Kubota MX5100 Workshop Manual Download

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9-S20

MX5100, WSM

ELECTRICAL SYSTEM

(9) Combination Switch

Combination Switch

1. Turn off the main switch (1).
2. Remove the panel board (2).
3. Perform the following checks.

W1107080

Connector Voltage (Wire Harness Side)

1. Disconnect the connector 8P (1) from the combination switch.
2. Measure the voltage with a voltmeter across the connector B1

terminal and chassis when the main switch is OFF position.

3. If the voltage differs from the battery voltage, the wiring harness

is faulty.

4. Measure the voltage with a voltmeter across the connector B2

terminal and chassis when the main switch is ON position.

5. If the voltage differs from the battery voltage, check the wiring

harness and main switch.

W1108114

(1) Main Switch
(2) Panel Board

(3) Combination Switch

Voltage

Main switch at
OFF position

B1 Terminal -
Chassis

Battery voltage

Main switch at
ON position

B2 Terminal -
Chassis

(1) Combination Switch
(2) 8P Connector (Combination Switch

Side)

(3) 8P Connector (Wire Harness Side)

(A) Connector 8P (Wire Harness Side)

Summary of Contents for MX5100

Page 1: ...actor Mechanism Workshop Manual Code No 9Y021 01874 9Y021 18201 for the one which has not been described to this workshop manual Servicing Information on the troubleshooting servicing specification li...

Page 2: ......

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

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

Page 5: ...ngine must 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...

Page 6: ...SM SAFETY 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...

Page 7: ...SAFETY INSTRUCTIONS The following safety decals are installed on the machine If a decal becomes damaged illegible or is not on the machine replace it The decal part number is listed in the parts list...

Page 8: ...6 MX5100 WSM SAFETY INSTRUCTIONS...

Page 9: ...7 MX5100 WSM SAFETY INSTRUCTIONS...

Page 10: ...ensions Overall length without 3P 3245 mm 127 8 in 3120 mm 122 8 in Overall width min tread 1770 mm 69 7 in Overall height with ROPS 2430 mm 95 7 in Wheel base 1895 mm 74 6 in Min ground clearance 405...

Page 11: ...out notice W10350650 Model MX5100 Tire size Rear 14 9 26 Range gear shift lever Main gear shift lever km h mph Forward Low 1 1 6 1 0 2 2 2 1 4 3 3 6 2 3 4 5 4 3 3 High 1 7 6 4 7 2 10 8 6 7 3 17 5 10 9...

Page 12: ...10 MX5100 WSM DIMENSIONS DIMENSIONS...

Page 13: ...11 MX5100 WSM DIMENSIONS...

Page 14: ...12 MX5100 WSM DIMENSIONS...

Page 15: ...G GENERAL...

Page 16: ......

Page 17: ...ENANCE G 14 1 DAILY CHECK G 14 2 CHECK POINTS OF INITIAL 50 HOURS G 19 3 CHECK POINTS OF EVERY 50 HOURS G 21 4 CHECK POINTS OF EVERY 100 HOURS G 23 5 CHECK POINTS OF EVERY 200 HOURS G 28 6 CHECK POINT...

Page 18: ......

Page 19: ...L NAME AND SERIAL NUMBER When you contact local KUBOTA distributor always specify the engine serial number the tractor serial number and hour meter reading W10106000 1 Tractor Identification Plate 2 T...

Page 20: ...NERAL 2 CYLINDER NUMBER The cylinder numbers of KUBOTA diesel engine is designated as shown in the figure The sequence of cylinder numbers is given as No 1 No 2 No 3 and No 4 starting from the front c...

Page 21: ...ing Use 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 s...

Page 22: ...er to perform periodic 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 batt...

Page 23: ...art where sag be required W10115870 In installing a part take care not to get wiring caught by it W10116700 After installing wiring check protection of terminals and clamped condition of wiring only c...

Page 24: ...with water immediately Before recharging the battery remove it from the machine Before recharging remove cell caps Do recharging in a well ventilated place where there is no open flame nearby as hydr...

Page 25: ...n that there is no female connector being too open W10124300 Make certain plastic cover is large enough to cover whole connector W10125190 5 HANDLING OF CIRCUIT TESTER Use tester correctly following m...

Page 26: ...Below 0 C 32 F SAE10W 10W 30 or 15W 40 0 to 25 C 32 to 77 F SAE20 10W 30 or 15W 40 Above 25 C 77 F SAE30 10W 30 or 15W 40 4 Transmission case 44 0 L 11 6 U S gals 9 7 Imp gals KUBOTA UDT fluid or KUB...

Page 27: ...with sulfur content greater than 1 0 Diesel fuel specified to EN 590 or ASTM D975 are recommended No 2 D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service SA...

Page 28: ...5 7 36 to 41 40 to 44 4 0 to 4 5 29 to 32 61 to 70 6 2 to 7 2 45 to 52 M12 12 mm 0 47 in 63 to 72 6 4 to 7 4 47 to 53 78 to 90 7 9 to 9 2 58 to 66 63 to 72 6 4 to 7 4 47 to 53 103 to 117 10 5 to 12 0...

Page 29: ...2 35 to 2 83 17 0 to 20 5 32 6 to 39 3 3 32 to 4 00 24 0 to 29 0 3 8 48 to 56 4 9 to 5 8 35 0 to 42 0 61 1 to 73 2 6 23 to 7 46 45 0 to 54 0 1 2 109 to 130 11 1 to 13 2 80 0 to 96 0 149 2 to 178 9 15...

Page 30: ...n every 100 Hr G 26 Replace every 400 Hr G 32 9 Air cleaner element Double type Primary element Clean every 100 Hr G 26 1 Replace every 1 year G 38 2 Secondary element Replace every 1 year G 38 10 Fue...

Page 31: ...he required maintenance on the engine according to the above instruction Please see the Warranty Statement in detail No Item Service Interval Since then Refer ence page Impor tant 50 100 150 200 250 3...

Page 32: ...ling CAUTION Do not smoke while refueling Be sure to stop the engine before refueling 1 Turn the key switch to ON check the amount of fuel by fuel gauge 2 Fill fuel tank when fuel gauge shows 1 4 or l...

Page 33: ...low add new oil to the prescribed level at the oil inlet See page G 8 IMPORTANT If oil level is low do not run the engine W10682390 Checking Coolant Level CAUTION Do not remove radiator cap while cool...

Page 34: ...t the brake and clutch pedals for free travel and smooth operation 2 Adjust if incorrect measurement is found See Adjusting Clutch Pedal and Adjusting Brake Pedal in CHECK POINTS OF EVERY 100 HOURS W1...

Page 35: ...ts Hazard Lights Turn Signal Lights and Tail Lights 1 Inspect the lights for broken bulbs and lenses of the lights 2 Replace it if it is broken W10724340 1 Head Light 2 Side Turn Signal Hazard Light 3...

Page 36: ...MX5100 WSM G GENERAL Checking Seat Belt and ROPS 1 Always check condition of seat belt 1 and ROPS 2 attaching hardware before operating tractor 2 Replace it if it is damaged W10729850 1 Seat Belt 2 R...

Page 37: ...o cool down sufficiently oil can be hot and can burn 1 To drain the used oil remove the both drain plugs 1 at the bottom of the engine and drain the oil completely into the oil pan 2 After draining re...

Page 38: ...oil can be hot and can burn 1 Remove the drain plugs at the bottom of the transmission case and drain the oil completely into the oil pan 2 After draining reinstall the drain plugs 3 Remove the oil f...

Page 39: ...muddy conditions lubricating grease fittings more often When apply a grease to the front axle support remove the breather plug and apply a grease until grease overflows from breather plug After greas...

Page 40: ...ey to START position 6 The engine must not crank Test 3 Switch for the operator s seat 1 Sit on operator s seat 2 Depress the clutch pedal fully 3 Start the engine 4 Engage the PTO gear shift lever 5...

Page 41: ...ater immediately and get medical attention Wear eye protection and rubber gloves when working around the battery The factory installed battery is of non refillable type If the indicator turns white do...

Page 42: ...ge in the standard fashion 2 A boost charge is only for emergencies It will partially charge the battery at a high rate and in a short time When using a boost charged battery it is necessary to rechar...

Page 43: ...osen the lock nut 2 remove the cotter pin 3 and adjust the rod length within acceptable limits 4 Retighten the lock nut 2 and split the cotter pin W10329220 Adjusting Brake Pedal Free Travel CAUTION S...

Page 44: ...ment in detergent for 15 minutes then wash it several times in water rinse with clean water and dry it naturally After element is fully dried inspect inside of the element with a light and check if it...

Page 45: ...aged 2 If hoses and clamps are found worn or damaged replace or repair them at once NOTE If the fuel line is removed be sure to properly bleed the fuel system See page G 41 IMPORTANT When the fuel lin...

Page 46: ...oil can be hot and can burn 1 Remove the oil filter 2 Place a oil pan under the engine oil filter cartridge Put a film of clean engine oil on the rubber seal of the new filter 3 Tighten the filter qui...

Page 47: ...s obtained 4 Retighten the tie rod nut 2 5 Attach the snap ring of the tie rod joint 3 2WD 1 Detach the snap ring 1 2 Loosen the tie rod nut 2 3 Turn the tie rod joint to adjust the rod length until t...

Page 48: ...ace 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 minutes or whil...

Page 49: ...ngine and check the oil level again add oil to the prescribed level 9 Make sure that the transmission fluid does not leak past the seal on the filter IMPORTANT To prevent serious damage to the hydraul...

Page 50: ...o premature wear W11084790 7 CHECK POINT OF EVERY 600 HOURS Adjusting Front Axle Pivot 1 Loosen the lock nut 2 tighten the adjusting screw 1 all the way and then tighten the adjusting screw 1 by 1 6 t...

Page 51: ...15 clockwise and counterclockwise to see if the piston is at the compression top dead center or the overlap position Now referring to the table below readjust the valve clearance 1 The piston is at t...

Page 52: ...k the nozzle spraying condition 2 If the spraying condition is defective replace the nozzle piece W10181310 Fuel Injection Pressure 1 Set the injection nozzle to a nozzle tester 2 Slowly move the test...

Page 53: ...o a nozzle tester Code No 07909 31361 2 Raise the fuel pressure and keep at 12 75 MPa 130 kgf cm2 1849 psi for 10 seconds 3 If any fuel leak is found replace the nozzle piece W1113031 Valve seat tight...

Page 54: ...re 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 13 73 MPa 140 kgf cm2 1991 psi 7 Now turn the flywheel back...

Page 55: ...is found retighten the bolts Compressor Side 1 Check the inlet hose to see if there is no air leak 2 Check for loosen connections or cracks in the suction side of the inlet hose 3 If any air leak is f...

Page 56: ...remove the radiator cap 2 The radiator cap 2 must be removed to completely drain the coolant 3 After all coolant is drained close the drain cock 1 4 Fill with clean water and cooling system cleaner 5...

Page 57: ...fore a long term storage let out cooling water completely or mix fresh water with long life coolant and fill the radiator and reserve tank with the mixture 1 Long life coolant hereafter LLC comes in s...

Page 58: ...nt has a service life of 2 years Be sure to change the coolant every 2 years NOTE The above date represent industry standards that necessitate a minimum glycol content in the concentrates anti freeze...

Page 59: ...p the engine 4 Close the air vent cock IMPORTANT Always close the air vent cock except for bleeding fuel lines Otherwise engine runs irregularly or stalls frequently W10390260 Draining Clutch Housing...

Page 60: ...tem Refer to TRABLESHOOTING section of this manual Protected Circuit W10393150 Replacing Light Bulb 1 Head lights and rear combination lights Take the bulb out of the light body and replace with a new...

Page 61: ...nder W10241000 Piston Ring Tool Code No 07909 32121 Application Use exclusively for removing or installing the piston ring with ease W10241500 Diesel Engine Compression Tester Code No 07909 30208 Asse...

Page 62: ...n Use to check of radiator cap pressure and leaks from cooling system W10245320 Connecting Rod Alignment Tool Code No 07909 31661 Application Use to check the connecting rod alignment Applicable Conne...

Page 63: ...k Code No 07909 31371 Application Use to check cracks on cylinder head cylinder block etc W11034030 Crankshaft Nut Socket 46 Code No 07916 30821 Application Use exclusively for removing or installing...

Page 64: ...9 in dia D 225 mm 8 86 in E 70 mm 2 76 in F 45 mm 1 77 in G 25 mm 0 98 in H 5 mm 0 197 in I 6 7 to 7 0 mm dia 0 263 to 0 275 in dia J 20 mm dia 0 787 in dia K 12 5 to 12 8 mm dia 0 492 to 0 504 in dia...

Page 65: ...83 in C R40 mm R1 57 in D 10 mm 0 39 in E 20 mm 0 79 in F 20 mm dia 0 79 in dia G 56 8 to 56 9 mm dia 2 236 to 2 240 in dia H 51 8 to 51 9 mm dia 2 039 to 2 043 in dia A 130 mm 5 12 in B 72 mm 2 83 i...

Page 66: ...N 21 947 to 21 960 mm dia 0 8641 to 0 8646 in dia D 0 52 rad 30 O 28 mm 1 10 in E 46 950 to 46 975 mm dia 1 8484 to 1 8494 in dia P 29 mm 1 14 in F 43 934 to 43 950 mm dia 1 7297 to 1 7303 in dia Q 5...

Page 67: ...1 38 in dia T 60 mm dia 2 36 in dia G 60 mm dia 2 36 in dia U 46 950 to 46 975 mm dia 1 8484 to 1 8494 in dia H 37 mm 1 46 in V 44 950 to 44 975 mm dia 1 7697 to 1 7707 in dia I 21 947 to 21 960 mm di...

Page 68: ...D 10 8 to 11 2 mm 0 426 to 0 440 in E 40 mm 1 6 in F 20 mm 0 79 in G 39 mm 1 5 in H 20 mm Hole 0 79 in Hole I 8 50 to 8 80 mm Drilled hole 0 335 to 0 346 in Drilled hole J 20 mm Spot faced hole 1 mm...

Page 69: ...71 mm 2 8 in H 10 mm 0 39 in I 85 mm 3 3 in J 0 52 rad 30 K 9 0 mm 0 35 in L 120 mm 4 72 in M 10 mm 0 39 in N 139 mm 5 12 in O 10 mm 0 39 in P 44 7 to 45 3 mm 1 76 to 1 78 in Q 10 mm 0 39 in R 65 mm 2...

Page 70: ...Puller Code No 07916 51090 Application Use for removing the steering wheel without damaging the steering shaft W10265330 Injector CH3 Code No 07916 52501 Application Use for injecting calcium chloride...

Page 71: ...ssure for power steering W10442870 Pinion Locking Tool Code No 07916 52311 Application Use for preventing the shaft from turning when removing or tighten a bevel pinion shaft staking nut W10445520 1 G...

Page 72: ...the hydraulic coupler This is available with the relief valve setting pressure tester W10623960 NOTE The following special tools are not provided so make them referring to the figure Pinion Shaft Rem...

Page 73: ...46 in B 24 5 to 25 5 mm 0 9646 to 1 0039 in 21 5 to 22 5 mm 0 8465 to 0 8858 in C 40 mm 1 57 in 40 mm 1 57 in D 32 mm 1 26 in 30 mm 1 18 in E 49 7 to 49 9 mm 1 9567 to 1 9646 in 44 7 to 44 9 mm 1 7598...

Page 74: ...dia 1 25 in dia C 25 0 mm dia 0 98 in dia D 50 0 mm 1 97 in E 26 0 mm 1 02 in F 200 0 mm 7 87 in G 276 0 mm 10 87 in 1 Clutch Center Tool A PS 1 4 B PT 3 8 C 7 mm dia 0 28 in dia D 20 mm 0 79 in E 3 m...

Page 75: ...07916 50330 Application Use for measuring three point system relief valve operating pressure etc W11117500 A 10 mm 0 39 in B 16 2 mm 0 64 in C PS 1 4 D M16 1 5 E 49 mm 1 93 in F 37 mm 1 46 in G 18 mm...

Page 76: ...0 3 in dia C 35 mm 13 8 in P 1 05 rad 60 D 23 to 23 3 mm 0 9055 to 0 9713 in Q 3 mm dia 1 18 in dia E 16 mm dia 0 63 in dia 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 di...

Page 77: ...ront Tire of 2WD only Farm Tire Turf Tire Industrial Tire Type of tire Front Rear 2WD Farm Tire 7 5L 15 6PR or 9 5L 15 6PR 13 6 28 4PR or 14 9 26 4PR Turf Tire 29 12 50 15 4PR 44 18 20 6PR 4WD Farm Ti...

Page 78: ...n and tighten them with the screws IMPORTANT After tread adjustment adjust toe in Toe in All models 2 to 8 mm 0 08 to 0 31 in The front width for the front loader application on 2WD models should not...

Page 79: ...l tread as wide as practical for the job for maximum stability IMPORTANT Always attach tires as shown in the drawings below If not attached as illustrated transmission parts may be damaged Do not use...

Page 80: ...G GENERAL 3 Wheel Hub W10433920 Front wheel hub Rear wheel hub Screw circle diameter A 152 4 mm 6 in 203 2 mm 8 0 in Number of screws 6 8 Screws M14 1 5 M16 1 5 Hub pilot diameter B 117 4 mm 4 625 in...

Page 81: ...pressure Do not inflate tires above the recommended pressure shown in the operator s manual W10440050 Tire sizes Inflation Pressure Rear 13 6 28 4 PR 150 kPa 1 5 kgf cm2 22 psi 14 9 26 4 PR 140 kPa 1...

Page 82: ...cium 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...

Page 83: ...air valve and pump air into the tire to the specified pressure Liquid weight per tire 75 filled W10334350 Tire sizes 14 9 26 13 6 28 17 5L 24 Slush free at 10 C 14 F Solid at 30 C 22 F Approx 1 kg 2...

Page 84: ...he bottom 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 and dire...

Page 85: ...h improper implements are not covered by the warranty NOTE Implement size may vary depending on soil operating conditions Tread max width Lower link end max lifting weight W0 Front Rear 2WD 4WD 1530 m...

Page 86: ...ax Weight 400 kg 880 lbs 7 Chisel Plow Max Cutting Width 1830 mm 72 in Max Weight 350 kg 770 lbs 8 Broad Caster Max Tank Capacity 300 L 80 U S gals Max Weight 100 kg 220 lbs 9 Manure Spreader Max Capa...

Page 87: ...1 ENGINE...

Page 88: ......

Page 89: ...MECHANISM NOTICE Regarding engine mechanism information please refer to Workshop Manual DIESEL ENGINE MECHANISM Code No 9Y021 01874...

Page 90: ......

Page 91: ...1 S17 3 Cooling System 1 S17 4 Fuel System 1 S19 2 DISASSEMBLING AND ASSEMBLING 1 S23 1 Separating Engine from Tractor 1 S23 2 Engine External Components 1 S35 3 Cylinder Head and Valves 1 S38 4 Pisto...

Page 92: ......

Page 93: ...ust 1 S19 Fuel camshaft worn Replace 1 S46 S47 Injection nozzle clogged Clean or replace 1 S39 Injection pump malfunctioning Replace 1 S43 Seizure of crankshaft camshaft piston cylinder or bearing Rep...

Page 94: ...e the turbocharger assembly 1 S37 Turbocharger fin or other part damaged due to foreign matters Replace the turbocharger assembly 1 S37 Either White or Blue Exhaust Gas Is Observed Excessive engine oi...

Page 95: ...6 Turbocharger compressor wheel turning heavily Replace the turbocharger assembly 1 S37 Excessive Lubricant Oil Consumption Piston ring s gap facing the same direction Shift ring gap direction 1 S50 O...

Page 96: ...8 Relief valve defective Replace Engine overheated Engine oil insufficient Replenish 1 S23 Fan belt broken or elongated Replace or adjust G 25 Coolant insufficient Replenish 1 S26 Radiator net and ra...

Page 97: ...inder Head Surface Flatness 0 05 mm 500 mm 0 002 in 19 7 in Valve Recessing Protrusion to Recessing Protrusion Recessing 0 05 mm 0 002 in 0 15 mm 0 0059 in 0 40 mm 0 016 in Valve Stem to Valve Guide V...

Page 98: ...in 100 N 35 0 mm 10 2 kgf 35 0 mm 22 5 lbf 1 38 in 1 0 mm 0 039 in Rocker Arm Shaft to Rocker Arm Rocker Arm Shaft Rocker Arm Oil Clearance O D I D 0 016 to 0 045 mm 0 00063 to 0 0017 in 13 973 to 13...

Page 99: ...r to Balancer Gear Backlash Backlash Backlash Backlash Backlash Backlash 0 04150 to 0 1122 mm 0 001634 to 0 004417 in 0 04150 to 0 1154 mm 0 001634 to 0 004543 in 0 04150 to 0 1154 mm 0 001634 to 0 00...

Page 100: ...0 0039 in Camshaft Side Clearance 0 070 to 0 22 mm 0 0028 to 0 0086 in 0 30 mm 0 012 in Camshaft Alignment 0 01 mm 0 0004 in Cam Height Intake Height Exhaust 33 90 mm 1 335 in 33 27 mm 1 310 in 33 85...

Page 101: ...ce O D I D 0 020 to 0 094 mm 0 00079 to 0 0037 in 21 947 to 21 960 mm 0 86406 to 0 86456 in 21 980 to 22 041 mm 0 86536 to 0 86775 in 0 20 mm 0 0079 in Piston Pin Bore I D 25 000 to 25 013 mm 0 98426...

Page 102: ...0 104 mm 0 00158 to 0 00409 in 59 921 to 59 940 mm 2 3591 to 2 3598 in 59 980 to 60 025 mm 2 3615 to 2 3631 in 0 20 mm 0 0079 in Crankpin to Crankpin Bearing Crankpin Crankpin Bearing Oil Clearance O...

Page 103: ...0 14 mm 0 0012 to 0 0055 in 0 2 mm 0 008 in Outer Rotor to Pump Body Clearance 0 11 to 0 19 mm 0 0044 to 0 0074 in 0 25 mm 0 0098 in Inner Rotor to Cover Clearance 0 105 to 0 150 mm 0 00414 to 0 00590...

Page 104: ...0 kgf cm2 1991 psi Delivery Valve Fuel Tightness 10 seconds 13 73 12 75 MPa 140 0 130 0 kgf cm2 1991 1849 psi 5 seconds 13 73 12 75 MPa 140 0 130 0 kgf cm2 1991 1849 psi Injection Nozzle Injection Pr...

Page 105: ...teering main delivery hose retaining nut 46 6 to 50 9 4 8 to 5 2 34 4 to 37 6 Power steering turning delivery hoses retaining nut 24 5 to 29 4 2 5 to 3 0 18 1 to 21 7 Engine and clutch housing mountin...

Page 106: ...lywheel screw M12 x 1 25 98 1 to 107 10 0 to 11 0 72 4 to 79 5 Connecting rod screw M8 x 1 0 45 to 49 4 5 to 5 0 33 to 36 Rocker arm bracket screw M8 x 1 25 24 to 27 2 4 to 2 8 18 to 20 Idle gear shaf...

Page 107: ...at steps 4 through 6 for each cylinder 8 If the measurement is below the allowable limit apply a small amount of oil to the cylinder wall through the nozzle hole and measure the compression pressure a...

Page 108: ...terclockwise to see if the piston is at the compression top dead center or the overlap position Now referring to the table below readjust the valve clearance 1 The piston is at the top dead center whe...

Page 109: ...tighten the engine oil pressure switch to the specified torque W1034952 3 Cooling System Fan Belt Tension 1 Measure the deflection A depressing the belt halfway between the fan drive pulley and alter...

Page 110: ...For water leak from the pinhole replace the radiator or repair with the radiator cement When water leak is excessive replace the radiator NOTE The pressure of the leak test is different from each rad...

Page 111: ...timing add or remove the shim to adjust Injection Timing NOTE The sealant is applied to both sides of the soft metal gasket shim The liquid gasket is not required for assembling Shims are available in...

Page 112: ...eed control lever to the maximum speed position 6 Run the starter to increase the pressure 7 If the pressure can not reach the allowable limit replace the pump with new one or repair with a Kubota aut...

Page 113: ...o 12 75 MPa 140 0 to 130 0 kgf cm2 1991 to 1849 psi DI 18 63 to 17 65 MPa 190 0 to 180 0 kgf cm2 2702 to 2560 psi 9 If the measurement is less than allowable limit replace the pump with new one or rep...

Page 114: ...ssure variation with 0 025 mm 0 00098 in difference of adjusting washer thickness Approx 590 kPa 6 0 kgf cm2 85 psi W10476390 Valve Seat Tightness 1 Set the injection nozzle to a nozzle tester 2 Raise...

Page 115: ...il When refilling After draining oil screw in the drain plugs Fill the engine oil up to the upper line on the dipstick 2 IMPORTANT Do not mix two different types of oil Use the proper SAE engine oil a...

Page 116: ...ning the engine for few minutes stop it and check the oil level again add the transmission fluid to prescribed level if its level is not correct level IMPORTANT Use only KUBOTA SUPER UDT fluid Use of...

Page 117: ...tive cable 3 3 Disconnect the head light connector 6 4 Remove the snap pins 8 5 Disconnect the bonnet dampers 7 from the bonnet 1 6 Remove the bonnet 1 carefully When reassembling To close the bonnet...

Page 118: ...operly fitted water may leak out and the engine could overheat W1029172 Disconnecting Wirings 1 1 Disconnected the fuel sensor lead 2 from the fuel level sensor and the ground lead 3 from the fuel tan...

Page 119: ...from the PTO lever neutral switch 4 Disconnect the 3P connector 7 from the seat switch 6 5 Disconnect the 2P connectors 9 from the shuttle shift neutral switch 8 W11097980 1 Seat 2 4P Rear Combination...

Page 120: ...r panel mounting screws 7 Disconnect the connector and the hour meter cable from the meter panel 8 Remove the rear bonnet mounting screws 9 Disconnect the connectors 10 Remove the rear bonnets 3 6 Whe...

Page 121: ...ands 1 2 3 6 2 Disconnect the wiring from the transmission housing case When reassembling Bind the code bands as shown in the pictures Reinstall the wirings to the original location as shown in the pi...

Page 122: ...tening torque Power steering main delivery hose retaining nut 46 6 to 50 9 N m 4 8 to 5 2 kgf m 34 4 to 37 6 lbf ft Power steering turning delivery hoses retaining nut 24 5 to 29 4 N m 2 5 to 3 0 kgf...

Page 123: ...ead mounting bolt 8 from the steering post 5 Remove the fuel tank stay mounting bolts 7 from the clutch housing case 6 Set the front axle rocking restrictors 10 to the front axle When reassembling Rei...

Page 124: ...e with a disassembling stand 2 Support the mid case with a disassembling stand 3 Remove the engine and clutch housing case mounting bolts and nuts 4 Separate the engine and the clutch housing case Whe...

Page 125: ...om the engine 6 Disconnect the fuel hose from the fuel feed pump 7 Hook the fuel tank stay using a nylon sling 8 Disconnect the water temperature sensor lead from the cylinder head 9 Disconnect the fu...

Page 126: ...the frame under the battery 2 Hoist the engine at the engine hooks 3 Remove the front axle frame mounting screw 4 Separate the engine from the front axle frame 2 When reassembling Lift the front of t...

Page 127: ...ove the accelerating wire 5 and the oil filter 6 4 Check oil leakage from the turbocharger 7 When reassembling If the oil leakage from the turbocharger is found replace the turbocharger as an assembly...

Page 128: ...nter tool Refer to G 56 NOTE Do not allow grease and oil on the clutch disc facing W12067660 Air Cleaner Muffler and Others 1 Remove the air cleaner and muffler 2 Remove the fan 1 fan belt 4 alternato...

Page 129: ...sition 1 Disconnect the inlet hose 1 2 Remove the joint bolt 2 7 and take off the oil pipe 1 8 3 Remove the bolts 1 3 and release the clamp 5 4 Disconnect the oil pipe 2 4 and pipe 3 6 5 Remove the bo...

Page 130: ...ection Pipes 1 Loosen the screws on the pipe clamps 2 2 Detach the injection pipes 1 When reassembling Blow out dust inside the pipes W1060970 Tightening torque Cylinder head cover screw 9 81 to 11 2...

Page 131: ...ole 2 Turn screw driver three or four times each way 3 While turning the screw driver slowly pull the heat seal 4 out together with the injection nozzle gasket 3 4 If the heat seal drops repeat the ab...

Page 132: ...en reassembling When putting the push rods 2 onto the tappets 3 check to see if their ends are properly engaged with the grooves IMPORTANT After installing the rocker arm be sure to adjust the valve c...

Page 133: ...essing from the level of crankcase cylinder face average of all pistons after installing the pistons and select the cylinder head gasket following the below table Selecting the cylinder head gasket 1...

Page 134: ...the valve stem and valve guide hole and apply engine oil sufficiently After installing the valve spring collets 4 lightly tap the stem to assure proper fit with a plastic hammer IMPORTANT Do not chan...

Page 135: ...ing body 4 stop solenoid 3 and stop solenoid guide 5 install the injection pump first into position Replace the hi idling body gasket with a new one Before fitting the boost compensator assembly 2 to...

Page 136: ...and bolts 3 Using the specific tool 1 undo the large governor spring 3 from the fork lever 2 4 Using the specific tool 1 undo the small governor spring 4 from the fork lever 2 5 Set the speed control...

Page 137: ...too long because otherwise it may get deformed permanently Using the specific tool 1 hook the large governor spring 3 onto the fork lever 2 Make sure both the governor springs 3 4 are tight on the for...

Page 138: ...Check to see if there are four O rings 2 inside the gear case 1 Apply a thin film of engine oil to the oil seal 3 and install it noting the lip come off Before installing the gear case gasket apply a...

Page 139: ...bolts and draw out the balancer shaft 1 2 3 Remove the balancer shaft 2 3 set bolts and draw out the balancer shaft 2 3 When reassembling When install the balancer shaft 1 2 and 2 3 be sure to place...

Page 140: ...are fixed to the fork lever shaft and that they can turn smoothly in the holder 7 W1025309 Oil Pump 1 Remove the nut 2 Draw out the oil pump drive gear 2 with gear puller 1 3 Remove the four oil pump...

Page 141: ...il strainer 1 and O ring 4 When reassembling After cleaning the oil strainer 1 check to see that the filter mesh in clean and install it Visually check the O ring 4 apply engine oil and install it Sec...

Page 142: ...ample mark 1 on the No 1 piston Place the piston rings with their gaps at 0 79 rad 45 from the piston pin s direction as shown in the figure Carefully insert the pistons using a piston ring compressor...

Page 143: ...the oil ring gap 11 Apply engine oil to the piston pin 9 When installing the connecting rod 7 to the piston 6 immerse the piston 6 in 80 C 176 F oil for 10 to 15 minutes and insert the piston pin 9 t...

Page 144: ...of bearing case cover 6 to remove it IMPORTANT The length of inside screws 5 and outside screws 3 are different Do not take a mistake using inside screws and outside screws When reassembling Fit the b...

Page 145: ...ght or Left When reassembling IMPORTANT Install the crankshaft sub assembly aligning the screw hole of main bearing case 2 2 with the screw hole of cylinder block When tightening the main bearing case...

Page 146: ...es vary install them in order of makings A B for 3 cylinders and A B C for 4 cylinders from the gear case side Match the alignment numbers 1 and mark 2 on the main bearing case When installing the mai...

Page 147: ...bushing NOTE After checking the top clearance be sure to assemble the cylinder head with a new cylinder head gasket W1020190 Cylinder Head Surface Flatness 1 Clean the cylinder head surface 2 Place a...

Page 148: ...g the valve replace the cylinder head W10768800 Clearance between Valve Stem and Valve Guide 1 Remove carbon from the valve guide section 2 Measure the valve stem O D with an outside micrometer 3 Meas...

Page 149: ...hammer during replacement W10278890 Valve Seating 1 Coat the valve face lightly with prussian blue and put the valve on its seat to check the contact 2 If the valve does not seat all the way around t...

Page 150: ...eat and fit them with valve lapping tool 4 Check the valve seating with prussian blue The valve seating surface should show good contact all the way around W10283500 Valve Lapping 1 Apply compound eve...

Page 151: ...t W10784360 Oil Clearance between Rocker Arm and Rocker Arm Shaft 1 Measure the rocker arm shaft O D with an outside micrometer 2 Measure the rocker arm I D with an inside micrometer and then calculat...

Page 152: ...the 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 W1029366 Push rod alignment...

Page 153: ...lash between idle gear and cam gear Factory spec 0 04150 to 0 1154 mm 0 001634 to 0 004543 in Allowable limit 0 15 mm 0 0059 in Backlash between idle gear and injection pump gear Factory spec 0 04150...

Page 154: ...3 Measure the camshaft alignment 4 If the measurement exceeds the allowable limit replace the camshaft W1031413 Cam Height 1 Measure the height of the cam at its highest point with an outside microme...

Page 155: ...ss out the used idle gear bushing using an idle gear bushing replacing tool See page SPECIAL TOOLS When installing 1 Clean a new idle gear bushing and idle gear bore and apply engine oil to them 2 Pre...

Page 156: ...t 1 Support the balancer shaft with V blocks on the surface plate and set a dial indicator with its tip on the intermediate journal at high angle 2 Rotate the balancer shaft on the V block and get the...

Page 157: ...ft bearing 1 I D Factory spec 43 980 to 44 045 mm 1 7315 to 1 7340 in Oil clearance of balancer shaft journal 2 Factory spec 0 0300 to 0 111 mm 0 00119 to 0 00437 in Allowable limit 0 20 mm 0 0079 in...

Page 158: ...placing Connecting Rod Small End Bushing When removing 1 Press out the used small end bushing using a small end bushing replacing tool See page SPECIAL TOOLS When installing 1 Clean a new small end bu...

Page 159: ...e allowable limit replace the ring W1032246 Clearance between Piston Ring and Groove 1 Clean the rings and the ring grooves and install each ring in its groove 2 Measure the clearance between the ring...

Page 160: ...the surface plate at both end journals 2 Set a dial indicator with its tip on the intermediate journal 3 Measure the crankshaft alignment 4 If the measurement exceeds the allowable limit replace the c...

Page 161: ...ankshaft while the connecting rod screws are tightened Reference Undersize dimensions of crankpin W1033106 Oil clearance between crankpin and crankpin bearing Factory spec 0 025 to 0 087 mm 0 00099 to...

Page 162: ...cing tool press in a new bearing 1 2 so that its seam 1 directs toward the exhaust manifold side See figure W1033946 Oil clearance between crankshaft journal and crankshaft bearing 1 Factory spec 0 04...

Page 163: ...rence Undersize dimensions of crankshaft journal W1083821 Oil clearance between crankshaft and crankshaft bearing 2 Factory spec 0 0400 to 0 104 mm 0 00158 to 0 00409 in Allowable limit 0 20 mm 0 0079...

Page 164: ...03 5 Cylinder Cylinder Wear 1 Measure the I D of the cylinder at the six positions see figure with a cylinder gauge to find the maximum and minimum I D s 2 Get the difference Maximum wear between the...

Page 165: ...r 1 Put a strip of plastigage onto the rotor face with grease 2 Install the cover and tighten the screws 3 Remove the cover carefully and measure the width of the press gauge with a sheet of gauge 4 I...

Page 166: ...1 S74 MX5100 WSM ENGINE...

Page 167: ...2 CLUTCH...

Page 168: ......

Page 169: ...CONTENTS MECHANISM 1 TRAVELLING CLUTCH 2 M1 1 LINKAGE MECHANISM 2 M1 2 PTO CLUTCH 2 M2 1 SHIFT LINKAGE 2 M2 2 STRUCTURE 2 M2 3 OIL FLOW 2 M3...

Page 170: ......

Page 171: ...ch pedal to have wider space about the platform W10126810 1 Flywheel 2 Pressure Plate 3 Clutch Cover 4 Diaphragm Spring 5 Pressure Plate Assembly 6 Release Bearing 7 Release Hub 8 25T Gear Shaft 9 18T...

Page 172: ...aft rotates When the shift lever is moved to the A side the PTO clutch valve 4 is set at the DISENGAGED position W10136710 2 STRUCTURE The hydraulic multiple disk clutch is used for tractor with indep...

Page 173: ...h pack The accumulator absorbs the engaging shock of the clutch pack When the shift lever is set at the DISENGAGED position the spool 2 is turned to B position then the oil from the regulator valve is...

Page 174: ...2 M4 MX5100 WSM CLUTCH...

Page 175: ...2 S4 4 CHECKING DISASSEMBLING AND SERVICING 2 S5 1 CHECKING AND ADJUSTING 2 S5 2 DISASSEMBLING AND ASSEMBLING 2 S7 1 Separating Engine from Clutch Housing 2 S7 2 Disassembling Clutch 2 S16 3 Disassemb...

Page 176: ......

Page 177: ...ace 2 S16 Chattering Grease or oil on clutch disc facing Replace 2 S16 Clutch disc or pressure plate warped Replace 2 S16 Clutch disc boss spline worn or rusted Replace or remove rust 2 S16 Clutch sha...

Page 178: ...2 S23 PTO Shaft Does Not Rotate PTO clutch malfunctioning Repair or replace 2 S23 PTO propeller shaft coupling disengaged Engage PTO Clutch Operating Pressure is Low Transmission oil improper or insu...

Page 179: ...ragm Spring Mutual Difference 0 5 mm 0 020 in PTO Clutch Valve Condition Engine Speed Idling Oil Temperature 40 to 60 C 104 to 140 F Relief Valve Setting Pressure 2 25 to 2 45 MPa 23 0 to 25 0 kgf cm2...

Page 180: ...7 1 to 66 5 Engine and clutch housing mounting stud bolt 39 2 to 49 0 4 0 to 5 0 28 9 to 36 2 Clutch pressure plate mounting screws 23 5 to 27 5 2 4 to 2 8 17 5 to 20 3 Release fork setting screws 23...

Page 181: ...press the clutch pedal and measure free travel at top of pedal stroke 3 If adjustment is needed loosen the lock nut remove the cotter pin and adjust the rod length within acceptable limits 4 Retighten...

Page 182: ...alve adjuster of the regulator valve 9 Condition Engine speed Idling speed Oil pressure 40 to 60 C 104 to 140 F Reference Turn to clockwise direction Pressure is increased Turn to counterclockwise dir...

Page 183: ...he line of the level gauge 3 After running the engine for few minutes stop it and check the oil level again add the transmission fluid to prescribed level if its level is not correct level IMPORTANT U...

Page 184: ...tive cable 3 3 Disconnect the head light connector 6 4 Remove the snap pins 8 5 Disconnect the bonnet dampers 7 from the bonnet 1 6 Remove the bonnet 1 carefully When reassembling To close the bonnet...

Page 185: ...roperly fitted water may leak out and the engine could overheat W1029172 Disconnecting Wirings 1 1 Disconnected the fuel sensor lead 2 from the fuel level sensor and the ground lead 3 from the fuel ta...

Page 186: ...from the PTO lever neutral switch 4 Disconnect the 3P connector 7 from the seat switch 6 5 Disconnect the 2P connectors 9 from the shuttle shift neutral switch 8 W10431400 1 Seat 2 4P Rear Combination...

Page 187: ...r panel mounting screws 7 Disconnect the connector and the hour meter cable from the meter panel 8 Remove the rear bonnet mounting screws 9 Disconnect the connectors 10 Remove the rear bonnets 3 8 Whe...

Page 188: ...ands 1 2 3 6 2 Disconnect the wiring from the transmission housing case When reassembling Bind the code bands as shown in the pictures Reinstall the wirings to the original location as shown in the pi...

Page 189: ...tening torque Power steering main delivery hose retaining nut 46 6 to 50 9 N m 4 8 to 5 2 kgf m 34 4 to 37 6 lbf ft Power steering turning delivery hoses retaining nut 24 5 to 29 4 N m 2 5 to 3 0 kgf...

Page 190: ...lead mounting bolt 8 from the steering post 5 Remove the fuel tank stay mounting bolts 7 from the clutch housing case 6 Set the front axle rocking restrictor 10 to the front axle When reassembling Rei...

Page 191: ...e with a disassembling stand 2 Support the mid case with a disassembling stand 3 Remove the engine and clutch housing case mounting bolts and nuts 4 Separate the engine and the clutch housing case Whe...

Page 192: ...ond 1901 or equivalent to the splines of clutch disc boss Install the pressure plate nothing the position of straight pins IMPORTANT Align the center of disc and flywheel by inserting the clutch cente...

Page 193: ...lutch lever 3 to remove the release fork 1 When reassembling Make sure the direction of the release fork 1 is correct Inject grease to the release hub 4 Be sure to set the snap pins 6 on both sides W1...

Page 194: ...om the brake lever 8 12 3 Remove the steering post mounting bolts 3 4 Remove the steering post 1 using a nylon sling 5 Remove the step When reassembling If the split pin is damaged replace it Install...

Page 195: ...nuts 7 Separate the clutch housing 9 and the mid case 8 When reassembling Apply liquid gasket Three Bond 1208D or equivalent to joint face of the clutch housing and the mid case W10462240 Tightening t...

Page 196: ...e the mid case and transmission case mounting bolts and nuts 7 Hoist the mid case with a nylon sling 8 Separate the mid case 1 from the transmission case 6 safety When reassembling Apply liquid gasket...

Page 197: ...emove the external cir clip 10 from the shift rod 7 6 Remove the PTO clutch bearing holder 2 with the shaft assemblies 1 4 5 6 When reassembling W10243240 Tightening torque PTO clutch bearing holder m...

Page 198: ...all the PTO clutch bearing holder 6 with the shafts 5 8 12 using a hammer as shown in the picture When reassembling W10251910 Tightening torque PTO clutch bearing holder mounting bolts M10 77 5 to 90...

Page 199: ...the three steel plates 6 10 and 12 are same positions while assembling them Refer to figure below Apply enough transmission fluid to the discs 5 Confirm the moving of the piston 13 smoothly when press...

Page 200: ...equivalent to the brake plate mounting screws 3 W10167880 Piston 1 Press the washer 6 lightly by the hand press using the hand made jig Refer to the figure left 2 Draw out the piston 4 When reassembli...

Page 201: ...In this case inspect transmission gear shaft oil seal engine rear oil seal and other points for oil leakage W10309250 Checking Pressure Plate Assembly and Flywheel 1 Wash the disassembling parts excep...

Page 202: ...ts 2 If the clearance exceeds the allowable limit replace it 3 When the pressure plate is worn around its outside and its inside surface only is in contact with the straight edge replace even if the c...

Page 203: ...st four points 3 If the gauge can be inserted replace it W10173580 Piston Return Spring Free Length 1 Measure the free length of spring with vernier calipers 2 If the measurement is less than the allo...

Page 204: ...asure the thickness of seal rings 1 with an outside micrometer 2 If the measurement is less than the allowable limit replace it W10176900 Thickness of seal ring Factory spec 2 45 to 2 50 mm 0 096 to 0...

Page 205: ...3 TRANSMISSION...

Page 206: ......

Page 207: ...TRAIN 3 M3 1 MAIN GEAR SHIFT SECTION 3 M3 2 SHUTTLE SHIFT SECTION 3 M3 3 RANGE GEAR SHIFT SECTION 3 M3 4 FRONT WHEEL DRIVE SECTION FOUR WHEEL DRIVE MODEL 3 M4 3 PTO SYSTEM 3 M5 1 STRUCTURE 3 M5 2 PTO...

Page 208: ......

Page 209: ...3 M1 MX5100 WSM TRANSMISSION 1 STRUCTURE 1 2WD...

Page 210: ...3 M2 MX5100 WSM TRANSMISSION 2 4WD...

Page 211: ...synchronizer ring 9 is installed on one side as shown in the figure W1012964 3 RANGE GEAR SHIFT SECTION The range gear shift section is located in the differential gear case It uses constant mesh gea...

Page 212: ...rential gear case Two wheel drive or four wheel drive is selected by operating the front wheel drive lever to shift the shifter gear 7 W1013518 1 Spiral Bevel Pinion Gear 2 Gear 3 Front Wheel Drive Ge...

Page 213: ...GED or DISENGAGED by operating the shift lever of the PTO clutch valve Mid PTO is not adopted The PTO power train from the clutch to the rear PTO shaft is composed as shown in the figure above 1 PTO G...

Page 214: ...set at the DISENGAGED position W1013899 2 Oil Flow The pressured oil adjusted by the regulator valve flows into the PTO clutch valve 2 When the PTO lever is at the DISENGAGED position the oil does no...

Page 215: ...to the accumulator and the PTO clutch pack Oil entering the clutch pack pushes the piston 6 to engage the PTO clutch pack The accumulator absorbs the engaging shock of the PTO clutch pack W1013678 1 C...

Page 216: ...ansmission case Thus the piston 6 is pushed back the brake plate 9 is also moved to contact the brake disc 8 so as to stop the rotation and the drag of the PTO shaft W1019106 1 Check Valve 2 Spool 3 A...

Page 217: ...NG AND ASSEMBLING 3 S5 1 Separating Engine and Clutch Housing Case 3 S5 2 Separating Clutch Housing and Mid Case 3 S15 3 Disassembling Clutch Housing 3 S17 4 Separating Mid Case and Transmission Case...

Page 218: ......

Page 219: ...S26 S39 Gears Clash When Shifting Clutch does not release Adjust or repair G 25 Gears worn or damaged Replace 3 S20 S26 S39 Differential Lock Can Not Be Set Differential lock shift fork damaged Replac...

Page 220: ...Bore to Differential Side Gear Boss Differential Case Bore Differential Case Cover Bore Differential Side Gear Boss Clearance I D I D O D 0 050 to 0 151 mm 0 00197 to 0 00594 in 40 500 to 40 550 mm 1...

Page 221: ...holder mounting bolts M10 77 5 to 90 2 7 9 to 9 2 57 1 to 66 5 Transmission bearing holder mounting bolt 48 1 to 55 9 4 9 to 5 7 35 5 to 41 2 22 staking nut 147 to 196 15 to 20 108 to 145 Pinion bear...

Page 222: ...108 to 145 PTO shaft bearing case mounting screw 23 5 to 27 5 2 4 to 2 8 17 4 to 20 3 Differential support mounting screw 48 1 to 55 9 4 9 to 5 7 35 5 to 41 2 Differential case cover mounting screw 48...

Page 223: ...rain plugs 1 to drain oil When refilling After draining oil screw in the drain plugs Fill the engine oil up to the upper line on the dipstick 2 IMPORTANT Do not mix two different types of oil Use the...

Page 224: ...r running the engine for few minutes stop it and check the oil level again add the transmission fluid to prescribed level if its level is not correct level IMPORTANT Use only KUBOTA SUPER UDT fluid Us...

Page 225: ...egative cable 3 3 Disconnect the head light connector 6 4 Remove the snap pins 8 5 Disconnect the bonnet dampers 7 from the bonnet 1 6 Remove the bonnet 1 carefully When reassembling To close the bonn...

Page 226: ...improperly fitted water may leak out and the engine could overheat W1029172 Disconnecting Wirings 1 1 Disconnected the fuel sensor lead 2 from the fuel level sensor and the ground lead 3 from the fuel...

Page 227: ...4 from the PTO lever neutral switch 4 Disconnect the 3P connector 7 from the seat switch 6 5 Disconnect the 2P connectors 9 from the shuttle shift neutral switch 8 W10429300 1 Seat 2 4P Rear Combinat...

Page 228: ...eter panel mounting screws 7 Disconnect the connector and the hour meter cable from the meter panel 8 Remove the rear bonnet mounting screws 9 Disconnect the connectors 10 Remove the rear bonnets 3 6...

Page 229: ...e bands 1 2 3 6 2 Disconnect the wiring from the transmission housing case When reassembling Bind the code bands as shown in the pictures Reinstall the wirings to the original location as shown in the...

Page 230: ...ightening torque Power steering main delivery hose retaining nut 46 6 to 50 9 N m 4 8 to 5 2 kgf m 34 4 to 37 6 lbf ft Power steering turning delivery hoses retaining nut 24 5 to 29 4 N m 2 5 to 3 0 k...

Page 231: ...nd lead mounting bolt 8 from the steering post 5 Remove the fuel tank stay mounting bolts 7 from the clutch housing case 6 Set the front axle rocking restrictor 10 to the front axle When reassembling...

Page 232: ...case with a disassembling stand 2 Support the mid case with a disassembling stand 3 Remove the engine and clutch housing case mounting bolts and nuts 4 Separate the engine and the clutch housing case...

Page 233: ...ods 2 6 from the brake lever 8 12 3 Remove the steering post mounting bolts 3 4 Remove the steering post 1 using a nylon sling 5 Remove the step When reassembling If the split pin is damaged replace i...

Page 234: ...nd nuts 7 Separate the clutch housing 9 and the mid case 8 When reassembling Apply liquid gasket Three Bond 1208D or equivalent to joint face of the clutch housing and the mid case W10134850 Tightenin...

Page 235: ...two M6 35 mm screws 2 into the shaft case 1 and pull it out 3 Take out the shaft case 1 When reassembling Apply liquid gasket Three Bond 1208D or equivalent to joint surface of the shaft case and clut...

Page 236: ...gear shaft 1 as an assembly from the clutch housing When reassembling Install the 25T gear shaft not to damage the oil seal 5 installed in the 25T gear shaft rear end using a vinyl tape W10199890 1 2...

Page 237: ...aft 4WD only 1 Remove the internal cir clip 2 2 Pull out the front axle drive shaft 1 to the front side When reassembling Do not damage the oil seal W10207270 1 18T PTO Gear Shaft 2 Cir clip 3 26T Gea...

Page 238: ...when pulling out the clutch housing bearing holder 7 When reassembling Install the three interlock balls 8 with a small amount of grease to the clutch housing bearing holder 7 after setting the shift...

Page 239: ...ON Removing 18T PTO Gear Shaft 1 After removing the clutch housing bearing holder 3 and the shafts remove the 18T PTO gear shaft 2 to the rear side W10215970 1 Clutch Housing 2 18T PTO Gear Shaft 3 Cl...

Page 240: ...older 10 W10218510 1 External Cir clip 2 Collar 3 Internal Cir clip 4 Ball Bearing 5 18T PTO Gear Shaft 6 Synchro Counter Shaft Assembly 7 Main Gear Shaft Assembly 8 PTO Counter Shaft Assembly 9 21T P...

Page 241: ...l guides 9 Install the clutch housing bearing holder 1 to the shaft assemblies 3 7 8 10 Set the clutch housing bearing holder mounting bolts 11 11 Install the three interlock balls 9 and clutch housin...

Page 242: ...wheel drive lever 6 Remove the mid case and transmission case mounting bolts and nuts 7 Hoist the mid case with a nylon sling 8 Separate the mid case 1 from the transmission case 6 safety When reassem...

Page 243: ...the outside 5 Remove the external cir clip 10 from the shift rod 7 6 Remove the PTO clutch bearing holder 2 with the shaft assemblies 1 4 5 6 When reassembling W10243240 Tightening torque PTO clutch b...

Page 244: ...TCH section 4 Install the PTO clutch bearing holder 6 with the shafts 5 8 10 using a hammer as shown in the picture When reassembling W10251910 Tightening torque PTO clutch bearing holder mounting bol...

Page 245: ...3 Disassemble the lever shaft assembly When reassembling If cir clip or bearing is damaged replace it W10259520 1 Shuttle Shaft 2 External Cir clip 3 Collar 4 Ball Bearing 5 18T Gear 6 Shifter 7 15T G...

Page 246: ...embling Replace the 22 staking nut with a new one After tightening the 22 staking nut to the specified torque punch and lock the 22 staking nut using a pin punch W10202440 Tightening torque Transmissi...

Page 247: ...folk in the transmission case 4 Remove the bolt 4 Slide the front wheel drive shift lever 5 to the outside 5 Disconnect the linkage between the front wheel drive shift lever 5 and the front wheel dri...

Page 248: ...and Thrust Collar 6 Ball Bearing 7 PTO Coupling 8 Hi Lo Gear Shaft 9 Ball Bearing 10 18T Gear 11 Shifter 12 33T Gear 13 Ball Bearing 14 Bearing Cover 15 22 Nut 16 Taper Roller Bearing Assembly 17 Bea...

Page 249: ...NTS FUEL AND COOLANT See page G 8 Do not mix different brands of fluid together W1031462 Battery Negative Cable 1 Disconnect the battery negative cable 1 W1031665 Rear Wheels and Seat 1 Place the disa...

Page 250: ...elivery pipe 2 6 4 Remove the hydraulic oil filter 4 with filter bracket and suction pipe 2 5 5 Disconnect the PTO clutch wire 7 When reassembling W10163390 Tightening torque Main gear shift lever mou...

Page 251: ...alternator 3 Remove the starter B terminal mounting nut 7 and disconnected the B terminal lead from the starter B terminal 4 Disconnect the ST terminal lead 6 from the battery ST terminal 5 Disconnect...

Page 252: ...2P connectors 3 from the PTO lever neutral switch 4 Disconnect the 3P connector 6 from the seat switch 5 5 Disconnect the 2P connectors 8 from the range shift neutral switch 7 W10400300 1 4P Rear Com...

Page 253: ...meter panel mounting screws 7 Disconnect the connector and the hour meter cable from the meter panel 8 Remove the rear bonnet mounting screws 9 Disconnect the connectors 10 Remove the rear bonnets Whe...

Page 254: ...nder R H L H 1 Remove the top link 7 lower link 5 and lift rod 6 2 Remove the ROPS center 1 and draw out the ROPS upper 2 3 Remove the ROPS mounting screw and ROPS lower 3 8 4 Remove the fender R H 4...

Page 255: ...trol rod if equipped See page 8 S13 W10190270 Rear Axle 1 Place the support stand under the rear axle case 2 Remove the rear axle mounting screws and nuts 3 Separate the rear axle case from brake case...

Page 256: ...ansmission case mounting screws and nuts 2 Separate the mid case and transmission case When reassembling Apply liquid gasket Three Bond 1208D or equivalent to joint face of mid case and transmission c...

Page 257: ...ighten the screws to specified torque W10369720 Shaft Assemblies 1 Take out the pinion shaft 1 the PTO drive shaft 2 and the four wheel drive shaft 3 2 Take out the Hi Lo range gear shaft 4 with the h...

Page 258: ...sure to stake it firmly Install the slinger 8 firmly Apply grease to the oil seal 4 and install it nothing its direction W10242030 Differential Gear Assembly 1 Remove the differential support noting...

Page 259: ...ircumferential surface of the differential side gear boss W10247220 Spiral Bevel Gear 1 Remove the spiral bevel gear When reassembling Check the spiral bevel gear for wear or damage If it is no longer...

Page 260: ...hree Bond 1901 or equivalent to the inner circumferential surface of the differential pinions Install the parts to their original position Install the differential pinion washer 4 noting its groove po...

Page 261: ...to measure the clearance 4 If the clearance exceeds the allowable limit replace them W10258480 Clearance between Shift Fork and Shift Gear Groove or Shifter Groove 1 Place for in the groove to check...

Page 262: ...tool 1 Turning Torque Tool Weld socket on the brake shaft Brake shaft Part No TA040 26710 3 Add or reduce the thickness of shims 3 to make the specified turning torque 4 After getting the specified tu...

Page 263: ...n 1 0 mm 0 039 in 0 5 mm 0 020 in 0 8 mm 0 031 in 1 2 mm 0 047 in 0 6 mm 0 024 in 0 9 mm 0 035 in 1 4 mm 0 055 in Thickness of shims 6 0 4 mm 0 016 in 0 8 mm 0 031 in 1 2 mm 0 047 in 0 6 mm 0 024 in 1...

Page 264: ...1 5 mm 0 059 in 1 7 mm 0 067 in 1 6 mm 0 063 in W10289200 Clearance between differential case bore and differential side gear boss Factory spec 0 050 to 0 151 mm 0 00197 to 0 00594 in Allowable limit...

Page 265: ...4 REAR AXLE...

Page 266: ......

Page 267: ...CONTENTS MECHANISM 1 STRUCTURE 4 M1...

Page 268: ......

Page 269: ...final gears 5 The rear axles are the semi floating type with the ball bearing 1 between the rear axle 2 and rear axle case 3 which support the rear wheel load besides transmitting power to the rear w...

Page 270: ...4 M2 MX5100 WSM REAR AXLE...

Page 271: ...CING 1 TROUBLESHOOTING 4 S1 2 TIGHTENING TORQUES 4 S2 3 CHECKING DISASSEMBLING AND SERVICING 4 S3 1 DISASSEMBLING AND ASSEMBLING 4 S3 1 Separating Rear Axle Case from Brake Case 4 S3 2 Disassembling R...

Page 272: ......

Page 273: ...erence Page Excessive or Unusual Noise at All Time Improper backlash between 11T gear and 67T gear Replace 4 S5 Bearing worn Replace 4 S5 Insufficient or improper type of transmission fluid used Reple...

Page 274: ...w and nut 197 to 226 20 to 23 145 to 166 ROPS mounting screw 166 7 to 196 1 17 to 20 123 to 144 Rear axle case mounting screw M10 48 1 to 55 9 4 9 to 5 7 35 4 to 41 2 Rear axle case mounting nut M10 6...

Page 275: ...D COOLANT See page G 8 Do not mix different brands of fluid together W1012439 Rear Wheel 1 Place the disassembling stand under the transmission case 2 Remove the rear wheel mounting screws and nuts 3...

Page 276: ...equivalent to joint face of the rear axle case and brake case after eliminate the water oil and stuck liquid gasket W10113490 Tightening torque Rear axle case mounting screw and nut M10 screws 48 1 t...

Page 277: ...g Apply grease to the oil seal 2 and install it Replace the lock nut with new one and after tightening it to specified torque stake it firmly Assemble the oil seal 2 with correct direction See figure...

Page 278: ...4 S6 MX5100 WSM REAR AXLE...

Page 279: ...5 BRAKES...

Page 280: ......

Page 281: ...CONTENTS MECHANISM 1 STRUCTURE 5 M1...

Page 282: ......

Page 283: ...ng brakes They are operated by the brake pedals through the mechanical linkages 2 4 6 7 The parking brake is a mechanical type which is designed to actuate the travelling brakes Pulling the parking br...

Page 284: ...640 1 Oil Seal 2 Needle Bearing 3 Brake Pedal 4 Return Spring 5 Brake Pedal LH 6 Brake Pedal Shaft 7 Parking Brake Lock 8 Brake Rod 1 9 Turnbuckle 10 Brake Rod 2 11 Brake Lever Link Shaft 12 Brake Lev...

Page 285: ...S1 2 SERVICING SPECIFICATIONS 5 S2 3 TIGHTENING TORQUES 5 S3 4 CHECKING DISASSEMBLING AND SERVICING 5 S4 1 CHECKING AND ADJUSTING 5 S4 2 DISASSEMBLING AND ASSEMBLING 5 S5 1 Separating Brake Case from...

Page 286: ......

Page 287: ...warped Replace 5 S8 Brake Drags Brake pedal play too small Adjust 5 S4 Ball holes of cam plate for uneven wear Replace 5 S8 Brake pedal return spring weaken or broken Replace 5 S4 Brake cam rusted Rep...

Page 288: ...Lever Link Shaft Brake Lever Link Bushing Clearance O D I D 0 125 to 0 195 mm 0 00492 to 0 00768 in 19 955 to 19 975 mm 0 78563 to 0 78642 in 20 100 to 20 150 mm 0 79134 to 0 79331 in 1 0 mm 0 039 in...

Page 289: ...S mounting screw 166 7 to 196 1 17 to 20 123 to 144 Rear axle case mounting screw M10 48 1 to 55 9 4 9 to 5 7 35 4 to 41 2 Rear axle case mounting nut M10 60 8 to 70 5 6 2 to 7 2 44 9 to 52 1 Rear axl...

Page 290: ...brake 2 Slightly depress the brake pedals and measure free travel at top of pedal stroke 3 If the measurement is not within the factory specifications loosen the lock nut 1 and adjust with the turnbu...

Page 291: ...ils may damage the transmission or hydraulic system Refer to LUBRICANTS FUEL AND COOLANT See page G 8 Do not mix different brands of fluid together W1014593 Rear Wheels and Seat 1 Place the disassembl...

Page 292: ...Three Bond 1208D or equivalent to joint face of the rear axle case and brake case after eliminate the water oil and stuck liquid gasket W10139100 Tightening torque ROPS mounting screw 166 7 to 196 1 N...

Page 293: ...that the hole A of brake discs should be overlapped 50 or more W10139950 Brake Cam and Brake Cam Lever 1 Remove the brake cam mounting nut and remove the brake cam 2 and brake cam lever 4 When reasse...

Page 294: ...on a diagonal line 3 If the measurement exceed the allowable limit replace it W10145650 Height of Cam Plate and Ball 1 Measure the dimension of the cam plate with the ball installed 2 If the measureme...

Page 295: ...W10148530 Brake Plate Wear 1 Measure the brake plate thickness with vernier calipers 2 If the measurement is less than the allowable limit replace it W10149690 Brake disc thickness Factory spec 4 6 to...

Page 296: ...5 S10 MX5100 WSM BRAKES...

Page 297: ...6 FRONT AXLE...

Page 298: ......

Page 299: ...CONTENTS MECHANISM 1 STRUCTURE 6 M1 1 2WD TYPE 6 M1 2 4WD TYPE 6 M2 2 FRONT WHEEL ALIGNMENT 6 M3...

Page 300: ......

Page 301: ...hape of the front axle is relatively simple and the front axle is supported at its center with the front axle brackets 7 8 on the front axle frame 10 so that steering operation is stable even on an un...

Page 302: ...by the bevel gears 17 13 then the power is transmitted to the axle 12 The differential system allows each wheel to rotate at a different speed to make turning easier 1 Bevel Gear Case 2 Bevel Gear 10T...

Page 303: ...lity in running W10128110 Kingpin Angle The Kingpin is titled from the vertical as viewed from the front This angle is called kingpin angle a As with the camber kingpin angle reduces rolling resistanc...

Page 304: ...is smaller than that between the heels It is called toe in The front wheels tend to roll outward due to the camber but toe in offsets it and ensures parallel rolling of the wheels Another purpose of...

Page 305: ...TORQUES 6 S5 4 CHECKING DISASSEMBLING AND SERVICING 6 S6 1 CHECKING AND ADJUSTING 6 S6 2 DISASSEMBLING AND ASSEMBLING 6 S8 1 Separating Front Axle 6 S8 2 Disassembling 2WD Type Front Axle 6 S10 3 Disa...

Page 306: ......

Page 307: ...ushings worn 2WD Type Replace 6 S16 Front axle rocking force too small Adjust 6 S7 Front wheel sway excessive Replace 6 S6 Tie rod end loose Tighten 6 S9 Air sucked in power steering circuit Bleed 7 S...

Page 308: ...o Bushing Knuckle Shaft Bushing Clearance O D I D 0 000 to 0 285 mm 0 00000 to 0 01122 in 27 880 to 27 900 mm 1 09764 to 1 09842 in 27 900 to 28 165 mm 1 09842 to 1 10886 in 0 4 mm 0 016 in Front Axle...

Page 309: ...in 0 20 mm 0 0079 in Pinion Shaft to Differential Pinion Pinion Shaft Differential Pinion Clearance O D I D 0 064 to 0 100 mm 0 00252 to 0 00394 in 13 950 to 13 968 mm 0 54921 to 0 54992 in 14 032 to...

Page 310: ...in 0 35 mm 0 0138 in Front Axle Case Boss Rear to Bracket Bushing Front Axle Case Boss Rear Bushing Clearance O D I D 0 025 to 0 190 mm 0 00098 to 0 00748 in 70 000 to 70 035 mm 2 75590 to 2 75728 in...

Page 311: ...2 57 2 to 66 5 Tie rod end nut 49 0 to 68 6 5 0 to 7 0 36 2 to 50 6 Front wheel hub slotted nut 78 5 to 117 7 8 0 to 12 0 57 9 to 86 8 Knuckle arm mounting bolt and nut 77 5 to 90 2 7 9 to 9 2 57 2 to...

Page 312: ...rod lock nut 1 and rod mounting screw 4WD 1 Detach the snap ring 4 2 Loosen the tie rod lock nut 5 3 Turn the tie rod joint 6 to adjust the rod length until the proper toe in measurement is obtained 4...

Page 313: ...1 can not be contacted with the bevel gear case 2 shorten the length of stopper 3 4 Keeping the front gear case 1 contact with the bevel gear case 2 make a specified clearance A as shown in the lower...

Page 314: ...t plug 2 IMPORTANT Use KUBOTA SUPER UDT fluid or SAE80 90 gear oil Refer to LUBRICANTS FUEL AND COOLANT See page G 8 W10128890 Propeller Shaft 4WD Only 1 Slide the propeller shaft cover 4 and 8 after...

Page 315: ...10136920 Tie rods 1 Pull out the cotter pin and remove the tie rod end slotted nuts 2 Remove the tie rod with a tie rod end lifter Code No 07909 39051 When reassembling After tightening the tie rod en...

Page 316: ...Replace cotter pin with a new one Apply grease to the oil seal in the front wheel hub IMPORTANT After tightening the slotted nut to the specified torque insert a cotter pin and bend it as shown in the...

Page 317: ...e mounting screws 2 Remove the bevel gear case 3 and front gear case 4 as a unit from the front axle case 1 When reassembling Apply grease to the O ring 2 and take care not to damage it Do not interch...

Page 318: ...g 1 2 Tap the bevel gear case 2 and separate it from the front gear case 3 W10160540 Bevel Gear Case Gears 1 Remove the internal snap ring 4 2 Take out the bevel gears 5 6 with ball bearings and shims...

Page 319: ...joint 1 right side 2 Remove the cylinder set screw 3 3 Remove the nipples 2 from steering cylinder 4 Remove the internal snap ring 4 5 Draw out the steering cylinder 5 When reassembling Apply liquid l...

Page 320: ...to the oil seal 6 Install the shims and collars to their original position Install the taper roller bearings correctly noting their direction and apply gear oil to them When press fitting an oil seal...

Page 321: ...erential pinions 4 and differential side gears 6 When reassembling Apply molybdenum disulfide Three Bond 1901 or equivalent to the inner circumferential surface of the differential side gears 6 and di...

Page 322: ...ing 1 Measure the shaft O D at several points where it contacts with the bushings 2 Measure the bushing I D in the same method and calculate the clearance 3 If the clearance exceeds the allowable limi...

Page 323: ...ry specifications adjust with the differential side gears shims Reference Thickness of adjusting shims 0 4 mm 0 016 in 1 0 mm 0 039 in 0 6 mm 0 024 in 1 2 mm 0 047 in 0 8 mm 0 031 in Tooth contact Mor...

Page 324: ...easure the backlash by moving the spiral bevel pinion shaft by hand lightly 3 If the backlash is not within the factory specifications change the adjusting collar 3 4 For example when the backlash is...

Page 325: ...r and 43T Bevel Gear 1 Stick a strip of fuse to three spots on the 43T bevel gear 1 with grease 2 Fix the axle flange and front gear case 3 Turn the axle 4 Remove the axle flange from front gear case...

Page 326: ...et bushing front Factory spec 0 025 to 0 160 mm 0 00098 to 0 00630 in Allowable limit 0 35 mm 0 0138 in Front axle case boss front O D Factory spec 49 950 to 49 975 mm 1 96653 to 1 96752 in Bracket bu...

Page 327: ...7 STEERING...

Page 328: ......

Page 329: ...CONTENTS MECHANISM 1 STRUCTURE 7 M1 1 STEERING LINKAGE 7 M1 2 OIL FLOW 7 M2 3 STEERING CYLINDER 7 M3...

Page 330: ......

Page 331: ...s steering gear drag link etc Therefore it is simple in construction In this model the non road reaction type is used With this type the wheels maintain their position when the operator releases his h...

Page 332: ...sses through control valve 9 and returns back into the regulator valve 5 4 When the engine is not operating and the steering wheel is turned gerotor 11 rotates to supply oil in the hose to the steerin...

Page 333: ...th knuckle 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...

Page 334: ...7 M4 MX5100 WSM STEERING...

Page 335: ...ICING 7 S5 1 CHECKING 7 S5 1 Hydraulic Pump Test Using Flow Meter Power Steering 7 S5 2 Relief Valve Power Steering 7 S7 2 DISASSEMBLING AND ASSEMBLING 7 S8 1 Hydraulic Pump 7 S8 2 Steering Wheel and...

Page 336: ......

Page 337: ...lace 7 S8 Overload Transmission fluid improper or insufficient Change G 31 Oil leak from pipe or hose joint Retighten 7 S13 S15 Insufficient tire pressure Inflate G 61 Steering controller malfunctioni...

Page 338: ...Page Wheels Are Turned to a Direction Opposite to Steering Direction Piping or hose connected in reversed Repair 7 S8 S13 S15 Noise Air sucked in pump due to lack of oil Replenish G 31 Air sucked in p...

Page 339: ...s min 3 56 Imp gals min Housing Depth of Scratch 0 09 mm 0 0035 in Bushing to Gear Shaft Clearance 0 020 to 0 081 mm 0 0067 to 0 0110 in 0 15 mm 0 0059 in Gear Shaft O D 14 970 to 14 980 mm 0 5894 to...

Page 340: ...1 13 0 to 15 2 Hydraulic pump assembling mounting screw and nut 23 6 to 27 4 2 4 to 2 8 17 4 to 20 2 Hydraulic pump cover mounting bolt M10 39 2 to 44 1 4 0 to 4 5 28 9 to 32 5 Steering wheel mounting...

Page 341: ...on 1 Remove the power steering main delivery hose 1 When reassembling Install the copper washers securely W10127320 Tightening torque Power steering main delivery hose joint bolt 49 0 to 58 8 N m 5 0...

Page 342: ...d approx 40 C 104 F 7 Open the loading valve completely 8 Set the engine speed Refer to Condition 9 Read and note the pump delivery at no pressure 10 Slowly close the loading valve to increase to the...

Page 343: ...elivery line adjust the relief valve by the adjusting screw 1 or repair the power steering Reference Install the spring 4 and check valve 3 firmly Install the copper washers firmly Condition Engine sp...

Page 344: ...m break in operation and ensure that there is nothing abnormal with the hydraulic pump 1 Hydraulic Pump Removing Hydraulic Hoses and Hydraulic Pipe 1 Remove the joint bolts 3 4 Remove the delivery pip...

Page 345: ...plate 2 drive gear 4 and driven gear 3 2 Take out the coupling 6 When reassembling Take care not to damage the gasket 7 Align the hole of the cover 1 and casing 5 Install the side plate noting its lo...

Page 346: ...suction pipe and delivery pipe securely 2 Set the engine speed at 1300 to 1500 min 1 rpm and operate the hydraulic pump at no load for about 10 minutes 3 Set the engine speed at 2000 to 2200 min 1 rpm...

Page 347: ...ng surfaces of those parts have seen precisely finished do not brush or grind with sandpaper Use transmission fluid for cleaning and compressed air for blowing off 2 When reassembling inspect each par...

Page 348: ...er panel mounting screws 7 Disconnect the connector and the hour meter cable from the meter panel 8 Remove the rear bonnet mounting screws 9 Disconnect the connectors 10 Remove the rear bonnets 3 6 Wh...

Page 349: ...htening torque Power steering main delivery hose retaining nut 46 6 to 50 9 N m 4 8 to 5 2 kgf m 34 4 to 37 6 lbf ft Power steering turning delivery hoses retaining nut 24 5 to 29 4 N m 2 5 to 3 0 kgf...

Page 350: ...an assembly When reassembling Apply grease to the joint shaft 3 Check the dust seal 4 Refer to figure left If the oil leakage is found replace the steering controller as an assembly W10335670 Tighteni...

Page 351: ...m the hose joints 6 3 Remove the set bolt 8 4 Place a disassembling stand under the engine and support it with a jack 5 Pull out the split pins 10 from the tie rod end slot nuts 2 Remove the tie rod a...

Page 352: ...te to cover the hose joints Before disassembling drain steering oil from power steering cylinder 1 Remove the tie rod joint 1 right and left 2 Remove the nipples 2 from steering cylinder 3 Remove the...

Page 353: ...and Gear Shaft 1 Measure the gear shaft O D with and outside micrometer 2 Measure the bushing I D with and inside micrometer or cylinder gauge and calculate the clearance 3 If the clearance exceeds t...

Page 354: ...ylinder gauge 2 Measure the rod O D with a outside micrometer and calculate the clearance 3 If the clearance exceeds the allowable limit replace as a unit W1023059 Steering cylinder I D Factory spec 2...

Page 355: ...8 HYDRAULIC SYSTEM...

Page 356: ......

Page 357: ...HYDRAULIC SYSTEM 8 M3 4 HYDRAULIC CYLINDER 8 M4 5 POSITION CONTROL VALVE 8 M5 6 LINKAGE MECHANISM 8 M6 1 POSITION CONTROL 8 M6 2 POSITION CONTROL VALVE Code No YR908 00100 OIL FLOW 8 M9 3 POSITION CO...

Page 358: ......

Page 359: ...lock 6 Position Control Valve 7 Cylinder Safety Valve 8 Hydraulic Cylinder Block 9 Auxiliary Control Valve Option 10 Hydraulic Pump for Power Steering and PTO Clutch 11 Regulator Valve Refer to CLUTCH...

Page 360: ...out hydraulic power from the front hydraulic block assembly 2 to operate an implement s hydraulic actuator Takes out hydraulic power from the quick couplers 7 induced in the auxiliary control valves a...

Page 361: ...position control valve 7 switches the oil to the hydraulic cylinder 9 for the three point hydraulic system or return to the oil tank transmission case 1 The hydraulic system has a relief valve 5 which...

Page 362: ...ting knob 1 attached to the hydraulic cylinder 4 Turning the lowering speed adjusting knob 1 clockwise decreases the lowering speed and counterclockwise increases lowering speed When the lowering spee...

Page 363: ...valve Code No YR908 00100 are shown in the figure above 1 Nut 1 2 Set Screw 3 Washer 4 Spring 5 Spring 6 Poppet 1 7 Valve Seat 8 Sleeve 9 Backup Ring 10 Poppet 2 11 Plug 12 Spring 13 Spring Holder 14...

Page 364: ...trol lever 1 The implement can be positioned at any height by moving the position control lever 1 Fine position adjustment is also easy The main components are shown in the figure above The main compo...

Page 365: ...e lift arm moves upward the feedback lever shaft 4 is rotated to the arrow since the feedback rod 5 is actuated Therefore the spool drive lever 1 moves around the fulcrum Q and pushes the spool 3 Refe...

Page 366: ...n the lift arm moves downward the feedback lever shaft 5 is rotated to the arrow since the feedback rod 6 is actuated Therefore the spool drive lever 1 moves around the fulcrum Q and pulls the spool 3...

Page 367: ...n The oil entered P port flows into the A chamber a B chamber b and closes unload poppet 2 and poppet 3 3 The pressure in the circuit slowly rises pushing open poppet 1 4 and the hydraulic oil flows i...

Page 368: ...mark direction When the neutral position comes near the tapered part 5 of the spool 1 makes the pressure difference at the P port and C port Therefore the poppet 1 4 gradually closes and absorbs any...

Page 369: ...he traction load applied to the tractor is sensed and is fed back to the control valve by means of the other linkage mechanism Position Control Operation W1019618 Lift 1 When the position control leve...

Page 370: ...alve becomes the lift circuit and the lift arm 1 goes up Movement of the Link Under decreased Load 1 When the lift arm 1 rises up the traction load is decreased and the draft control rod 16 is returne...

Page 371: ...mplement lower to the height set by the position control lever With the position control only when traction load increases slippage or engine stop may occur unless the implement is raise With the draf...

Page 372: ...the tractor to operate the hydraulic cylinders on the implement such as front loader front blade and so on 1 Cap 2 Front Hydraulic Block 3 Relief Valve A To Implement Control Valve B From Implement C...

Page 373: ...Hydraulic Pump Test Using Flow meter 3 Points Hydraulic System 8 S9 4 Relief Valve 3 Points Hydraulic System 8 S11 2 DISASSEMBLING AND ASSEMBLING 8 S14 1 Hydraulic Pump Power Steering 3 Point Hydrauli...

Page 374: ......

Page 375: ...ximum Height Position control feedback rod improperly adjusted Adjust 8 S12 Top link length improperly adjusted Adjust Position control valve spool joint 1 improperly adjusted Adjust 8 S21 S22 Hydraul...

Page 376: ...lve Replace 8 S21 S22 Poppet 2 sleeve O ring damaged control valve Replace 8 S21 S22 Poppet 2 adjusting set screw improperly adjusted Adjust 8 S21 S22 Draft Control Malfunctioning if equipped Draft co...

Page 377: ...gals min 18 17 L min 4 80 U S gals min 4 00 Imp gals min 16 17 L min 4 27 U S gals min 3 56 Imp gals min Housing Bore Depth of Scratch 0 09 mm 0 0035 in Bushing to Gear Shaft Clearance 0 020 to 0 081...

Page 378: ...gals min 6 45 Imp gals min Housing Bore Depth of Scratch 0 09 mm 0 0035 in Bushing to Gear Shaft Clearance 0 020 to 0 081 mm 0 0008 to 0 0032 in 0 15 mm 0 0059 in Hydraulic Pump Gear Shaft O D 14 970...

Page 379: ...aft to Bushing Clearance Right Clearance Left 0 125 to 0 230 mm 0 00492 to 0 00906 in 0 125 to 0 220 mm 0 00492 to 0 00866 in 0 50 mm 0 0197 in 0 50 mm 0 0197 in Hydraulic Arm Shaft O D Right O D Left...

Page 380: ...2 to 49 0 4 0 to 5 0 29 0 to 36 2 Regulator valve mounting screws 17 6 to 20 6 1 8 to 2 1 13 0 to 15 2 Hydraulic pump assembly mounting screw and nut 23 5 to 27 5 2 4 to 2 8 17 4 to 20 3 Hydraulic pu...

Page 381: ...reparation 1 Open the bonnet 2 Remove the delivery pipe joint bolt 2 and power steering main delivery hose 3 When reassembling Install the copper washers firmly W1012497 Tightening torque Power steeri...

Page 382: ...ached approx 40 C 104 F 7 Open the loading valve completely 8 Set the engine speed Refer to Condition 9 Read and note the pump delivery at no pressure 10 Slowly close the loading valve to increase to...

Page 383: ...ipe mounting bolts 2 2 Remove the 3 points delivery pipe joint bolt 7 3 Remove the 3 points delivery pipe 1 When reassembling Apply grease to the O ring and take care not to damage it Install the copp...

Page 384: ...until oil temperature reached approx 40 C 104 F 7 Open the loading valve completely 8 Set the engine speed Refer to Condition 9 Read and note the pump delivery at no pressure 10 Slowly close the load...

Page 385: ...valve 6 of front hydraulic block 7 and adjust with the adjusting shims 8 7 After finishing the relief valve setting pressure test reset the position control lever stopper firmly Condition Engine spee...

Page 386: ...g position control feedback rod again W1020369 Cylinder Safety Valve Operating Pressure 1 Install the cylinder safety valve to the cylinder safety valve setting pressure adaptor 2 Set the cylinder saf...

Page 387: ...eft 6 Set the engine speed at the maximum 7 Attach the test bar 3 see page G 55 to the top link bracket 2 8 Pull the test bar 3 upward and adjust the draft control rod 6 so that the lower link is rais...

Page 388: ...ic pump assembly When reassembling Apply grease to the O ring and take care not to damage it W1016911 Tightening torque Independent PTO delivery pipe joint bolt 34 3 to 39 2 N m 3 5 to 4 0 kgf m 25 3...

Page 389: ...heck should be performed 1 Install the hydraulic pump to the tractor and mount the suction pipe and delivery pipe securely 2 Set the engine speed at 1300 to 1500 mm 1 rpm and operate the hydraulic pum...

Page 390: ...ulic cylinder 7 Disconnect 3 points delivery pipe 1 12 fender stay 13 and fenders 14 When reassembling Install the copper washers to the 3 points delivery pipe 1 12 firmly W1021098 Tightening torque 3...

Page 391: ...ectors 4 from the PTO lever neutral switch 4 Disconnect the 3P connector 7 from the seat switch 6 5 Disconnect the 2P connectors 9 from the shuttle shift neutral switch 8 W10295000 1 Seat 2 4P Rear Co...

Page 392: ...equivalent to joint face of the hydraulic cylinder assembly and transmission case after eliminate the water oil and stuck liquid gasket When replacing the hydraulic cylinder assembly mounting stud bol...

Page 393: ...iston 4 CAUTION Do not put your hand into the hydraulic cylinder block because the hydraulic piston jumps out with a strong force which is dangerous When reassembling Install the piston noting O ring...

Page 394: ...ar 3 and O ring 2 When reassembling Align the alignment marks 7 of the hydraulic arm 1 and hydraulic arm shaft 5 Align the alignment marks 8 of the lift arms 6 4 and hydraulic arm shaft 5 Apply grease...

Page 395: ...imensions as shown in Assembly Position Control Valve IMPORTANT Set screw 2 and spool joint 1 are adjusted to very close accuracy Do not disassemble them or cause them to be out of order unless necess...

Page 396: ...mm 0 0039 to 0 079 in W1032363 Lowering Speed Adjusting valve 1 Remove the lowering speed adjusting valve assembly from hydraulic cylinder block 2 Remove the internal snap ring 4 and remove the hydra...

Page 397: ...e the O rings 8 IMPORTANT After disassembling and assembling the relief valve be sure to adjust the relief valve setting pressure W1024698 Tightening torque Relief valve plug 49 0 to 69 0N m 5 0 to 7...

Page 398: ...the O ring 8 10 Component parts of the cylinder safety valve assembly 7 are not shown in the parts list Component parts are not provided by Kubota IMPORTANT After disassembling and assembling the cyl...

Page 399: ...curely fit the rod stay stopper 20 into the groove of the hydraulic arm shaft After reassembling be sure to adjust the position control feedback rod and draft control rod if equipped See page 8 S12 13...

Page 400: ...ear Shaft 1 Measure the gear shaft O D with and outside micrometer 2 Measure the bushing I D with an inside micrometer or cylinder gauge and calculate the clearance 3 If the clearance exceeds the allo...

Page 401: ...the clearance exceeds the allowable limit replace the bushing W1026122 Hydraulic cylinder I D Factory spec 90 000 to 90 050 mm 3 54330 to 3 54527 in Allowable limit 90 150 mm 3 54921 in Clearance bet...

Page 402: ...8 S28 MX5100 WSM HYDRAULIC SYSTEM...

Page 403: ...9 ELECTRICAL SYSTEM...

Page 404: ......

Page 405: ...TRIC CIRCUIT 9 M3 2 SAFETY SWITCH 9 M4 1 PTO Neutral Switch 9 M4 2 Shuttle Lever Neutral Switch 9 M4 3 OPC OPERATOR PRESENCE CONTROL SYSTEM 9 M5 1 ELECTRICAL CIRCUIT 9 M5 2 SAFETY SWITCH 9 M11 1 PTO N...

Page 406: ......

Page 407: ...9 M1 MX5100 WSM ELECTRICAL SYSTEM 1 WIRING DIAGRAM...

Page 408: ...Or Blue Orange W White B Y Black Yellow Lg Light Green W B White Black Br Brown Lg B Light Green Blue W G White Green G Green Lg Y Light Green Yellow W L White Blue G L Green Blue Or Orange W R White...

Page 409: ...Lever Neutral Switch 2 12 Seat Switch a Seated b Vacant c Turn Over No PTO Lever Synchro Shuttle Shift Lever Engine Starting Disengaged PTO neutral switch ON Engaged PTO neutral switch OFF 1 Shift to...

Page 410: ...system It consists of 2 electric switches The electric switch 1 4 is connected to the engine starting circuit B C And the electric switch 2 3 is connected to OPC circuit A D W1014861 1 PTO Shift Lever...

Page 411: ...w Fuse 50A 4 Starter Relay 5 Fuse 5A 6 Slow Blow Fuse 50A 7 Key Switch 8 Key Stop Solenoid 9 Key Stop Solenoid Relay 10 Slow Blow Fuse 30A 11 OPC Timer 12 Fuse 5A 13 Seat Switch 14 PTO Neutral Switch...

Page 412: ...ch 13 and the OPC timer 11 and maintains the key stop solenoid relay 9 2 When standing up from the operator s seat the circuit from the seat switch 13 to the OPC timer 11 is cut However if the PTO shi...

Page 413: ...0A 4 Starter Relay 5 Fuse 5A 6 Slow Blow Fuse 50A 7 Key Switch 8 Key Stop Solenoid 9 Key Stop Solenoid Relay 10 Slow Blow Fuse 30A 11 OPC Timer 12 Fuse 5A 13 Seat Switch 14 PTO Neutral Switch 1 15 PTO...

Page 414: ...Fuse 50A 4 Starter Relay 5 Fuse 5A 6 Slow Blow Fuse 50A 7 Key Switch 8 Key Stop Solenoid 9 Key Stop Solenoid Relay 10 Slow Blow Fuse 30A 11 OPC Timer 12 Fuse 5A 13 Seat Switch 14 PTO Neutral Switch 1...

Page 415: ...Fuse 50A 4 Starter Relay 5 Fuse 5A 6 Slow Blow Fuse 50A 7 Key Switch 8 Key Stop Solenoid 9 Key Stop Solenoid Relay 10 Slow Blow Fuse 30A 11 OPC Timer 12 Fuse 5A 13 Seat Switch 14 PTO Neutral Switch 1...

Page 416: ...w Fuse 50A 4 Starter Relay 5 Fuse 5A 6 Slow Blow Fuse 50A 7 Key Switch 8 Key Stop Solenoid 9 Key Stop Solenoid Relay 10 Slow Blow Fuse 30A 11 OPC Timer 12 Fuse 5A 13 Seat Switch 14 PTO Neutral Switch...

Page 417: ...ystem It consists of 2 electric switches The electric switch 1 4 is connected to the engine starting circuit B C And the electric switch 2 3 is connected to OPC circuit A D W1017845 1 PTO Shift Lever...

Page 418: ...witch AC terminal G to the OPC timer When operator sits on the operator s seat 1 the seat switch lever 3 is set to Seated position D The battery current flows from the key switch AC terminal through t...

Page 419: ...tor Presence Control 9 S12 5 Starter and Starter Relay 9 S15 6 Glow Control System 9 S17 7 Engine Stop Solenoid 9 S17 8 Charging System 9 S19 9 Combination Switch 9 S20 10 Hazard Switch 9 S22 11 Flash...

Page 420: ......

Page 421: ...S7 Alternator defective Repair or replace 9 S19 Wiring harness disconnected or improperly connected between battery positive terminal and alternator B terminal Repair or replace Cooling fan belt slip...

Page 422: ...switch defective PTO lever switch defective Shuttle lever neutral switch defective Replace Replace 9 S11 Charging Lamp Does Not Light When Main Switch is Turned ON Fuse blown 10 A Replace G 42 Wiring...

Page 423: ...own 15 A Replace G 42 Wiring harness disconnected or improperly connected between combination switch T terminal and tail lights Repair or replace Hazard and Turn Signal Light Does Not Light Fuse blown...

Page 424: ...ective Replace 9 S25 Wiring harness disconnected or improperly connected between panel board and engine oil pressure switch Repair or replace Circuit in panel board defective Replace G 16 Fuel Gauge D...

Page 425: ...29 0 mm 1 142 in 0 20 mm 0 0079 in 11 0 mm 0 433 in Glow Plug Resistance Approx 0 9 Fuel Level Sensor Float at Upper most Position Float at Lower most Position Resistance Resistance 1 to 5 103 to 117...

Page 426: ...TORQUES Tightening torques of screws bolts and nuts on the table below are especially specified For general use screws bolts and nuts See page G 10 G 11 W1012736 Item N m kgf m lbf ft Alternator pull...

Page 427: ...mage to alternator and regulator may result 1 CHECKING AND ADJUSTING 1 Battery Battery Voltage 1 Stop the engine and turn the main switch to OFF position 2 Connect the COM lead of the voltmeter to the...

Page 428: ...the hydrometer at eye level The hydrometer reading must be taken at the highest electrolyte level Reference Specific gravity slightly varies with temperature To be exact the specific gravity decrease...

Page 429: ...ance with an ohmmeter across the B terminal and the AC terminal B terminal and ST terminal and B terminal and G terminal 3 If infinity is not indicated the contacts of the main switch are faulty W1062...

Page 430: ...indicated these contacts of the main switch are faulty W1063250 Main Switch Key at PREHEAT Position 1 Turn and hold the main switch key at the PREHEAT position 2 Measure the resistance with an ohmmet...

Page 431: ...ross PTO lever safety switch terminals When switch is pushed 0 When switch is released Infinity Resistance Across shuttle lever neutral switch terminals When switch is pushed 0 When switch is released...

Page 432: ...IMPORTANT Main gear shift lever is set to NEUTRAL position Checking Procedure Step PTO lever Synchro shuttle shift lever Operator OPC system is NORMAL if 1 OFF position Switch ON Forward or Reverse S...

Page 433: ...low 4 If resistance is not correct switch is faulty W1042630 Sensor bar angle Measuring terminal Resistance Approx 18 Angle A a c 0 a b b c Infinity Approx 25 Angle B a b a c b c Infinity Approx 5 Ang...

Page 434: ...and across the battery negative terminal and the bulb terminal 4 Connect jumper leads across the timer c terminal and the bulb terminal 5 The lead lamp lights 4 up when disconnecting a jumper lead fr...

Page 435: ...ead momentarily between the starter motor housing and the battery negative terminal post 7 If the motor does not run check the motor W1025047 Magnet Switch Test Pull in Holding Coils 1 Remove the moto...

Page 436: ...battery voltage between terminal 2 and 4 and check for continuity between terminal 1 and 3 3 If 0 ohm is not indicated renew the starter relay W1088137 Resistance Terminal 1 Terminal 3 0 1 Starter Rel...

Page 437: ...nal and the chassis 3 If 0 ohm is indicated the screw at the tip of the glow plug and the housing are short circuited 4 If the factory specification is not indicated the glow plug is faulty W1093427 7...

Page 438: ...iffers from the battery voltage the wiring harness is faulty 5 Turn the main switch on 6 Measure the voltage across the terminal 1 Positive and chassis Negative 7 If the voltage differs from the batte...

Page 439: ...negative cable from the battery 5 Measure the voltage between the B terminal 2 and the chassis 6 If the measurement is less than the factory specifications disassemble the alternator and check the IC...

Page 440: ...If the voltage differs from the battery voltage the wiring harness is faulty 4 Measure the voltage with a voltmeter across the connector B2 terminal and chassis when the main switch is ON position 5 I...

Page 441: ...al and the B1 terminal to the 2 terminal 2 If 0 ohm is not indicated renew the head light switch W1114916 Connector Voltage Turn Signal Switch 1 Disconnect the connector 8P from the combination switch...

Page 442: ...across the battery terminal and chassis 3 If the voltage differs from the battery voltage the wiring harness is faulty W1053948 Resistance Switch at OFF a Terminal c Terminal Infinity Resistance Switc...

Page 443: ...re the resistance across the sensor terminal and its body 3 If resistance does not meet reference value the sensor is faulty W1121151 Resistance Sensor terminal its body Reference value Float at upper...

Page 444: ...he chassis If the voltage differs from the battery voltage the wiring harness fuse or coolant temperature gauge is faulty 2 Sensor Continuity 1 Measure the resistances with an ohmmeter across the sens...

Page 445: ...he panel board circuit or the wiring harness is faulty W10259540 Engine Oil Pressure Switch Continuity 1 Measure the resistance with an ohmmeter across the switch terminal and the chassis 2 If 0 ohm i...

Page 446: ...armature 1 W1128720 Disassembling Magnet Switch 1 Remove the drive end frame 1 mounting screws 2 Take out the overrunning clutch 2 ball 3 spring 4 gears 5 rollers 6 and retainer 7 When reassembling A...

Page 447: ...0 Rear End Cover 1 Unscrew the three rear end cover screws and the B terminal nut and remove the rear end cover W1067274 Brush Holder 1 Unscrew the two screws holding the brush holder and remove the b...

Page 448: ...drive end frame and the rear end frame 2 Remove the rear end frame 1 W1161022 Rotor 1 Press out the rotor 1 from drive end frame 3 IMPORTANT Take special care not to drop the rotor and damage the sli...

Page 449: ...s out the bearing from drive end frame 3 with a press and jig 1 W1137587 Bearing at Slip Ring Side 1 Lightly secure the rotor 1 with a vise to prevent damage and remove the bearing 2 with a puller 3 W...

Page 450: ...f the difference of the O D s exceeds the allowable limit correct the commutator on a lathe to the factory specification 5 Measure the mica undercut 6 If the undercut is less than the allowable limit...

Page 451: ...it conducts replace the armature 3 Check the continuity across the segments of the commutator with an ohmmeter 4 If it does not conduct replace the armature W1148803 Field Coil 1 Check the continuity...

Page 452: ...0941 Rotor 1 Measure the resistance across the slip rings with an ohmmeter 2 If the resistance is not the factory specification replace it 3 Check the continuity across the slip ring and core with an...

Page 453: ...measuring because it will destroy the rectifier NOTE Do not use an auto digital multimeter Because it s very hard to check the continuity of rectifier by using it W1152035 IC Regulator 1 Check the con...

Page 454: ...9 S34 MX5100 WSM ELECTRICAL SYSTEM...

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Kubota MX5100, Workshop Manual

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