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Kubota R540, Operator'S Manual, Page: 9 / 146

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1. Checking the electrical leads and the terminals ...................................................................................... 117
2. Checking the exhaust manifold for cracks, gas, leakage, and mounting screw ...................................... 117
3. Checking the intake air line for air leaks.................................................................................................. 117
4. Checking the air-flow-sensor (AFS)......................................................................................................... 118
5. Checking the condition of diesel particulate filter (DPF) muffler .............................................................. 118
6. Checking the diesel particulate filter (DPF) differential pressure sensor and rubber piping for gas leak 118
7. Checking the diesel particulate filter (DPF) exhaust gas temperature sensor......................................... 118
8. Checking the EGR piping for gas leak..................................................................................................... 118
9. Checking the brake hose......................................................................................................................... 118

BIENNIAL SERVICING ..................................................................................................................................... 118

1. Replacing the brake hose........................................................................................................................ 118
2. Changing the brake fluid.......................................................................................................................... 118
3. Replacing the rubber parts of master cylinder......................................................................................... 118
4. Replacing the fuel hoses and the clamps................................................................................................ 118
5. Changing the coolant............................................................................................................................... 118
6. Replacing the intake air line .................................................................................................................... 119
7. Replacing the rubber piping related oil separator.................................................................................... 119
8. Replacing the diesel particulate filter (DPF) differential pressure sensor rubber piping (front and back) 119
9. Replacing the suction pipe downstream the air-flow-sensor (AFS)......................................................... 119
10. Replacing the EGR cooler hose ............................................................................................................ 119
11. Replacing the radiator hoses (water pipes) ........................................................................................... 120

PERIODIC PARTS REPLACEMENT ................................................................................................................ 120

1. Replacing the air conditioner pipes and hoses [Cabin type only] ............................................................ 120

SERVICING AS REQUIRED............................................................................................................................. 120

1. Replacing and repairing the electrical system ......................................................................................... 120

1.1 Replacing the fuses.......................................................................................................................... 120
1.2 Replacing the slow blow fuses ......................................................................................................... 122

2. Draining the fuel filter by draining the water separator ............................................................................ 123
3. Bleeding the fuel system ......................................................................................................................... 123

SERVICE FOR TIRES ...................................................................................................................................... 124

1. Precautions for handling the tires ............................................................................................................ 124
2. Checking the tire pressure....................................................................................................................... 124
3. Changing the tires ................................................................................................................................... 124
4. Mounting the tires .................................................................................................................................... 125
5. Tire chains ............................................................................................................................................... 125

COMPLETION OF OPERATION AND STORING ...................................................................126

STORING THE MACHINE ................................................................................................................................ 126
CAUTION WHEN WASHING THE MACHINE .................................................................................................. 126

RECOMMENDED OILS ...........................................................................................................127

RECOMMENDED OIL LIST.............................................................................................................................. 127
BIODIESEL FUEL (BDF) .................................................................................................................................. 129

TROUBLESHOOTING .............................................................................................................130

TROUBLESHOOTING OF THE ENGINE AND OTHER SYSTEMS................................................................. 130
LIST OF ERROR CODE NUMBERS ................................................................................................................ 132

APPENDIX ...............................................................................................................................137

SERVICE HOUR METER ................................................................................................................................. 137

INDEX.......................................................................................................................................138

R540

5

Summary of Contents for R540

Page 1: ... 4400 Malaysia KUBOTA MALAYSIA SDN BHD Lot 766 Jalan Subanɡ 4 off Persiaran Subanɡ Sunɡai Penaɡa Industrial Park 47500 Subanɡ Jaya Telephone 60 3 7890 3533 Philippines KUBOTA PHILIPPINES INC 232 Quirino Hiɡhway Baesa Quezon City 1106 Philippines Telephone 63 2 422 3500 Taiwan SHIN TAIWAN AGRICULTURAL MACHINERY CO LTD 16 Fenɡpinɡ 2nd Rd Taliao Shianɡ Kaohsiunɡ 83107 Taiwan R O C Telephone 886 7 702...

Page 2: ...s Institut für Normung GERMANY German Institute for Standardization European Standard Falling Objects Protective Structures Hydrostatic Transmission International Organization for Standaridization Japanese Industry Standard Militaly Standard Roll Over Protective Structures Revolutions Per Minute Revolutions Per Second Society of Automotive Engineers USA Slow Moving Vehicle R540 English Australia ...

Page 3: ...Speed High Travel Speed Parking Brake Neutral Travel Forward Travel Backward Lock Unlock Hydraulic lock indicator Auxiliary port indicator Auxiliary hold indicator Read the Operating instructions Diesel Particulate Filter regeneration Parked Diesel Particulate Filter Regeneration Diesel Particulate Filter Regeneration Inhibit Parked Regeneration switch Bucket Up Bucket Down Bucket Tilt Bucket Dump...

Page 4: ...ury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury Indicates that equipment or property damage could result if instructions are not followed Gives helpful information This symbol the industry s Safety Alert Symbol is used throughout thi...

Page 5: ...azard light switch 36 8 Attachment unlock switch 36 9 Diesel particulate filter DPF switch 36 10 Differential lock switch 37 11 Hydraulic lock switch 37 12 AUX port enable switch 37 13 AUX port variable switch 38 14 AUX hold switch 38 15 Float switch 38 16 Display selector switch 39 16 1 Setting the clock 39 CHECKS FOR THE INDICATORS 40 1 Battery charge indicator 40 2 Engine oil pressure warning i...

Page 6: ...HE ENGINE 53 EXHAUST AFTERTREATMENT DEVICES 53 1 Diesel oxidation catalyst and diesel particulate filter DPF muffler 53 2 Handling points for DPF regeneration 54 3 DPF regeneration process 54 3 1 Operating procedure for Auto Regeneration Mode 55 3 1 1 Regeneration operating procedure for Auto Regeneration Mode 55 3 1 2 PM warning level and required procedures for Auto Regeneration Mode 56 3 2 Oper...

Page 7: ...SING A WHEEL LOADER 83 1 Digging and loading job 83 1 1 Loading a sand pile 83 1 2 Digging and loading from flat ground 84 2 Refilling 84 3 Leveling the ground 84 4 Loading method onto a truck 85 4 1 Loading onto a truck by cross loading method 85 4 2 Loading onto a truck by V shift loading method 85 TRANSPORTING BY TRUCK 86 LOADING THE MACHINE ON AND FROM A TRUCK 86 PRECAUTIONS FOR TRANSPORTING 8...

Page 8: ... HOURS 107 1 Checking the fan belt tension 107 2 Checking the radiator hoses and the clips 108 3 Cleaning and checking the air cleaner element 108 4 Checking the fuel line and the intake air line 109 5 Checking the wheel nuts 109 6 Cleaning the air cleaner element 109 7 Replacing the water separator filter element 110 8 Changing the engine oil 110 9 Replacing the engine oil filter cartridge 111 SE...

Page 9: ...diesel particulate filter DPF differential pressure sensor rubber piping front and back 119 9 Replacing the suction pipe downstream the air flow sensor AFS 119 10 Replacing the EGR cooler hose 119 11 Replacing the radiator hoses water pipes 120 PERIODIC PARTS REPLACEMENT 120 1 Replacing the air conditioner pipes and hoses Cabin type only 120 SERVICING AS REQUIRED 120 1 Replacing and repairing the ...

Page 10: ...6 R540 ...

Page 11: ...ny equipment while under the influence of alcohol or other drugs or while fatigued Before allowing other people to use your machine give instruction to the operator on safe and correct use of the machine and make sure that the operator reads and understands the Operator s Manual for the machine Inspect your seat belt daily for signs of fraying wear or other weakness that could endanger your safety...

Page 12: ...belt Always use the seat belt when the machine is equipped with canopy or cab OSHA regulations and SAE standard require the ROPS and FOPS on wheel loaders bulldozers truck type loaders graders and scrapers 1 ROPS and FOPS Never modify structural members of ROPS by welding drilling bending grinding or cutting because modifying may weaken the structure If any component is damaged replace it Do not a...

Page 13: ...lapse under the weight of the machine especially when the ground is loose or wet Slow down for turns uneven terrain and slopes to avoid tipping over When transporting a load keep the loader bucket as low as possible to avoid tipping over Be extremely careful when working on inclines Operation on slopes can be dangerous Rain snow gravel soft ground and so on will change the ground conditions Do not...

Page 14: ...t in the proper position for travel then lock the control lever First check the area around the machine then gradually increase the engine rpm and slowly move the machine Do not move the machine abruptly To move the machine on a steep slope press the accelerator pedal gradually while releasing the inching and brake pedal so that the machine does not move backwards The steering wheel for this machi...

Page 15: ...trol levers 5 Remove the key PRECAUTIONS FOR SAFELY LOADING AND TRANSPORTING THE MACHINE When loading or unloading the machine on or from a truck or trailer be sure to use strong ramps Never use wet lumber etc Keep the ramps at an angle such that the machine cannot slip Never try to change direction while on the ramps Angle of ramps 10 degrees to 15 degrees When loading or unloading the machine on...

Page 16: ...he engine Wait for the engine to cool Do not allow an unauthorized person to service or maintain the machine Do not perform any work or equipment that is not authorized Do not try to do any repairs that you do not understand Follow the maintenance and service procedures Service or check the machine after it has completely cooled off Do not touch the muffler and the radiator until they have cooled ...

Page 17: ... cardboard It is strongly recommended to use a face mask or eye protection Should injuries occur with leaking hydraulic fluid contact a doctor immediately This fluid can cause gangrene or serious allergic reactions 1 Cardboard 2 Hydraulic line 3 Magnifying glass Towing in case of problems If the machine breaks down and requires towing please contact your nearest KUBOTA dealer In case of an emergen...

Page 18: ...scribed pollution control and safety regulations If you have questions about the correct disposal or storage of refuse and toxic waste contact your KUBOTA dealer or a local waste management contractor Do not open high pressure fuel system High pressure fluid remaining in fuel lines can cause serious injury Do not disconnect nor repair fuel lines sensors or any other components between the high pre...

Page 19: ...exhaust pipes and muffler more frequently when working in severe conditions Clean out all accumulated flammable debris such as leaves straw pine needles branches bark small wood chips and any other combustible materials from inside the machine belly pans or lower unit structures as well as from area in proximity to the engine Inspect the exhaust system daily for any signs of leakage Check for brok...

Page 20: ...SAFETY LABELS SAFE OPERATION 16 R540 ...

Page 21: ...SAFE OPERATION R540 17 ...

Page 22: ...SAFE OPERATION 18 R540 ...

Page 23: ...SAFE OPERATION R540 19 ...

Page 24: ... Canopy Cabin SAFE OPERATION 20 R540 ...

Page 25: ... Canopy Cabin Cabin SAFE OPERATION R540 21 ...

Page 26: ... Canopy Cabin SAFE OPERATION 22 R540 ...

Page 27: ...ace damaged or missing safety labels with new safety labels from your local KUBOTA dealer If a component with safety label s affixed is replaced with new part make sure that new safety label s is are attached in the same location s as the replaced component Mount new safety labels by applying on a clean dry surface and pressing any bubbles to outside edge SAFE OPERATION R540 23 ...

Page 28: ...24 R540 ...

Page 29: ...fication number of the wheel loader and the serial number of the engine Note the product identification number of the wheel loader and the serial number of the engine right away in the supplied lines Machine Product identification number Dealer s name To be filled in through the owner Date of purchase Model Serial No Engine 1 Product identification number and engine number label 2 Product identifi...

Page 30: ...her KUBOTA Corporation nor its affiliated companies provide warranty for any product which is re sold or retailed in any country other than the country for which the product s were designed or manufactured 2 Procedure for scrapping the wheel loader To put the wheel loader out of service correctly follow the local rules and regulations of the country or territory where you reside If you ask questio...

Page 31: ...30 Wheel base mm 2000 Tread mm 1355 Angle of articulation Deg 40 each Angle of oscillation Deg 8 each Loader clearance circle mm 4146 Bucket Hinge pin height mm 3230 Dump height w cutting edge mm 2525 Reach fully raised w cutting edge mm 730 Tipping load Straight ISO 14397 1 kg 3280 3440 Full turn ISO 14397 1 kg 2880 3020 Rated operating capacity ISO 14397 1 kg 1440 1510 Lifting capacity at ground...

Page 32: ...nk L 70 Hydraulic oil tank L 39 Hydraulic oil system L 55 NOTE The dimensions in the table are based on the machine with std tires quick coupler standard bucket and ROPS FOPS canopy cabin Mean value and value for use on concrete roads are given for tipping load and operating capacity Specifications subject to change without notice 1 Operating weight is with 75 kg operator 289 kg standard general p...

Page 33: ...el 5 Rear wheel 6 Bucket cylinder 7 Lift cylinder 8 ROPS FOPS canopy 9 ROPS FOPS cabin 10 Headlight 11 Turn signal light Clearance light 12 Working light 13 Rearview mirror A Canopy B Cabin Right side 14 Fuel tank cap 15 Lift arm support DESCRIPTION OF MACHINE PARTS MACHINE PARTS R540 29 ...

Page 34: ... 16 Towing pin 17 Rear combination light Turn signal Tail light Brake light Back light 18 Rear working light option 19 Rotary beacon option MACHINE PARTS 30 R540 ...

Page 35: ...ntial lock switch 37 13 Attachment unlock switch 36 14 Starter switch 34 15 AUX port enable switch 37 16 Float switch 38 17 AUX hold switch 38 18 Hydraulic lock switch 37 19 Headlight switch 35 20 Diesel particulate filter DPF switch 36 21 Engine stop knob 62 22 Electrical outlet 90 23 Working light switch 36 24 Beacon light switch 25 Rear wiper washer switch Cabin type only 47 26 Blower switch Ca...

Page 36: ...CONTROL PEDALS AND LEVERS 1 Steering wheel 2 Multi function operating lever control lever 3 Inching and brake pedal 4 Accelerator pedal INSTRUMENT PANEL AND CONTROLS CONTROL PEDALS AND LEVERS 32 R540 ...

Page 37: ...e warning indicator 13 Speed mode indicator 14 LCD 15 Forward backward and neu tral indicator 16 Periodic check indicator 17 Hazard turn signal indicator 18 Parking brake indicator 19 Differential lock indicator 20 Headlight high beam indicator 21 Headlight low beam indicator 22 Clearance light indicator 23 Fuel gauge 24 Fuel stock indicator 25 HST oil temperature warning indicator 26 HST charge p...

Page 38: ...s to be used when parking the machine 1 When you press the parking brake switch on the marked side the parking brake is applied and the mark on the instrument panel appears 2 When you press the parking brake switch again the parking brake is released and the mark on the instrument panel lights off 1 Parking brake switch 2 Starter switch STOP You can insert the starter key at the STOP position RUN ...

Page 39: ...rn signal B To blink left turn signal 4 2 High low beam changing Pull up the multi function switch toward the steering wheel and the high beams light up You can switch the high and low beams each other by moving up and down the multi function switch 1 Multi function switch 5 Headlight switch WARNING To avoid personal injury or death For night operation keep all machine mounted lights operating Che...

Page 40: ...aulic quick coupler The attachment unlock switch has a guard to protect against inadvertent activation To press the attachment unlock switch slide the guard During the attachment unlock switch is depressed an acoustic signal sounds Apply the attachment unlock switch for safety reason when the attachment locking shall be unlocked The quick coupler is ready for unlocking only while the attachment un...

Page 41: ...l lock is available only while the differential lock switch is depressed 1 Differential lock switch 2 Accelerator pedal IMPORTANT You can not activate the differential lock switch at high speed mode 11 Hydraulic lock switch WARNING To avoid personal injury or death To avoid injuries check safety aspects all around the machine When the hydraulic lock switch is engaged the hydraulic lock indicator l...

Page 42: ...hold switch NOTE AUX hold switch will be canceled if you operate the AUX port variable switch when press the AUX hold switch 1 AUX port variable switch A To Port A B To Port B 15 Float switch WARNING To avoid personal injury or death Make sure that the bucket is lowered to the ground before putting the lift arms in the FLOAT position Putting the lift arms in the FLOAT position while they are off t...

Page 43: ...ressing the display selector switch The clock setting request indicator on the instrument panel lights up 1 User setting switch 2 Display selector switch 3 Clock setting request indica tor NOTE Press the display selector switch for a long time and the year month day hour and minute will be selected in this order While setting the clock the clock setting request indicator on the instrument panel is...

Page 44: ...e larger 1 Hour A Blinking User setting switch Display selector switch 11 10 9 10 11 12 8 Set the minute Press the user setting switch and the numeric setting will be smaller Press the display selector switch and the numeric setting will be larger 1 Minute A Blinking User setting switch Display selector switch 50 49 48 50 51 52 If you press the display selector switch for a long time the new setti...

Page 45: ...y charge indicator 3 Engine oil pressure warning indicator 3 Grow plug indicator With the starter key at the RUN position the preheat status of the engine is indicated NOTE When the starter switch is turned to the RUN position the engine will be preheated for a given period of time and the grow plug indicator will turn on The indication of the grow plug indicator appears momentarily when the engin...

Page 46: ... 5 1 1 How to use the fuel level audible indication switch You can use the fuel level audible indication switch to check the fuel level when refueling 1 With the starter key at the STOP position press the fuel level audible indication switch you can check the fuel level with buzzer sound 2 Start refueling the machine The buzzer beeping intervals vary according to how much fuel is poured into the t...

Page 47: ...ue to failure of the lubricating system with the engine running When the starter key is turned to the RUN position with the engine off the engine oil pressure warning indicator lights up and the engine warning indicator blinks When the engine starts the engine oil pressure warning indicator and the engine warning indicator go out If the engine oil pressure warning indicator stays on with the engin...

Page 48: ...ing in yellow Warnings and errors are displayed and an alarm buzzer beeps Let your KUBOTA dealer inform you of details concerning care and maintenance 1 Warning indicator red 2 Warning message A Blinking 7 1 Overheat warning 1 If the coolant temperature becomes elevated the coolant temperature warning indicator blinks and the warning message E 9114 appears on LCD as long as the temperature remains...

Page 49: ... loader lift arms from falling when servicing the machine 1 Lift arm support device 2 1 Installing the lift arm support WARNING To avoid personal injury or death Before installing the lift arm support remove the front attachment set the direction switch to the neutral position and remove the starter key 1 Remove the front attachment 2 Raise the loader lift arms completely 3 Stop the engine and rem...

Page 50: ...the steering frame lock before servicing hauling or transporting the machine 1 Steering frame lock IMPORTANT Store the steering frame lock securely after use 3 1 Attaching the steering frame lock 1 Align the front and rear frames 2 Shut off the engine and remove the starter key 3 Attach the steering frame lock with snap pins 4 If holes are not aligned move the steering wheel slightly with the engi...

Page 51: ...ystem Cabin type only 1 To move the rear wiper turn on the rear wiper washer system for the rear wiper when the starter key in position RUN 2 A further push on the rear wiper washer switch will activate the washer system Even when the rear wiper switch is in position OFF the rear washer system functions if it is pressed Do not activate the rear washer system if the tank for the cleaning fluid is e...

Page 52: ...n 2 Grip 3 Release lever A Pull 2 Push side cabin window by release lever to open 1 Side cabin window 3 To close the side cabin window pull it by the release lever until the lock snaps in at the window frame 6 Emergency hammer Cabin type only Emergency hammer is for breaking the window pane to escape from wheel loader if the window rail locking mechanism should fail WARNING To avoid personal injur...

Page 53: ...ctly into the fresh air port while washing the vehicle During the summer turn the heater valve clockwise to close the valve 1 Heater valve A Open B Close 1 1 Recirculation fresh air selection lever Cabin type only Turn the recirculation fresh air selection lever and you can switch RECIRCULATION and FRESH AIR each other FRESH AIR Fresh air will flow into the cabin This is helpful when you work in d...

Page 54: ...ngine seizure or other serious failure Scratches cracks or swelling in water hoses Water leakage at water hose joints Missing or damaged water hose protective wrap or grommets Loose mounting bolts and damaged brackets Do not touch the water hoses and the heater with your hand You may get burned If the window fails to defrost in extreme conditions or becomes cloudy when dehumidifying the cabin wipe...

Page 55: ...pe only Set the temperature control dial at the desired position to obtain the desired air temperature Turn the temperature control lever to the left to obtain cooler air Move the temperature control dial to the right to obtain warmer air 1 Temperature control dial 3 3 Blower switch Cabin type only You can change the air volume in 3 steps At the 3 position of the blower switch you can obtain the l...

Page 56: ...ch 2 Turn on the blower switch 1 2 or 3 3 Adjust the temperature control dial to achieve the desired temperature level NOTE If the vehicle has been not used for a long time longer than 1 week and the air conditioner will be not used turn on the air conditioner switch under the engine idling This method is to protect the compressor Defrosting or demisting To defrost or demist the windshield take th...

Page 57: ...ctures which may be susceptible to harm or damage from hot exhaust gases During regeneration white exhaust gases may be visible Do not allow the regeneration in a non ventilated garage or confined area During regeneration do not leave the machine 1 Diesel oxidation catalyst and diesel particulate filter DPF muffler The diesel oxidation catalyst and diesel particular filter Hereinafter called DPF s...

Page 58: ... DPF switch A Inhibit side B Parked Regeneration side Auto Regeneration Mode The machine has been set to Auto Regeneration Mode by default When an amount of PM more than specified has built up in the DPF muffler the DPF is automatically regenerated whether the machine is in motion or parked For jobs not affected by hot gases emitted out of the DPF muffler during regeneration the Auto Regeneration ...

Page 59: ...area because DPF and exhaust temperature will rise NOTE Even if the Auto Regeneration Mode is selected DPF regeneration may not begin because system requirements have not been satisfied If the engine load is light regeneration may not begin 3 When the regeneration conditions are satisfied the regeneration indicator stops flashing and remains constant ON The regeneration starts automatically whethe...

Page 60: ...ec onds sounding sufficient The regeneration indica tor starts flashing Start the regeneration referring to the pre ceding PM warning level 1 Now the parked regeneration indicator starts flashing and the parked regeneration can al so be started If the conditions of regeneration are not met perform the procedure for parked regenera tion cycle See Operating the machine for Parked Re generation Mode ...

Page 61: ...hat the regeneration indicator and the parked regeneration switch lamp stay ON while regenerating the DPF The regeneration indicator and the parked regeneration switch lamp turn OFF when the regeneration cycle is complete During the regeneration cycle do not touch the levers and switches operated in this procedure nor change the engine rpm Otherwise the regeneration will be interrupted Never leave...

Page 62: ...r A Inhibit side B Parked Regeneration side 1 The machine has been set to Auto Regeneration Mode by default switch lamp ON Inhibit Mode is activated OFF Auto Regeneration Mode is activated 2 When the parked regeneration indicator starts flashing follow the procedure in Operating the machine for Parked Regeneration Mode on page 57 OPERATION OF THE ENGINE EXHAUST AFTERTREATMENT DEVICES 58 R540 ...

Page 63: ...ration operating procedure for Auto Regeneration Mode on page 55 The parked regeneration indicator starts flashing If the parked regeneration cycle is interrupted or the machine is continuously operated in the PM warning level 2 DPF system becomes in the PM warning level 3 3 Constantly sounds 50 The regeneration indica tor starts flashing Immediately stop working the machine move the machine to a ...

Page 64: ...the regenerating while the engine is warm Do not unnecessarily start and interrupt the regeneration process Otherwise a small amount of fuel becomes mixed with the engine oil which degrades the oil quality While the DPF is being regenerated the air flow rate of engine is automatically limited to keep up the exhaust temperature Because of limit of the air flow rate of engine the engine may sound di...

Page 65: ...diately If any following conditions should occur stop the engine immediately The engine rpm increases or decreases suddenly Sudden abnormal noises are heard Exhaust is black Warning indicator for engine oil lights up during operation IMPORTANT In the preceding cases check the machine and ask your local KUBOTA dealer to service STARTING THE ENGINE UNDER COLD CONDITIONS Start the engine in the manne...

Page 66: ...l position 3 Wear eye protection and rubber gloves 4 Make sure that the vent caps are securely in place if equipped 5 Connect the terminal of the red jumper cable with the plus terminal of the low battery 6 Connect the other end of the cable to the plus terminal of the auxiliary battery 7 Connect the black negative cable to the minus terminal of the auxiliary battery 8 Connect the other end of the...

Page 67: ...er lines take any possible movements of the wheel loader into consideration Unevenness of the ground or sloping the wheel loader can reduce the safe distance Wind can cause the overhead power lines to sway thus reducing the safe distance In case of a power cross over leave the danger zone with the wheel loader if possible by taking suitable measures If leaving the danger zone with the wheel loader...

Page 68: ...ckwise C Turn anticlockwise Horizontal seat adjustment 1 Pull the horizontal seat adjustment lever up A and move the operator s seat to the desired position by moving it forward or back 2 Then release the horizontal seat adjustment lever Seat height adjustment You can be adjust the height of operator s seat height to several stop positions 1 To adjust the height of operator s seat slowly raise the...

Page 69: ...at belt reels itself and gets retracted to the right side 4 Adjusting the tilt steering WARNING To avoid personal injury or death Do not adjust the steering wheel while the machine is in motion 1 Press down the steering wheel tilt lever to release the lock so that the steering wheel can be adjusted to desired position 1 Steering wheel tilt lever A Press down TRAVELING WITH MACHINE 1 Starting to tr...

Page 70: ...al controls the engine rpm The more the accelerator pedal is pressed the greater the engine rpm 1 Accelerator pedal NOTE When the accelerator pedal is released the engine speed will drop Press the accelerator pedal gradually when starting the machine 3 Inching and brake pedal Press the inching and brake pedal down slightly then the HST pump comes in neutral and cuts off the engine power on the way...

Page 71: ... running direction of machine forward or back To move forward Move the direction switch forward and press the accelerator pedal NOTE on the instrument panel goes on 1 Direction switch 2 Accelerator pedal A Lighting B Forward To move backward Move the direction switch backward and press the accelerator pedal NOTE When the machine begins to travel BACKWARD the back buzzer starts sounding on the inst...

Page 72: ...e following values Limited speed 4 6 km h 1 Left speed control switch 2 Right speed control switch A 4 6 km h B 20 km h IMPORTANT Do not decelerate the travel speed suddenly by speed control switches during driving There is a risk of being overrun and the engine may be damaged If the overrun occurs the warning indicator flashes 7 Precautions for turning the machine WARNING To avoid personal injury...

Page 73: ...er 10 Precautions for traveling on snow WARNING To avoid personal injury or death There is the risk of the machine slipping excessively on frozen ground Install chains on the front wheels For operation on snow install chains on both front and rear wheels When traveling on snow it is important to keep the wheels and their related parts in good condition After traveling be sure to remove all snow an...

Page 74: ...NING To avoid personal injury or death Do not exceed the rated operating capacity of the unit If loads exceed the rated operating capacity the unit can experience a hydraulic imbalance when half or medium lift arms raise command and bucket roll back or auxiliary hydraulic control command are input together which can result in the lift arms lowering slowly If you begin to experience the hydraulic i...

Page 75: ...rol lever A Roll back To dump 1 Tilt the control lever to the right 1 Control lever A Dump NOTE To stop the operation of bucket return the control lever to the neutral position OPERATION OF THE MACHINE R540 71 ...

Page 76: ...over one after another and the icon and action mode number on the screen change accordingly 1 Indicator 2 Display selector switch 3 AUX port enable switch a Mode 0 AUX disable normal screen b Mode 1 c Mode 2 a No lighting b Lighting c Blinking A No activation B MAX flow volume C Limited flow volume Checking the setting volume 1 Press the display selector switch when the action mode number AUX 1 is...

Page 77: ...aulic lock switch 2 Hydraulic lock indicator 4 Push the AUX port enable switch 1 AUX port enable switch 2 AUX operation indicator 5 Move the AUX port variable switch to send oil to the port as follows Move the AUX port variable switch forward to send oil to the port A Move the AUX port variable switch downward to send oil to the port B 1 AUX port variable switch A To port A B To port B AUXILIARY P...

Page 78: ...switch to decrease the volume or press the display selector switch to increase the volume 1 User setting switch 2 Display selector switch 3 Max flow volume value A Press user setting switch to decrease the volume B Press display selector switch to increase the volume 4 Press the display selector switch for a long time to go to the next port and set for this port Changing the port 1 Value of left s...

Page 79: ...en the AUX port is not used for a long period dirt particles can settle in the lower part of the AUX port lines When the plugs on the AUX port lines are removed to connect attachments drain the following amount of oil before connecting the AUX port lines Oil Approx 100 cc NOTE Suppose that the same attachment is mounted on another machine Even if the same limit setting is performed their machines ...

Page 80: ...etting 2 AUX port LH and RH maxi mum flow volume setting 0 to 19 A Push and hold the display se lector switch B Push and hold the user selec tor switch C Push the display selector switch D Lighting E Blinking OPERATION OF THE MACHINE AUXILIARY PORT OPERATION 76 R540 ...

Page 81: ...s is not minimized If the pressure is removed after minimizing the flow volume in the AUX port released pressure is not removed completely and the hose coupler may be unable to connect and disconnect 1 Display selector switch QUICK COUPLER This machine utilizes a multi coupler for easy connection and disconnection of various attachments By replacing the front attachments you can use this machine i...

Page 82: ...h backward while pressing the attachment unlock switch forward in order to retract the locking pins 1 Auxiliary port enable switch 2 Auxiliary port variable switch 3 Attachment unlock switch A Move backward B Press forward 2 Position the machine squarely in front of the attachment 1 Attachment 2 Quick coupler 3 Attachment bracket 3 Tilt the quick coupler forward approx 15 degrees and align the upp...

Page 83: ...iable switch A Move forward WARNING To avoid personal injury or death If you are uncertain as to whether or not that the attachment is securely be sure by pressing the edge of the attachment against the ground so that the front end of machine rises slightly When changing an attachment the operator should make sure to check visually that the left and right locking pins of attachment bracket are in ...

Page 84: ... Press forward 2 Move the control lever to the left and then lower the lifting arm to disengage from the attachment 1 Attachment 3 Reverse away from the attachment 1 Attachment CONNECTING AND DISCONNECTING THE HYDRAULIC HOSE When activating an attachment with a hydraulic cylinder by using AUX port connect or disconnect hydraulic hoses At this time follow the following procedures 1 Before starting ...

Page 85: ...to 0 and cuts the driving power to slow down or stop the machine 2 Press the inching and brake pedal completely The disc brake will be applied to stop the machine completely 1 Inching and brake pedal A Press with force To approach slowly 1 Press the inching and brake pedal slightly while pressing the accelerator pedal The machine approaches slowly 1 Inching and brake pedal A Press slightly The mac...

Page 86: ...y Bucket operation speed is thus maintained 2 Press the inching and brake pedal slightly to allow the machine to approach to the desired stop position 3 Then press the inching and brake pedal all the way to stop the machine completely 1 Inching and brake pedal A Press slightly B Press all the way Refilling 1 Press the inching and brake pedal slightly to approach the desired stop position 2 Then pr...

Page 87: ...nnot be ascertained such as ground covered with weeds or snow Check for hidden projections dents road shoulders and so on beforehand and take care not to approach them during work Be sure to ease up on the accelerator at the end of backfilling grooves the areas at the edge of cliffs the pond banks or at the end of an ascent Upon removal of the external load the machine speed will automatically inc...

Page 88: ...igging depth per pass Between 10 cm and 15 cm 2 While adjusting the vertical movement of the bucket lift the bucket so that sand can be removed by layers Continue lifting the bucket as you advance the machine 1 Bucket A Driving direction B Lift 2 Refilling 1 Direct the bucket horizontally and push the piled sand toward the ditch 2 When the bucket reaches the ditch dump the bucket to discharge the ...

Page 89: ...direction of the machine 2 After digging and shoveling with the bucket move the machine backward 3 Then drive the truck to a point between the machine and the piled sand 4 Then load the sand onto the truck 1 Piled sand 2 Truck A Shoveling direction B Perpendicular to shoveling direction 4 2 Loading onto a truck by V shift loading method 1 Position a truck at an angle of about 60 degrees from the s...

Page 90: ...ne onto a truck apply the parking brake of the truck and block the front and rear wheels 1 Block 2 Fix the ramps securely to the truck so that the machine and the truck cannot slip 1 Lock plate A 500 mm to 600 mm B 650 mm C 4 x H or more 3 Support the rear end of the bed to prevent the front of truck from rising 1 Rear end of bed 4 When loading or unloading the machine on or from a truck keep the ...

Page 91: ...3 Release the hydraulic pressure in the hydraulic system by operating control levers 4 Remove the starter key 5 Secure the steering frame lock 6 Block the wheels of machine 7 Securely fasten the machine to the truck with straps or chains 1 Strap or chain 1 Block 1 Lug both sides WARNING To avoid personal injury or death Use the locations indicated by marks in the diagram to tie down the machine 1 ...

Page 92: ...tly over the load and lift the load so that it remains horizontal Do not enter and do not allow others to enter the working area under the suspended load and do not move the load over people Move the load only in an area where the equilibrium can be maintained Always inspect the attaching hardware including chains hooks and master links before each use Do not use any worn or damaged attaching hard...

Page 93: ...ter 5 30 70 10 30 70 15 30 70 20 35 65 25 40 60 30 45 55 35 50 50 40 55 45 IMPORTANT Use a permanent type antifreeze or long life coolant Be sure to drain the cooling water and deposits completely from the radiator interior before adding a new mixture of water and antifreeze Antifreeze contains anticorrosive It is not necessary to add a cleaner to the coolant Engine coolant capacity is as follows ...

Page 94: ... and safety shoes Do not carry out any work or modifications on hydraulic components To safely use the machine and prevent any trouble from occurring be sure to conduct daily inspections and periodic servicing You can use the 12 V socket as a source of power for illumination if you have to check the machine at night 1 Electrical outlet power sock et 12 V IMPORTANT If you cannot operate and must to...

Page 95: ... Only use commercially available noncombustible washing agents Only wash at the designated places such as oil and grease traps available MAINTENANCE R540 91 ...

Page 96: ...ater separator drain Daily check 103 9 Tire air pressure check Daily check 102 10 Brake check Daily check 103 11 Brake fluid check Daily check 100 change every 2 years 118 2 12 Fan belt tension check Daily check 103 adjust every 250 hrs 107 13 Greasing points grease Daily check 100 14 Battery condition check every 50 hrs 106 15 Cabin type only Air filter clean every 250 hrs 109 replace every 1000 ...

Page 97: ...en every 500 hrs 111 25 Fuel filter replace every 500 hrs 113 1 26 Hydraulic return fil ter element replace every 500 hrs 112 1 27 Oil for front rear axle differential case check every 500 hrs 112 change every 1000 hrs 113 1 28 HST oil filter change every 1000 hrs 114 1 29 Hydraulic suction fil ter element replace every 1000 hrs 115 1 30 Engine valve clear ance adjust every 1000 hrs 116 2 31 Injec...

Page 98: ...ing replace every 2 years 119 2 46 DPF differential pressure sensor rubber piping front and back replace every 2 years 119 2 47 Suction pipe down stream the AFS air flow sensor replace every 2 years 119 2 48 EGR cooler hose replace every 2 years 119 2 49 Coolant hoses and hose clamps replace every 2 years 50 Hydraulic hoses replace every 2 years 51 Cabin type only Refrigerant gas check service as ...

Page 99: ...ey into the key hole and turn it clockwise to unlock the engine cover 2 Push the key hole 3 Pull up the hood until it will be held 4 To close the engine cover release the lock of the gas damper 5 Lower the hood and hold it down tightly 6 Turn the starter key counterclockwise to lock the engine cover 1 Engine cover 2 Key hole 3 Gas damper 4 Lock A Open B Close 3 Opening the side cover 1 Insert the ...

Page 100: ...there are any leaks take proper measures to stop them If repair is impossible contact your KUBOTA dealer Check for loose bolts and nuts and tighten if necessary Especially check for the wheel nuts Check the electrical circuit for any damage shorts or loose connections 1 Checking and replenishing the engine oil WARNING To avoid personal injury or death Be sure to stop the engine before checking the...

Page 101: ...F regeneration can increase the small amount of fuel that gets mixed with the engine oil thereby degrading it If the oil rises above the oil level gauge upper limit it means the oil has been diluted too much resulting in a trouble In such case immediately change the oil for new one 2 Checking and replenishing the hydraulic oil WARNING To avoid personal injury or death Never open the oil port immed...

Page 102: ...ing always set the parking brake stop the engine lower the bucket and attachment to the ground release the hydraulic pressure in the hydraulic system by operating the control levers and remove the starter key While refueling the wheel loader smoking naked flames and operation of other sources of ignition are prohibited Serious personal injury or death could result IMPORTANT Use proper diesel fuel ...

Page 103: ...the key inserted 1 Starter key 2 Fuel tank cap 3 Tank cap cover 4 Checking and replenishing the coolant WARNING To avoid personal injury or death Do not remove the radiator cap while the coolant is hot When the coolant is cool rotate the radiator cap to the first stop to allow excessive pressure to escape Then remove the radiator cap completely The radiator is equipped with a recovery tank When th...

Page 104: ...dicator light up check the brake fluid reservoir and refill brake fluid up to a height of 35 mm from the bottom 1 Brake fluid reservoir 2 Brake fluid warning indicator 1 Brake fluid reservoir A 35 mm IMPORTANT If a large amount of brake fluid has to be refilled check the brake system for leaks before using the machine again If the brake fluid warning indicator lights up a short time after adding b...

Page 105: ... Bucket link pin 1 place 3 Lift arm attachment pin 2 places 4 Bell crank arm pin 3 places 5 Bucket cylinder bottom pin 1 place 6 Lift cylinder rod pin 2 pla ces 7 Lift cylinder bottom pin 2 places Greasing the rear frame 1 Apply the grease to the rear frame at 1 grease fitting 1 Grease fitting Greasing the articulation joint 1 Apply the grease to the articulation joint at 2 grease fittings 1 Greas...

Page 106: ... out them with a jet of compressed air or water 3 Check the cooling water hoses for damage 4 If the cooling water hoses are broken or cracked change them 5 Also check to see that the hose clamps are tight 1 Radiator grill 2 Oil cooler NOTE Clean the fins and the ribs of radiator and oil cooler in order not to overheat the engine and allow free flow of air through the cooling elements Pressure of c...

Page 107: ...ey before cleaning the wiring cables and engine 1 Before starting the engine check whether flammable substances have gathered on the battery the cables and wiring the muffler or the engine Remove flammable substances thoroughly 2 Check the electrical circuitry for disconnections shorts or loose terminals 13 Checking the fan belt WARNING To avoid personal injury or death Stop the engine and remove ...

Page 108: ...forget to open the shutoff valve after drain of the water was over 1 Screw 2 Cup 3 Shutoff valve 4 Red float 5 Drain plug A Close B Open C Loosen D Tighten 16 Cleaning the evacuator valve 1 Open the evacuator valve to get rid of large particles of dust and dirt 1 Evacuator valve 17 Checking the dust indicator 1 If the air cleaner warning indicator on the instrument panel lights up clean the air cl...

Page 109: ... wiring for short circuits and loose terminals WARNING To avoid personal injury or death Never wear metal rings or metal watch bands You can be as a ground for the electric circuit and get a burn on your hand or arm Know the electrical circuit before you connect or disconnect an electrical component A wrong connection can cause injury or damage Only qualified electricians are allowed to work on th...

Page 110: ...losion caused by sparks Always wear eye protection when working with the battery 1 Battery A Upper level B Lower level Mishandling the battery shortens the service life and adds to maintenance costs The original battery is maintenance free but needs some servicing If the battery is weak the engine will be difficult to start and the lights will be dim It is important to check the battery periodical...

Page 111: ...e procedure in this section 1 Remove the battery from machine 2 Adjust the electrolyte to the proper level 3 Store the batter in a dry place out of direct sunlight The battery self discharges while it is stored Recharge it once every 3 months in hot seasons and once every 6 months in cold seasons SERVICE EVERY 250 HOURS Perform inspection and servicing for every 50 hours of operation at the same t...

Page 112: ...are properly fixed every 250 hours of operation or 6 months whichever comes first WARNING To avoid personal injury or death Do not check the radiator hoses until the engine has cooled down 1 If the clips are loose or water leaks tighten the clips securely 2 Replace the hoses and the hose clamps every 2 years or earlier if checked and found that hoses are swollen hardened or cracked 1 Radiator hose...

Page 113: ... are dry elements Do not oil the elements Do not operate the machine without the air filter installed 4 Checking the fuel line and the intake air line 1 Check to see that all lines and hose clamps are tight and not damaged 2 If hoses and hose clamps are found worn or damaged replace or repair them at once 1 Hose 2 Hose clamp 5 Checking the wheel nuts 1 Check the wheel nuts according to Changing th...

Page 114: ...ve to the CLOSE position 2 Loosen and remove the cup properly and replace the water separator filter element 3 Check the condition of the O ring and replace if necessary 4 Tighten up the cup properly 5 Set the shutoff valve to the OPEN position 1 Water separator 2 Screw 3 Cup 4 Shutoff valve 5 Float 6 Drain plug 7 Head cover 8 Water separator filter ele ment 9 O ring A Close B Open C Loosen D Tigh...

Page 115: ...acing the engine oil filter cartridge WARNING To avoid personal injury or death Always stop the engine before replacing the engine oil filter cartridge Never remove the oil filter immediately after the engine has stopped or hot engine oil may escape causing scalding 1 Replace the engine oil filter cartridge at the same time engine oil is changed 2 Use the supplied filter wrench to remove the oil f...

Page 116: ...njury 1 Remove the oil port plug check the oil level in the front and the rear axle case The oil level in the axle cases must be at the lower rim of the thread 2 Add the axle cases oil if necessary 3 Screw in and tighten the oil port plug Front Rear Side 1 Oil port plug Front axle case 2 Reduction gear case 3 Rear axle case 4 Front axle case both sides 5 Rear axle case both sides 6 Oil plug 3 Repl...

Page 117: ...nsor connector 7 Open the shut off valve on the water separator 8 Bleed the fuel system See Bleeding the fuel system on page 123 1 Water separator 2 Shut off valve A Close B Open 3 Fuel filter 4 Water sensor connector SERVICE EVERY 1000 HOURS Perform inspection and servicing for every 50 250 and 500 hours of operation at the same time 1 Changing the oil for the front and the rear axle differential...

Page 118: ...dge of the thread hole on the oil port 5 Screw in and tighten the oil port plug Axle case oil capacity Front rear axle case 4 5 L Reduction gear case 0 6 L Reduction gear case at wheel each 0 9 L 2 Replacing the HST oil filter WARNING To avoid personal injury or death Never remove the filter immediately after the engine has stopped or hot hydraulic oil may escape causing scalding 1 Loosen the nut ...

Page 119: ... the tank bottom cover and then remove the tank bottom cover 3 Replace the suction filter Suction filter Hexagon nut 60 mm 1 Suction filter 2 Hydraulic oil tank 3 Bottom cover 4 Check the gasket of the tank bottom cover for damage and replace it if necessary 5 Retighten the drain plug and attach the tank bottom cover 6 Open the access flap and the oil port cap for the hydraulic oil tank and fill h...

Page 120: ...eaner elements and the air cleaner cover being careful to install the cover so that its TOP mark arrow faces upwards 1 Outer element 2 Inner element 3 Cramp 4 Air cleaner cover 5 Adjusting the engine valve clearance Consult your local KUBOTA dealer for adjusting the engine valve clearance SERVICE EVERY 1500 HOURS Perform all 50 100 and 500 hour servicing at the same time 1 Checking the injector Co...

Page 121: ... 1500 2000 and 3000 hour servicing at the same time 1 Cleaning the diesel particulate filter DPF The longer the DPF operates the more ash burnt residue is collected in the DPF Too much ash build up adversely affects the DPF performance Consult your local KUBOTA dealer to clean up the DPF IMPORTANT To clean up the DPF a specific machine is required Do not try to clean it in any other way such as di...

Page 122: ...ake hose 2 Changing the brake fluid Consult your local KUBOTA dealer for changing the brake fluid 3 Replacing the rubber parts of master cylinder Consult your local KUBOTA dealer for replacing the rubber parts of master cylinder 4 Replacing the fuel hoses and the clamps WARNING To avoid personal injury or death A broken fuel line will cause the fuel to leak Be sure to check the fuel line Fire or i...

Page 123: ...Radiator cap 6 Replacing the intake air line 1 Replace the hoses and clamps if necessary See Checking the fuel line and the intake air line on page 109 1 Hoses 2 Hose clamps 7 Replacing the rubber piping related oil separator Consult your local KUBOTA dealer for replacing the rubber piping related oil separator 8 Replacing the diesel particulate filter DPF differential pressure sensor rubber pipin...

Page 124: ...UBOTA dealer for replacing the air conditioner pipes and hoses SERVICING AS REQUIRED 1 Replacing and repairing the electrical system Damage to cables and loose connections of the electrical system cause malfunctioning and lead to short circuits leakage and fires 1 Replace and repair the electrical system such as fuse as quickly as possible if necessary Fuse See Replacing the fuses on page 120 1 Fu...

Page 125: ...switch 2 30 A Blower motor 3 5 A Instrument panel B 4 20 A Main ECU power 5 10 A Horn 6 15 A Beacon light 7 not used 8 5 A Interior light 9 not used 10 30 A Front wiper 11 not used 12 not used 13 not used 14 10 A Head lamp LH 15 10 A Head lamp RH 16 5 A Clearance lamp LH Tail lamp LH 17 5 A Clearance lamp RH Tail lamp RH 18 5 A Starter signal 19 5 A Horn sub 20 not used 21 15 A Air ride power 22 n...

Page 126: ... slow blow fuses 1 Disconnect the negative cord of the battery 2 Remove the slow blow fuse case 3 Open the slow blow fuse case cap and the cover then remove the bolts and draw out the slow blow fuse 1 and 2 1 Slow blow fuse case cap 2 Cover 3 Bolt 4 Slow blow fuse 1 Alternator 5 Slow blow fuse 2 Main 1 Slow blow fuse Rating Applied circuit 1 100 A Alternator 2 60 A Main 1 3 50 A Main 2 4 50 A Main...

Page 127: ...g the water completely close the shutoff valve on the water separator 5 Attach the drain bolt 6 Open the shutoff valve on the water separator 1 Water separator 2 Shut off valve A Close B Open 3 Fuel filter 4 Drain bolt IMPORTANT After draining the fuel filter drain the water separator as soon as possible 3 Bleeding the fuel system WARNING To avoid personal injury or death Keep sparks and flames aw...

Page 128: ...e Bucket Pallet forks front rear front rear 12 5 18 2 5 bar 2 0 bar 3 0 bar 2 0 bar 2 Checking the tire pressure Check the tires and rims for damage and eliminate problems before starting operation If the air pressure in the tire is too high or too low the life of the tire will be shortened Check the air pressure in tires routinely 1 Check the tire pressure 1 Ground level A Deficient B Correct C E...

Page 129: ...ghtening torque 490 N m 4 Mounting the tires Off road tires are used to provide strong traction and buoyancy on soft ground 1 Tires should only be mounted on a rim by qualified personnel with the proper equipment When mounting ensure that the tread pattern is mounted in the correct direction See the following figure 1 Tire A Correct B Incorrect C Forward 5 Tire chains Tire chains are not applicabl...

Page 130: ...sed 4 Remove and store the battery separately 5 Check the antifreeze in the coolant Add the antifreeze for adequate protection when temperatures down to the following values Temperature 25 Measures during storing 1 Recharge the battery regularly Restarting after storing 1 Remove the grease applied to the piston rods of the hydraulic cylinders 2 Check all oil levels the sediment trap of the fuel sy...

Page 131: ... tures SAE 30 SAE 40 SAE 50 All weather hydraulic oil SAE 10W 40 Brake fluid ISO VG 22 Grease Shell Alvania EP2 Mobilux EP2 Fuel Diesel Fuel No 2 D S15 Fuel under 5 Diesel Fuel No 1 D S15 NOTE Engine oil Use the engine oil of suitable American petroleum institute API service classification and proper SAE engine oil standards according to the ambient temperatures Above 25 SAE 30 or SAE 10W 30 SAE 1...

Page 132: ...Refer to SAE J313 JUN87 Distillate fuel No 2 D Indicated capacities of water and oil are manufacture s estimate IMPORTANT If you use different fuel or engine oil the cleaning efficiency of the DPF 6000 hours will be reduced and the DPF longevity will be shorter than expected Filters must trap sulfate additives of fuel and lubricant Zn Pb Na K Ca Mg Cu Ba P and so on as ash during combustion Contro...

Page 133: ...rt often 5 Do not use biodiesel concentrations higher than 5 i e greater than B5 Engine performance and fuel consumption will be affected and degradation of the fuel system components may occur 6 Do not readjust the engine fuel control system as this will violate emission control levels for which the equipment was approved 7 Compared with soybean based and rapeseed based feedstock palm oil based f...

Page 134: ...ddenly stops Low fuel level Check the fuel and add if necessary Purge the fuel system Abnormal exhaust gas color Poor fuel Use high quality fuel Too much engine oil Drain the engine oil to prescribed oil level Water temperature in red zone overheating Damaged seal of the water pump Replace Worn or torn V belt Adjust or replace Thermostat is damaged Replace Coolant level is too low Fill to prescrib...

Page 135: ...termeasure Electric system mark appears in the instrument panel Electric system is malfunction Check the error code number of LIST OF ERROR CODE NUMBERS on page 132 and contact your lo cal dealer TROUBLESHOOTING R540 131 ...

Page 136: ...ct your local dealer E 022 Hydraulic lock Lock is not active Immediately contact your local dealer E 023 Speed control switch It is impossible to change the speed setting by the speed control switch Immediately contact your local dealer E 024 Differential lock Differential lock does not work Immediately contact your local dealer E 025 Parking brake Parking brake is not active The machine would be ...

Page 137: ...but unable to start DPF regenera tion Immediately contact your local dealer E 9004 Requirement for DPF replacement DPF must be replaced Immediately contact your local dealer E 9100 Rpm sensor system Immediately contact your local dealer E 9101 Fuel or rail pressure system Immediately contact your local dealer E 9102 SCV system Immediately contact your local dealer E 9103 Intake air tempera ture se...

Page 138: ...Engine ECU Immediately contact your local dealer E 9122 ECU communication failure Immediately contact your local dealer E 9200 Mass air flow sensor system Immediately contact your local dealer E 9203 Intake air throttle Immediately contact your local dealer E 9204 Differential pressure sensor system Immediately contact your local dealer E 9205 Exhaust temperature sensor DOC inlet Immediately conta...

Page 139: ...clog ged 2 If E 9303 still appears immediately contact your local dealer E 9304 Engine fuel system supply pump 1 Check the fuel level and see if the fuel filter is clog ged 2 If E 9304 still appears immediately contact your local dealer E 9305 Engine air intake system poor air in take 1 Check to see if any air in take hose is disconnected and if the air cleaner ele ment is clogged 2 If E 9305 stil...

Page 140: ...s specified 1 Check the fuel level and see if the fuel filter is clog ged 2 Check to see if any air in take hose is disconnected and if the air cleaner ele ment is clogged 3 If E 9309 still appears immediately contact your local dealer E 9310 Starter turn on limit ed The starter is limited for its ac tivation in response to any oth er error Immediately contact your local dealer E 9320 Particulate ...

Page 141: ...00 hrs 5 Engine oil filter every 250 hrs 6 Front rear axle oil change every 1000 hrs 7 Hydraulic return filter replace every 500 hrs 8 Hydraulic suction filter every 1000 hrs 9 HST oil filter every 1000 hrs 10 DPF clean every 6000 hrs NOTE The maintenance periodic check message can be automatically disappeared The maintenance message reappears on the hour meter when the hour meter reaches next des...

Page 142: ...luid changing 118 brake fluid reservoir checking oil level 100 brake hose checking 118 replacing 118 bucket operating 70 C cabin door cabin type only opening and closing 47 checking for leaks 105 clamp replacing 118 clip checking 108 clock setting 39 control panel cabin type only 51 operating 51 control pedal 32 coolant changing 118 checking level 99 replenishing 99 coolant temperature gauge funct...

Page 143: ...ine stop knob 62 engine tachometer 43 engine valve clearance adjusting 116 error code number 132 evacuator valve cleaning 104 exhaust aftertreatment device 53 exhaust manifold checking for cracks gas leakage and mounting screw 117 F fan belt checking 103 checking tension 107 filter of air conditioner changing 50 float switch 38 flow volume setting maximum 74 front attachment greasing 100 front axl...

Page 144: ...truck 86 loading on 86 running in 63 machine parts 29 maintenance interval 92 master cylinder replacing rubber parts 118 multi function switch front wiper washer system cabin type only 47 high low beam changing 35 rear wiper washer system cabin type only 47 turn signal blinking 35 N neutral switch 67 nut checking 105 tightening 105 O oil 127 oil cooler checking 102 cleaning 102 oil in brake fluid ...

Page 145: ...40 27 speed control switch 68 starter motor checking 117 starter switch 34 starting to travel 65 steering checking 102 steering cylinder bearing greasing 100 steering frame lock attaching 46 function 46 stopping machine 69 storing machine 126 suction filter changing 115 suction pipe replacing 119 sun visor cabin type only 49 switch 31 T temperature control dial cabin type only 51 terminals checkin...

Page 146: ...wheel loader scrapping 26 wheel nut checking 102 109 working light switch 36 142 R540 ...

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