model 1 Measure the clutch pedal free travel L 2 If adjustment is needed change with clutch wire cable 3 retaining nut 2 so that the free...

Page 212: ...O clutch engaged position is low check the hydraulic PTO clutch system 9 If the measurement is not within the factory specifications measure the system pressure and adjust the system pressure with rel...

Page 213: ...ASSEMBLING at 10 CABIN section for separating cabin from tractor W1013737 2 PTO Clutch Pack and Holder Hand Brake Disc and Steel Plate 1 Remove the stopper screw 5 and upper pin 6 2 Remove the disc 3...

Page 214: ...e damaged IMPORTANT Q After assembling the PTO clutch assembly be sure to check the piston operation by air pressure W1023169 2 SOLENOID VALVE PTO 1 Removing Solenoid Valve Assembly Solenoid Valve Ass...

Page 215: ...ns while assembling them Refer 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...

Page 216: ...asher 4 using the hydraulic clutch spring compressor Refer to 8 SPECIAL TOOLS at G GENERAL section 2 Remove the external circlip 3 3 Remove the piston 6 When reassembling Apply enough transmission flu...

Page 217: ...t W1025149 Plate 1 Check the contact surface to belleville washer cupped spring washer 2 If the back plate has deformed or is scratched and or scared replace it W1026255 Piston Return Spring Free Leng...

Page 218: ...surement is less than the allowable limit replace it W1025453 2 SOLENOID VALVE PTO Solenoid Valve PTO 1 Refer to the 4 CHECKING AND ADJUSTING at 9 ELECTRICAL SYSTEM W1015800 Thickness of seal ring Fac...

Page 219: ...3 TRANSMISSION KiSC issued 09 2008 A...

Page 220: ...4 HI LO CREEP SHIFT SECTION 3 M13 5 SHIFT FORK ROD AND FORK 3 M14 6 HI LO DUAL SPEED SHIFT SECTION F36 R36 TRANSMISSION MODEL 3 M15 1 Hydraulic Clutch Pack 3 M15 2 Dual Speed Valve 3 M16 3 LUBRICATION...

Page 221: ...Section 2 Main Gear Shift Section 3 Hydraulic Pump Drive Section 4 PTO Clutch Section 5 PTO Gear Section 540 540E min 1 rpm 6 Parking Brake Section 7 Four Wheel Drive Clutch Section 8 Creep Gear Secti...

Page 222: ...Drive Section 4 PTO Clutch Section 5 PTO Gear Section 540 540 min 1 rpm 6 Interchange Type PTO Gear Section 540 1000 min 1 rpm 7 Parking Brake Section 8 Four Wheel Drive Clutch Section 9 Creep Gear Se...

Page 223: ...ward and reverse running function as the 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...

Page 224: ...clutch 2 3 respectively When clutch pedal 5 is depressed feeding oil returns to the tank through the spool 6 and the clutch is in a Disengage position 1 Shuttle Valve 2 Reverse Clutch 3 Forward Clutc...

Page 225: ...sc and Plate 2 28T Gear 11 26T Gear 10 Shaft 1 9 24T Gear 7 30T Gear 6 1st Shaft 5 W1013292 F36 R36 Speed Transmission Model Forward Shaft 1 10 Shuttle Clutch Body 7 Clutch Disc and Plate 6 24T Gear 5...

Page 226: ...ng 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 Shuttle Reverse...

Page 227: ...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 Valve...

Page 228: ...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 Shuttle...

Page 229: ...e 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 Modulatin...

Page 230: ...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 Modulating...

Page 231: ...ission 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 does n...

Page 232: ...t 17 Q 4th Speed 1st Shaft 1 Coupling 4 Shifter 3 26T Gear 2 30T Gear 20 14T Gear Shaft 17 Q 5th Speed 1st Shaft 1 Coupling 7 Shifter 8 29T Gear 9 27T Gear 16 14T Gear Shaft 17 Q 6th Speed 1st Shaft 1...

Page 233: ...cates on the 3rd shaft 4 and shifter 16 for creep locates on the creep shaft 2 15 They operated by one piece type shift fork same time Hi Range 14T Gear Shaft 2 30T Gear 1 25T Gear 3 Shifter 6 Couplin...

Page 234: ...ect lever 12 There for select arm 2 engage to A 1st 2nd shift fork rod 10 or B 3rd 4th shift fork 1 or C 5th 6th shift lock rod 11 4 When operate the H L C lever 15 operate the H L C fork engage to Hi...

Page 235: ...ve is operated to the Hi or Lo position hydraulic clutch is engaged to the Hi or Low by the hydraulic Then the power is transmitted as follows Hi Input Shaft 1 Dual Speed Clutch Body 4 Clutch Disc and...

Page 236: ...ide of dual speed clutch with DS spool 2 When one of clutches are engaged pilot valve HI 3 and pilot valve LO 4 are object in free which makes it do as for the other clutch W1018064 1 Valve Body 2 DS...

Page 237: ...PTO valve lubricates to PTO clutch holder and the each sections through PTO propeller shaft and 1st shaft 2 F36 R36 SPEED TRANSMISSION MODEL Hydraulic shuttle section Hi Lo dual speed section main sh...

Page 238: ...TO gear section does not have neutral position 540 1000 Interchange Type By interchanging the PTO shafts 16 17 two different PTO shaft speeds are available Power is transmitted as follows Q With 6 spl...

Page 239: ...n 4 to the neutral position and power is not transmitted from 33T gear 2 to DT propeller shaft 1 When both brake pedals are depressed together while driving in 2WD mode 2 brake switches operate the 4W...

Page 240: ...WD switch turned on the 4WD solenoid valve is electrified the oil flow is switched and engage the 4WD clutch 6 The maximum pressure against the clutch piston is regulated under approx 2 16 MPa 22 0 kg...

Page 241: ...the piston 2 The differential lock pin 3 engages and as a result right and left shaft 1 and 4 rotates as a unit through differential case 3 On the other hand oil is not supplied when the switch is OF...

Page 242: ...d engage the differential lock pin to lock position The maximum pressure against the clutch piston is regulated under approx 2 16 MPa 22 0 kgf cm2 313 psi by the relief valve 2 of system pressure On t...

Page 243: ...PREPARATION FOR SEPARATING EACH BLOCK 3 S19 1 Lubricant and Coolant 3 S19 2 4WD Propeller Shaft and Power Steering Hose 3 S19 3 Front Axle Rocking Restrictor 3 S20 4 Bonnet ROPS Model 3 S20 5 Bonnet C...

Page 244: ...isassembling 4WD Hydraulic Pack 3 S58 6 Removing Differential Gear and Bevel Pinion Shaft 3 S60 7 Differential Gear 3 S61 8 Differential Lock Piston 3 S63 11 PTO GEAR CASE 3 S64 1 540 540E Shift Type...

Page 245: ...ive Transmission Noise Transmission fluid insufficient Replenish G 9 Improper backlash between bevel pinion shaft and bevel gear Adjust 3 S72 Improper backlash between differential pinion and side gea...

Page 246: ...disc or drive plate excessively worn Replace 3 S58 70 Deformation of piston steel plate or pressure plate Replace 3 S58 71 Front Wheel Does Not Rotate 4WD clutch malfunctioning Repair or replace 3 S58...

Page 247: ...pped Spring Washer of Shuttle Hydraulic Pack Clearance 1 8 to 2 0 mm 0 071 to 0 079 in 3 6 mm 0 142 in Damper Disc Boss to Gear Shaft Backlash Displacement Around Disc Edge 2 0 mm 0 079 in Valve Lever...

Page 248: ...92760 to 1 92913 in 0 35 mm 0 014 in Differential Pinion Shaft to Differential Pinion Differential Pinion Shaft Differential Pinion Clearance O D I D 0 06 to 0 102 mm 0 00236 to 0 00402 in 22 959 to 2...

Page 249: ...under frame mounting screw M16 9T 259 9 to 304 0 26 5 to 31 0 191 7 to 224 2 Brake pipe retaining nut 15 7 to 23 5 1 6 to 2 4 11 6 to 17 4 PTO pipe eye joint screw 49 0 to 68 6 5 0 to 7 0 36 2 to 50...

Page 250: ...ttle 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 th...

Page 251: ...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 is...

Page 252: ...1 Check the engine start 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...

Page 253: ...he length of main 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 NOTE Q The...

Page 254: ...hift rod 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 NOTE Q The main gear shift lev...

Page 255: ...ling abnormal shifting check the length of range gear shift rod 1 3 and 2 1 W1102254 Length of range gear shift rod 2 L1 Factory spec 279 mm 10 98 in Length of range gear shift rod 1 L2 Initial adjust...

Page 256: ...he parking brake lever to parking position NOTE Q Pressure gauge is 5 MPa 50 kgf cm2 700 psi full scale Apply Three Bond 1324N or equivalent to the plugs F R and M when install them Plug F R M thread...

Page 257: ...D clutch engaged position is low check the hydraulic 4WD clutch system 9 If the measurement is not within the factory specifications measure the system pressure and adjust the system pressure with rel...

Page 258: ...4 Set the hi low dual speed switch Hi or Lo position and measure the oil pressure 5 If only the pressure in the clutch engaged position is low check the dual speed clutch system 6 If the measurement i...

Page 259: ...the auxiliary step 3 2 Disconnect the wire harness from fuel level sensor 1 3 Remove the fuel filling port screw 4 Remove the fuel hose and overflow hose 5 Remove the fuel tank 2 W1017026 2 Removing...

Page 260: ...6 Remove the both fuel tank band 3 7 Draw out the fuel tank and disconnect the breather hose 4 and 5 8 Disconnect the fuel hose 6 and return hose 7 When reassembling Be sure to connect the fuel sensor...

Page 261: ...3 Disconnect the connector 3 4 Remove the solenoid valve assembly 5 When reassembling Apply transmission fluid to the O rings 6 Apply liquid gasket Three Bond 1208D or equivalent to joint face of tran...

Page 262: ...livery pipe 1 3 Remove the dual speed solenoid valve 3 When reassembling Be sure to fix the O rings 4 in position as shown photo and apply transmission fluid to the O rings 4 W1019547 Tightening torqu...

Page 263: ...ng 1 to the rear When reassembling Apply grease to the splines of the propeller shaft 5 and pinion shaft Tap in the roll pins 2 as shown in figure W1054851 Power Steering Hose 1 Disconnect both power...

Page 264: ...net ROPS Model Bonnet 1 Open the bonnet 1 and disconnect the battery negative terminal 2 Disconnect the connector 2 for head lights 3 Disconnect the damper 4 4 Remove the bonnet 1 and side cover 2 for...

Page 265: ...ced within the space of controller pipe 7 power steering controller 5 and stay 6 IMPORTANT Q When disconnecting the battery cables disconnect the grounding cable first When connecting positive cable f...

Page 266: ...er 5 alternator 4 water temperature switch 3 and engine oil pressure switch 7 When reassembling NOTE Q There are three bands for power steering hose Hose band under the radiator is not in photo W10407...

Page 267: ...e the engine from the clutch housing When reassembling Apply molybdenum disulphide Three Bond 1901 or equivalent to the splines of damper disc boss Apply liquid gasket Three Bond 1141 1211 or equivale...

Page 268: ...slide out the condenser 2 2 Remove the hose clamps 3 3 Remove the slow blow fuse boxes 4 and relays 6 4 Disconnect 1P connector 5 of magnetic clutch 5 Remove the compressor bracket 7 mounting screw 8...

Page 269: ...d sensor 5 and engine stop solenoid 9 When reassembling Be sure to fix the heater hose to the original position Note the inlet hose and outlet hoses W1022765 Tightening torque Compressor bracket mount...

Page 270: ...ove the seat under cover 3 and duct 2 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 equiva...

Page 271: ...urn pipe 11 11 Remove the outlet block 6 with pipe 12 Remove the trailer brake return pipe 12 NOTE Q Procedure 8 9 and 10 with marks relate for F36 R36 speed transmission model When reassembling W1024...

Page 272: ...ing W1015170 Connectors and Rod 1 Remove the fuel filling port 8 mounting screw 2 Disconnect the connectors for trailer coupler 3 electric outlet 2 and number plate licence light 1 3 Disconnect the co...

Page 273: ...nnect the 2 1P connector 9 for differential lock switch NOTE Q After assembling check the speed change lever movement and adjust them if necessary After assembling check the hydraulic control rod and...

Page 274: ...very hose 2 3P delivery hose 1 2 3 4 and solenoid valve delivery hose 5 2 Remove the brake pipes 6 3 Remove the master cylinder return hose When reassembling W1026554 Parking brake rod 1 3 length Refe...

Page 275: ...haft Apply liquid gasket Three Bond 1211 1141 or equivalent to the seam of engine and clutch housing W1012254 Separating Clutch Housing Case from Transmission Case 1 Remove the transmission case mount...

Page 276: ...e Bond 1206C or equivalent to joint face W1012984 Rear Axle Case Assembly 1 Remove the rear axle case mounting screws and nuts 2 Remove the rear axle case assembly 1 When reassembling Apply liquid gas...

Page 277: ...mounting screws and nuts 2 Remove the shuttle case assembly 1 by using M10 x Pitch 1 25 mm screws into holes a When reassembling Be sure to fit the O rings 2 and apply transmission fluid The oil pass...

Page 278: ...gear with shuttle shaft 4 together When reassembling Replace the seal rings 5 oil seal 1 and external circlip 2 with new ones Apply transmission fluid to seal rings 5 and bearings Apply grease to oil...

Page 279: ...ng M10 x Pitch 1 25 mm screws into holes a When reassembling Be sure to fit the O rings 3 The oil passage hole b is free from liquid gaskets Apply liquid gaskets Three Bond 1206C or equivalent to join...

Page 280: ...k 7 in the housing case 4 Pull out the 31T gear 6 with bearing 8 5 Remove the shuttle clutch pack 7 NOTE Q Remove the 31T gear 6 then remove the shuttle pack When reassembling Put in the shuttle clutc...

Page 281: ...ssion Model W1029782 1 Seal Ring 2 Shuttle Shaft 3 Key 4 28T Gear 5 Internal Circlip 6 Belleville Washer Cupped Spring Washer 7 Pressure Plate 8 Rubber 9 Steel Plate with Rubber 10 Steel Plate without...

Page 282: ...Shaft 3 Key 4 28T Gear 5 Internal Circlip 6 Belleville Washer Cupped Spring Washer 7 Pressure Plate 8 Rubber 9 Steel Plate with Rubber 10 Steel Plate without Rubber 11 Piston 12 Disc 13 Spring 14 Clu...

Page 283: ...the shuttle shaft 1 with gear 5 to the forward Q NOTE When reassembling Align the key 6 and groove W1030900 F18 R18 speed transmission model F36 R36 speed transmission model Gear 2 26T gear 24T gear G...

Page 284: ...split portion to the notched portion of clutch body as shown in photo When assemble the shuttle shaft 10 with gear 11 for reverse side temporary align the spline and clutch disc s teeth using the gear...

Page 285: ...rnal 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...

Page 286: ...ft 7 with clutch pack 5 4 Remove the external circlip 8 and 29T gear 6 5 Tap out the dual speed shaft 7 with 27T gear 4 to forward When reassembling Align the key 9 and groove of clutch pack 5 Replace...

Page 287: ...wn in photo When assembling the input shaft 8 with 27T gear 7 for low speed side temporary align the spline and clutch disc s teeth using the 29T gear 6 Insert the steel piece a between the internal c...

Page 288: ...ernal circlip 3 2 Remove the springs 7 3 Draw out the piston 5 using a air pressure NOTE Q 21 springs for one side The passage holes for the piston are beside the feather key groove When reassembling...

Page 289: ...tion and shifters in the transmission on neutral position and range shift fork 5 and shifter in the transmission on H side forward Apply liquid gaskets Three Bond 1206C or equivalent to joint face W10...

Page 290: ...rearward 5th speed 2 Remove the roll pin 1 fork rod 3 and range shift fork 2 3 Remove the ball detent 5 and spring 6 NOTE Q Take care not to lose the detent ball 5 and spring 6 W1017369 1 Roll Pin 2 R...

Page 291: ...the balls and springs The springs 1 13 and 14 are paired large and small one When reassembling Be sure to assemble the detent balls 2 12 15 with springs 1 13 14 and inter lock ball 11 17 W1018064 1 S...

Page 292: ...ssembling Replace the seal caps with new one Assemble the main shift arm 2 and main shift lever 1 with spline align the both levers are the same direction as shown in the photo Apply transmission flui...

Page 293: ...l circlip 8 6 Tap out the creep shaft 1 7 with gears 7 Remove the bearing 7 8 Remove the gears When reassembling Apply oil to needle bearings 3 and thrust collar 14 Replace the external circlip 1 and...

Page 294: ...stopper plate 3 2 Draw out the range shift arm 4 When reassembling Be sure to assemble the range shift lever 1 as an original direction as shown in photo W1040290 1 Range Shift Lever 2 Roll Pin 3 Sto...

Page 295: ...collar 7 Reference Thickness of adjusting collar 7 2 8 mm 0 110 in Code No 3C081 28490 3 0 mm 0 118 in Code No 3C081 28410 3 2 mm 0 126 in Code No 3C081 28420 3 4 mm 0 133 in Code No 3C081 28430 3 6...

Page 296: ...ogether by step by step 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 hou...

Page 297: ...ing 3 4 Speed 7 Synchronizer Key 8 Shifter 9 23T Gear 10 32T Gear 11 Coupling 5 6 Speed 12 29T Gear 13 Synchronizer Spring 14 19T Gear 15 Coupling 1 2 Speed 16 1st Shaft 17 Thrust Needle Bearing 18 Be...

Page 298: ...ng 20 on the 1st shaft then install the 16T gear 19 Install the thrust needle bearing 21 toward the needle side to 16T gear 19 Replace the external circlip 23 with new one W1091413 3 2nd Shaft 2nd Sha...

Page 299: ...5 DT Propeller Shaft DT Propeller Shaft 1 Tap out the DT propeller shaft 1 to rearward When reassembling Apply grease to the oil seal W1020906 6 Creep Gear Creep Gear and Shaft 1 Refer to 7 SHIFT COV...

Page 300: ...ternal circlip 6 and bearing 7 When reassembling Fill the transmission fluid to the hydraulic pump holder from the window 2 before install the hydraulic pump holder assembly to the transmission case N...

Page 301: ...riginal position as shown fig W1014172 3 PTO Clutch Pack Removing PTO Clutch Pack and Holder 1 Remove the PTO clutch holder mounting screws 2 Remove the PTO clutch 4 with holder 5 When reassembling W1...

Page 302: ...Disassembling 4WD Hydraulic Pack 4WD Hydraulic Pack 1 Tap and remove the 4WD shaft 2 to rearward 2 Remove the 35T gear 3 from the clutch pack 3 Remove the external circlip 3 and neutral cover 5 When...

Page 303: ...f steel plates The steel plate with plug rubbers 6 and without rubbers 7 Two steel plates match the position of rubber 8 from the piston side and one remaining steel plate is not matched Do not confus...

Page 304: ...emove the differential lock collar 5 and thrust bearing 4 When reassembling Be sure to adjust the turning torque of spiral bevel pinion shaft refer to 6 SERVICING in this section Be sure to adjust the...

Page 305: ...king nut after installing the differential gear assembly W1023487 7 Differential Gear Spiral Bevel Gear 1 Remove the spiral bevel gear 1 When reassembling Check the spiral bevel gear for wear or damag...

Page 306: ...ing 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 differential p...

Page 307: ...ON 8 Differential Lock Piston Piston 1 Remove the piston 1 from the differential lock support 2 When reassembling Apply transmission fluid to the O rings 3 W1041076 1 Piston 2 Differential Lock Suppor...

Page 308: ...e PTO shaft staking nut 7 with new one and stake it firmly after tightening Apply molybdenum disulfide Three Bond 1901 or equivalent to the inner rings 11 and 16 Apply grease to the oil seal 22 and O...

Page 309: ...ssembling Apply grease to the oil seal 18 and O ring 17 W1042266 1 PTO Gear Case Cover 2 Ball Bearing 3 PTO Drive Gear Shaft 4 18T Gear 5 Ball Bearing 6 Ball Bearing 7 Bearing 8 49T Gear 9 Bearing 10...

Page 310: ...e is any doubt as to the condition of a taper roller bearing replace it W1070816 Clearance between Shift Fork and Shifter Groove 1 Measure the width of shift fork 2 Measure the shifter groove width an...

Page 311: ...isc edge 4 If the measurement exceeds the allowable limit replace the damper disc W1024206 Shuttle Lever and Inching Lever Bushing 1 Measure the lever pin O D with an outside micrometer 2 Measure the...

Page 312: ...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 thickness There...

Page 313: ...able limit measure the thickness of clutch disc and steel plate with vernier calipers 4 If the thickness is less than the allowable limit replace them 5 Remeasure to confirm the correct clearance Refe...

Page 314: ...vernier calipers 2 If the thickness is less than the allowable limit replace it W1016467 Steel Plate and Pressure Plate Wear 1 Measure the thickness of steel plate and pressure plate with vernier cal...

Page 315: ...Thickness of Seal Ring 1 Measure the thickness of seal rings 1 with an outside micrometer 2 If the measurement is less than the allowable limit replace it W1016857 Flatness of piston Allowable limit...

Page 316: ...actory specification adjust with shim IMPORTANT Q Do not drop the fuse in the transmission case Reference Thickness of 18T bevel gear shim 0 1 mm 0 004 in Code No 35533 42350 0 2 mm 0 008 in Code No 3...

Page 317: ...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 shaft 4 If the measurem...

Page 318: ...e spiral bevel pinion shaft while pressing a wooden piece against the periphery on the spiral bevel gear 7 Check the tooth contact If not proper adjust according to the instructions next page Referenc...

Page 319: ...kward 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 thin...

Page 320: ...mm 0 00276 to 0 00744 in Allowable limit 0 35 mm 0 014 in Differential case bore I D Factory spec 49 07 to 49 15 mm 1 93189 to 1 93504 in Differential side gear boss O D Factory spec 48 961 to 49 066...

Page 321: ...3 If the measurement is not within the factory specifications adjust with the differential side gear washer Reference Thickness of differential side gear washer 1 5 mm 0 059 in Code No 33740 32760 1 6...

Page 322: ...4 REAR AXLE KiSC issued 09 2008 A...

Page 323: ...CONTENTS MECHANISM 1 FEATURES 4 M1 KiSC issued 09 2008 A...

Page 324: ...drive the rear axles The rear axles 1 are semi floating type with the ball bearing between the rear axle 1 and rear axle case 2 which support the rear wheel load as well as transmitting power to the...

Page 325: ...4 S3 4 DISASSEMBLING AND ASSEMBLING 4 S4 1 SEPARATING REAR AXLE 4 S4 1 Removing Rear Axle ROPS Model 4 S4 2 Removing Rear Axle CABIN Model 4 S5 2 DISASSEMBLING REAR AXLE 4 S6 1 Brake Section 4 S6 2 R...

Page 326: ...Probable Cause Solution Reference Page Excessive or Unusual Nose at All Time Improper backlash between planetary gear and internal gear Replace 4 S9 Bearing worn Replace 4 S9 Insufficient or improper...

Page 327: ...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 to 0...

Page 328: ...general use screws bolts and nuts Refer to 5 TIGHTENING TORQUES at G GENERAL section W1012736 Item N m kgf m lbf ft Rear axle case mounting screw and nut 197 to 225 20 0 to 23 0 145 to 166 Cabin mount...

Page 329: ...mounting screws and nuts 4 Support the rear axle case with nylon lift strap and hoist 5 Separate the rear axle case from transmission case When reassembling Apply liquid gasket Three Bond 1206C or equ...

Page 330: ...sure the balance for support position Hoist up and support the rear axle under neath as shown photo When reassembling Apply liquid gasket Three Bond 1206C or equivalent to joint face of the rear axle...

Page 331: ...ernal circlip 1 Face the external circlip 1 gap to brake shaft W1012450 2 Rear Axle Case Planetary Gear Support 1 Remove the retainer mounting screw 1 2 Carefully remove the planetary gear support 3 3...

Page 332: ...surface of planetary gear 2 Tap in the roll pin 1 as shown in the figure W1012932 Rear Axle 1 Remove the external circlip 1 2 Tap out the rear axle 2 half way 3 Remove the ball bearing 3 and external...

Page 333: ...emble the oil seal 2 3 to the rear axle 4 Assemble the rear axle to rear axle case 5 Assemble the external circlip 5 then tap in the ball bearing 4 to the rear axle shaft When reassembling Apply trans...

Page 334: ...klash between 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 ba...

Page 335: ...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 spec 0...

Page 336: ...5 BRAKES KiSC issued 09 2008 A...

Page 337: ...TRUCTURE FOR TRAILER BRAKE 5 M3 4 MASTER CYLINDER ASSEMBLY 5 M4 5 HYDRAULIC TRAILER BRAKE VALVE 5 M5 1 Structure 5 M5 2 Operation 5 M6 2 PARKING BRAKE 5 M10 1 GEAR LOCK BRAKE 5 M10 1 Structure 5 M10 2...

Page 338: ...ke Coupler 3 Trailer Brake Pipe 4 Delivery Pipe Hose To 3P Hydraulic System 5 Delivery Pipe To Outlet Block 6 Delivery Pipe Hose From Hydraulic Pump 7 Brake Pipe 8 Brake Pedal 9 Master Cylinder 10 Ret...

Page 339: ...4WD solenoid valve to switch the 4WD travelling mode Therefore all 4 wheels are put on brakes to provide for greater braking effect NOTE Q Refer to 5 BRAKES section in the workshop manual of tractor m...

Page 340: ...e trailer brake valve 5 through the pilot pipe 6 Then the trailer brake valve 5 feeds pressurized oil to the trailer through the coupler 2 corresponding to the brake oil pressure 1 Outlet Block 2 Deli...

Page 341: ...including oil tank 3 master cylinder 2 and equalizer 6 The function for each parts refer to 5 BRAKES section in the workshop manual of tractor mechanism Code No 9Y021 18200 W1012749 1 Master Cylinder...

Page 342: ...relief element 3 with pre loaded spring 4 for limiting the trailer braking pressure Control head 6 with piston 7 and bleed valve 5 for operating the trailer brake valve through the tractor brake line...

Page 343: ...voir through restrictor 11 throttle 9 bore 8 control spool 2 and port R Thus the pressure drop at throttle 9 holds the flow control valve 10 in the open flow position a The flow control valve 10 has n...

Page 344: ...ctor 11 bore 12 check valve 13 and port B The restrictor 11 is designed for the constant flow Qk A residual flow Qp Qk bypasses the flow control valve 10 and then passes to the tractor hydraulic throu...

Page 345: ...10 is thus switched into position a and has no regulating function As in the case of the released trailer brake the delivery flow Qp from the pump passes through port N and flows as Qp Qx to the trac...

Page 346: ...rnal factor control spool 2 momentarily opens brake line B to the reservoir and avoids further increasing of the braking pressure In all control positions of the trailer brake valve the tractor hydrau...

Page 347: ...RANSMISSION section 1 GEAR LOCK BRAKE 1 Structure W1013735 The parking brake is gear lock type Parking brake lever 10 and parking lever 1 are connected with cable When the parking brake lever 10 is in...

Page 348: ...hift lever 1 The main shift lever 1 can operate for selecting direction d and shifting direction c b At Gear Lock Brake ON The restriction lever 3 moves into the main shift lever 1 by gear lock brake...

Page 349: ...the parking brake linkage As the parking brake cam 3 moves the steel plate 1 are pressed by the brake pads 2 and 6 causing frictional force This frictional force provides braking effect W1013031 1 St...

Page 350: ...3 Gear Lock Brake 5 S7 4 Parking Brake 5 S11 2 DISASSEMBLING AND ASSEMBLING 5 S12 1 Removing Master Cylinder ROPS Model 5 S12 2 Removing Master Cylinder CABIN Model 5 S13 3 Master Cylinder 5 S16 4 Br...

Page 351: ...ake pipes bleeder master cylinder or equalizer Repair or replace Master cylinder or equalizer malfunctioning Repair or replace 5 S16 Brake Drags Brake pedal free travel too small Adjust 5 S4 Master cy...

Page 352: ...l Shaft Clearance I D O D 0 03 to 0 246 mm 0 012 to 0 0097 in 25 030 to 25 146 mm 0 9854 to 0 9900 in 24 9 to 25 0 mm 0 9803 to 0 9843 in 0 5 mm 0 0197 in Brake Piston Flatness 0 3 mm 0 012 in Brake D...

Page 353: ...ts Refer to 5 TIGHTENING TORQUES at G GENERAL section W1012736 Item N m kgf m lbf ft Brake pipe retaining nut 16 0 to 24 0 1 6 to 2 5 11 8 to 17 7 Master cylinder pipe retaining nut 49 0 to 68 6 5 0 t...

Page 354: ...push rod 2 4 After adjustment tighten the lock nut firmly IMPORTANT Q Keep the free travel in the right and left brake pedals equal NOTE Q Step on the right brake and the trailer hydraulic brake allow...

Page 355: ...G GENERAL section joint Code No 07916 50401 cable Code No 07916 50331 and pressure gauge Code No 07916 52961 2 Set the pedal fixing plate between the pedal and pedal stopper after depressing the brake...

Page 356: ...pedal close the master cylinder outlet by a finger and when lowering release the finger Repeat this operation several times Prepare the oil can 3 After bleeding the master cylinder install the front...

Page 357: ...System 1 When the gear lock brake lever 1 at PARKING position main change lever 2 does not shift to 1st 2nd and 3rd 4th direction 2 Check the gear lock brake lever 1 does not shift to PARKING positio...

Page 358: ...ever 1 pushed to outside 2 If the clearance L is not within the factory specification adjust with adjusting screw 2 When reassembling Be sure to tighten the lock nut W1016030 Clearance between gear lo...

Page 359: ...2 and gear lock brake lever 1 when gear lock brake lever 1 push to outside 2 If the length L is not with factory specification adjust with set screw 3 When reassembling Be sure to tighten the lock nut...

Page 360: ...play is not inline adjust the gear lock brake cable 2 retaining position with retaining nuts 3 so that the alignment point g on the guide plate 5 to be inline as shown photo When reassembling Be sure...

Page 361: ...1 free stroke if the measurement is not within the factory specification adjust the length of brake cam rod 3 NOTE Q The ROPS mode and cabin mode are same measurement W1014103 Parking brake lever fre...

Page 362: ...H 5 and R H 4 W1013011 Master Cylinder 1 Remove the master cylinder mounting nuts 1 2 Remove the master cylinder assembly When reassembling After mounting the master cylinder assembly be sure to blee...

Page 363: ...1 When reassembling The connector 2 should be placed within the space of controller pipe 6 power steering controller 4 and stay 5 IMPORTANT Q When disconnecting the battery cables disconnect the groun...

Page 364: ...onnectors from hazard switch 2 and display mode switch 3 2 Remove the air outlet 4 then remove the panel under cover R H 5 3 Disconnect the connector from main key switch 6 W1025033 1 Panel Cover 2 Ha...

Page 365: ...ting nuts 1 2 Remove the master cylinder assembly When reassembling After mounting the master cylinder assembly be sure to bleed air Refer to 1 Traveling Brake in this section W1023223 1 Pedal Shaft S...

Page 366: ...nd plug noting the O ring W1013503 4 Brake Pedal Brake Pedal ROPS Model 1 Remove the panel cover refer to 1 CLUTCH PEDAL at 2 CLUTCH section 2 Remove the springs 2 and master cylinder rod pin 3 3 Remo...

Page 367: ...G AND ASSEMBLING at 4 REAR AXLE Section Brake Piston 1 Remove the bleeder 2 Remove the brake piston with compressed air Slowly inject an air from bleeder hole 1 When reassembling Replace the brake sea...

Page 368: ...e the external circlip 6 4 Remove the brake plate 9 collar 3 and pin 2 When reassembling Place the brake discs 8 so that the holes aligned to next holes The pin 2 does not have groove for external cir...

Page 369: ...33T gear 2 3 Remove the bearing holder mounting screws and take out the bearing holder 1 If the shaft comes out with bearing holder tap in the shaft during take out the bearing holder 1 When reassemb...

Page 370: ...2 Remove the roll pin 4 and remove the gear lock gear pin 7 and gear lock gear 6 When reassembling Be sure to hook the springs 2 5 as shown photo W1014851 1 Gear Lock Cam Shaft 2 Gear Lock Cam Spring...

Page 371: ...pper pin 6 2 Remove the disc 3 and 4 3 Remove the 47T gear 1 with steel plates 2 When reassembling Be sure to assemble the disc 3 and 4 to the original position as shown fig W1014172 1 47T Gear 2 Stee...

Page 372: ...e disc thickness with vernier calipers 2 If the measurement is less than the allowable limit replace it W1014578 Brake Plate Wear 1 Measure the brake plate thickness with vernier calipers 2 If the mea...

Page 373: ...r caliper 3 If the thickness is less than the allowable limit replace it W1021315 Brake pad thickness Factory spec Pad 1 5 0 to 5 2 mm 0 197 to 0 204 in Pad 2 4 7 mm 0 18 in Allowable limit Pad 1 2 70...

Page 374: ...6 FRONT AXLE KiSC issued 09 2008 A...

Page 375: ...CONTENTS MECHANISM 1 STRUCTURE 6 M1 1 FRONT AXLE 6 M1 2 LIMITED SLIP DIFFERENTIAL LSD 6 M2 KiSC issued 09 2008 A...

Page 376: ...Front Axle Case Support 2 18T Bevel Gear 3 41T Bevel Gear 4 23T Planetary Gear 5 Planetary Gear Pin 6 Planetary Gear Support 7 Front Axle 8 Front Axle Case Cover 9 62T Internal Gear 10 15T Bevel Gear...

Page 377: ...ndition 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 different spee...

Page 378: ...SSEMBLING AND SERVICING 6 S5 1 CHECKING AND ADJUSTING 6 S5 2 DISASSEMBLING AND ASSEMBLING 6 S7 1 Separating Front Axle 6 S7 2 Disassembling Front Axle 6 S8 3 Removing Differential Gear and Bevel Pinio...

Page 379: ...o small Adjust 6 S6 Front wheel sway excessive Replace 6 S5 Tie rod end loose Tighten 6 S8 Aeration of the hydraulic fluid in power steering circuit Bleed Front Wheels Can Not Be Driven Propeller shaf...

Page 380: ...50 mm 1 26083 to 1 26181 in 31 959 to 31 975 mm 1 25823 to 1 25886 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...

Page 381: ...0 0079 to 0 0118 in 0 4 mm 0 016 in Bevel Gear in Front Wheel Case Backlash 0 20 to 0 30 mm 0 0079 to 0 0118 in 0 4 mm 0 016 in Internal Gear to Planetary Gear Backlash 0 10 to 0 30 mm 0 0039 to 0 01...

Page 382: ...ounting screw 166 7 to 196 1 17 0 to 20 0 123 0 to 144 7 Front wheel mounting nut M16 259 to 304 26 5 to 31 0 191 7 to 224 2 Tie rod end slotted nut 156 9 to 176 5 16 0 to 18 0 115 7 to 130 2 Tie rod...

Page 383: ...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 Jack up the front...

Page 384: ...ckle arm 1 can not be contacted with the bevel gear 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...

Page 385: ...inion shaft Tap in the roll pins 2 as shown in figure W1012954 Front Wheel and Power Steering Hoses 1 Check the front axle and engine are securely mounted on the disassembly stand 2 Remove the front w...

Page 386: ...move the bevel gear case 2 and the front wheel case 3 as a unit from the front differential case 1 When reassembling Apply grease to the O ring Install the bevel gear case to the front differential ca...

Page 387: ...ront wheel case 2 Remove the internal circlip 9 and take out the adjusting shims 8 3 Tap the bevel gear to downward and take out the 15T bevel gear 6 with bearing When reassembling Apply grease to the...

Page 388: ...en reassembling Apply transmission fluid to the needle bearing 4 Tap in the roll pin 6 as shown in the figure left Replace the external circlip 1 with new one W1016767 Front Axle 1 Tap out the front a...

Page 389: ...er 8 When reassembling Replace oil seal 3 with new one Install the oil seal 3 to the front axle case so that its lip faces the inward Apply grease to the DX bushing for bracket 1 2 Reference Adaptor f...

Page 390: ...ive wear If these parts are damaged or excessively worn replace there parts thy are in mesh with or they sliding on Apply molybdenum disulfide Three Bond 1901 or equivalent to inner circumferential su...

Page 391: ...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 LSD a...

Page 392: ...r and roughness 2 Apply transmission fluid to the bearing and hold the inner race Then turn the outer race to check rotation 3 If there is any defect replace it W1035672 Needle Bearing 1 Check the nee...

Page 393: ...e No 35533 44110 1 0 mm 0 039 in Code No 35533 44120 1 2 mm 0 047 in Code No 35533 44130 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 mm 0...

Page 394: ...re 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 67211 15180 Standard size of shim 1 0 mm 0 039 in W1021715 Clea...

Page 395: ...re 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 0 032...

Page 396: ...oto 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 0 4...

Page 397: ...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 L 0 5...

Page 398: ...with the shims 1 Reference Thickness of adjusting shims 1 0 1 mm 0 004 in Code No 35533 44020 0 2 mm 0 008 in Code No 35533 44030 0 4 mm 0 016 in Code No 35533 44040 0 8 mm 0 032 in Code No 35533 4405...

Page 399: ...ove only the planetary gear 3 If the measurement exceeds the allowable limit check the planetary gear and planetary shaft W1022069 Clearance between Planetary Gear and Shaft 1 Measure the planetary ge...

Page 400: ...ess 1 Measure the thickness of the thrust collar 2 If the measurement is less than the allowable limit replace it W1021223 Thrust collar thickness Factory spec 0 75 to 0 85 mm 0 02953 to 0 03346 in Al...

Page 401: ...7 STEERING KiSC issued 09 2008 A...

Page 402: ...CONTENTS MECHANISM 1 STEERING MECHANISM 7 M1 2 STEERING CYLINDER 7 M2 KiSC issued 09 2008 A...

Page 403: ...o 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 type is used...

Page 404: ...arm guarantees 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...

Page 405: ...7 S4 1 CHECKING AND ADJUSTING 7 S4 1 Steering Controller 7 S4 2 Hydraulic Pump 7 S4 2 REMOVING STEERING CONTROLLER 7 S5 1 ROPS Model 7 S5 2 CABIN Model 7 S8 3 REMOVING STEERING CYLINDER 7 S10 4 DISAS...

Page 406: ...epair or replace 7 S7 9 Steering Wheel Turns SpontaneouslyWhen Released Controller malfunctioning Repair or replace 7 S7 9 Front Wheels Wander to Right and Left Controller malfunctioning Repair or rep...

Page 407: ...ng Pressure At Idling Engine Speed At Maximum Engine Speed Above 12 3 MPa 125 kgf cm2 1777 9 psi Below 18 1 MPa 185 kgf cm2 2631 3 psi Steering Cylinder I D 55 000 to 55 074 mm 2 16535 to 2 16827 in 5...

Page 408: ...to 34 3 3 0 to 3 5 21 7 to 25 3 Oil cooler pipe retaining nut 49 0 to 68 6 5 0 to 7 0 36 2 to 50 6 Master cylinder pipe retaining nut 29 4 to 34 3 3 0 to 3 5 21 7 to 25 3 Brake pipe R H and L H retain...

Page 409: ...factory specifications adjust the relief pressure by the adjust plug 4 Q IMPORTANT Air Bleeding Start the engine then turn the steering wheel slowly in both directions all the way alternately a few ti...

Page 410: ...sconnect the grounding cable first When connecting positive cable first W1013836 Panel Cover 1 Remove the steering port cover 6 2 Detach the panel cover 1 3 Disconnect the connectors for main key swit...

Page 411: ...er be sure to adjust the shuttle lever Neutral position refer to 4 CHECKING AND ADJUSTING at 3 TRANSMISSION section W1010629 1 Steering Support Under Cover Tightening torque Power steering delivery ho...

Page 412: ...DJUSTING in the 5 BRAKES section W1010873 Controller 1 Remove the controller mounting screw 2 Remove the controller 1 to right side When reassembling Be sure to fit the controller to the controller su...

Page 413: ...embling The connector 2 should be placed within the space of controller pipe 6 power steering controller 4 and stay 5 IMPORTANT Q When disconnecting the battery cables disconnect the grounding cable f...

Page 414: ...emove the controller mounting screws 3 and remove the controller 4 W1022567 Tightening torque Power steering delivery hose 1 and 2 retaining nut 22 6 to 27 5 N m 2 3 to 2 8 kgf m 16 6 to 20 3 lbf ft C...

Page 415: ...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 steering cyl...

Page 416: ...ply 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 Tighteni...

Page 417: ...groove of the 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 splin...

Page 418: ...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 po...

Page 419: ...el W1017763 Clearance between Rod and Bushing 1 Measure the bushing I D with a cylinder gauge 2 Measure the rod O D with an outside micrometer and calculate the clearance 3 If the clearance exceeds th...

Page 420: ...8 HYDRAULIC SYSTEM KiSC issued 09 2008 A...

Page 421: ...eed Transmission Model 8 M4 2 F36 R36 Speed Transmission Model 8 M5 2 OIL COOLER RELIEF VALVE ROPS MODEL 8 M6 3 THREE POINT HITCH HYDRAULIC SYSTEM 8 M7 1 HYDRAULIC CIRCUIT 8 M7 2 HYDRAULIC BLOCK 8 M8...

Page 422: ...ler 6 Brake Master Cylinder 7 Oil Cooler Relief Valve 8 Oil Cooler 9 Hydraulic Outlet 10 Hydraulic Pump 11 Solenoid Valve Assembly PTO 4WD Differential Lock 12 Relief Valve System Pressure 13 Auxiliar...

Page 423: ...oller 8 Oil Cooler 9 Hi Lo Dual Speed Valve 10 Hydraulic Outlet 11 Return Pipe F36 R36 Speed Transmission Model 12 Hydraulic Pump 13 Solenoid Valve Assembly PTO 4WD Differential Lock 14 Relief Valve S...

Page 424: ...ng with operation of 3 point hitch Oil flow from 3 point hitch pump can be connected with oil flow from auxiliary control valve Hydraulic oil flow is 64 3 L min 17 0 U S gal min 14 1 Imp gal min Opera...

Page 425: ...r 3 point 13 Steering Cylinder 14 Power Steering Controller 15 Brake Master Cylinder 16 Brake Piston 17 Oil Cooler Check Valve Cabin Model 18 Oil Cooler 19 Shuttle Valve 20 Shuttle Clutch Pack 21 Hydr...

Page 426: ...Controller 15 Brake Master Cylinder 16 Brake Piston 17 Oil Cooler Check Valve Cabin Model 18 Oil Cooler 19 Shuttle Valve 20 Shuttle Clutch Pack 21 Hydraulic Pump Power Steering and System Line 22 Reli...

Page 427: ...relieving shock pressure caused by engine starting If pressure in the oil cooler line becomes to great oil pressure forces the ball 5 off the seat of valve body 3 compressing the coil spring 2 and al...

Page 428: ...mum pressure in the circuit The hydraulic cylinders 6 have a cylinder safety valve 5 to relieve shock pressure due to heavy implement bounce 5 The control valve 3 is actuated by the mechanical linkage...

Page 429: ...sm Code No 9Y021 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 9Y021 18200 3 To ope...

Page 430: ...k 1 3 rotates and press down the position link 2 4 The position lever shaft 2 5 rotates and pushes the spool 6 by the spool drive lever 7 opening the LIFT circuit 2 When the lift arm 11 moves upward p...

Page 431: ...ack shaft 8 rotates via position feedback rod 10 and push the spool 6 by the spool drive lever 7 The lift arm stops when the spool returns to the neutral position C 1 Position Control Lever 2 Position...

Page 432: ...he position of the draft control lever 1 When the draft control lever is positioned in the floating range 1 the implement lowers to the ground 2 When the draft control lever is positioned in the draft...

Page 433: ...draft feedback link shaft 8 and the other end is fixed with the draft link shaft 5 pulling out or pushing in the spool 7 by the rotation of the draft link shaft 5 The angle of the draft link shaft 5 i...

Page 434: ...the torsion bar is restored to return the spool 7 to neutral point C 3 When the traction load decreases the torsion bar is restored and its displacement is transmitted to the draft feedback link shaf...

Page 435: ...arms implement lower to the height set by the position control only when traction load increases slippage or engine stop may occur unless the implement is raised With the draft control only plowing de...

Page 436: ...nder 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 ring...

Page 437: ...7 2 CABIN Model 8 S18 5 OIL COOLER RELIEF VALVE 8 S19 5 DISASSEMBLING AND ASSEMBLING 8 S20 1 HYDRAULIC PUMP 8 S20 2 3 POINT HITCH HYDRAULIC BLOCK ASSEMBLY 8 S21 1 Removing Top Cover 3 Point Hitch Hydr...

Page 438: ...ace 8 S20 Implement Does Not Reach Maximum Height Position rod and feedback rod improperly adjusted Adjust 8 S9 Draft rod and feedback rod improperly adjusted Adjust 8 S9 Implement Does Not Lower Cont...

Page 439: ...mp for 3 point Linkage Condition Engine speed Approx 2600 min 1 rpm Rated pressure 19 1 MPa 195 kgf cm2 2770 psi Oil temperature 50 to 60 C 122 to 140 F Delivery Above 64 3 L min 17 0 U S gals min 14...

Page 440: ...th Approx 178 mm 7 01 in Position Feedback Rod ROPS and CABIN Length Approx 210 mm 8 3 in Draft Feedback Rod ROPS and CABIN Length Approx 272 mm 10 7 in Position Control Length 10 to 30 mm 0 39 to 1 1...

Page 441: ...OP LINK BRACKET W1013874 Item Factory Specification Allowable Limit Oil cooler relief valve Operating Pressure 4 4 to 4 9 MPa 45 0 to 50 0 kgf cm2 640 to 711 psi Oil cooler check valve Operating Press...

Page 442: ...36 2 to 50 6 Housing cover mounting screw 39 2 to 44 1 4 0 to 4 5 28 9 to 32 5 3 point hitch delivery pipe nut 107 9 to 117 7 11 0 to 12 0 79 6 to 86 8 Cylinder hose retaining nut 45 1 to 53 0 4 6 to...

Page 443: ...onnect 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 Turn...

Page 444: ...140 F W1011083 Hydraulic pump delivery at no pressure Factory spec Above 21 8 L min 5 76 U S gals min 4 80 Imp gals min Hydraulic pump delivery at rated pressure Factory spec 21 3 L min 5 63 U S gals...

Page 445: ...ntrol valve operation lever to the UP position 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...

Page 446: ...ANTS FUEL AND COOLANT at G GENERAL section to test the operating pressure of the cylinder safety valve W1012986 Adjusting Position Feedback Rod and Draft Feedback Rod 1 Be sure to adjust the position...

Page 447: ...adjust 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 155 mm 6 10 in Draft control rod len...

Page 448: ...adjusting nut 4 clockwise by 3 turns or turn the turnbuckle 5 1 5 turns to shorten the position feedback rod 3 7 Tighten the nut 4 8 Move the position control lever 2 to the lowest position to check t...

Page 449: ...Raise the lift arm 3 to the top dead center by hand and mark hydraulic cylinder 1 with S respectively 5 Measure the cylinder free play L from S to cylinder body end 6 If the cylinder free play is not...

Page 450: ...3 and check the point where the lift arms begin to rise 5 When the lift arms 4 begin to rise turn back the adjusting nut 5 2 turns or turn the turnbuckle 6 1 turn to shorten the draft feedback rod 3 6...

Page 451: ...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 begin to down C2...

Page 452: ...y 6 Slowly shift the draft control lever 5 upward to mid way of the lift arm guide At this time the lift arm should rise Then slowly shift the draft control lever 5 downward until the lift arms begin...

Page 453: ...draft control lever operating force 2 If measurement is not within the factory specification adjust the with tightening nuts 3 W1017524 Operating force for position and draft control lever Factory spe...

Page 454: ...ol lever 1 and stopper 5 3 Fix the wire 3 with retaining nut 6 center of thread Valve Side 1 Pull the auxiliary valve lever 8 to a full engage position 2 Pull out the wire 3 fully and fix the wire wit...

Page 455: ...ve lever 8 2 Assemble the cable with retaining nut 7 to the left end side of thread 3 Adjust the retaining nut 6 so that the clearance L between control lever 10 and to stopper plate 9 to be factory s...

Page 456: ...le tester with a relief valve adaptor refer to 8 SPECIAL TOOLS at G GENERAL section 2 Measure the operating pressure of the oil cooler check valve 1 3 If the pressure is not within the factory specifi...

Page 457: ...g cover mounting screw and separate the flange 6 and housing cover 2 from the housing 4 3 Remove the backup plate 8 4 Take out the gears 9 10 When reassembling When installing the backup plate 8 with...

Page 458: ...t the ground harness 19 14 Disconnect the lowering speed rod 18 NOTE Q Take care not to damage the grease nipple when remove the hydraulic cylinder pin When reassembling Apply grease to the grease nip...

Page 459: ...case and top cover NOTE Q After reassembling the top cover assembly to the tractor be sure to adjust the position and draft levers and position and draft feedback rods Top cover mounting screw has two...

Page 460: ...ple when remove the hydraulic cylinder pin When reassembling Apply grease to the grease nipples Take care not to damage the grease nipples when reassemble the hydraulic cylinder To assemble the auxili...

Page 461: ...own figure W1077358 3 HYDRAULIC LINKAGE Position and Draft Linkage 1 Remove the link cover 2 2 Unscrew the nuts 8 then draw out the spring plates 6 springs 5 and plate 4 3 Tap out the roll pin then dr...

Page 462: ...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 Re...

Page 463: ...lever 6 4 Remove the control valve 3 then remove the position spool lever 7 When reassembling Fix the with groove side 9 on the draft spool lever 6 and shorter side 8 on the position spool lever 7 fa...

Page 464: ...ssembling Remove the O ring 7 from position control shaft Insert the position control shaft and draft control shaft to the body until the both O ring grooves comes out Apply grease to the O ring then...

Page 465: ...When reassembling Be sure to fit the O rings Q Adjusting Spool Joint 1 Measure the length L 2 If the measurement is not within the factory specifications loosen the lock nut 4 and adjust by the spool...

Page 466: ...stall the poppet valve noting O ring and backup ring W1020366 Check Valve 1 Remove the seat plug 3 2 Draw out the spring 2 and check valve 1 When reassembling Install the plug noting O ring W1020605 T...

Page 467: ...le on the cylinder tube position 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...

Page 468: ...vise 3 Loosen the lock nut 10 4 Remove the adjuster 9 and remove the spring 8 and then pilot valve 7 5 Remove the valve seat 2 and draw out the valve seat 5 the spring 4 and the main valve 3 When rea...

Page 469: ...cotter pin and take out the clevis pins 1 and 2 3 Draw out the torsion bar 3 When reassembling Apply grease to the torsion bar bushing Replace the cotter pin with new one and assemble as shown figure...

Page 470: ...022677 10 LOWERING SPEED ADJUSTING VALVE Lowering Speed Adjusting Valve 1 Tap out the roll pin 2 then remove the plate 1 2 Remove the roll pin 4 using a vice grip pliers 3 3 Remove the lowering speed...

Page 471: ...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 to...

Page 472: ...stalling 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 face to rear When press fit...

Page 473: ...9 ELECTRICAL SYSTEM KiSC issued 09 2008 A...

Page 474: ...ing System 9 M10 3 4WD T M Control System 9 M11 4 Instrument Panel Board Meter Panel 9 M12 5 Working Light and Radio 9 M13 6 Air Conditioner 9 M14 7 Wiper System 9 M15 3 WIRING COLOR 9 M16 3 STARTING...

Page 475: ...5 G 0 85 G R 0 85 B 0 85 G R 0 85 BR 0 85 OR 0 85 B 0 85 R B 0 85 B 0 85 G B 0 85 Y R 0 85 B 0 85 B 0 85 B 0 85 B 0 85 B 0 85 B 0 85 LG R 0 50 B 0 50 W L 0 50 W G 2 00 B 2 00 B M8 0 85 LG R 0 85 LG R...

Page 476: ...50 Y B 0 50 G W 0 50 B Y 0 50 W L 0 50 Y L 0 50 L G 0 50 G Y 0 50 L 0 50 L OR 0 50 W B 0 50 P L 0 50 G 0 50 P W 0 50 Y 3 00 W R 3 00 B 3 00 R B 3 00 R L 3 00 W 3 00 Y B 3 00 B 3 00 Y R 3 00 Y B 3 00 W...

Page 477: ...B 0 85 R B 0 85 B 0 85 B 0 85 B 0 85 B 0 85 B 0 85 B 0 85 B 0 85 R G 0 85 B 0 85 R G 0 85 B 0 85 G B 2 00 B WIRE HARNESS CABIN WIRE HARNESS RADIO 0 50 G B 0 50 R B 0 50 L Y 0 50 Y B 0 50 B Y 0 50 W L...

Page 478: ...50 R G 0 50 Y 0 50 B W 0 85 R G 0 85 V W 1 2 3 Diode PTO DT Sol 0 50 L R 0 50 W G 0 50 B 4 1 1 2 3 0 50 B DS Valve Solenoid 0 50 Y L 0 50 Y L 0 50 GY B Diode DS Sol 0 50 GY B 0 85 BR Y 0 50 GY B 0 50...

Page 479: ...Back Up g Fuse Position Lamp Number Lamp h Fuse Flasher Hazard i Fuse Horn j Fuse Head Light k Fuse Turn signal Stop Lamp l Fuse Auxiliary Power m Fuse T M Control n Fuse AUX Socket o Fuse Work Light...

Page 480: ...1 2 0 5BR 0 5OR 4 5 1 2 3 0 85OR 4 5 1 2 3 0 5B H4 H4 0 85OR 0 85OR 0 85BR 0 85B 0 85B L H E L H E 0 85BR 0 85BR 0 85B 0 5BR 15A 10A 10A B3 H FREE PUSH 0 85L W 0 85B c d e 0 85G R 0 85G 0 85G R 7 5 8...

Page 481: ...F Lock Valve Solenoid A Key IG a Fuse T M Control b To Brake Switch R H c To Meter Panel d To PTO Valve Solenoid 4 0 85GY B 0 85R G 0 85L W 3 5 4 0 5W G 0 5BR W 0 5R 0 5G W 0 5W G 1 2 1 3 2 0 85V 0 5W...

Page 482: ...Switch c To Heater Relay d To Engine Stop Relay e To Light Switch High Beam f To Flasher Unit Output L g To Flasher Unit Output R h To Flasher Unit Trailer i To DT Switch j Rear DIFF Lock Switch k To...

Page 483: ...tioner Compressor r Fuse Air Conditioner Fan Motor s To DT Solenoid Valve t Fuse Working Light Rear u Fuse Working Light Front v Fuse Cigarette Lighter M6 3TMACBH9P025A ST GL M ACC AM OFF ACC ON GL ST...

Page 484: ...21 Illumination i To A C Control Panel j To Meter Panel 15 High Beam k To Meter Paenl 38 Back Up l To Radio Back Up 2 B1 T 1 OFF 1 2 20A 0 85OR 0 85OR 0 85BR 0 85B 0 85B 0 85OR 0 85B 0 85B 0 85B 0 85B...

Page 485: ...8 R18 Speed Transmission Model A Key IG a Fuse T M Control Alternator PTO Engine b To PTO Switch c To Brake Switch R H d To Meter Panel e To PTO Valve Solenoid 10A FREE LOCK R B 0 5B 0 5R 0 85L W B R...

Page 486: ...Relay e To Light Switch High Beam f To Flasher Unit Output L g To Flasher Unit Output R h To Flasher Unit Trailer i To 4WD Switch j To Diff Lock Switch k To Light Switch l To Alternator m To Dome Lig...

Page 487: ...Speaker L H A Light DEF B Blower Motor C ACC D Key ACC a Fuse Work Light Front b Fuse Work Light Front Side c Fuse Radio d To Dome Light 0 5Y B 0 5Y 0 5R B 0 5W B 0 5W 0 5B 0 5L Y 0 5L Y 6 5 4 1 2 3...

Page 488: ...ight Switch b Fuse Air Con Control c Fuse Air Con Compressor d Fuse Air Con Fan Motor 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...

Page 489: ...ear Wiper Motor A Key ACC a Fuse Wiper 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 IN...

Page 490: ...een Yellow R Y Red Yellow GY Gray L B Blue Black V W Violet White Lg Light Green L G Blue Green W B White Black Or Orange L Or Blue Orange W G White Green Sb Sky Blue L R Blue Red W L White Blue B G B...

Page 491: ...sition 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 PTO sa...

Page 492: ...ty 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 flows to...

Page 493: ...i valve design can be implemented and that the starting performance and serviceability are enhanced Structure The 12 V battery s positive terminal is connected with the main terminal When the key swit...

Page 494: ...ndicator 5 Liquid Crystal Display 6 Electrical Charge Indicator 7 Engine Oil Pressure Indicator 8 Tachometer 9 4WD Indicator 10 Heater Indicator 11 Air Cleaner Indicator 12 Rear Wheel Differential Loc...

Page 495: ...If the fuel in the tank goes below the prescribed level the warning lamp in the Easy Checker TM will come on If this should happen during operation refuel as soon as possible Q Electrical Charge If t...

Page 496: ...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 Met...

Page 497: ...ent 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 fact...

Page 498: ...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 Idlin...

Page 499: ...er unit lights the position light 5 when the light switch 11 is turned on Lo or Hi 4 The flasher unit lights the position light 5 when the position light switch 6 is turned on 5 The blinking frequency...

Page 500: ...Color of wire harness ROPS Model CABIN Model 1 Turn signal light L H Black Green Black 2 Green White 3 Ground Yellow Black Green Blue 4 Turn signal light R H Green White Green Yellow 5 Tail light Sid...

Page 501: ...TO Hour Meter Select Switch and Traveling Speed Select Switch 9 S24 4 Switch and Sensor 9 S26 8 LIGHTING SWITCHES AND FLASHER UNIT 9 S34 1 Combination Switch ROPS Model 9 S34 2 Lever Combination Switc...

Page 502: ...nal and alternator B terminal Repair or replace Cooling fan belt slipping Adjust tension G 26 Starter Motor Does Not Operate Battery discharged or defective Recharge or replace 9 S9 Slow blow fuse blo...

Page 503: ...her unit defective Replace 9 S37 Hazard switch defective Replace 9 S36 Turn signal switch defective Replace 9 S34 35 Hazard and Turn Signal Indicator Lamp Does Not Light Meter panel defective Replace...

Page 504: ...Repair or replace 9 S18 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 harness...

Page 505: ...fective Repair or replace 9 S33 Short circuit between air cleaner sensor lead and chassis Replace 9 S33 Circuit panel board defective Repair or replace 9 S24 Air Cleaner Clogged Lamp Does Not Light Wh...

Page 506: ...ture Gauge Does Not Function Coolant temperature gauge defective Replace 9 S24 Coolant temperature sensor defective Replace 9 S26 Wiring harness disconnected or improperly connected between meter pane...

Page 507: ...stance Approx 0 3 Brush Length 18 5 mm 0 728 in 5 0 mm 0 20 in Slip Ring O D 22 7 mm 0 894 in 22 1 mm 0 870 in Float at Uppermost Position Resistance 3 0 to 5 0 Float at Lowermost Position Resistance...

Page 508: ...y 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 Pulley nut Alternator 58 3 to 78 9 5 95 to 8 05 43 0 to 58 2 Air hea...

Page 509: ...amage 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 to...

Page 510: ...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 char...

Page 511: ...use 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 new one of the same capacity Q Protected Circuit W1015983 Tempe...

Page 512: ...r 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 Meter Radio...

Page 513: ...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 does...

Page 514: ...ain 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 Sw...

Page 515: ...he 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 co...

Page 516: ...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 con...

Page 517: ...y 2 Disconnect the battery positive cable and the leads from the starter terminal C 1 3 Remove the starter from the engine 4 Disconnect the connecting lead 2 from the starter terminal C 1 5 Connect a...

Page 518: ...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 terminal Connect the jumper leads fro...

Page 519: ...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 regulato...

Page 520: ...y 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 coeffi...

Page 521: ...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 will be cancelled if the key switch is turned O...

Page 522: ...0 for the remaining digits in the 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 monito...

Page 523: ...d 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 to OFF position to exit N...

Page 524: ...sition 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 alt...

Page 525: ...contact with other terminal or chassis while checking When applying the test pin of the tester to the connector terminals use care not to damage to the connector terminal Checking Connector Voltage Se...

Page 526: ...ch Battery voltage Main switch at ON and PTO speed lever shifted at 540E position T20 B W GND analogue T21 G W Illumination light Battery voltage Main switch at ON and head light switch ON T22 T23 B Y...

Page 527: ...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 Measure...

Page 528: ...PTO Change Switch Continuity 1 Check the continuity with an ohmmeter across the switch terminals 2 If it does not conduct or any value is indicated when the switch is pushed the switch is faulty 3 If...

Page 529: ...y W1029574 Rear Differential Lock Switch 1 Rear Differential Lock Switch Continuity 1 Check the continuity with an ohmmeter across the switch terminals 2 If it does not conduct or any value is indicat...

Page 530: ...3 Measure the voltage across the terminal and chassis 4 If the voltage differs from battery voltage the wiring harness fuse or main switch is faulty 2 Parking Brake Switch Continuity 1 Remove the par...

Page 531: ...minal 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 lowermos...

Page 532: ...h W L terminal and chassis 3 If the voltage differs from the battery voltage the wiring harness is faulty W1024064 2 4WD Switch 1 Check the continuity through switch with an ohmmeter 2 If continuity s...

Page 533: ...h is faulty W1036530 Hi Lo Dual Speed Switch F36 R36 Speed Transmission Model 1 Dual Switch Continuity 1 Check the continuity with an ohmmeter across the switch 1P connectors 2 If it does not conduct...

Page 534: ...ed lamp does not light the panel board circuit or wiring harness is faulty W1050130 2 Air Cleaner Sensor 1 Disconnect the leads from the air cleaner sensor 1 after turning the main switch OFF 2 Measur...

Page 535: ...ch 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 Terminal B2 B3 Chas...

Page 536: ...ch and Turn Signal Switch 1 Test the continuity through the switch with an ohmmeter 2 If the continuity specified below is not indicated the switch is faulty W1032505 Voltage Main switch at OFF Termin...

Page 537: ...tage 1 Connect the battery negative code then measure the voltage with a voltmeter across the each terminal c e and chassis 2 If the voltage differ from the battery voltage the wiring harness is fault...

Page 538: ...Then move the turn signal switch to the right and make sure the right hand light gives flashes Make sure the same actions as above result 3 If both the hazard switch and the turn signal switch and the...

Page 539: ...witch 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 following below the switch or the bulb...

Page 540: ...al b of 3P connector for front work light switch and beacon light switch are white black color wire for rear light switch is white blue color wire W1028416 Checking Switch Continuity 1 Test the contin...

Page 541: ...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 across t...

Page 542: ...position Terminal c Chassis Approx battery voltage 3 Work light relay front main switch at OFF position Terminal e Chassis Approx battery voltage 4 Key stop relay main switch at OFF position Terminal...

Page 543: ...switch at OFF position Terminal e Chassis Approx battery voltage 4 Key stop relay main switch at OFF position Terminal e Chassis Approx battery voltage 5 A C compressor relay main switch at OFF posit...

Page 544: ...faulty 2 Solenoid Valve 1 Disconnect the wire harness connector 1 2 Measure the resistance with an ohmmeter across the each terminal 1 2 3 on the connector 1 and chassis 3 If infinity is indicated th...

Page 545: ...s fuse or main switch is faulty 2 Solenoid Valve 1 Disconnect the wire harness connector 1 2 Measure the resistance with an ohmmeter across the each terminal 1 on the connector 1 and chassis 3 If infi...

Page 546: ...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 Whe...

Page 547: ...tor 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 to...

Page 548: ...sition 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 section 3...

Page 549: ...ry 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 Be...

Page 550: ...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 it...

Page 551: ...s 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 or...

Page 552: ...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 is n...

Page 553: ...easurement 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 recti...

Page 554: ...10 CABIN KiSC issued 09 2008 A...

Page 555: ...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 556: ...itioner 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 winds...

Page 557: ...e 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 then p...

Page 558: ...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 in...

Page 559: ...tion 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 ai...

Page 560: ...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 Out...

Page 561: ...erature 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 Slo...

Page 562: ...rectly 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 that...

Page 563: ...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 O M...

Page 564: ...AND SERVICING 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 Cont...

Page 565: ...ir Does Not Cool Compressor Does Not Rotate Fuse blown Replace 9 S11 Magnetic clutch defective Repair or replace 10 S22 A C switch defective Replace 10 S25 Pressure switch defective Replace 10 S30 Bel...

Page 566: ...Check and repair Too Low Air Flow Rate Flow Rate Does Not Change in 4 Steps Blower resistor defective Replace 10 S27 45 Relay defective Replace 9 S42 Blower fan switch defective Replace 10 S24 Too Low...

Page 567: ...ansion 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 pressure and...

Page 568: ...ent of link mechanism Repair 10 S53 Wiper arm seized or rusted Lubricate or replace 10 S53 Windshield Wiper Operating Speed Is Too Low Wiper motor defective Short circuit of motor armature worn motor...

Page 569: ...ide 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 Less than approx 0 196 MPa 2 0 kgf cm2 28 4 psi Sett...

Page 570: ...o 11 8 0 8 to 1 2 5 8 to 8 7 High pressure pipe 2 retaining nut receiver side 11 8 to 14 7 1 2 to 1 5 8 7 to 10 8 Compressor mounting screw 24 5 to 29 4 2 5 to 3 0 18 1 to 21 7 Compressor bracket moun...

Page 571: ...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 charg...

Page 572: ...osed 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 ar...

Page 573: ...ort 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 2...

Page 574: ...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 in...

Page 575: ...id valve the valve closes to keep out the outside air and allow the vacuum to build up but when the current stops the valve opens to allow in air and end the vacuum 2 Attaching this adaptor to the R12...

Page 576: ...m 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 Insta...

Page 577: ...harging 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 set...

Page 578: ...r Insufficient Condenser Cooling 1 Symptoms seen in refrigerating cycle Both LO and HI pressure side 1 2 pressures too high LO pressure side 1 0 20 to 0 35 MPa 2 0 to 3 5 kgf cm2 28 4 to 49 8 psi HI p...

Page 579: ...6771 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 sid...

Page 580: ...alve 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 expa...

Page 581: ...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 high p...

Page 582: ...7 to evacuate the refrigerant cycle For approx 15 minutes 5 When LO pressure gauge 1 reading is more than 750 mmHg 299 in Hg stop the vacuum pump 7 and close both valves 3 9 of manifold gauge fully 6...

Page 583: ...mpletely 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 Allo...

Page 584: ...he 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 and...

Page 585: ...ss 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 0...

Page 586: ...er 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 feel...

Page 587: ...per 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 it i...

Page 588: ...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 If t...

Page 589: ...h 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 or...

Page 590: ...eter 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 it...

Page 591: ...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 th...

Page 592: ...ecking 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 eac...

Page 593: ...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 pos...

Page 594: ...tch 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 Press...

Page 595: ...itch 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 of...

Page 596: ...below is not indicated the switch is faulty W1023782 14 Rear Wiper Motor 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 to ON posi...

Page 597: ...o the stop to relieve any excess pressure before removing cap completely 1 Stop the engine and let cool down 2 To drain the coolant open the radiator drain plug 1 When opening the drain plug set the h...

Page 598: ...front axle rocking restrictor 11 to the front axle bracket When reassembling The 6P connector 5 should be placed within the space of controller pipe 9 power steering controller 7 and stay 8 IMPORTANT...

Page 599: ...M9540 WSM CABIN Preparation 2 1 Remove the both side cover guides 3 2 Remove the both side panels 1 3 Remove the air cleaner hose 2 W1025955 1 Side Panel 2 Air Cleaner Hose 3 Side Cover Guide KiSC iss...

Page 600: ...t the condenser 2 2 Remove the hose clamps 3 3 Remove the slow blow fuse boxes 4 and relays 6 4 Disconnect 1P connector 5 of magnetic clutch 5 Remove the compressor bracket 7 mounting screw 8 from eng...

Page 601: ...refer to 3 Charging the Refrigerant in this section Apply compressor oil DENSO CO ND OIL8 to the O rings and take care not to damage them W1052713 Tightening torque Compressor bracket mounting screw...

Page 602: ...int shaft 6 from steering joint When reassembling Be sure to fix the heater hose to the original position Note the inlet hose and outlet hoses W1027330 Tightening torque Master cylinder hose retaining...

Page 603: ...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 Fil...

Page 604: ...sconnect the shuttle cable 3 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 c...

Page 605: ...7 Remove the 3P external control rod 5 8 Remove the parking brake upper rod 6 When reassembling Be sure to adjust the auxiliary control lever movement by auxiliary control wire 2 Refer to 1 CHECKING...

Page 606: ...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 W1029973 Length L1 Draft control rod Factory spec Approx 178...

Page 607: ...are not to damage them S letter is marked on the compressor for connecting the low pressure pipe suction side D letter is marked on the compressor for connecting the high pressure pipe discharge side...

Page 608: ...ssembling 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 mi...

Page 609: ...Discharging Refrigerant Gas 1 Refer to 1 Discharging the Refrigerant in this section W1031483 Seat Floor Mats and Floor Cover 1 Disconnect the battery negative cable from battery 2 Remove the seat 1 3...

Page 610: ...ove the duct 2 4 5 Remove the seat under cover 1 5 6 Remove the seat under cover 2 8 7 Remove the relay box 9 from seat under cover 2 8 8 Remove the duct 3 mounting screw 7 for removing duct 3 6 W1037...

Page 611: ...2 3 and low pressure pipe 2 4 Take off the unit NOTE Q Open parts are cap and moisture is prevented from going into the system at once When reassembling When reconnecting the cooler pipes with the un...

Page 612: ...ely to keep moisture out of the system When reassembling Apply compressor oil DENSO CO ND OIL8 to the O rings and take care not to damage them W1033365 Seat Mats and Floor Cover 1 Refer to 3 Removing...

Page 613: ...mage them W1033968 5 Removing Heater Hoses Draining Coolant 1 Refer to 2 DISASSEMBLING AND ASSEMBLING in this section W1034298 Side Cover R H and Heater Hoses 1 Remove the side cover R H 1 2 Disconnec...

Page 614: ...ter 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 2 When reassembling When connecting the heater hose w...

Page 615: ...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 In...

Page 616: ...rafast 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 a u...

Page 617: ...ng 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 wiper...

Page 618: ...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 lbf...

Page 619: ...I EI e Code No 9Y111 01420 KUBOTA Corporation EDITOR KUBOTA FARM INDUSTRIAL MACHINERY SERVICE LTD 64 ISHIZU KITAMACHI SAKAI KU SAKAI CITY OSAKA 590 0823 JAPAN PHONE 81 72 241 1129 FAX 81 72 245 2484 E...

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Summary of Contents for M9540

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Kubota M9540, Workshop Manual, Page: 505 / 619

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Summary of Contents for M9540

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