Kubota WSM L3540-II Workshop Manual Download Page 100

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ENGINE

L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM

1-M2

2. EGR (EXHAUST GAS RECIRCULATION) SYSTEM

(IF EQUIPPED)

The EGR (Exhaust Gas Recirculation) system is used to lower the combustion temperature and efficiently cool

EGR gas, with the aim of reducing the NOx that is in the exhaust gas of diesel engine.

9Y1211167ENM0002US0

(1) Boost Compensator
(2) Thermo Valve
(3) Exhaust Manifold
(4) Crankcase
(5) EGR Cooler
(6) EGR Valve
(7) Water Flange
(8) Inlet Manifold

(A) Boost Pressure
(B) EGR Gas
(C) Coolant

KiSC issued 02, 2015 A

Summary of Contents for WSM L3540-II

Page 1: ...L3540 II L4240 II L5040 II L5240 II L5740 II WORKSHOP MANUAL TRACTOR KiSC issued 02 2015 A...

Page 2: ...with the subsequent sections make sure that you read this section Refer to the latest version of Workshop Manual for diesel engine tractor mechanism that this manual does not include Booklet Code No...

Page 3: ...I INFORMATION KiSC issued 02 2015 A...

Page 4: ...CALS I 4 3 SPECIFICATIONS I 7 1 HST MODEL I 7 2 GST MODEL I 9 3 MANUAL TRANSMISSION MODEL I 11 4 TRAVELLING SPEEDS I 13 1 HST MODEL I 13 2 GST MODEL I 14 3 MANUAL TRANSMISSION MODEL I 15 5 DIMENSIONS...

Page 5: ...ral positions or in disengaged positions Do not start the engine when you stay on the ground Start the engine only from operator s seat M00000002INI0001US1 SAFETY FIRST This symbol the industry s Safe...

Page 6: ...pressure before you disconnect hydraulic or fuel lines Tighten all connections before you apply the pressure Do not open a fuel system under high pressure The fluid under high pressure that stays in f...

Page 7: ...rotection regulations when you discard oil fuel coolant electrolyte and other dangerous waste WSM000001INI0007US0 PREVENT ACID BURNS Keep electrolyte away from your eyes hands and clothing Sulfuric ac...

Page 8: ...I 4 2 SAFETY DECALS 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 9: ...INFORMATION L3540 II L4240 II L5040 II L5240 II L5740 II WSM I 5 9Y1211167INI0002US0 KiSC issued 02 2015 A...

Page 10: ...soap and water dry with a soft cloth 3 Replace damaged or missing danger warning and caution labels with new labels 4 If a component with danger warning and caution label s affixed is replace with new...

Page 11: ...2 V RC 133 min CCA 582 A Capacities Fuel tank 44 L 11 6 U S gals 9 68 Imp gals 50 L 13 2 U S gals 11 0 Imp gals 54 L 14 3 U S gals 11 9 Imp gals Engine crankcase with filter 6 7 L 7 1 U S qts 5 9 Imp...

Page 12: ...g radius with brake 2 7 m 8 9 feet 3 2 m 10 5 feet Hydraulic unit Hydraulic control system Position control Pump capacity 31 5 L 8 3 U S gals 6 9 Imp gals min 37 0 L 9 8 U S gals 8 14 Imp gals min 3 p...

Page 13: ...imum torque 162 2 N m 16 5 kgf m 133 2 lbf ft Battery capacity 12 V RC 133 min CCA 582 A Capacities Fuel tank 54 L 14 3 U S gals 11 9 Imp gals Engine crankcase with filter 9 4 L 9 9 U S qts 8 3 Imp qt...

Page 14: ...brake not applicable Trailer brake coupler not applicable Min turning radius with brake 3 2 m 10 5 feet Hydraulic unit Hydraulic control system Position control Pump capacity 35 6 L 9 4 U S gals 7 83...

Page 15: ...ery capacity 12 V RC 133 min CCA 582 A Capacities Fuel tank 50 L 13 2 U S gals 11 0 Imp gals 54 L 14 3 U S gals 11 9 Imp gals Engine crankcase with filter 8 2 L 8 7 U S qts 7 2 Imp qts 9 4 L 9 9 U S q...

Page 16: ...Wet disk type Trailer brake not applicable Trailer brake coupler not applicable Min turning radius with brake 2 7 m 8 9 feet 3 2 m 10 5 feet Hydraulic unit Hydraulic control system Position control P...

Page 17: ...km h mph km h mph km h mph km h mph Forward L L 3 4 2 1 3 5 2 2 3 4 2 1 3 6 2 2 M 7 0 4 3 7 1 4 4 7 0 4 3 7 3 4 5 H 17 7 11 0 17 8 11 1 17 6 10 9 18 3 11 4 H L 5 8 3 6 5 8 3 6 5 8 3 6 6 0 3 7 M 11 8...

Page 18: ...ngine rpm 1 1 71 1 06 0 19 0 12 2 2 42 1 50 0 27 0 17 3 3 12 1 94 0 35 0 22 4 3 92 2 44 0 44 0 27 5 4 61 2 86 0 52 0 32 6 5 79 3 60 0 65 0 40 7 6 85 4 26 0 77 0 48 8 8 61 5 35 0 97 0 60 9 9 69 6 02 1...

Page 19: ...7 3 3 86 2 40 0 43 0 27 3 92 2 44 0 44 0 27 4 5 71 3 55 0 64 0 40 5 79 3 60 0 65 0 40 High 1 8 49 5 28 0 95 0 59 8 61 5 35 0 97 0 60 2 12 00 7 46 1 34 0 83 12 18 7 57 1 37 0 85 3 19 49 12 11 2 19 1 36...

Page 20: ...INFORMATION L3540 II L4240 II L5040 II L5240 II L5740 II WSM I 16 5 DIMENSIONS no caption KiSC issued 02 2015 A...

Page 21: ...G GENERAL KiSC issued 02 2015 A...

Page 22: ...ILY CHECK G 18 2 CHECK POINTS OF INITIAL 50 HOURS G 21 3 CHECK POINTS OF EVERY 50 HOURS G 23 4 CHECK POINTS OF EVERY 100 HOURS G 27 5 CHECK POINTS OF EVERY 200 HOURS G 32 6 CHECK POINTS OF EVERY 400 H...

Page 23: ...AL NUMBERS When contacting your local KUBOTA distributor always specify engine serial number tractor serial number and hour meter reading 9Y1211167GEG0001US0 1 Tractor Identification Plate 2 Tractor S...

Page 24: ...habet or Number Year Alphabet or Number Year 1 2001 F 2015 2 2002 G 2016 3 2003 H 2017 4 2004 J 2018 5 2005 K 2019 6 2006 L 2020 7 2007 M 2021 8 2008 N 2022 9 2009 P 2023 A 2010 R 2024 B 2011 S 2025 C...

Page 25: ...s with the specific emission regulations designated by the appropriate Kubota Parts List and perform all maintenance services listed in the appropriate Kubota Operator s manual or in the appropriate K...

Page 26: ...hen inserting spring pins their splits must face the direction from which a force is applied See the figure left side To prevent damage to the hydraulic system use only specified fluid or equivalent C...

Page 27: ...riodic check for a fee Do not try to modify or remodel any electrical parts and wiring When removing the battery cables disconnect the negative cable first When installing the battery cables connect t...

Page 28: ...vable part where sag be required WSM000001GEG0068US0 In installing a part be careful not to get wiring caught by it WSM000001GEG0069US0 After installing wiring check protection of terminals and clampe...

Page 29: ...ith water immediately Before you recharge the battery remove it from the machine Before you recharge remove cell caps Recharge in a well ventilated place where there is no open flame nearby as hydroge...

Page 30: ...ure that there is no female connector being too open WSM000001GEG0076US0 Make sure that plastic cover is large enough to cover whole connector WSM000001GEG0077US0 5 CIRCUIT TESTER Use tester correctly...

Page 31: ...color codes This symbol of shows color with stripe s An example Red stripe on white color W R WSM000001GEG0079US0 Color of wiring Color code Black B Brown Br Green G Gray Gy or Gr Blue L Light Green...

Page 32: ...7 U S qts 7 2 Imp qts Engine oil API service classification CF or better Above 25 C 77 F SAE30 10W 30 or 15W 40 0 to 25 C 32 to 77 F SAE20 10W 30 or 15W 40 Below 0 C 32 F SAE10W 10W 30 or 15W 40 4 Tr...

Page 33: ...oil API service classification CF or better Above 25 C 77 F SAE30 10W 30 or 15W 40 0 to 25 C 32 to 77 F SAE20 10W 30 or 15W 40 Below 0 C 32 F SAE10W 10W 30 or 15W 40 4 Transmission case 46 0 L 12 2 U...

Page 34: ...s a distillate fuel of lower volatility for engine in industrial and heavy mobile service SAE J313 JUB87 Since this engine adopts EPA Tier 4 and Interim Tier 4 standards the use of low sulfur fuel or...

Page 35: ...25 M10 40 to 45 4 0 to 4 6 29 to 33 32 to 34 3 2 to 3 5 24 to 25 48 to 55 4 9 to 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 63 to 72 6 4 to 7 4 47 to 53 78 to 90 7 9 to...

Page 36: ...8 13 to 21 1 3 to 2 2 9 4 to 15 13 to 19 1 3 to 2 0 9 4 to 14 R1 4 25 to 44 2 5 to 4 5 18 to 32 25 to 34 2 5 to 3 5 18 to 25 R3 8 49 to 88 5 0 to 9 0 37 to 65 49 to 58 5 0 to 6 0 37 to 43 R1 2 58 9 t...

Page 37: ...el line Check every 100 Hr G 29 Replace every 2 years G 40 10 Fuel filter element Clean every 100 Hr G 28 Replace every 400 Hr G 36 11 Parking brake cable Adjust every 100 Hr G 32 Replace every 2 year...

Page 38: ...y 400 Hr G 38 23 Front axle pivot Adjust every 600 Hr G 38 24 Engine valve clearance Adjust every 800 Hr G 38 25 Fuel injection nozzle injection pressure Check every 1500 Hr G 38 26 Injection pump Che...

Page 39: ...nnually 9Y1211167GEG0008US0 No Item Service Interval After since Refer ence page 50 100 150 200 250 300 350 400 450 500 550 600 650 700 1 Air conditioner condenser screen Clean Daily G 20 2 Tension of...

Page 40: ...ure 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 less fuel in tank IMPORTANT Do not permit dirt...

Page 41: ...he level is too low add new oil to the prescribed level at the oil inlet See page G 37 IMPORTANT If oil level is low do not run engine 9Y1211167GEG0014US0 Checking Coolant Level WARNING Do not remove...

Page 42: ...r Screen WARNING Be sure to stop the engine before removing the screen The condenser and receiver become hot while the air conditioner is running Before checking or cleaning them wait enough until the...

Page 43: ...tom of the engine and drain the oil completely into the oil pan All the used oil can be drained out easily when the engine is still warm 2 After draining reinstall the drain plug 3 Fill with the new o...

Page 44: ...he seal and be sure to check the oil level on the dipstick Then replenish the engine oil up to the prescribed level IMPORTANT To prevent serious damage to the engine use only a KUBOTA genuine filter 9...

Page 45: ...leak past the seal on the filter IMPORTANT To prevent serious damage to the hydraulic system use only a KUBOTA genuine filter Do not operate the tractor immediately after changing the transmission flu...

Page 46: ...l switch 5 Turn the key to START position 6 The engine must not crank Test 2 Switch for the PTO clutch control switch 1 Sit on operator s seat 2 Engage the PTO clutch control switch 3 Depress the clut...

Page 47: ...utch pedal fully 4 Place the speed control pedal to the neutral position 5 Turn the key to START position 6 The engine must not crank Test 3 Switch for the operator s seat 1 Sit on operator s seat 2 S...

Page 48: ...grease to forward front axle support remove the breather plug and apply a grease until grease overflows from breather plug port After greasing reinstall the breather plug 9Y1211167GEG0029US0 1 Grease...

Page 49: ...g brake pedal 1 Release the parking brake 2 Slightly depress the brake pedals and measure free travel L at top of pedal stroke 3 If the measurement is not within the factory specifications loosen the...

Page 50: ...t If the cover is improperly fitted evacuator valve will not function and dust will adhere to the element Do not touch the secondary element except in cases where replacing is required Evacuator Valve...

Page 51: ...he belt falls within the factory specifications 4 Replace fan belt if it is damaged 9Y1211167GEG0035US0 Checking Fuel Line 1 Check to see that all line and hose clamp are tight and not damaged 2 If ho...

Page 52: ...water immediately and get medical attention Keep open sparks and flames away from the battery at all times Hydrogen gas mixed with oxygen becomes very explosive Wear eye protection and rubber gloves...

Page 53: ...ashion 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 recharge the battery as ea...

Page 54: ...k nut and adjust the parking brake cable length with in acceptable limit 3 Retighten the lock nut 9Y1211167GEG0038US0 5 CHECK POINTS OF EVERY 200 HOURS Changing Engine Oil 1 See page G 21 9Y1211167GEG...

Page 55: ...on at Overheating Take the following actions in the event the coolant temperature be nearly or more than the boiling point what is called Overheating 1 Stop the machine operation in a safe place and k...

Page 56: ...nut 2 and turn the tie rod joint 3 to adjust the tie rod length until the proper toe in measurement is obtained 3 Retighten the tie rod nut 2 4 Attach the snap ring 1 of the tie rod joint IMPORTANT A...

Page 57: ...ust the belt tension 4 If belt is damaged replace it 9Y1211167GEG0046US0 Cleaning Inner Air Filter 1 Remove the inner filter and blow air from the direction opposite to the filter s normal air flow 2...

Page 58: ...se gasoline thinner or similar chemicals to clean the filter as damage to the filter may occur If may also cause an unpleasant odor in the CABIN when the system is used next Do not hit the filter If t...

Page 59: ...tick Refer to 4 LUBRICANTS FUEL AND COOLANT on page G 10 8 After running the engine for a few minutes stop the engine and check the oil level again add oil to the prescribed level 9 Make sure that the...

Page 60: ...evel check port 7 Reinstall and tighten the oil level check plug 1 and filling 2 9Y1211167GEG0052US0 7 CHECK POINT OF EVERY 600 HOURS Adjust Front Axle Pivot 1 Loosen the lock nut 2 tighten the adjust...

Page 61: ...ent 1 Replace the both primary and secondary elements Refer to Cleaning Air Cleaner Primary Element See page G 28 9Y1211167GEG0058US0 Checking Air Conditioner Pipes and Hoses 1 Check to see that all l...

Page 62: ...ng HST Oil Line 1 Replace the hoses and clamps Refer to Checking HST Oil Line and Power Steering Line See page G 34 9Y1211167GEG0064US0 Replacing Power Steering Hose 1 Replace the hoses and clamps Ref...

Page 63: ...add coolant if necessary NOTE On cabin type machines coolant circulates through the heater This means that one more liter or so of coolant is required In changing coolant pour coolant up to the filte...

Page 64: ...the same mixture percentage 6 When the LLC is mixed do not employ any radiator cleaning agent The LLC contains anticorrosive agent If mixed with the cleaning agent sludge may build up adversely affec...

Page 65: ...the engine 4 Close the air vent shutoff valve IMPORTANT Always close the air vent shutoff valve except for bleeding fuel lines Otherwise engine runs irregularly or stalls frequently 9Y1211167GEG0070US...

Page 66: ...damage to the tractor electrical system Refer to troubleshooting section of this manual If any of them should blow replace with a new one of the same capacity Protected Circuit 9Y1211167GEG0072US0 Fu...

Page 67: ...G0074US0 Adding Washer Liquid 1 Add a proper amount of automobile washer liquid 9Y1211167GEG0075US0 Light Capacity Head lights 45 W 40 W Tail light 10 W Hazard and Turn signal light rear 21 W Hazard a...

Page 68: ...amount of refrigerant is extremely low inspect and charge Refer to 10 CABIN service section Checking Procedure 1 Run the air conditioner in the following conditions Engine speed About 1500 min 1 rpm...

Page 69: ...GEG0012US0 Piston Ring Tool Code No 07909 32121 Application Use exclusively to remove or install the piston ring with ease WSM000001GEG0013US0 Diesel Engine Compression Tester for Injection Nozzle Cod...

Page 70: ...pressure and leaks from cooling system Remarks Adaptor 1 BANZAI Code No RCT 2A 30S WSM000001GEG0017US0 Connecting Rod Alignment Tool Code No 07909 31661 Application Use to check the connecting rod ali...

Page 71: ...C 129 mm 5 08 in 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...

Page 72: ...7909 31371 Application Use to check cracks on cylinder head cylinder block etc WSM000001GEG0023US0 A 217 mm 8 54 in B 140 mm 5 51 in C 49 mm 1 9 in D 44 mm 1 7 in E 20 mm Hole 0 79 in Hole F 30 mm 1 2...

Page 73: ...on Use to fix the crankshaft sleeve of the diesel engine To be continued A 100 mm 3 94 in B 25 0 mm 0 98 in C 27 0 mm 1 06 in D 45 0 mm dia 1 77 in dia E 35 0 mm dia 1 38 in dia F 62 5 mm dia 2 46 in...

Page 74: ...o 3 1437 in dia V 10 0 mm 0 3937 in W 0 04 mm dia 0 0016 in dia X 140 mm 5 5118 in Y 120 mm 4 7244 in Z 110 mm 4 3307 in a 50 0 mm 1 9685 in b 39 9 to 40 0 mm 1 5709 to 1 5748 in c 25 0 mm 0 9843 in d...

Page 75: ...1211167GEG0083US0 A 20 mm dia 0 79 in dia B 11 7 to 11 9 mm dia 0 460 to 0 468 in dia C 6 5 to 6 6 mm dia 0 256 to 0 259 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...

Page 76: ...mm dia 0 31 in dia J 1 0 mm 0 039 in K 17 mm dia 0 67 in dia L 6 10 to 6 20 mm dia 0 2402 to 0 2441 in dia M 8 mm 0 31 in N 4 mm 0 16 in O 11 97 to 11 99 mm dia 0 4713 to 0 4721 in dia P PF 1 2 Q 23 m...

Page 77: ...m 0 79 in C 30 mm 1 18 in D 8 mm 0 31 in E 10 mm dia 0 39 in dia A 135 mm 5 31 in B 72 mm 2 83 in C 40 mm radius 1 57 in radius D 10 mm 0 39 in E 20 mm 0 79 in F 20 mm dia 0 79 in dia G 64 8 to 64 9 m...

Page 78: ...r 0 3 mm 0 01 in 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...

Page 79: ...2 in F 35 mm dia 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 94...

Page 80: ...M000001GEG0030US0 Injector CH3 Code No 07916 52501 Application Use to put calcium chloride solution into a rear wheel and to remove it WSM000001GEG0031US0 Clutch Center Tool For B and L Series Tractor...

Page 81: ...on Use for test of the hydraulic system WSM000001GEG0037US0 Power Steering Adaptor Code No 07916 54021 Application Use to measure the relief valve setting pressure for power steering WSM000001GEG0038U...

Page 82: ...pplication This allows easy measurement of relief valve setting pressure from the hydraulic coupler This is available with the relief valve setting pressure tester WSM000001GEG0041US0 NOTE The followi...

Page 83: ...G R15 mm R0 59 in H 22 mm 0 87 in I 67 mm 2 6 in J 31 mm 1 2 in K 10 mm 0 39 in 1 Screw M8 P1 25 L50 mm 2 in 2 Screw M14 P1 5 L50 mm 2 in 3 Rocking Restrictor Right Left A 54 7 to 54 9 mm 2 1535 to 2...

Page 84: ...t range and floating range of hydraulic draft control 9Y1211167GEG0094US0 A 1045 mm 41 14 in B 1000 mm 29 37 in C 20 mm dia 0 79 in dia D 30 mm dia 1 18 in dia E 90 mm 3 54 in F 30 mm 1 18 in G 30 mm...

Page 85: ...1 57 in O 7 5 mm dia 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 9173 in Q 3 mm dia 0 18 in dia E 16 mm 0 63 in R 36 mm 1 42 in F 40 mm dia 1 58 in dia S 60 mm 2 36 in G 32 4...

Page 86: ...No DENSO 95046 00130 AC220V DENSO 95046 00140 AC240V Application Use to evacuate the air conditioning system WSM000001GEG0044US0 Adaptor For R134a Code No DENSO 95048 10190 AC220V DENSO 95048 10200 AC...

Page 87: ...ial tool is not provided so make it referring to the figure 9Y1211167GEG0096US0 A 125 mm 4 92 in H 4 52 rad 120 B 40 mm dia 1 57 in dia I Radius 27 mm Radius 1 06 in C Radius 33 mm Radius 1 30 in J Ra...

Page 88: ...ring to the figure 9Y1211167GEG0098US0 Valve Adaptor Application Use for measuring the system pressure of shuttle valve 9Y1211167GEG0099US0 A 12 mm 0 47 in B 35 mm 1 38 in C 7 mm 0 28 in D 0 4 mm 0 01...

Page 89: ...ze A to size R are same size as adaptor 61 9Y1211167GEG0100US0 A 22 mm 0 872 in K 135 mm 5 31 in B 11 mm 0 437 in L 7 mm dia 0 28 in dia C 24 mm dia 0 94 in dia M 8 5 mm dia 0 33 in dia D 18 mm dia 0...

Page 90: ...cessary NOTE Maintain the maximum pressure in front tires if using a front loader or when equipped with a full load of front weights 9Y1211167GEG0101US0 Tire sizes Inflation Pressure Front 11 2 24 4PR...

Page 91: ...en recheck after driving the tractor 200 m 200 yards and thereafter according to service interval Refer to G 23 9Y1211167GEG0102US0 1 Front Wheels Front axle is not adjustable 9Y1211167GEG0103US0 WARN...

Page 92: ...riving the tractor 200 m 200 yards and 10 times of shuttle movement by 5 m 5 yards and thereafter according to service interval 9Y1211167GEG0105US0 Models L3540 II 11 2 24 Farm 1205 mm 47 44 in 1300 m...

Page 93: ...specific gravity is higher than that of water by about 20 Below is an explanation of calcium chloride solution injection IMPORTANT Do not fill the front tires with liquid 9Y1211167GEG0107US0 Preparat...

Page 94: ...0 II WSM G 72 Attaching Injector 1 Lift the rear tires off the ground 2 Turn the tire so that the air valve is at the top 3 Remove the air valve and attach the injector Code No 07916 52501 9Y1211167GE...

Page 95: ...F Solid at 30 C 22 F Approx 1 kg 2 lbs CaCl2 per 4 L 1 gal of water 103 kg 227 lbs 117 kg 258 lbs 153 kg 337 lbs Slush free at 24 C 11 F Solid at 47 C 53 F Approx 1 5 kg 3 5 lbs CaCl2 per 4 L 1 gal of...

Page 96: ...the 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 di...

Page 97: ...1 ENGINE KiSC issued 02 2015 A...

Page 98: ...CONTENTS 1 FEATURES 1 M1 2 EGR EXHAUST GAS RECIRCULATION SYSTEM IF EQUIPPED 1 M2 1 EGR VALVE 1 M3 2 EGR COOLER 1 M3 MECHANISM KiSC issued 02 2015 A...

Page 99: ...These are 03 M series engine In order to meet the strict emission regulations Kubota has adapted the Exhaust Gas Recirculation EGR system on the V2403 M TE3 for L5240 and L5740 9Y1211167ENM0001US0 Tr...

Page 100: ...is used to lower the combustion temperature and efficiently cool EGR gas with the aim of reducing the NOx that is in the exhaust gas of diesel engine 9Y1211167ENM0002US0 1 Boost Compensator 2 Thermo...

Page 101: ...returns the cooled exhaust gas to the engine suction side The EGR cooler 1 has resistance to clogging up compact and efficient tubes 3 internally 9Y1211167ENM0004US0 1 Thermo Valve 2 Diaphragm Cover...

Page 102: ...S22 1 SEPARATING ENGINE FROM TRACTOR 1 S22 6 DISASSEMBLING AND ASSEMBLING 1 S36 1 OUTER PARTS 1 S36 2 EGR VALVE AND EGR COOLER IF EQUIPPED 1 S37 3 CYLINDER HEAD AND VALVES 1 S38 4 TIMING GEARS CAMSHAF...

Page 103: ...Excessive valve clearance Adjust 1 S13 14 Improper valve timing Correct or replace timing gear 1 S47 15 Incorrect injection timing Adjust 1 S17 16 Piston ring and cylinder worn Replace 1 S65 1 S71 17...

Page 104: ...em and guide worn Replace 1 S56 4 Piston ring groove worn Replace the piston 1 S66 5 Oil leaking due to damaged seals or packing Replace Fuel Mixed Into Lubricant Oil 1 Injection pump s plunger worn R...

Page 105: ...d Use the specified fuel G 10 5 Fan belt broken or elongated Change or adjust G 29 6 Radiator net and radiator fin clogged with dust Clean 7 Radiator cap damaged Replace 1 S15 8 Inside of radiator cor...

Page 106: ...lve Guide Clearance O D I D 0 040 to 0 070 mm 0 0016 to 0 0027 in 7 960 to 7 975 mm 0 3134 to 0 3139 in 8 015 to 8 030 mm 0 3156 to 0 3161 in 0 1 mm 0 004 in Valve Face Angle Intake Angle Exhaust 1 0...

Page 107: ...048 to 0 018 in 0 9 mm 0 035 in Camshaft Side Clearance 0 07 to 0 22 mm 0 0028 to 0 0086 in 0 30 mm 0 012 in Balancer Shaft Balancer Model Only Side Clearance 0 07 to 0 22 mm 0 0028 to 0 0086 in 0 30...

Page 108: ...0 0059 in Piston Pin Bore I D 25 000 to 25 013 mm 0 98426 to 0 98476 in 25 050 mm 0 98622 in Piston Pin to Small End Bushing Piston Pin Small End Bushing Clearance O D I D 0 014 to 0 038 mm 0 00056 to...

Page 109: ...nkshaft Sleeve Wear 0 10 mm 0 0039 in Cylinder Bore Standard D1703 M D1803 M V2203 M V2403 M V2403 M T I D 87 000 to 87 022 mm 3 4252 to 3 4260 in 0 15 mm 0 0059 in Cylinder Bore Oversize D1703 M D180...

Page 110: ...lling from 88 to 59 kPa from 0 9 to 0 6 kgf cm2 from 13 to 9 psi Radiator Water Tightness No leaks at 137 kPa 1 4 kgf cm2 20 psi Thermostat Valve Opening Temperature At Beginning Valve Opening Tempera...

Page 111: ...efore T D C Pump Element Fuel Tightness 13 7 MPa 140 kgf cm2 1991 psi Delivery Valve Fuel Tightness 10 seconds or more for pressure falling from 13 7 to 12 8 MPa from 140 to 130 kgf cm2 from 1990 to 1...

Page 112: ...int bolt for delivery pipe 2 Valve side 49 to 68 5 0 to 7 0 37 to 50 Joint bolt for power steering delivery pipe 49 to 68 5 0 to 7 0 37 to 50 Retaining nut for delivery pipe 1 89 to 100 9 0 to 11 65 t...

Page 113: ...to 8 31 Injection pipe retaining nut M12 1 5 25 to 34 2 5 to 3 5 18 to 25 Nozzle holder assembly M20 1 5 49 to 68 5 0 to 7 0 37 to 50 Overflow pipe assembly retaining nut 20 to 24 2 0 to 2 5 15 to 18...

Page 114: ...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 again 9 If the compression...

Page 115: ...5 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 A The piston is at the...

Page 116: ...ssure switch to the specified torque 9Y1211167ENS0007US0 3 COOLING SYSTEM Fan Belt Tension 1 Measure the deflection A depressing the belt halfway between the fan drive pulley and alternator pulley at...

Page 117: ...13 psi and measure the time for the pressure to fall to 59 kPa 0 6 kgf cm2 9 psi 3 If the measurement is less than the factory specification replace the radiator cap 9Y1211167ENS0008US0 Radiator Water...

Page 118: ...perature when the valve opens and leaves the string 3 Continue heating and read the temperature when the valve opens approx 6 mm 0 236 in 4 If the measurement is not within the factory specifications...

Page 119: ...rn the flywheel further and stop turning when the fuel begins to flow over to get the present injection timing 6 The flywheel has mark 1TC and four lines indicating every 0 087 rad 5 of crank angle fr...

Page 120: ...2 Remove the injection pipes and glow plugs 3 Install the injection pump pressure tester to the injection pump 4 Install the injection nozzle 2 jetted with the proper injection pressure to the injecti...

Page 121: ...eel at this position and clock the time taken for the pressure to drop from 13 7 to 12 8 MPa from 140 to 130 kgf cm2 from 1990 to 1850 psi 8 Measure the time needed to decrease the pressure from 13 7...

Page 122: ...o measure the pressure at which fuel begins jetting out from the nozzle 3 If the measurement is not within the factory specifications replace the adjusting washer 1 in the nozzle holder to adjust it R...

Page 123: ...0016US0 Compressor Side 1 Check the inlet pipe 1 1 of the compressor cover 3 to see if there is no air leak 2 Check for loose connections or cracks in the suction side of the intake pipe 3 If any air...

Page 124: ...bottom of the engine and drain the oil completely into the oil pan All the used oil can be drained out easily when the engine is still warm 2 After draining reinstall the drain plug 3 3 Fill with the...

Page 125: ...eater This means that one more liter or so of fresh water is required In changing fresh water pour fresh water up to the filter port of the recovery tank Turn ON the heater shift the temperature contr...

Page 126: ...op it and check the oil level again add the fluid to prescribed level if it is not correct level IMPORTANT Use only KUBOTA SUPER UDT fluid Use of other oils may damage the transmission or hydraulic sy...

Page 127: ...erator sensor 8 is equipped in HST model only 5 Disconnect the heater hoses 3 and then reconnect their hoses to make loop NOTE Put a mark to the each heater hose before disconnecting 6 Disconnect the...

Page 128: ...stay 12 NOTE The bolt mounting the ground cable 11 is different from the others When reassembling Be sure to check and adjust the clutch and brake pedal free travel Refer to 7 CHECK AND MAINTENANCE at...

Page 129: ...e gear shift lever 4 6 Remove the grip for main gear shift lever 6 7 Remove the grip for creep lever 7 8 Remove the grip for PTO speed change lever GST Model 5 Remove the grip for creep lever 7 6 Remo...

Page 130: ...temperature sensor connector 13 When reassembling IMPORTANT In installing the connector of the proportional valve pay attention to the color of the connector to ensure correct installation 9Y1211167C...

Page 131: ...sembling Adjust the front loader cables with the front loader control lever in the locked position Neutral position Lock the position cable at the center of the screw NOTE By using the window on the r...

Page 132: ...play Refer to CHEKING AND ADJUSTING at 5 BRAKES section 9Y1211167CLS0029US0 Remote Control Valve Lever Link If Equipped 1 Remove the snap pins 1 2 Disconnect the remote control valve lever link 2 9Y1...

Page 133: ...steering post cover 2 4 3 Remove the panel cover 2 4 Remove the brake rods 7 and clutch rod 5 5 Remove the universal joint bolt 6 and disconnect the steering joint shaft 1 8 9Y1211167CLS0016US0 1 Mat...

Page 134: ...m tractor body NOTE When lifting the cabin make sure that the cabin does not catch anything When reassembling Be sure to install the washers and mount rubbers etc in their original positions as shown...

Page 135: ...ropeller shaft 1 3 9Y1211167CLS0019US0 Tightening torque Joint bolt for delivery pipe 2 Hydraulic pump side 40 to 49 N m 4 0 to 5 0 kgf m 29 to 36 lbf ft Joint bolt for delivery pipe 2 Valve side 49 t...

Page 136: ...ate 3 4 Remove the fuel tank 2 with fuel tank frame 1 5 Remove the power steering delivery pipe 10 6 Disconnect the power steering return hose 6 7 Remove the fuel filter 8 with fuel filter bracket 7 8...

Page 137: ...OLS at G GENERAL section 5 Lift the engine by the chain at the engine hook 6 Remove the dipstick stay mounting screw and front axle frame mounting screws 7 Separate the front axle frame 4 from engine...

Page 138: ...g Direct the shorter end of the clutch disc boss toward the flywheel Apply molybdenum disulphide Three Bond 1901 or equivalent to the splines of clutch disc boss Install the pressure plate nothing the...

Page 139: ...the EGR valve 1 and A side of thermo valve 4 When connecting the air tube 2 5 to the inlet manifold and B side of thermo valve 4 Replace the gasket with new one 9Y1211167ENS0027US0 EGR Cooler CAUTION...

Page 140: ...S0 Injection Pipes 1 Loosen the screws on the pipe clamps 1 2 Remove the injection pipes 2 When reassembling Blow out dust inside the pipes 9Y1211167ENS0030US0 Tightening torque Cylinder head cover sc...

Page 141: ...seal and copper gasket must be changed when the injection nozzle is removed for cleaning or for service 9Y1211167ENS0032US0 Rocker Arm and Push Rod 1 Remove the rocker arm bracket nuts 2 Remove the ro...

Page 142: ...ng run IMPORTANT To replace the cylinder head gasket 4 in advance make sure the marking 5 of cylinder head gasket in the original engine and replace the same marking as the original cylinder head gask...

Page 143: ...Select the suitable cylinder head gasket refer to the table below 9Y1211167ENS0034US0 Tappets 1 Remove the tappets 1 from the crankcase When reassembling Visually check the contact between tappets and...

Page 144: ...m seal 6 4 Remove the valve 7 When reassembling Wash the valve stem and valve guide hole and apply engine oil sufficiently After installing the valve spring collets lightly tap the stem to assure prop...

Page 145: ...position Replace the hi idling body gasket 5 with a new one Before fitting the stop lever 3 to the gear case install the stop solenoid guide 6 first into position Then attach the stop lever and use it...

Page 146: ...al tool 1 undo the large governor spring 2 from the fork lever 3 4 Using the governor spring hooking special tool 1 undo the small governor spring 4 from the fork lever 3 5 Set the speed control lever...

Page 147: ...ing too long because otherwise it may get deformed permanently Using the governor spring hooking special tool 1 hook the large governor spring 2 onto the fork lever 3 Make sure both the governor sprin...

Page 148: ...ar case gasket Check to see if there are four O rings 1 inside the gear case 2 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...

Page 149: ...rank gear 5 cam gear 3 and balancer gear 4 2 Marks Cam gear 3 and idle gear 2 3 Marks Idle gear 2 and injection pump gear 1 4 Marks Idle gear 2 and balancer gear 7 9Y1211167ENS0043US0 Camshaft for D18...

Page 150: ...rk lever holder mounting screws 2 4 Draw out the fuel camshaft assembly 5 6 and fork lever assembly 3 4 7 at the same time When reassembling After installation check to see that the fork lever 1 3 and...

Page 151: ...o the oil pan as shown in the figure Make sure that the liquid gasket coating surface is free of water dust and oil in order to keep sealing effect Carefully apply the adhesive evenly NOTE Make sure t...

Page 152: ...example 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 compres...

Page 153: ...of 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...

Page 154: ...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 bea...

Page 155: ...ft For V2403 M 1 Remove the main bearing case screw 2 1 2 Turn the crankshaft to set the crank pin of the 4th cylinder to the horizontal directions Right or Left Then draw out all the crankshaft holdi...

Page 156: ...es vary install them in order of markings 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 ma...

Page 157: ...er checking the top clearance be sure to assemble the cylinder head with a new cylinder head gasket 9Y1211167ENS0056US0 Cylinder Head Surface Flatness 1 Clean the cylinder head surface 2 Place a strai...

Page 158: ...909 33102 or valve seat grinder 6 Then correct the cylinder head surface with a surface grinder or replace the cylinder head 9Y1211167ENS0059US0 Clearance between Valve Stem and Valve Guide 1 Remove c...

Page 159: ...ith a hammer during replacement 9Y1211167ENS0061US0 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 t...

Page 160: ...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 9Y1211167ENS0063US0 Valve Lapping 1 Apply compound evenl...

Page 161: ...066US0 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 calculate the...

Page 162: ...appet 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 9Y1211167ENS0069US0 Push rod align...

Page 163: ...ication 0 04150 to 0 1122 mm 0 00164 to 0 004417 in Allowable limit 0 15 mm 0 0059 in Backlash between idle gear and cam gear Factory specification 0 04150 to 0 1154 mm 0 001634 to 0 004543 in Allowab...

Page 164: ...de Clearance for V2203 M and V2403 M 1 Set a dial indicator with tip on the balancer shaft 2 Measure the side clearance by moving the balancer shaft to the front and rear 3 If the measurement exceeds...

Page 165: ...bearing 1 I D Factory specification 43 980 to 44 045 mm 1 7315 to 1 7340 in Oil clearance of balancer shaft journal 2 Factory specification 0 030 to 0 111 mm 0 00119 to 0 00437 in Allowable limit 0 20...

Page 166: ...nment 4 If the measurement exceeds the allowable limit replace the camshaft 9Y1211167ENS0077US0 Cam Height 1 Measure the height of the cam at its highest point with an outside micrometer 2 If the meas...

Page 167: ...an inside micrometer and calculate the oil clearance 3 If the oil clearance is more than the allowable limit replace the bushing If it stays more than the allowable limit replace the piston pin 9Y121...

Page 168: ...the clearance between the ring and the groove with a feeler gauge or depth gauge 3 If the clearance exceeds allowable limit replace the ring since compression leak and oil shortage result 4 If the cl...

Page 169: ...ournal wear replace it with an oversize one referring to the table and figure Reference Oversize dimensions of crankshaft journal 9Y1211167ENS0086US0 Crankshaft Alignment 1 Support the crankshaft with...

Page 170: ...ting rod screws are tightened Reference Undersize dimensions of crankpin 9Y1211167ENS0088US0 Oil clearance between crankpin and crankpin bearing Factory specification 0 025 to 0 087 mm 0 00099 to 0 00...

Page 171: ...w bearing 1 2 so that its seam 1 directs toward the exhaust manifold side 9Y1211167ENS0090US0 Oil clearance between crankshaft journal and crankshaft bearing 1 Factory specification 0 0400 to 0 118 mm...

Page 172: ...eeds the allowable limit or when the engine oil leaks replace the crankshaft sleeve 9Y1211167ENS0092US0 Oil clearance between crankshaft and crankshaft bearing 2 Factory specification 0 0400 to 0 104...

Page 173: ...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 maximum and the minimum I D s 3 If the wear exceeds the allowable lim...

Page 174: ...h 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 If the clearance exceeds the factory specifications re...

Page 175: ...2 CLUTCH KiSC issued 02 2015 A...

Page 176: ...CONTENTS 1 FEATURE 2 M1 MECHANISM KiSC issued 02 2015 A...

Page 177: ...d the pedal 5 and release fork 3 have been linked as shown in figure 9Y1211167CLM0001US0 1 Clutch Disc 2 Pressure Plate Assembly 3 Release Fork 4 Clutch Pedal Rod 5 Clutch Pedal 6 Release Bearing 7 Re...

Page 178: ...ERVICING SPECIFICATIONS 2 S3 3 TIGHTENING TORQUES 2 S4 4 CHECKING AND ADJUSTING 2 S5 5 PREPARATION 2 S6 1 SEPARATING CLUTCH HOUSING AND ENGINE 2 S6 6 DISASSEMBLING AND ASSEMBLING 2 S18 7 SERVICING 2 S...

Page 179: ...warped Replace 2 S20 5 Diaphragm spring weaken or broken Replace 2 S19 Chattering 1 Grease or oil on clutch disc facing Replace 2 S18 2 Clutch disc or pressure plate warped Replace 2 S20 3 Clutch disc...

Page 180: ...2 S2 9Y1211167CLS0001US0 Vibration 1 Main shaft bent Replace 3 S53 3 S72 3 S99 2 Clutch disc rivet worn or broken Replace 2 S19 3 Clutch parts broken Replace 2 S18 Symptom Probable Cause and Checking...

Page 181: ...tion Allowable Limit Clutch Pedal Free travel 20 to 30 mm 0 78 to 1 18 in Clutch Disc Boss to Gear Shaft Backlash Displacement Around Disc Edge 2 0 mm 0 079 in Clutch Disc Disc Surface to Rivet Top De...

Page 182: ...ing screw 3 5 to 4 0 0 36 to 0 40 2 6 to 2 9 Cabin mounting bolt and nut 124 to 147 12 6 to 15 0 91 2 to 108 Joint bolt for delivery pipe 2 Hydraulic pump side 40 to 49 4 0 to 5 0 29 to 36 Joint bolt...

Page 183: ...lutch pedal and measure free travel L at top of clutch pedal 2 If the measurement is not within the factory specifications loosen the lock nut 2 remove the clevis pin 3 adjust the length of rod 1 with...

Page 184: ...engine for few minutes stop it and check the oil level again add the fluid to prescribed level if it is not correct level IMPORTANT Use only KUBOTA SUPER UDT fluid Use of other oils may damage the tr...

Page 185: ...eater This means that one more liter or so of fresh water is required In changing fresh water pour fresh water up to the filter port of the recovery tank Turn ON the heater shift the temperature contr...

Page 186: ...rator sensor 8 is equipped in HST model only 5 Disconnect the heater hoses 3 and then reconnect their hoses to make loop NOTE Put a mark to the each heater hose before disconnecting 6 Disconnect the w...

Page 187: ...stay 12 NOTE The bolt mounting the ground cable 11 is different from the others When reassembling Be sure to check and adjust the clutch and brake pedal free travel Refer to 7 CHECK AND MAINTENANCE at...

Page 188: ...e gear shift lever 4 6 Remove the grip for main gear shift lever 6 7 Remove the grip for creep lever 7 8 Remove the grip for PTO speed change lever GST Model 5 Remove the grip for creep lever 7 6 Remo...

Page 189: ...temperature sensor connector 13 When reassembling IMPORTANT In installing the connector of the proportional valve pay attention to the color of the connector to ensure correct installation 9Y1211167C...

Page 190: ...sembling Adjust the front loader cables with the front loader control lever in the locked position Neutral position Lock the position cable at the center of the screw NOTE By using the window on the r...

Page 191: ...play Refer to CHEKING AND ADJUSTING at 5 BRAKES section 9Y1211167CLS0029US0 Remote Control Valve Lever Link If Equipped 1 Remove the snap pins 1 2 Disconnect the remote control valve lever link 2 9Y1...

Page 192: ...steering post cover 2 4 3 Remove the panel cover 2 4 Remove the brake rods 7 and clutch rod 5 5 Remove the universal joint bolt 6 and disconnect the steering joint shaft 1 8 9Y1211167CLS0016US0 1 Mat...

Page 193: ...m tractor body NOTE When lifting the cabin make sure that the cabin does not catch anything When reassembling Be sure to install the washers and mount rubbers etc in their original positions as shown...

Page 194: ...ropeller shaft 1 3 9Y1211167CLS0019US0 Tightening torque Joint bolt for delivery pipe 2 Hydraulic pump side 40 to 49 N m 4 0 to 5 0 kgf m 29 to 36 lbf ft Joint bolt for delivery pipe 2 Valve side 49 t...

Page 195: ...housing mounting screws and nuts 3 Separate the engine and clutch housing When reassembling Apply grease to the spline of clutch shaft Apply liquid gasket Three Bond 1206D or equivalent to joint face...

Page 196: ...sc facing 9Y1211167CLS0021US0 Release Hub and Clutch Lever 1 Draw out the clutch release hub 7 and the release bearing 5 as a unit 2 Remove the release fork setting screws 4 and fork keys 2 3 Draw out...

Page 197: ...e disc In this case inspect transmission gear shaft oil seal engine rear oil seal and other points for oil leakage 9Y1211167CLS0025US0 Checking Pressure Plate Assembly and Flywheel 1 Wash the disassem...

Page 198: ...oints 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 th...

Page 199: ...3 TRANSMISSION KiSC issued 02 2015 A...

Page 200: ...STEM OUTLINE 3 M9 2 POWER TRAIN 3 M10 3 ELECTRICAL CONTROL SYSTEM 3 M11 1 Electrical Control 3 M11 2 Construction and Function of Components 3 M11 4 HYDRAULIC CONTROL SYSTEM 3 M12 1 Hydraulic Circuit...

Page 201: ...L5740 II WSM 3 M1 1 STRUCTURE 1 MANUAL TRANSMISSION MODEL 1 Main Gear Shift Section 2 PTO Clutch Section 3 Shuttle Shift Section 4 Range Gear Creep Gear Shift Section 5 Front Wheel Drive Shift Sectio...

Page 202: ...II WSM 3 M2 2 GLIDE SHIFT TRANSMISSION GST MODEL 1 Main Gear Shift Section 2 Clutch Pack for GST 3 PTO Clutch Section 4 Hi Lo Shift Shuttle Shift Section 5 Range Gear Shift Creep Gear Shift Section 6...

Page 203: ...L4240 II L5040 II L5240 II L5740 II WSM 3 M3 3 HYDROSTATIC TRANSMISSION HST MODEL 1 Hydrostatic Transmission Section 2 PTO Clutch Section 3 Range Gear Shift Section 4 Front Wheel Drive Shift Section...

Page 204: ...er to shift the shifters and transmits to the counter shaft 3 9Y1211167TRM0005US0 2 Shuttle Shift Section The shuttle shift section is located in the mid case and it uses a single cone type synchromes...

Page 205: ...tion to reduce a travelling speed It is shifted by the creep shift lever to shift the shifter 3 The power train of creep speed is as shown in figure 9Y1211167TRM0008US0 1 Shuttle Gear Shaft 2 Gear for...

Page 206: ...n the differential gear case Two wheel drive or four wheel drive is selected by operating the front wheel drive lever to shift the shifter gear 4 9Y1211167TRM0009US0 1 Spiral Bevel Pinion 2 Gear 3 Fro...

Page 207: ...Shuttle Lever The links are connected from the shift lever 1 to the shift fork 7 as shown in the figure When the shift lever 1 is moved to the F side the shift fork 7 is moved toward the F side allowi...

Page 208: ...rk 2 is also moved to the A side then the front wheel drive is Engaged When the shift lever 1 is moved to the B side the front wheel drive is Disengaged 9Y1211167TRM0013US0 5 Creep Gear Shift Lever Th...

Page 209: ...ion the movement and gear shifting according to the oil temperature and the traveling speed can be achieved by having electronically controlled the GST system and a smoother operation can be done More...

Page 210: ...ft pattern input to the electric control unit ECU The shift pattern is shown in the table below Front wheel drive section is basically similar to manual transmission model Forward shift pattern Revers...

Page 211: ...ed engine speed and oil temperature from various sensors and pressure in the hydraulic clutch is raised according to the respective condition NOTE By means of speed increasing speed decreasing traveli...

Page 212: ...Main Range Shift 13 3 4 Shift Piston 14 Solenoid Valve 4 15 1 2 Shift Piston 16 Solenoid Valve 2 17 Shift Piston Sub range Shift 18 Shift Check Valve Main Range Shift 19 3 4 Shift Check Valve 20 1 2...

Page 213: ...tch valve 24 is actuated And oil flows through the low pass valve 25 and the proportional reducing valve 26 to the GST clutch 27 This oil flows until becoming the compound pressure which is both of se...

Page 214: ...sure in the GST system circuit to 2 45 MPa 25 0 kgf cm2 356 psi The oil from the power steering pump passes through the regulating valve 3 and check valve 4 and then it flows to power steering circuit...

Page 215: ...ng operation When the solenoid is not excited oil from regulating valve flows to the shift piston through the surrounding of the ball 10 in the valve When the solenoid is excited plunger 9 presses the...

Page 216: ...h are connected to each shift rod and shift the gear There are neutral positions in 1 2 shift piston 2 and 3 4 shift piston 1 9Y1211167TRM0024US0 1 3 4 Shift Piston 2 1 2 Shift Piston 3 Main Range Shi...

Page 217: ...2 shift check valve 6 and 3 4 shift check valve 5 compose a serial circuit When either valve is closed the oil in the pilot circuit will not be drained into the tank In case of the shuttle shifting t...

Page 218: ...ary to flow oil to the GST clutch quickly It is the low pass valve that does this operation with the proportional reducing valve 10 simultaneously The oil from the regulating valve flows in from the I...

Page 219: ...microcomputer of ECU calculates and judges the charging of pressure and its time according to the oil temperature sensor and gear shifting period and the traveling speed and speed acceleration accordi...

Page 220: ...rt flows out from the D port and flows to the GST clutch 6 When the pilot circuit pressure is zero that is from the start to the left with the spring 3 to cut the oil flow of B and C port and stopping...

Page 221: ...are neutral position between from start to end of the gear shifting The oil of the GST clutch 1 is pushed out with return spring 9 and piston 6 and flowed to the tank 9Y1211167TRM0029US0 5 FRONT WHEEL...

Page 222: ...As a result the HST pedal feels extremely light and smoother pedal operation can be done HST assembly chiefly consists of HST case clutch housing variable displacement piston pump variable displaceme...

Page 223: ...Pump 11 Piston Hi 12 Cylinder Block Motor 13 Output Shaft Motor Shaft 14 Piston Motor 15 Hi Lo Solenoid Valve 16 Variable Swashplate Motor 17 Piston Lo 18 Variable Swashplate Pump 19 Check and High P...

Page 224: ...gh the spool pressure selector and flows to the piston H 9 Oil from the hydraulic pump is fed to the c port of the regulator valve The regulator valve sets the pressure of the PTO valve and proportion...

Page 225: ...8200 for the operation of the servomechanism that is the operation of servo piston Valves Check and high pressure relief As for the mechanism and function of valve charge relief valve and case relief...

Page 226: ...by the regulator valve and sent to the PTO valve power steering controller and proportional control valve respectively 9Y1211167TRM0038US0 1 Pump Swashplate 2 Pump Piston 3 Pump Cylinder Block 4 HST...

Page 227: ...tion of the pedal 9Y1211167TRM0039US0 1 Pump Swashplate 2 Pump Piston 3 Pump Cylinder Block 4 HST Filter 5 Charge Pump 6 Check and High Pressure Relief Valve 7 Charge Relief Valve 8 Motor Cylinder Blo...

Page 228: ...otion of the pedal 9Y1211167TRM0040US0 1 Pump Swashplate 2 Pump Piston 3 Pump Cylinder Block 4 HST Filter 5 Charge Pump 6 Check and High Pressure Relief Valve 7 Charge Relief Valve 8 Motor Cylinder Bl...

Page 229: ...Cylinder Block 9 Motor Piston 10 Motor Swashplate 11 Out Put Shaft Motor Shaft 12 Piston H 13 Piston L 14 Hi Lo Spool 15 Spool Pressure Selector 16 Hi Lo Solenoid Valve 17 Oil Cooler 18 Power Steerin...

Page 230: ...ough the two speed change spool to the pistons on the Hi side and the angle of the swashplate on the motor side is changed as shown in the drawing the inclination angle becomes smaller As a result the...

Page 231: ...Valve 8 Motor Cylinder Block 9 Motor Piston 10 Motor Swashplate 11 Out Put Shaft Motor Shaft 12 Piston H 13 Piston L 14 Hi Lo Spool 15 Spool Pressure Selector 16 Hi Lo Solenoid Valve 17 Oil Cooler 18...

Page 232: ...wo speed change spool to the piston on the Lo side and the angle of the swashplate on the motor side is changed as shown in the drawing The inclination angle becomes larger As a result the revolving s...

Page 233: ...Relief Valve 8 Motor Cylinder Block 9 Motor Piston 10 Motor Swashplate 11 Out Put Shaft Motor Shaft 12 Piston H 13 Piston L 14 Hi Lo Spool 15 Spool Pressure Selector 16 Hi Lo Solenoid Valve 17 Oil Co...

Page 234: ...upply from the regulator by the proportional control valve the servo piston is moved toward the neutral direction As a result the swashplate on the pump side moves toward the neutral direction This de...

Page 235: ...e Pump 6 Check and High Pressure Relief Valve 7 Charge Relief Valve 8 Motor Cylinder Block 9 Motor Piston 10 Motor Swashplate 11 Out Put Shaft Motor Shaft 12 Piston H 13 Piston L 14 Hi Lo Spool 15 Spo...

Page 236: ...oads applied on the engine are controlled by returning the swashplate on the pump side toward the neutral side When the loads cannot be controlled just by returning the swashplate on the pump side tow...

Page 237: ...mp 6 Check and High Pressure Relief Valve 7 Charge Relief Valve 8 Motor Cylinder Block 9 Motor Piston 10 Motor Swashplate 11 Out Put Shaft Motor Shaft 12 Piston H 13 Piston L 14 Hi Lo Spool 15 Spool P...

Page 238: ...swashplate on the pump side returns to its original position before speed reduction 5 The position of the swashplate on the motor side is also automatically changed toward the Hi side The pump and mot...

Page 239: ...ocated in the differential gear case 2 wheel drive or 4 wheel drive is selected by operating the front wheel drive lever to shift the shifter gear 6 9Y1211167TRM0048US0 1 Counter Shaft 2 Gear for L 3...

Page 240: ...ft linkage mechanism of Front Wheel Drive Lever refer to page 9Y1211167TRM0049US0 1 Range Gear Shift Lever The links are connected from the shift lever 3 to the shift fork 1 as shown in figure 9Y12111...

Page 241: ...pin 10 As a result when the HST pedal 8 is operated engine speed is increased and decreased in response to the operation of the HST neutral holder arm 6 When the ATA lever 3 is changed from ON to OFF...

Page 242: ...ssion Model GST Model HST Model 9Y1211167TRM0052US0 1 PTO Gear Shaft 1 2 PTO Gear Shaft 2 3 PTO Clutch Pack 4 PTO Counter Shaft 5 PTO Drive Shaft 6 PTO Shaft 7 Output Shaft Motor Shaft 8 PTO Gear Shaf...

Page 243: ...is stopped by PTO solenoid valve 6 When PTO switch is at ON position the oil flows PTO clutch through the PTO solenoid valve and PTO clutch is engaged 9Y1211167TRM0053US0 1 Transmission Case 2 Oil Fil...

Page 244: ...the figure When the PTO speed change lever 1 is moved to L side the shift fork 4 is moved to the L side by means of the rod 2 to the Lo speed side When the PTO speed change lever 1 is moved to the H s...

Page 245: ...Hydraulic Checking and Adjusting 3 S36 5 PREPARATION 3 S40 1 DISMOUNTING CABIN FROM TRACTOR 3 S40 6 DISASSEMBLING AND ASSEMBLING 3 S50 1 MANUAL TRANSMISSION MODEL 3 S50 1 Clutch Housing 3 S50 2 Mid Ca...

Page 246: ...ifferential Gears 3 S120 5 GST Clutch 3 S120 3 HYDROSTATIC TRANSMISSION HST MODEL 3 S122 1 Bearing Gear and Shaft 3 S122 2 PTO Clutch 3 S122 3 Differential Gears 3 S122 4 HST 3 S122 KiSC issued 02 201...

Page 247: ...roper backlash between spiral bevel pinion and spiral bevel gear Adjust 3 S116 9 Improper backlash between differential pinion and differential side gear Adjust 3 S119 Gear Slip Out of Mesh 1 Interloc...

Page 248: ...urn 1 Differential lock pedal return spring weaken or damaged Replace 2 Differential lock shifter pin bent or damaged Replace 3 S64 3 S85 3 S109 3 Differential lock fork shaft bent Replace 3 S64 3 S85...

Page 249: ...TRANSMISSION L3540 II L4240 II L5040 II L5240 II L5740 II WSM 3 S3 2 MANUAL TRANSMISSION MODEL Electrical Diagnosis by Electrical Instrument Panel Intelipanel 9Y1211167TRS0002US0 KiSC issued 02 2015 A...

Page 250: ...ause Solution Reference Page Electronic instrument panel memory device has failed Electronic instrument panel memory device failure Replace the electronic instrument panel 9 S36 Communication of the e...

Page 251: ...TRANSMISSION L3540 II L4240 II L5040 II L5240 II L5740 II WSM 3 S5 3 GST SYSTEM Electrical Diagnosis by Electronic Instrument Panel Intellipanel 9Y1211167TRS0004US0 KiSC issued 02 2015 A...

Page 252: ...en ECU and electronic instrument panel at ECU connector 9 S42 Replace ECU 9 S45 ECU memory device has failed ECU memory device failure Replace ECU 9 S45 Input voltage to lever sensor from ECU is faile...

Page 253: ...ecification Valve wire broken or short circuited Proportional reducing valve damaged Check the connector of proportional reducing valve Check the proportional reducing valve resistance at valve or ECU...

Page 254: ...etween solenoid and GND 9 S47 Replace GST valve 3 S70 Solenoid 2 failure At forward or neutral Able to travel at speeds other than 2 9 and 10 Forward or 2 and 6 Reverse Check the wiring connector of s...

Page 255: ...At forward or neutral Able to travel at speeds other than 1 to 6 Forward or 1 to 4 Reverse Check the wiring connector of solenoid Solenoid 6 Main range gear shift failure At reverse Check the resista...

Page 256: ...3 S88 2 Check the filter of proportional reducing valve 3 S93 3 Check the clutch valve 3 S92 4 Check the GST clutch pack 3 S78 7 GST clutch pack damaged Repair or replace GST clutch pack 3 S78 8 Sync...

Page 257: ...TRANSMISSION L3540 II L4240 II L5040 II L5240 II L5740 II WSM 3 S11 4 HST SYSTEM Electrical Diagnosis by Electronic Instrument Panel Intellipanel 9Y1211167TRS0007US0 KiSC issued 02 2015 A...

Page 258: ...9 S45 Check the communication line between ECU and electronic instrument panel at ECU connector 9 S39 9 S45 Replace ECU 9 S45 ECU memory device has failed ECU memory device failure Replace ECU 9 S45 I...

Page 259: ...or short circuited Input line broken Sensor damaged Travel motion is possible Check the sensor connector Check the sensor voltage by Test mode Mode A 9 S22 Check the sensor wire connector voltage or c...

Page 260: ...roken HST response control dial damaged Travel motion is possible The HST response control is fixed in the center Check HST response control dial connector Check HST response control dial voltage by T...

Page 261: ...out of specification Valve wire broken or short circuited Proportional valve damaged Travel motion is possible on the forward only Check the proportional valve by Test mode Mode A 9 S22 Automatic shif...

Page 262: ...r level G 37 2 Charge pressure is too low Solution order 1 Replace oil filter cartridge G 23 2 Check charge pressure 3 S37 3 Inspect or flush charge relief valve 3 S37 3 Check and high pressure relief...

Page 263: ...ridge G 23 3 Replace check and high pressure relief valve 3 S36 4 Inspect and replace charge relief valve 3 S37 5 Check and high pressure relief valve damaged Inspect or replace check and high pressur...

Page 264: ...piston or return plate Replace 3 S114 PTO Shaft Does Not Rotate 1 PTO clutch malfunctioning Repair or replace 3 S114 2 PTO propeller shaft coupling disengaged Engage PTO Clutch Operating Pressure is L...

Page 265: ...Turning Torque 4 0 to 6 3 N m 0 40 to 0 65 kgf m 2 9 to 4 7 lbf ft Spiral Bevel Gear to Spiral Bevel Pinion Shaft Backlash 0 15 to 0 30 mm 0 0059 to 0 012 in 0 4 mm 0 02 in Differential Case Bore Diff...

Page 266: ...1st Shuttle Lever Forward or Reverse Operating Pressure 2 30 to 2 50 MPa 23 5 to 25 5 kgf cm2 334 to 363 psi GST System Pressure Condition Engine Speed Idling Oil Temperature 40 to 60 C 104 to 140 F...

Page 267: ...2 341 to 369 psi Cruise Control Lever Operating Force Forward Direction 14 7 to 29 4 N 1 50 to 2 99 kgf 3 31 to 6 60 lbs Item Factory Specification Allowable Limit PTO Clutch Valve Condition Engine Sp...

Page 268: ...s bolts and nuts on the table below are especially specified For general use screws bolts and nuts Refer to 5 TIGHTENING TORQUES on page G 13 CABIN Item N m kgf m lbf ft Outer roof mounting screw 3 5...

Page 269: ...w 23 5 to 27 4 2 40 to 2 74 17 4 to 20 2 Mid case bearing holder mounting screw 48 to 55 4 9 to 5 7 36 to 41 Rear wheel mounting screw and nut 220 22 160 Brake case mounting screw and nut 78 to 90 7 9...

Page 270: ...m N m kgf m lbf ft Joint bolt for power steering delivery pipe 39 to 49 4 0 to 4 9 29 to 36 Joint bolt for main delivery pipe 2 39 to 49 4 0 to 4 9 29 to 36 Joint bolt for oil cooler 88 to 98 9 0 to 9...

Page 271: ...O clutch system 6 If the measurement is not within the factory specifications measure the system pressure and adjust the system pressure with regulator valve 4 if necessary Condition Engine speed Maxi...

Page 272: ...ch to ON position 3 The Mode Selection Display a is indicated on the LCD 1 And release the switches 4 Press the display mode switch 2 to move the flashing part and flash the E 5 Hold down the display...

Page 273: ...P 04 f Operate the speed selection lever GST lever as follows disengaged the clutch select forward with the shuttle lever and shift the GST lever from 1 to 12 several times Set the GST lever at the po...

Page 274: ...section 9 3 SHOCK is displayed b first and then the numerical code setting is displayed c The number 9 through 9 can be displayed This has been factory adjusted to 0 4 Setting For lighter shifting sho...

Page 275: ...ng speed Set the shift levers to Neutral 5 Measure the pressure 6 If the measurement is not within factory specifications adjust the pressure reducing valve adjustor 4 on the regulating valve assembly...

Page 276: ...the pilot pressure checking port plug PT 1 8 on the GST valve 2 3 Install the adaptor D or GST valve adaptor 3 to the checking port 1 and then install the threaded joint cable and pressure gauge 4 Sta...

Page 277: ...nd clutch pack 8 Check the pressure changes while shifting the shuttle shift lever Reverse to Forward and shifting the GST lever from Neutral to 12th or 8th 9 If the pressure does not change correctly...

Page 278: ...witch 2 to move the flashing part and flash the I 5 Hold down the display mode switch 2 for more than 2 seconds at this condition and the buzzer rings and Mode I is selected 6 MHG is displayed b and t...

Page 279: ...ling speed 2 Select mode K 3 Hold down the display mode switch for more than 2 seconds 4 HST ADJ b is displayed and release the switch NOTE When indication HST ADJ does not change the engine is not id...

Page 280: ...reverse position 10 STEP 04 is displayed h After completing the above 9 STEP 04 is displayed Then proceed to the next step NOTE When ERROR xx m refers to the below chart 11 PUSH SW is displayed i Hol...

Page 281: ...ing ERROR 75 is displayed h indicated errors as follows The accelerator lever is not in the position of idling The accelerator lever is out of position 5 PUSH SW is displayed c Hold down the displayed...

Page 282: ...eaded joint in order 5 Run the engine at rated speed 6 Place the range gear shift lever in H position 7 Release the parking brake lever 8 Depress the brake pedal 9 Depress the HST pedal and measure th...

Page 283: ...engine at rated speed 7 Release the HST pedal to set in neutral and measure the charge pressure 8 If the measurement is not within the factory specifications check charge relief valve or adjust with a...

Page 284: ...Lift up the entire steps as shown below so that the piston can be adjusted 7 If any of the servo piston parts has been replaced readjust the HST neutral position referring to the dimension A of the s...

Page 285: ...rely 9Y1211167TRS0032US0 HST Pedal NOTE When removing the HST pedal do the following adjustment 1 Adjust the rod length L so that the face of the HST pedal A becomes horizontal 2 After adjusting the H...

Page 286: ...e engine for few minutes stop it and check the oil level again add the fluid to prescribed level if it is not correct level IMPORTANT Use only KUBOTA SUPER UDT fluid Use of other oils may damage the t...

Page 287: ...e heater This means that one more liter or so of fresh water is required In changing fresh water pour fresh water up to the filter port of the recovery tank Turn ON the heater shift the temperature co...

Page 288: ...celerator sensor 8 is equipped in HST model only 5 Disconnect the heater hoses 3 and then reconnect their hoses to make loop NOTE Put a mark to the each heater hose before disconnecting 6 Disconnect t...

Page 289: ...ss stay 12 NOTE The bolt mounting the ground cable 11 is different from the others When reassembling Be sure to check and adjust the clutch and brake pedal free travel Refer to 7 CHECK AND MAINTENANCE...

Page 290: ...ange gear shift lever 4 6 Remove the grip for main gear shift lever 6 7 Remove the grip for creep lever 7 8 Remove the grip for PTO speed change lever GST Model 5 Remove the grip for creep lever 7 6 R...

Page 291: ...oil temperature sensor connector 13 When reassembling IMPORTANT In installing the connector of the proportional valve pay attention to the color of the connector to ensure correct installation 9Y12111...

Page 292: ...eassembling Adjust the front loader cables with the front loader control lever in the locked position Neutral position Lock the position cable at the center of the screw NOTE By using the window on th...

Page 293: ...ree play Refer to CHEKING AND ADJUSTING at 5 BRAKES section 9Y1211167CLS0029US0 Remote Control Valve Lever Link If Equipped 1 Remove the snap pins 1 2 Disconnect the remote control valve lever link 2...

Page 294: ...he steering post cover 2 4 3 Remove the panel cover 2 4 Remove the brake rods 7 and clutch rod 5 5 Remove the universal joint bolt 6 and disconnect the steering joint shaft 1 8 9Y1211167CLS0016US0 1 M...

Page 295: ...from tractor body NOTE When lifting the cabin make sure that the cabin does not catch anything When reassembling Be sure to install the washers and mount rubbers etc in their original positions as sho...

Page 296: ...clutch shaft Apply liquid gasket Three Bond 1211 or equivalent to joint face of the flywheel housing and clutch housing 9Y1211167TRS0035US0 Tightening torque Joint bolt for delivery pipe 118 to 137 N...

Page 297: ...pins 3 of main shift rod 1 4 3 Remove the shuttle shift arm stopper mounting screw and then pull the shuttle shift shaft 2 with shuttle shift arm 6 up When reassembling Tap in the spring pins 3 so tha...

Page 298: ...S0039US0 Shaft Case 1 Remove the shaft case mounting screws 2 Screw down the two M6 jack bolts 1 into the shaft case 2 and pull it out 3 Remove the shaft case 2 When reassembling Apply liquid gasket T...

Page 299: ...tch housing bearing holder 5 with using two jack bolts 6 NOTE Be careful not to fly out the detent balls 3 and springs 4 when pull out the bearing holder 5 When reassembling Tap in the clutch housing...

Page 300: ...install the synchronizer keys 9 in the key grooves of the synchronizer rings 6 firmly 9Y1211167TRS0044US0 1 External Snap Ring 2 Collar 3 Counter Shaft Assembly 4 Shift Rods 5 18T Gear Shaft Assembly...

Page 301: ...ng their mounting screws When reassembling Make sure to insert the PTO shaft to PTO clutch firmly turning the PTO shaft Apply liquid gasket Three Bond 1208C or equivalent to joint face of the mid case...

Page 302: ...ve the PTO clutch valve 2 as a unit 2 Pull out the pipe 1 When reassembling Apply small amount of grease for the O ring 3 Install the pipe 1 to the hole 4 of the PTO clutch valve 2 firmly Replace the...

Page 303: ...ernal snap ring 7 and remove the hub 10 with shifter 9 and synchronizer ring 5 5 Remove the 22T gear 4 When reassembling Apply enough transmission fluid to the needle bearings 3 and thrust collar 13 D...

Page 304: ...rubbers 11 portion 08 the clutch plates 6 are same positions while assemble them Apply the enough transmission fluid to the clutch discs 5 Make sure the moving of the piston 10 smoothly when pressure...

Page 305: ...the hand made jig Refer to the figure left 2 Remove the external snap ring 1 washer 2 and spring 3 3 Draw out the piston 4 4 Draw out the ring 5 outer ring 6 brake plate 7 and brake disc 8 When reasse...

Page 306: ...the PTO shaft cover 2 2 Remove the drawbar frame 3 3 Remove the main gear shift lever 4 range gear shift lever 5 and four wheel drive lever 6 4 Disconnect the brake rods 7 When reassembling 9Y1211167...

Page 307: ...f the differential case and cover 2 9Y1211167TRS0061US0 Rear Axle 1 Separate the rear axle case from brake case When reassembling Apply liquid gasket Three Bond 1208C or equivalent to joint face of th...

Page 308: ...e Bond 1208C or equivalent to joint face of the mid case and transmission case 9Y1211167TRS0064US0 Pinion Bearing Cover 1 Remove the stake of lock nut 5 2 Lock the turning of spiral bevel pinion and r...

Page 309: ...p in the spring pin 8 so that its split portion may face forward Refer to figure 9Y1211167TRS0066US0 Shaft Assemblies 1 Remove the traveling speed sensor 1 2 Remove the spiral bevel pinion shaft assem...

Page 310: ...pin 3 from the top and install the washer and cotter pin Tap in the spring pin 4 so that its split portion a may face outward as shown in the figure 9Y1211167TRS0069US0 1 20T 49T Gear 2 Range Gear Sha...

Page 311: ...bly noting the number of right shims When reassembling Check the spiral bevel gear for wear or damage If it is no longer serviceable replace it Then also replace the spiral bevel pinion Use same numbe...

Page 312: ...t 1 and remove the differential pinion 2 and differential pinion washer NOTE Arrange the parts to know their original position When reassembling Check the differential pinions 2 and 3 and pinion shaft...

Page 313: ...d differential side gear washer 1 When reassembling Check the thrust and bearing surface of both differential side gears 2 If they are worn or damaged bores in the differential case may also be damage...

Page 314: ...Apply liquid gasket Three Bond 1211 or equivalent to joint face of the flywheel housing and clutch housing 9Y1211167TRS0078US0 Tightening torque Joint bolt for delivery pipe 118 to 137 N m 12 0 to 14...

Page 315: ...raw out the clutch 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 7 Be sure to set the snap pins 6 9Y1...

Page 316: ...the GST valve assembly Install the GST valve 5 by hand and then tighten the screws Do not use the hummer Replace the pipe 10 with a new one if damaged 9Y1211167TRS0079US0 Separating Clutch Housing and...

Page 317: ...and pull it out 3 Remove the shaft case 2 When reassembling Apply liquid gasket Three Bond 1208C or equivalent to joint face of the shaft case and clutch housing When replacing oil seal in shaft case...

Page 318: ...lts 3 When reassembling Tap in the clutch housing bearing holder 4 with plastic hammer until contact to clutch housing case and then tighten the screws to specified torque Install the three interlock...

Page 319: ...nt side after assembling the clutch housing and mid case Then install the bearing 13 sleeve 14 collar 15 oil seal 12 internal snap ring 11 O ring 16 and spacer 17 in order 9Y1211167TRS0083US0 1 Extern...

Page 320: ...5 When reassembling Reinstall the synchronizer keys 9 in the key grooves of the synchronizer rings 6 firmly 9Y1211167TRS0084US0 1 Internal Snap Ring 2 Bearing 3 Needle Bearing 4 24T Gear 4th 5 Extern...

Page 321: ...pe 5 with a new one if damaged 9Y1211167TRS0086US0 Separating Mid Case and Transmission Case 1 Separate the mid case and transmission case after removing their mounting screws When reassembling Make s...

Page 322: ...ve the PTO clutch valve 2 as a unit 2 Pull out the pipe 1 When reassembling Apply small amount of grease for the O ring 3 Install the pipe 1 to the hole 4 of the PTO clutch valve 2 firmly Replace the...

Page 323: ...pressure air at 0 29 to 0 39 MPa 3 to 4 kgf cm2 42 to 57 psi is sent to clutch pack Air must be sent from hole A 9Y1211167TRS0089US0 Shaft Assemblies 1 Pull out the sub range shift rod 4 and remove th...

Page 324: ...e the external snap ring 1 while pushing the spring retainer 2 by hand press 2 Remove the spring retainer 2 springs 3 and piston 4 When reassembling Apply small amount of the grease to the seal rings...

Page 325: ...ring 18 and remove the hub 17 with shifter and synchronizer rings When reassembling Direct the groove side of the thrust collars 4 21 to the gear side Reinstall the synchronizer keys in the key groove...

Page 326: ...rive lever 6 4 Disconnect the brake rods 7 When reassembling 9Y1211167TRS0059US0 Tightening torque Joint bolt for delivery pipe 118 to 137 N m 12 0 to 14 0 kgf m 86 8 to 101 lbf ft Front loader pipe r...

Page 327: ...f the differential case and cover 2 9Y1211167TRS0061US0 Rear Axle 1 Separate the rear axle case from brake case When reassembling Apply liquid gasket Three Bond 1208C or equivalent to joint face of th...

Page 328: ...GST valve by hand and then tighten the screws Do not use the hummer Apply liquid gasket Three Bond 1208C or equivalent to joint face of the GST valve assembly Replace the pipe 3 with a new one if dama...

Page 329: ...ing the two shafts 2 4 by copper hammer or soft hammer 4 Jack up more and remove the transmission bearing holder 1 When reassembling Tap in the transmission bearing holder with soft hammer until conta...

Page 330: ...Sensor 2 Front Wheel Drive Shaft 3 PTO Drive Shaft 4 Spiral Bevel Pinion Shaft 5 Range Gear Shaft 6 Shift Fork 1 20T 49T Gear 2 Range Gear Shaft 3 17T Gear 4 Needle Bearing 5 34T Gear L3240 L3540 L42...

Page 331: ...he bearing case mounting screws and draw out the PTO shaft 1 with bearing case 6 3 Remove the internal snap ring 2 4 Top out the PTO shaft 1 to the front When reassembling If the lock nut 7 was remove...

Page 332: ...hose 3 and power steering delivery pipe 4 from regulating valve assembly 2 2 Remove the delivery pipe 1 3 Loosen and remove the regulating valve mounting screws 4 Remove the regulating valve assembly...

Page 333: ...en remove the spring 13 and the poppet 9 5 Remove the spring retainer 5 and spring 10 When reassembling Be careful not to damage the O rings IMPORTANT After reassembling the adjustment of regulating p...

Page 334: ...proportional reducing valve connector 2 solenoid connector 4 and oil temperature sensor connector 5 3 Disconnect the GST delivery pipe 3 4 Remove the GST valve assembly 6 with using two jack bolts NOT...

Page 335: ...positions as shown in the photo and table below 9Y1211167TRS0108US0 No Solenoid Name Color of wiring 6 Shift Solenoid 1 1st shift Black 1 Shift Solenoid 2 2nd shift White 3 Shift Solenoid 3 3rd shift...

Page 336: ...the springs 13 balls 12 and filter 14 from upper body 2 When reassembling Be careful so that only the main range shift check pin 6 is short length 9Y1211167TRS0109US0 Tightening torque Lower body moun...

Page 337: ...piston 4 Remove the internal snap ring 12 and cover 8 and then remove the shift piston 7 11 For main range and sub range shift piston When reassembling Be careful not to damage the O ring 13 and pisto...

Page 338: ...Remove the plug 5 3 Remove the stopper plate 6 and remove the low pass poppet 4 and spring 3 9Y1211167TRS0111US0 Clutch Valve 1 Separate the upper body and lower body 2 Remove the stopper plate 4 whi...

Page 339: ...9Y1211167TRS0113US0 Check Valve Oil Temperature Sensor Orifice and Filter 1 Remove the oil temperature sensor 3 and remove the spring 2 and ball 1 2 Remove the plug 6 and remove the spring 5 and orifi...

Page 340: ...ssembling Apply grease to the spline of clutch shaft Apply liquid gasket Three Bond 1211 or equivalent to joint face of the flywheel housing and clutch housing 9Y1211167TRS0116US0 Tightening torque Jo...

Page 341: ...d case Then install the bearing 12 sleeve 14 collar 13 oil seal 15 internal snap ring O ring 10 and spacer 9 in order Apply grease to the oil seal 11 9Y1211167TRS0117US0 PTO Delivery Pipe and Brake Ro...

Page 342: ...ng screws and nuts 2 Separate the clutch housing and mid case When reassembling Be sure to install the gasket 9Y1211167TRS0119US0 Tightening torque Clutch housing and mid case mounting nut 103 to 117...

Page 343: ...67TRS0121US0 Cylinder Block Assemblies 1 Remove both motor and pump cylinder block 1 2 with pistons 2 Remove the motor swashplate 3 When reassembling Apply clean hydrostatic transmission oil to cylind...

Page 344: ...ere is no necessary 1 Remove the servo piston under cover 2 Remove the servo piston assembly mounting hex socket head screw 3 Push the piston from bottom side slightly and pull out the servo piston as...

Page 345: ...install the gasket 5 When replacing oil seal in shaft case Install the oil seal 7 as shown in the figure noting its direction Apply grease to the oil seal 7 Replace the gasket 5 with a new one 9Y1211...

Page 346: ...w 11 and remove the pressure selector 10 When reassembling Be sure to install direction of the belleville spring 6 Replace the gasket 4 with a new one 9Y1211167TRS0126US0 Tightening torque Hi Lo solen...

Page 347: ...and High Pressure Relief Valve 1 Remove the hex socket head plug 1 and remove the spring 3 and relief valve assembly 4 5 When reassembling Be careful not to damage the O ring on the plug 9Y1211167TRS0...

Page 348: ...clutch firmly turning the PTO shaft Apply liquid gasket Three Bond 1208C or equivalent to joint face of the mid case and transmission case 9Y1211167TRS0130US0 Tightening torque Joint bolt for deliver...

Page 349: ...bling Tap in the mid case bearing holder 2 5 with plastic hummer until contact to mid case and then tighten the screws to specified torque 9Y1211167TRS0132US0 Disassembling PTO Clutch 1 Refer to 2 Mid...

Page 350: ...34US0 Hydraulic Pipes 1 Remove the suction pipe 2 2 Remove the delivery pipes 1 3 Remove the brake rods 3 4 Remove the PTO delivery pipe 4 When reassembling 9Y1211167TRS0135US0 Tightening torque Rear...

Page 351: ...e to the steel ball seats Do not grease excessively Apply liquid gasket Three Bond 1208C or equivalent to joint face of the brake case and transmission case Be sure to apply liquid gasket to A positio...

Page 352: ...the lock nut 5 3 Remove the pinion bearing case mounting screws 4 Remove the pinion bearing cover 4 and shims 1 When reassembling Make sure of the number of shims in the pinion bearing case Replace th...

Page 353: ...smission bearing holder 1 When reassembling Tap in the transmission bearing holder with soft hummer until contact to transmission case and then tighten the screws to specified torque Tap in the spring...

Page 354: ...2 When reassembling Apply transmission fluid to needle bearings 12 9Y1211167TRS0140US0 1 Traveling Speed Sensor 2 Front Wheel Drive Shaft 3 PTO Drive Shaft 4 Spiral Bevel Pinion Shaft 5 Range Gear Sha...

Page 355: ...the bearing case mounting screws and draw out the PTO shaft 1 with bearing case 6 3 Remove the internal snap ring 2 4 Top out the PTO shaft 1 to the front When reassembling If the lock nut 7 was remov...

Page 356: ...lt from regulating valve 8 5 Remove the PTO delivery pipe 7 6 Remove the regulating valve assembly 8 When reassembling IMPORTANT When installing the connector of the proportional valve pay attention t...

Page 357: ...he plugs 12 15 4 Remove the spring retainers 8 21 with balls 7 22 5 Remove the springs 9 20 6 Remove the collar 11 and retainer 8 with ball 7 7 Remove the spools 10 17 When reassembling Be careful not...

Page 358: ...Shift Gear Groove 1 Place for in the groove to check clearance with feeler gauge 2 If the clearance exceeds allowable limit replace 9Y1211167TRS0145US0 Clearance between Gear and Shaft 1 Measure the s...

Page 359: ...he spring for fatigue or wear on the area where the spring contacts with the keys 3 If there is any damage replace them 9Y1211167TRS0149US0 Side Clearance between Synchronizer Ring and Gear In Contact...

Page 360: ...gauge allowable limit size underneath it at least four points 3 If the gauge can be inserted replace it 9Y1211167TRS0153US0 Piston Return Spring Free Length 1 Measure the free length of spring with v...

Page 361: ...the turning torque by using turning torque 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 tur...

Page 362: ...itions equally spaced on the spiral bevel gear 6 Turn the spiral bevel pinion shaft while pressing a wooden piece against the periphery on the spiral bevel gear 7 Check the tooth contact If not proper...

Page 363: ...gear rightward reduce right side shim 5 and add shim 6 of the same thickness as the right side to left side 9Y1211167TRS0159US0 Replace the shim 2 with a thinner one to move the spiral bevel pinion sh...

Page 364: ...mm 0 0020 to 0 00594 in Allowable limit 0 35 mm 0 014 in Differential case bore I D Factory specification 40 500 to 40 550 mm 1 5945 to 1 5964 in Differential side gear boss O D Factory specification...

Page 365: ...the differential pinion to measure the backlash 3 If the measurement is not within the factory specifications adjust with the differential side gear washer Reference Thickness of differential side gea...

Page 366: ...ness is less than the allowable limit replace it 9Y1211167TRS0168US0 Steel Plate Wear 1 Measure the thickness of GST steel plate with vernier calipers 2 If the thickness is less than the allowable lim...

Page 367: ...Thickness of Seal Ring 1 Measure the thickness of seal rings 1 with an outside micrometer 2 If the measurement is less than the allowable limit replace it 9Y1211167TRS0172US0 Piston return spring fre...

Page 368: ...US0 Pump Shaft and Motor Shaft 1 Check the seal surface 4 and the bearing surface 3 2 If the shaft is rough or groove replace it 9Y1211167TRS0177US0 Cylinder Block Bore and Pistons 1 Lift the pistons...

Page 369: ...g coat them with transmission oil Valve plates are not interchangeable 9Y1211167TRS0181US0 Swashplate and Cradle Bearing 1 Check the piston contact face of swashplate 1 for scratched and excessive wea...

Page 370: ...ressure See page Refer to 3 HYDRAULIC TRANSMISSION HST MODEL of 4 CHECKING AND ADJUSTING in this section 9Y1211167TRS0185US0 Servo Piston 1 Check the surface of servo piston for scratches and excessiv...

Page 371: ...4 REAR AXLE KiSC issued 02 2015 A...

Page 372: ...CONTENTS 1 STRUCTURE 4 M1 MECHANISM KiSC issued 02 2015 A...

Page 373: ...ar wheels The rotation speed is reduced by the final gears 9 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...

Page 374: ...5740 II 9Y1211167RAM0002US0 1 Rear Axle Cover 2 Ball Bearing 3 Rear Axle 4 Rear Axle Case 5 Differential Gear Shaft 6 Brake Case 7 Brake Disc 8 Differential Pinion 9 Ring Gear 10 Final Gear 11 Differe...

Page 375: ...CONTENTS 1 TROUBLESHOOTING 4 S1 2 TIGHTENING TORQUES 4 S2 3 PREPARATION 4 S3 4 DISASSEMBLING AND ASSEMBLING 4 S6 SERVICING KiSC issued 02 2015 A...

Page 376: ...erence Page Excessive or Unusual Noise at All Time 1 Insufficient or improper type of transmission fluid used Fill or change G 37 2 Improper backlash between differential gear shaft and final reductio...

Page 377: ...o 23 0 145 to 166 Lift arm mounting pin nut 78 to 90 7 9 to 9 2 58 to 66 Lift arm mounting pin lock nut 63 to 72 6 4 to 7 4 47 to 53 Cabin mounting bolt and nut 128 to 147 13 0 to 15 0 94 1 to 108 Cab...

Page 378: ...nutes stop it and check the oil level again add the fluid to prescribed level if it is not correct level IMPORTANT Use only KUBOTA SUPER UDT fluid Use of other oils may damage the transmission or hydr...

Page 379: ...9Y1211167RAS0004US0 Tightening torque Rear wheel mounting screw and nut 197 to 225 N m 20 0 to 23 0 kgf m 145 to 166 lbf ft Lift arm mounting pin nut 78 to 90 N m 7 9 to 9 2 kgf m 58 to 66 lbf ft Lif...

Page 380: ...g screws and nuts 4 Separate the rear axle case from brake case When reassembling Apply liquid gasket Three Bond 1206C or equivalent to joint face of the rear axle case and brake case 9Y1211167RAS0005...

Page 381: ...hen reassembling 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 direct...

Page 382: ...5 BRAKES KiSC issued 02 2015 A...

Page 383: ...CONTENTS 1 STRUCTURE 5 M1 2 OPERATION 5 M2 MECHANISM KiSC issued 02 2015 A...

Page 384: ...pedals through the mechanical linkages The parking brake is a mechanical type which is designed to actuate the travelling brakes Pulling the parking brake lever 10 results in the same state as that o...

Page 385: ...brake discs are provided respectively and the plate 6 fixed to the brake case are arranged between the brake discs During Braking When the brake pedal is pressed the force causes the brake cam lever...

Page 386: ...SPECIFICATIONS 5 S2 3 TIGHTENING TORQUES 5 S3 4 CHECKING AND ADJUSTING 5 S4 1 BRAKE PEDAL 5 S4 2 PARKING BRAKE LEVER 5 S4 5 DISASSEMBLING AND ASSEMBLING 5 S5 1 BRAKE PEDAL 5 S5 2 BRAKE CASE 5 S7 6 SER...

Page 387: ...c worn Replace 5 S11 3 Cam plate warped Replace 5 S11 Brake Drags 1 Brake pedal play too small Adjust 5 S4 2 Ball holes of cam plate for uneven wear Replace 5 S11 3 Brake cam rusted Replace 5 S9 Poor...

Page 388: ...e Travel 15 to 20 mm 0 59 to 0 78 in Cam Plate Flatness 0 30 mm 0 012 in Cam Plate and Ball Height 20 9 to 21 1 mm 0 823 to 0 830 in 20 5 mm 0 807 in Brake Disc Thickness 4 60 to 4 80 mm 0 181 to 0 18...

Page 389: ...nut 63 to 72 6 4 to 7 4 47 to 53 Cabin mounting bolt and nut 128 to 147 13 0 to 15 0 94 1 to 108 Cabin mount bracket mounting screw 7T 124 to 147 12 6 to 15 0 91 2 to 108 Cabin mount bracket mounting...

Page 390: ...e Play CAUTION Stop the engine and chock the wheels before checking parking brake lever 1 Release the parking brake lever 1 2 Measure the length of L 3 Make sure there is free play in a right and left...

Page 391: ...eter Panel Electronic Instrument Panel 1 Disconnect the hazard switch connector 4 main switch connector 5 and mode switch connector 6 2 Remove the meter panel 1 with panel frame 3 as a unit 9Y1211167B...

Page 392: ...dals 5 8 and springs 6 7 Remove the parking brake lever 1 9Y1211167BRS0008US0 Parking Brake Rod 1 Remove the parking brake rod 2 from the brake cam lever 1 When reassembling Adjust the parking brake f...

Page 393: ...tes stop it and check the oil level again add the fluid to prescribed level if it is not correct level IMPORTANT Use only KUBOTA SUPER UDT fluid Use of other oils may damage the transmission or hydrau...

Page 394: ...9Y1211167RAS0004US0 Tightening torque Rear wheel mounting screw and nut 197 to 225 N m 20 0 to 23 0 kgf m 145 to 166 lbf ft Lift arm mounting pin nut 78 to 90 N m 7 9 to 9 2 kgf m 58 to 66 lbf ft Lift...

Page 395: ...ld be overlapped 50 or more Apply liquid gasket Three Bond 1208C or equivalent to joint face of the brake case and differential gear case Be sure to apply the liquid gasket to a position Apply grease...

Page 396: ...nut and remove the brake cam 2 and brake cam lever 4 When reassembling Apply grease to the O ring 3 and be careful not damage the O ring 9Y1211167BRS0011US0 Tightening torque Brake cam lever mounting...

Page 397: ...replace the cam plate and balls 3 Inspect the ball holes of cam plate for uneven wear If the uneven wear is found replace it 9Y1211167BRS0014US0 Brake Disc Wear 1 Measure the brake disc thickness with...

Page 398: ...6 FRONT AXLE KiSC issued 02 2015 A...

Page 399: ...CONTENTS 1 STRUCTURE 6 M1 1 4WD TYPE 6 M1 MECHANISM KiSC issued 02 2015 A...

Page 400: ...gear case 6 The revolution is greatly reduced by the bevel gears 23 4 then the power is transmitted to the axle 1 The differential system allows each wheel to rotate at a different speed to make turni...

Page 401: ...se Support 7 Bevel Gear 8 Bevel Gear Case 9 Differential Side Gear 10 Differential Pinion 11 Pinion Shaft 12 Collar 13 Front Axle Bracket Front 14 Spiral Bevel Gear 15 Spiral Bevel Pinion Shaft 16 Fro...

Page 402: ...CATIONS 6 S2 3 TIGHTENING TORQUES 6 S4 4 CHECKING AND ADJUSTING 6 S5 5 DISASSEMBLING AND ASSEMBLING 6 S7 1 SEPARATING FRONT AXLE ASSEMBLY 6 S7 2 DISASSEMBLING 4WD TYPE FRONT AXLE 6 S9 6 SERVICING 6 S1...

Page 403: ...le rocking force too small Adjust 6 S6 7 Clearance between front axle case boss and front axle bracket front rear bushing excessive Replace 6 S18 Front Wheels Can Not Be Driven 1 Coupling displaced Re...

Page 404: ...0 0079 in for L5040 II L5740 II Differential Case Differential Case Cover to Differential Side Gear Differential Case Differential Case Cover Differential Side Gear Clearance I D I D O D 0 050 to 0 1...

Page 405: ...t Axle Case Boss Rear to Bracket Bushing Front Axle Case Boss Rear Bushing Clearance O D I D 0 100 to 0 292 mm 0 00394 to 0 0114 in 69 970 to 70 000 mm 2 7548 to 2 7559 in 70 100 to 70 262 mm 2 7599 t...

Page 406: ...ut L3540 II L4240 II 78 to 90 7 9 to 9 2 58 to 66 Bracket mounting screw and nut L5040 II L5240 II and L5740 II 103 to 117 10 5 to 12 0 76 0 to 86 7 Tie rod end nut L3540 II L4240 II 40 to 45 4 0 to 4...

Page 407: ...ock nut 1 3 Turn the tie rod joint 2 to adjust the rod length until the proper toe in measurement is obtained 4 Retighten the tie rod lock nut 1 5 Attach the snap ring 3 IMPORTANT A right and left tie...

Page 408: ...e front gear case 1 contacts with the bevel gear case 2 at right hand side of the front axle 3 If the front gear case 1 can not be contacted with the bevel gear case 2 shorten the length of stopper 3...

Page 409: ...se to the splines of propeller shaft 1 3 9Y1211167FAS0009US0 Power Steering Hoses 1 Disconnect the power steering hoses 1 2 from steering cylinder 2 Remove the cylinder cover When reassembling 9Y12111...

Page 410: ...Remove the bracket rear mounting screws and nuts 6 Separate the front axle from front axle bracket When reassembling NOTE Be sure to adjust the front axle rocking force Refer to 4 CHECKING AND ADJUST...

Page 411: ...ing plug 2 and check plug 1 IMPORTANT Use KUBOTA SUPER UDT fluid or SAE80 90 gear oil Refer to 4 LUBRICANTS FUEL AND COOLANT on page G 10 9Y1211167FAS0012US0 Propeller Shaft 1 Slide the propeller shaf...

Page 412: ...L5240 II and L5740 II 1 Remove the bevel gear case 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 ri...

Page 413: ...gear case 2 and separate it from the front gear case 3 4 Remove the internal snap ring 4 5 Remove the bevel gears 5 6 with ball bearings and shims 8 When reassembling Install the shims 8 to their ori...

Page 414: ...gure below Be sure to set the collar 1 to the grove of the axle 3 9Y1211167FAS0019US0 Power Steering Hoses 1 Disconnect the power steering hoses 1 2 from steering cylinder 2 Remove the cylinder cover...

Page 415: ...ove the cylinder set screw 3 5 Remove the fittings 2 from steering cylinder 6 Remove the internal snap ring 4 7 Draw out the steering cylinder 5 When reassembling Apply liquid lock Three Bond 1342B or...

Page 416: ...ith new ones Apply grease 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 Tight...

Page 417: ...in 13 4 Pull out the pinion shaft 10 and remove the differential pinions 4 and differential side gears 12 When reassembling Apply molybdenum disulfide Three Bond 1901 or equivalent to the inner circum...

Page 418: ...e limit 0 20 mm 0 0079 in Differential case bore I D Factory specification 32 000 to 32 062 mm 1 2599 to 1 2622 in Differential case cover bore I D Factory specification 32 000 to 32 025 mm 1 2599 to...

Page 419: ...ssembly only to the front axle case 2 Measure the turning torque of spiral bevel pinion shaft 3 If the turning torque is not within the factory specifications adjust with the lock nut If the turning t...

Page 420: ...11167FAS0027US0 Backlash between Bevel Gear and Bevel Gear 1 Stick a strip of plastigauge to three spots on the bevel gear 1 with grease 2 Fix the front axle case bevel gear case and front gear case 3...

Page 421: ...he thickness of the fuse with an outside micrometer 5 If the backlash is not within the factory specifications adjust with shim 3 Reference Thickness of adjusting shims 0 4 mm 0 016 in 0 5 mm 0 020 in...

Page 422: ...ront axle case boss front O D Factory specification 49 950 to 49 975 mm 1 9666 to 1 9675 in Bracket bushing front I D Factory specification 50 095 to 50 225 mm 1 9723 to 1 9773 in Clearance between fr...

Page 423: ...I D and calculate the clearance 3 If the clearance exceeds the allowable limit replace it 9Y1211167FAS0031US0 Clearance between bevel gear case boss and front axle support bushing Factory specificati...

Page 424: ...7 STEERING KiSC issued 02 2015 A...

Page 425: ...CONTENTS 1 STRUCTURE 7 M1 2 HYDRAULIC CIRCUIT 7 M2 3 HYDRAULIC PUMP 7 M3 4 STEERING CONTROLLER 7 M4 5 STEERING CYLINDER 7 M6 MECHANISM KiSC issued 02 2015 A...

Page 426: ...ering system consists of steering wheel steering joint shafts steering controller steering cylinder and other components shown in the figure 9Y1211167STM0001US0 1 Steering Wheel 2 Steering Joint Shaft...

Page 427: ...linder rod then moves to control the directional movement of the front wheels Return oil from steering cylinder 2 passes through control valve 10 is sent to the PTO clutch valve HST GST valve etc When...

Page 428: ...ents as shown in the figure The hydraulic pump pressure fed the oil drawn from the transmission case through oil filter to power steering circuit and main hydraulic circuit 9Y1211167STM0003US0 1 Drive...

Page 429: ...amount corresponding to the turn of the steering wheel 1 and the gerotor performs the metering function and lets oil through it the amount of which corresponds to the turn of the steering wheel 1 The...

Page 430: ...eft turn as well except that oil flows into and out of steering cylinder in the directions opposite to those at a right turn 9Y1211167STM0006US0 1 Steering Wheel 2 Valve Plate 3 Gerotor 4 Steering Cyl...

Page 431: ...efer to TRACTOR MECHANISM workshop manual The tie rods connected to both knuckle arm guarantees equal steering movement to both front wheels The steering cylinder provides force in both directions Dep...

Page 432: ...TIGHTENING TORQUES 7 S4 4 CHECKING AND ADJUSTING 7 S5 1 STEERING CONTROLLER 7 S5 5 DISASSEMBLING AND ASSEMBLING 7 S6 1 STEERING CONTROLLER 7 S6 2 STEERING CYLINDER 7 S7 3 STEERING LINKAGE 7 S8 6 SERVI...

Page 433: ...between front axle center pivots and bracket bushing excessive Replace 6 S20 6 Steering controller malfunctioning Replace 7 S6 Hard Steering 1 Overload 2 Insufficient tire pressure Inflate G 68 3 Oil...

Page 434: ...r worn Retighten or replace 7 S7 6 Steering linkage worn Replace 7 S8 7 Clearance between front axle center pivots and brackets bushings excessive Replace 6 S20 8 Steering controller malfunctioning Re...

Page 435: ...Temperature 40 to 60 C 104 to 140 F Setting Pressure L3540 II L4240 II L5040 II L5240 II L5740 II 10 7 to 11 7 MPa 110 to 119 kgf cm2 1560 to 1690 psi 12 7 to 13 7 MPa 130 to 139 kgf cm2 1850 to 1980...

Page 436: ...retaining nut 49 to 58 5 0 to 6 0 37 to 43 Steering hose RH and LH retaining nut 25 to 29 2 5 to 3 0 18 to 21 Front wheel mounting nut 124 to 147 12 6 to 15 0 91 2 to 108 Tie rod end slotted nut L354...

Page 437: ...ng wheel to the left and read the pressure when the relief valve functions 6 Stop the engine 7 If the pressure is not within the factory specifications check the pump delivery line and regulator setti...

Page 438: ...ghten the steering joint shaft support mounting screw after adjusting the position of steering joint shaft support 4 for smooth rotation of the steering wheel 9Y1211167STS0006US0 Steering Controller A...

Page 439: ...e the head cover 7 and draw out the cylinder rod 6 When reassembling Apply transmission fluid to the oil seal and O ring Apply liquid lock Three Bond 1342B or equivalent to the thread of tie rod joint...

Page 440: ...ion of steering joint shaft support 2 for smooth rotation of the steering wheel Be sure to insert the screw 3 to the notch of the steering joint shaft 2 1 9Y1211167STS0012US0 Steering Joint Shaft 1 an...

Page 441: ...d Bushing 1 Measure the bushing I D with a cylinder 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 9...

Page 442: ...8 HYDRAULIC SYSTEM KiSC issued 02 2015 A...

Page 443: ...HYDRAULIC SYSTEM 8 M7 1 THREE POINT HITCH HYDRAULIC CIRCUIT 8 M7 2 REAR HYDRAULIC BLOCK 8 M8 3 POSITION CONTROL VALVE 8 M8 4 POSITION CONTROL LINKAGE 8 M10 5 LOWERING SPEED ADJUSTING VALVE 8 M11 6 HY...

Page 444: ...ts of a hydraulic pump 4 front loader control valve 6 hydraulic cylinder 7 and other components 9Y1211167HYM0001US0 1 Power Steering Controller 2 Power Steering Cylinder 3 Regulating Valve 4 Hydraulic...

Page 445: ...of a hydraulic pump 3 front loader control valve 6 hydraulic cylinder 7 and other components 9Y1211167HYM0002US0 1 Power Steering Controller 2 Power Steering Cylinder 3 Hydraulic Pump 4 Regulating Val...

Page 446: ...Position Control Valve 2 Hydraulic Cylinder 3 Cylinder Safety Valve 4 Lowering Speed Adjusting Valve 5 Auxiliary Control Valve 6 Power Steering Controller Refer to STEERING Section 7 PTO Clutch Valve...

Page 447: ...and 3 point hitch 9Y1211167HYM0004US0 1 Position Control Valve 2 Hydraulic Cylinder 3 Cylinder Safety Valve 4 Lowering Speed Adjusting Valve 5 Auxiliary Control Valve 6 Power Steering Controller 7 PTO...

Page 448: ...9Y1211167HYM0005US0 1 Position Control Valve 2 Hydraulic Cylinder 3 Cylinder Safety Valve 4 Lowering Speed Adjusting Valve 5 Auxiliary Control Valve 6 Power Steering Controller 7 Oil Filter 8 Oil Coo...

Page 449: ...mponents as shown in the figure The hydraulic pump pressure fed the oil drawn from the transmission case through oil filter to power steering circuit and main hydraulic circuit 9Y1211167HYM0006US0 1 D...

Page 450: ...tral position oil is channeled from N port to the control valve 1 4 The hydraulic system has a relief valve 9 which restricts the maximum pressure in the circuit The hydraulic cylinders 2 have a cylin...

Page 451: ...port The oil in the chamber A behind the unload poppet 1 4 returns to the tank from T4 port The oil in the hydraulic cylinder does not flow out because the circuit is cut off by the actions of poppet...

Page 452: ...f low pressure in chamber B and then the oil from the pump returns to the transmission case through T3 port until unload poppet 1 2 opens 9Y1211167HYM0011US0 Lowering When the control lever is moved t...

Page 453: ...otated to the arrow since the feedback rod is actuated Therefore the spool drive lever 3 moves around the fulcrum Q and pull the spool 1 3 The lift arm stops when the spool returns to the neutral posi...

Page 454: ...eases lowering speed of the three points linkage When the rotor shaft 2 is completely closed the three point linkage is held at its position since oil in the hydraulic cylinder is sealed between the h...

Page 455: ...r is single acting type and it is installed directly between hydraulic lift arm and lower link The main components of the hydraulic cylinder are shown in the figure 9Y1211167HYM0015US0 1 Cylinder Tube...

Page 456: ...lve housing spool load check valve etc This valve has A1 and B1 ports and controls oil flow to the boom cylinder 3 Bucket Control Section The bucket control valve is of 4 position 6 connection no dete...

Page 457: ...2 FRONT LOADER HYDRAULIC CIRCUIT 9Y1211167HYM0017US0 1 Relief Valve 2 Boom Control Valve 3 Bucket Control Valve 4 Front Loader Control Valve P Pump Port T Tank Port A1 A1 Port A2 A2 Port B1 B1 Port B2...

Page 458: ...HYM0018US0 1 Boom Control Section 2 Bucket Control Section 3 Spool for Bucket Control 4 Spool for Boom Control 5 PB Passage 1 6 PB Passage 2 7 Load Check Valve 8 Relief Valve P Pump Port T Tank Port A...

Page 459: ...load check valve 7 and flows through the notched section of the spool 4 and B1 port to extend the boom cylinder 11 3 Return oil from the boom cylinder 11 flows from the port through the passage in th...

Page 460: ...ve 7 and flows through the notched section of the spool 4 and A1 port to retract the boom cylinder 11 3 Return oil from the boom cylinder 11 flows from the B1 port through the passage in the spool 4 a...

Page 461: ...rom the A1 port and B1 port through the T port to the transmission case 3 Oil entering the P port flows to the bucket control section 2 through the neutral passage 1 10 and PB passage 1 5 9Y1211167HYM...

Page 462: ...he PB passage 2 6 is closed by the spool 3 this oil opens the load check valve 7 and flows through the notched section of the spool 3 and B2 port to retract the bucket cylinder 11 3 Return oil from th...

Page 463: ...B passage 2 6 is closed by the spool 3 this oil opens the load check valve 7 and flows through the notched section of the spool 3 and A2 port to extend the bucket cylinder 11 3 Return oil from the buc...

Page 464: ...transmission case through T port 9Y1211167HYM0026US0 Down When the spool 2 is moved in the direction of the arrow the pressure fed oil in the P port opens the check valve 1 and flows to the implement...

Page 465: ...II L5040 II L5240 II L5740 II WSM 8 M22 7 OTHER 1 SAFETY VALVE 1 Operation of safety valve refer to 8 HYDRAULIC SYSTEM section in the workshop manual of tractor mechanism Code No 9Y021 18200 9Y1211167...

Page 466: ...ITCH HYDRAULIC BLOCK ASSEMBLY 8 S17 1 Separating Hydraulic Block Assembly 8 S17 2 Disassembling Hydraulic Assembly 8 S18 3 POSITION CONTROL VALVE 8 S19 1 Separating Control Valve 8 S19 4 LIFT ARM SUPP...

Page 467: ...sition control feedback rod improperly adjusted Adjust 8 S13 4 Hydraulic arm shaft lift arm improperly assembled Adjust 8 S22 Implement Does Not Lower 1 Position control valve malfunctioning Spool dam...

Page 468: ...ls min Hydraulic Pump for Three Point Hitch Condition Engine Speed Approx 2700 min 1 rpm Except L5040 II L5240 II Approx 2600 min 1 rpm L5040 II L5240 II Rated pressure L3540 II 17 1 to 18 1 MPa 175 t...

Page 469: ...L4240 II L5040 II L 5240 II L5740 II 17 1 to 18 1 MPa 175 to 184 kgf cm2 2480 to 2620 psi 18 1 to 19 1 MPa 185 to 194 kgf cm2 2630 to 2770 psi Item Factory Specification Allowable Limit Lift Arm Free...

Page 470: ...to 2 1 13 to 15 Hydraulic pump assembly mounting screw and nut 24 to 27 2 4 to 2 8 18 to 20 Pump cover mounting screw 40 to 44 4 0 to 4 5 29 to 32 Hydraulic cylinder hose retaining nut 35 to 48 3 5 to...

Page 471: ...ry pipe 2 5 When reassembling Install the copper washers firmly Tighten the steering joint shaft support mounting screw after adjusting the position of steering joint shaft support 3 for smooth rotati...

Page 472: ...enerate pressure approx 9 8 MPa 100 kgf cm2 1422 psi Hold in this condition until oil temperature reaches approx 40 C 104 F 7 Open the loading valve completely 8 Set the engine speed Refer to Conditio...

Page 473: ...ivery at rated pressure Factory specification Above 17 5 L min 4 62 U S gals min 3 85 lmp gals min Allowable limit 15 6 L min 4 12 U S gals min 3 43 lmp gals min Hydraulic pump delivery at no pressure...

Page 474: ...8 2 HYDRAULIC PUMP FOR THREE POINT HITCH 1 Pump Test Using Flow meter Preparation 1 Open the bonnet 2 Remove the side skirt RH 3 Remove the delivery pipe 1 1 When reassembling Install the copper washe...

Page 475: ...lve to generate pressure approx 14 7 MPa 150 kgf cm2 2133 psi Hold in this condition until oil temperature reached approx 40 C 104 F 7 Open the loading valve completely 8 Set the engine speed Refer to...

Page 476: ...livery at rated pressure Factory specification Above 30 9 L min 8 16 U S gals min 6 80 Imp gals min Allowable limit 27 6 L min 7 29 U S gals min 6 07 Imp gals min Hydraulic pump delivery at no pressur...

Page 477: ...ot within the factory specification adjust the shim 2 Condition Engine speed Approx 2700 min 1 rpm Except L5040 II L5240 II Approx 2600 min 1 rpm L5040 II L5240 II Oil temperature 40 to 60 C 104 to 14...

Page 478: ...e lock nut 3 firmly When reassembling Install the safety valve to the rear hydraulic block taking care not to damage the O ring and apply transmission fluid NOTE Use specified transmission fluid Refer...

Page 479: ...5 7 Set the engine speed at the maximum 8 Move the position control lever 1 to the lowest position and uppermost position to check the relief valve does not operate 9 Set the position control lever 1...

Page 480: ...bly Bonnet and Side Skirt RH 1 Open the bonnet 1 2 Remove the side skirt RH 2 9Y1211167HYS0012US0 Regulating Valve Manual Transmission and GST Models 1 Disconnect the power steering delivery pipe 4 an...

Page 481: ...1 Disconnect the suction hose 1 and main delivery pipe 3 2 Remove the hydraulic pump assembly 2 When reassembling Apply grease to the O ring and be careful not to damage it 9Y1211167HYS0015US0 Tighten...

Page 482: ...ticeably during running in recheck 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 min 1 rp...

Page 483: ...sition control rod 5 Remove the hydraulic pipe 7 6 Remove the rear hydraulic block 8 When reassembling Install the copper washers firmly Visually inspect the gasket if damaged replace with new one Aft...

Page 484: ...raw out the spring 4 seat 5 and ball 6 When reassembling Be careful not to damage the O rings IMPORTANT After disassembling and assembling the cylinder safety valve assembly be sure to check the opera...

Page 485: ...ot loosen the adjusting screw 27 unless necessary If disassembled due to unavoidable reasons be sure to set the dimension A to 0 2 mm 0 008 in When reassembling Be careful not to damage the backup rin...

Page 486: ...1 2 When reassembling Apply grease to the hydraulic cylinder pins Install the cylinder pin lower from right hand side 9Y1211167HYS0028US0 Tightening torque Lift arm pin mounting nut 78 to 90 N m 7 9 t...

Page 487: ...ply transmission fluid to the piston 2 head 5 and cylinder tube 3 Be careful not to damage the O ring backup ring and seal Apply liquid gasket Three Bond 1208C or equivalent to the top of head 5 while...

Page 488: ...1 and lift arm LH 7 as a unit 4 Remove the collar 4 and O ring 3 When reassembling Align the alignment marks 8 of the lift arm shaft and lift arms Apply grease to the right and left bushings of lift a...

Page 489: ...emove the fender cover 2 5 Remove the stay 5 and disconnect the position control cable 4 6 Disconnect the front loader control cables 3 6 When reassembling Lock the position cable at the center of the...

Page 490: ...ove the front loader pipes 3 3 Remove the front loader control valve assembly 4 When reassembling 9Y1211167HYS0033US0 Tightening torque Joint bolt for delivery pipe 1 118 to 137 N m 12 0 to 14 0 kgf m...

Page 491: ...ing 26 and ball 28 4 Draw out the spool 15 16 with other component parts from valve body 14 Relief Valve 1 Remove the plug 1 and remove the spring 5 and poppet 6 7 9Y1211167HYS0034US0 1 Plug 2 O ring...

Page 492: ...screw 2 4 Draw out the spring 4 seat 5 and ball 6 When reassembling Install the safety valve to the hydraulic cylinder block taking care not to damage the O ring 9Y1211167HYS0035US0 Tightening torque...

Page 493: ...bushing is worn beyond the alloy portion A replace it Reference 9Y1211167HYS0036US0 Lift Arm Bushing 1 Visually inspect the DX bushings for signs of wear or damage The DX bushing tends to show concen...

Page 494: ...orn beyond the alloy portion A replace it Reference 9Y1211167HYS0038US0 Hydraulic Cylinder I D 1 Measure the hydraulic cylinder I D with a cylinder gauge 2 If the cylinder I D exceed the allowable lim...

Page 495: ...0US0 Side Plate Thickness 1 Measure the side plate thickness with an outside micrometer 2 If the thickness is less than the allowable limit replace it 9Y1211167HYS0041US0 Clearance between bushing and...

Page 496: ...9 ELECTRICAL SYSTEM KiSC issued 02 2015 A...

Page 497: ...Display 9 M17 2 Attention Display At Engine Starting 9 M18 3 Service Interval Alert 9 M21 4 Warning Display or Warning Information 9 M21 5 Lamp Control 9 M23 4 ASSISTANT CONTROL SYSTEM 9 M24 1 Fail s...

Page 498: ...ELECTRICAL SYSTEM L3540 II L4240 II L5040 II L5240 II L5740 II WSM 9 M1 1 WIRING DIAGRAM 1 MANUAL TRANSMISSION MODEL MAIN HARNESS KiSC issued 02 2015 A...

Page 499: ...ELECTRICAL SYSTEM L3540 II L4240 II L5040 II L5240 II L5740 II WSM 9 M2 2 GST MODEL MAIN HARNESS KiSC issued 02 2015 A...

Page 500: ...ELECTRICAL SYSTEM L3540 II L4240 II L5040 II L5240 II L5740 II WSM 9 M3 3 HST MODEL MAIN HARNESS KiSC issued 02 2015 A...

Page 501: ...ELECTRICAL SYSTEM L3540 II L4240 II L5040 II L5240 II L5740 II WSM 9 M4 4 CABIN HARNESS KiSC issued 02 2015 A...

Page 502: ...l transmission In data communication the transmission capacity of the line and the capacity of signal transmission reception are represented by the number of bits that can be transmitted or received f...

Page 503: ...re etc on the LCD which are basic information necessary for the tractor operation Attention Display at engine starting Display the operator s guidance of levers and pedals at the engine starting on th...

Page 504: ...osition Sensor 13 Range Gear Shift Sensor 14 Hi Lo Solenoid Valve 15 Proportional Valve Reverse 16 Proportional Valve Forward 17 Electronic Instrument Panel InteliPanel 18 Electronic Control Unit ECU...

Page 505: ...c instrument panel detects the signals and determines whether the engine can be started safety 9Y1211167ELM0010US0 Multi Function Combination Lever Turn Signal and Head Light Switch The multi function...

Page 506: ...ot lamp at the electronic instrument panel 9Y1211167ELM0014US0 PTO Switch This switch 1 is mounted on the right cover sends a 12 V signal to light up the lamp at the electronic instrument panel when P...

Page 507: ...rom the battery charge The alternator sends a signal for making the alarm lamp at the electronic instrument panel to light up if the electricity charge system becomes abnormal 9Y1211167ELM0019US0 Engi...

Page 508: ...ture sensor 9Y1211167ELM0022US0 Electric Control Unit ECU for GST and HST Model The ECU 1 functions to operate GST and HST in accordance with information coming from various sensors It has the role of...

Page 509: ...s a signal to the electronic instrument panel and ECU 9Y1211167ELM0026US0 Oil Pressure Switch for GST Model This switch 1 is designed to detect that the gear shift completion of GST and pressurizing o...

Page 510: ...of the HST pedal When the HST pedal is operated signals are sent to the ECU 9Y1211167ELM0030US0 Cruise Control Lever Position Sensor for HST Model The cruise control lever position sensor is located...

Page 511: ...ctor is operated by shuttle lever Be sure to connect the ECU connector 3 when using the emergency connector 9Y1211167ELM0033US0 Flusher Unit Flusher unit controls the blinking frequency as a only one...

Page 512: ...r is operated signals are sent to the ECU When the H DS lever is pulled up the HST motor is changed to the Hi side When the H DS lever is pushed down the HST motor is changed to the Lo side When the H...

Page 513: ...itching the valve 9Y1211167ELM0041US0 Proportional Valve The proportional valves are located on the right of the HST There are two proportional valves one for forward motion and the other for the reve...

Page 514: ...NOTE Trip meter can be reset to 0 0 h by pushing and holding the display mode switch for about two seconds with trip meter displayed 9Y1211167ELM0044US0 1 Intellipanel Electronic Instrument Panel 2 Li...

Page 515: ...switch for engine starting is adapted for the shuttle lever and the PTO shift lever in these models Reference As for the manual transmission model selected speed displayed on left edge is not indicate...

Page 516: ...HST pedal to set the Neutral position 9Y1211167ELM0049US0 When the PTO shift lever is not set at a Neutral position Shift the PTO shift lever to Neutral position 9Y1211167ELM0050US0 When the clutch pe...

Page 517: ...M0053US0 When the PTO shift lever is not set a Neutral position and the clutch pedal is not depressed Shift the PTO shift lever to Neutral position and depress the clutch pedal 9Y1211167ELM0054US0 Whe...

Page 518: ...nge to other standard display by pushing the display mode switch Clearing Operation Keep pushing both switches 2 3 for two seconds or more while displaying the hour meter Normal Display 1 9Y1211167ELM...

Page 519: ...comes on when the overheat display 1 1 is displayed and it keeps being on until water temperature is becoming 100 C 212 F or less 9Y1211167ELM0058US0 Engine Oil Pressure and Electric Charging Warning...

Page 520: ...H DS Lamp HST Model Only If the HST mode select switch is pushed and stall guard lamp and Auto H DS lamp will come 7 H DS Low Range Speed Lamp If the H DS lever is pushed down the H DS low speed lamp...

Page 521: ...which position the shift lever stays in 9Y1211167ELM0061US0 2 Self diagnosis Function If any of the following troubles occurs its related error code gets displayed flashing in the panel s LCD screen a...

Page 522: ...olenoid 3 in trouble ERROR 64 Shift solenoid 4 in trouble ERROR 65 Shift solenoid 5 in trouble ERROR 66 Shift solenoid 6 in trouble For HST Model ERROR 80 Range gear shift sensor in trouble ERROR 81 H...

Page 523: ...E GST Lever Sensor Fine adjustment Mode For setting the Neutral position of GST lever sensor Input the sensor information to ECU F GST Valve Fine adjustment Mode For setting the function of proportio...

Page 524: ...temperature of the coolant is detected with the coolant temperature sensor and the time to supply current to the glow plug and the glow indicator lamp is controlled by CPU according to the detected te...

Page 525: ...ING SYSTEM AND STOPPING SYSTEM 1 MANUAL TRANSMISSION MODEL 9Y1211167ELM0066US0 1 Main Switch 2 Shuttle Switch 3 Parking Brake Switch 4 PTO Switch 5 Seat Switch 6 OPC Controller 7 Meter panel 8 Starter...

Page 526: ...II WSM 9 M29 2 GST MODEL 9Y1211167ELM0067US0 1 Main Switch 2 Shuttle Switch 3 PTO Switch 4 Seat Switch 5 Parking Brake Switch 6 ECU 7 Meter panel 8 Starter Relay 9 Starter 10 Engine Stop Solenoid Rel...

Page 527: ...9Y1211167ELM0068US0 1 Main Switch 2 Seat Switch 3 Parking Brake Switch 4 PTO Switch 5 Clutch Pedal Switch 6 Mid PTO Switch Option 7 ECU 8 Meter panel 9 Starter Relay 10 Starter 11 Engine Stop Solenoi...

Page 528: ...tion this switch is pushed in and electric circuit is closed 9Y1211167ELM0070US0 Shuttle Switch Manual Transmission and GST Model This switch is mounted on the clutch housing case When the shuttle lev...

Page 529: ...rol Unit for GST and HST Model The ECU is located under the floor sheet 9Y1211167ELM0074US0 OPC Operator Presence Control Controller Engine Stop Solenoid Relay and Starter Relay OPC controller and rel...

Page 530: ...and the engine can be started 9Y1211167ELM0076US0 1 Shuttle Shift Lever 2 PTO Clutch Switch 3 Seat Switch 4 Parking Brake Lever 5 Clutch Pedal 6 HST Pedal A Manual Transmission and GST Model B HST Mo...

Page 531: ...ols engine stop solenoid 9Y1211167ELM0077US0 1 Shuttle Shift Lever 2 PTO Clutch Switch 3 Seat Switch 4 Parking Brake Lever 5 Clutch Pedal 6 HST Pedal A Manual Transmission and GST Model B HST Model Sh...

Page 532: ...l Reducing Valve 9 S27 8 Mode G GST Shift Shock Fine adjustment Mode Adjusting the Clutch Engaging Interval 9 S28 9 Mode H Error Information Display Mode Be carefuling or Reviewing the Error Informati...

Page 533: ...S65 5 Lamp Relay 9 S65 6 Brake Lamp Switch 9 S66 7 Head Light 9 S67 9 WARNING LAMPS 9 S67 1 Checking 9 S67 10 MONITOR LAMP 9 S68 1 Checking 9 S68 11 GAUGES 9 S69 1 Fuel Level Sensor 9 S69 2 Coolant Te...

Page 534: ...le disconnected or improperly connected Repair or replace 9 S16 4 Slow blow fuse blown Replace 9 S35 Fuse Blown Frequently 1 Short circuited Repair or replace Symptom Probable Cause Solution Reference...

Page 535: ...t panel damaged Replace 9 S36 Glow Lamp Does Not Light 1 Main switch damaged Replace 9 S53 2 Wiring harness disconnected or improperly connected between main switch terminal and panel between panel an...

Page 536: ...pressure too low Repair engine 1 S14 3 Engine oil pressure switch damaged Replace 9 S67 4 Short circuit between engine oil pressure switch lead and chassis Repair 9 S67 5 Circuit in panel damaged Rep...

Page 537: ...TO Speed in Not Indicating 1 Wiring harness disconnected Repair 2 Engine tachometer sensor damaged Replace 9 S41 Fuel Gauge is Indicating Always E 1 Wiring harness GND disconnected Repair or replace 2...

Page 538: ...ween ECU and electronic instrument panel at ECU connector 9 S45 Replace ECU 9 S45 ECU memory device has failed ECU memory device failure Replace ECU 9 S45 Input voltage to lever sensor from ECU is fai...

Page 539: ...specification Valve wire broken or short circuited Proportional reducing valve damaged Check the connector of proportional reducing valve Check the proportional reducing valve resistance at valve or E...

Page 540: ...e between solenoid and GND 9 S47 Replace GST valve 9 M24 Solenoid 2 failure At forward or neutral Able to travel at speeds other than 2 9 and 10 Forward or 2 and 6 Reverse Check the wiring connector o...

Page 541: ...or neutral Able to travel at speeds other than 1 to 6 Forward or 1 to 4 Reverse Check the wiring connector of solenoid Solenoid 6 Main range gear shift failure At reverse Check the resistance between...

Page 542: ...minals voltage is out of specification Engine stop solenoid relay broken or short circuited Wiring harness broken or short circuited Engine is stopped Engine does not start Check the engine stop solen...

Page 543: ...ctor 9 S45 Check the communication line between ECU and electronic instrument panel at ECU connector 9 S45 Replace ECU 9 S42 ECU memory device has failed ECU memory device failure Replace ECU 9 S42 In...

Page 544: ...circuited Input line broken Sensor damaged Travel motion using HST pedal is possible Check the sensor connector Check the sensor voltage by Test mode Mode A 9 S22 Check the sensor wire connector volt...

Page 545: ...en HST response control dial damaged Travel motion is possible The HST response control is fixed in the center Check HST response control dial connector 9 S51 Check HST response control dial voltage b...

Page 546: ...t mode Mode A 9 S22 Automatic shift function is not reformed Replace the proportional valve 9 S49 Hi Lo solenoid failed Hi Lo solenoid output terminals voltage is out of specification Hi Lo solenoid b...

Page 547: ...ance 1 8 to 4 2 106 5 to 113 5 Coolant Temperature Sensor at 20 C 4 F at 40 C 104 F at 100 C 212 F Resistance Resistance Resistance Approx 18 80 1 136 0 1553 Starter Commutator Mica Brush Brush Holder...

Page 548: ...s bolts and nuts on the table below are especially specified For general use screws bolts and nuts Refer to 5 TIGHTENING TORQUES on page G 13 9Y1211167ELS0006US0 Item N m kgf m lbf ft Starter terminal...

Page 549: ...terminal post and the lead to the positive terminal post and measure the battery voltage 3 If the battery voltage is less than the factory specification check the battery specific gravity and recharge...

Page 550: ...tery as early as possible Failure to do this will shorten the battery s service life 3 The battery is charge if the indicator display turns green from black 4 When exchanging an old battery for a new...

Page 551: ...tor 2 Remover the seat 1 3 Remove the seat bracket 2 4 Disconnect the ECU connector 3 NOTE HST Model When replacing the ECU be sure to adjust the mode N first Then adjust the mode K and mode L GST Mod...

Page 552: ...ver 1 2 Disconnect the panel connectors 4 5 3 Remove the electronic instrument panel 3 from panel frame 2 NOTE When replacing the electronic instrument panel be sure to adjust the mode I first Then ad...

Page 553: ...nt the setting and the checking respectively 1 While holding down both the display mode switch and the travel speed switch at once turn the main switch to ON or START position 2 Mode selection display...

Page 554: ...Mode When the shifting shock is not comfortable H Error Information Display Mode When checking the error history I Transmission Model Input Mode When the Intellipanel is replaced or changed J Speed U...

Page 555: ...at once turn the main switch to ON or START position 2 Select the mode A 3 T1 is displayed b 4 Each time the display mode switch is pressed the symbol changes from T1 to T16 with the buzzer sound 5 T...

Page 556: ...41 to 1 01 2 77 to 3 37 3 91 to 4 51 V T8 Oil temperature sensor voltage 20 60 100 C 4 140 212 F 4 46 to 4 57 1 71 to 1 91 0 34 to 0 38 V T9 Throttle sensor voltage Idling Max 0 63 to 1 95 3 19 to 4 5...

Page 557: ...ctor model and tire size Numeric modification Each time the display mode switch is pressed the flashing number shifts Press the travel speed switch to change the number 5 Hold down the display mode sw...

Page 558: ...NG is displayed d The code number has not been input correctly Repeat the procedure 9Y1211167ELS0019US0 5 Mode D Error Information Reset Mode Delete the Error Information from the Electronic Instrumen...

Page 559: ...more than 2 seconds This preserve the adjusted value to the ECU 6 OK is displayed d on LCD screen to tell that preserving to ECU has been made correctly Turn off the main switch to end the mode 7 If N...

Page 560: ...ows disengaged the clutch select forward with the shuttle lever and shift the GST lever from 1 thru 12 several times Set the GST lever at the positions other than neutral 8 STEP 05 is displayed g Set...

Page 561: ...will be put in memory NOTE If the shift shock has been adjusted but no remarkable effect can be felt keep the setting at 0 9Y1211167ELS0023US0 9 Mode H Error Information Display Mode Be carefuling or...

Page 562: ...d The tractor model has not been input correctly Repeat the procedure 9Y1211167ELS0025US0 11 Mode J Speed Unit Selection Mode Input the Traveling Speed Unit to the Electronic Instrument Panel 1 While...

Page 563: ...engine at idling speed 2 Select the mode K 3 Hold down the display mode switch for more than 2 seconds 4 HST ADJ b is displayed and release the switch NOTE When indication HST ADJ does not change the...

Page 564: ...imum reverse position 10 STEP 04 is displayed h After completing the above 9 STEP 04 is displayed Then proceed to the next step NOTE When ERROR xx m refers to the below chart 11 PUSH SW is displayed i...

Page 565: ...on is not idling ERROR 75 is displayed h indicated errors as follows The accelerator lever is not in the position of idling The accelerator lever is out of position 5 PUSH SW is displayed c Hold down...

Page 566: ...ELECTRICAL SYSTEM L3540 II L4240 II L5040 II L5240 II L5740 II WSM 9 S33 14 Mode M Mode for Factory NOTE This mode is used in factory only 9Y1211167ELS0029US0 KiSC issued 02 2015 A...

Page 567: ...d down the display mode switch for more than 2 seconds Reference 8 OK is displayed e The code number has been input correctly IMPORTANT After setting mode N set mode K and mode L The tractor does not...

Page 568: ...hen connecting or disconnecting the connector for the purpose of checking be sure to turn OFF the main switch before hand Moreover pay attention not to allow the terminal to come in contact with other...

Page 569: ...anel Connector 1 Disconnect the connectors 1 2 and check their terminals for contamination and deformation 2 Check to see that cable does not broken or terminals are not shelled off 3 If any damaged p...

Page 570: ...w Shuttle switch Manual transmission GST Orange Black Clutch pedal switch HST 4 5 Black Red PTO switch 6 7 Brown Yellow Hi beam 8 Blue Travel speed switch 9 Light green Black Display mode switch 10 11...

Page 571: ...w Blue Fuel unit 2 White Coolant temperature 3 4 Brown Communication line 5 Brown White Communication line 6 Black Yellow GND for sensor 7 Black GND 8 Red Power supply 12 V from battery 9 Green Red Li...

Page 572: ...67ELS0036US0 Connector Voltage Main Voltage 1 Measure the voltage between the terminal 8 and terminal 14 2 If the voltage differs from the battery voltage 11 to 14 V the wiring harness or battery is f...

Page 573: ...he sensor in mode A 2 Measure the voltage and resistance of the wire harness connector 3 If measured values are normal the switch is damaged NOTE It is not necessary to adjust any kind of mode 9Y12111...

Page 574: ...ecessary to adjust any kind of mode 9Y1211167ELS0040US0 Voltage Main switch at ON position Terminal 1 of the sensor connector chassis Approx battery voltage Resistance Terminal 3 of the sensor connect...

Page 575: ...ECU Connector 1 Disconnect the connector 1 and check their terminals for contamination and deformation 2 Check to see that cable does not broken or terminals are not shelled off 3 If any damaged part...

Page 576: ...lay 27 Pink Blue PTO solenoid 6 Red 12 V power source from battery 28 Black Red Starter relay 7 Pink TXD for check connector 29 Black GND ground for circuit line 8 Violet RXD for check connector 30 Re...

Page 577: ...nd for sensor 10 Red Black Seat switch 32 Green White Return line terminal for proportional valve Forward 11 Green Red Brake switch 33 Green Red Parking brake switch 12 Orange Traveling speed sensor 3...

Page 578: ...onnect the connector B 16P from electronic instrument panel 2 Measure the resistance between terminal 4 of panel connector and terminal 14 of ECU connector and between terminal 5 of panel connector an...

Page 579: ...ls when the engine is started 6 It is OK if the resistance comes to have the value shown in the table below NOTE It is not necessary to adjust any kind of mode CAUTION Be sure to depress the clutch pe...

Page 580: ...y kind of mode 9Y1211167ELS0050US0 4 Checking Sensor and Switch for HST Model H DS Lever Continuity 1 Remove the steering post cover 1 2 Disconnect the connector 2 3 Measure the resistance between con...

Page 581: ...and b 3 while shifting the range gear shift lever 2 It is OK if the resistance is smoothly changing NOTE When replacing the sensor be sure to adjust the mode K Reference The maximum resistance value...

Page 582: ...e table below NOTE When replacing the each sensor be sure to adjust the mode K Swashplate position sensor has different moving angle from other 2 sensors Reference The change of resistance can be chec...

Page 583: ...a 2 and b 3 while slowly turning the sensor shaft 3 It is OK if the resistance value approximates to the value shown in the table below NOTE When replacing the sensor be sure to adjust the mode L Refe...

Page 584: ...between as the table dial is faulty HST Mode Switch 1 Measure the resistance between terminal 4 and terminal 5 while pushing the HST mode select switch 3 2 It is OK if 0 ohm is indicated NOTE When re...

Page 585: ...mode K 9Y1211167ELS0057US0 Hi Lo Solenoid 1 Remove the cover 2 Disconnect the connector 1 3 Remove the Hi Lo solenoid valve assembly 4 Disassembling the Hi Lo solenoid valve assembly 5 Measure the res...

Page 586: ...sition 2 Measure the resistances across the B terminal and the ACC terminal across B terminal and IG1 terminal and B terminal and IG2 terminal 3 If 0 ohm is not indicated renew the main switch 9Y12111...

Page 587: ...under cover 2 Disconnected the shuttle switch connector 1 3 Measure the resistance across four terminal referring to the table below 4 If 0 ohm is not indicated the shuttle switch is faulty 9Y1211167...

Page 588: ...t does not conduct or any value is indicated when the switch is pushed ON seat the switch is faulty 4 If infinity is not indicated when the switch is released OFF seat the switch is faulty 9Y1211167EL...

Page 589: ...ost 6 Connect a jumper lead momentarily between the starter motor housing and the battery negative terminal post 7 If the motor does not operate check the motor WSM000001ELS0009US0 Magnet Switch Test...

Page 590: ...1 Remove the panel cover and meter panel 2 Remove the starter relay 1 3 Apply battery voltage across terminals 3 and 4 and check for continuity across terminals 1 and 2 4 If continuity is not establis...

Page 591: ...position differs from the battery voltage the wiring harness or main switch is faulty 9Y1211167ELS0075US0 Glow Plug Continuity 1 Disconnect the lead from the glow plugs 2 Measure the resistance betwe...

Page 592: ...Turn the main switch on 6 Measure the voltage across the terminal 3 Positive and chassis Negative 7 If the voltage differs from the battery voltage the wiring harness is faulty 2 Glow Relay Test 1 Re...

Page 593: ...noid relay 1 3 Measure the voltage across the terminal 1 Positive and chassis Negative 4 If the voltage differs from the battery voltage the wiring harness is faulty 5 Turn the main switch on 6 Measur...

Page 594: ...and Automatic Engine Stop Conditions Refer to 3 ENGINE STARTING SYSTEM AND STOPPING SYSTEM of MECHANISM in this section 2 If the tractor does not operate appropriately check all parts according to th...

Page 595: ...ect the 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...

Page 596: ...terminal to chassis when the main switch is ON position 2 If the voltage differs from the battery voltage the wiring harness fuse lamp relay or fuse is faulty 9Y1211167ELS0079US0 2 Light Switch and Tu...

Page 597: ...0 3 Flasher Unit Flasher Unit 1 Disconnect the connector from the flasher unit 2 Turn the main switch to ON position 3 Measure the voltage across the terminal A 2 and chassis 4 Measure the voltage acr...

Page 598: ...arness is faulty 5 Turn the main switch on 6 Measure the voltage across the terminal 3 Positive and chassis Negative 7 If the voltage differs from the battery voltage the wiring harness is faulty 2 La...

Page 599: ...nnect the connector for brake lamp switch 1 2 Check the resistance across the terminals 3 If the measured value is different from the table below the switch is damaged 9Y1211167ELS0086US0 Resistance A...

Page 600: ...1211167ELS0087US0 Engine Oil Pressure Switch Continuity 1 Measure the resistance across the switch terminal and the chassis 2 If 0 ohm is not indicated in the normal state the switch is faulty 3 If in...

Page 601: ...rnator wiring harness or fuse is fault 9Y1211167ELS0089US0 10 MONITOR LAMP 1 Checking Parking Brake Switch 1 Disconnect the parking brake switch connector 2 2 Measure the resistance between connector...

Page 602: ...Measure the resistance across the sensor terminal and the chassis 2 If the measurement is not indicated the sensor is faulty When galvanometer shows 0 zero When galvarnometer shows 0 zero 9Y1211167EL...

Page 603: ...rs from the battery voltage the wiring harness is faulty 5 Turn the main switch on 6 Measure the voltage across the terminal 3 Positive and chassis Negative 7 If the voltage differs from the battery v...

Page 604: ...ssembling Apply grease to the gear teeth of the gears 5 and overrunning clutch 2 and ball 3 WSM000001ELS0021US0 Plunger 1 Remove the end cover 1 2 Remove the plunger 2 WSM000001ELS0022US0 2 ALTERNATOR...

Page 605: ...SM000001ELS0025US0 IC Regulator 1 Remove the three screws holding the IC regulator and remove the IC regulator 1 WSM000001ELS0026US0 Rectifier 1 Remove the four screws holding the rectifier and the st...

Page 606: ...olding the retainer plate and remove the retainer plate 1 WSM000001ELS0030US0 Bearing on Drive End Side 1 Press out the bearing from drive end frame 3 with a press and jig 1 WSM000001ELS0031US0 Bearin...

Page 607: ...nce 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 correct it wi...

Page 608: ...If 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 WSM000001ELS0037US0 Field Coil 1 Check t...

Page 609: ...uity across the slip ring and core with an ohmmeter 4 If the measurement is not within the factory specifications replace it WSM000001ELS0041US0 Slip Ring 1 Check the slip ring for score 2 If scored c...

Page 610: ...digital multimeter Because it s very hard to check the continuity of rectifier by using it WSM000001ELS0044US0 IC Regulator 1 Check the continuity across the B terminal and the F terminal of IC regula...

Page 611: ...10 CABIN KiSC issued 02 2015 A...

Page 612: ...YSTEM 10 M1 1 OUTLINE OF AIR CONDITIONING SYSTEM 10 M1 2 SYSTEM CONTROL 10 M3 3 ELECTRICAL SYSTEM 10 M4 1 Electrical Circuit 10 M4 2 Air Conditioner Relay Blower Relays and Compressor Relay 10 M5 MECH...

Page 613: ...1167CAM0001US0 1 Heater Hose Out Side 2 Heater Hose In Side 3 Water Valve 4 Control Panel 5 Outside Air Filter 6 Inner Roof 7 Inside Air Filter 8 Side Air Outlet 9 Front Air Outlet 10 High Pressure Pi...

Page 614: ...n the refrigerant circulates through the air conditioning cycle and functions to lubricate the compressor But the conventional compressor oil for R12 doesn t dissolve in R134a so it doesn t circulate...

Page 615: ...The air flows to door D3 12 side passing through the heater core 3 Outlet air flow is controlled by door D3 Moving the mode switch 2 opens and shuts door D3 and establishes the air passage according t...

Page 616: ...Electrical Circuit 9Y1211167CAM0004US0 1 Battery 2 Slow Blow Fuse 3 Main Switch 4 Blower Relay 5 Blower Motor 6 Blower Resistor 7 Blower Switch 8 Compressor Relay 9 Compressor 10 Pressure Switch 11 Th...

Page 617: ...to turn off the blower motor 6 could result in a discharged battery 3 To protect against such trouble relays have been provided These relays have been made so that when current flows through its coil...

Page 618: ...erant 10 S19 4 Checking Charge Refrigerant Amount 10 S21 6 CHECKING DISASSEMBLING AND SERVICING 10 S22 1 CHECKING AND ADJUSTING 10 S22 1 Compressor 10 S22 2 Control Panel Blower Switch A C Switch Mode...

Page 619: ...aged Replace 10 S23 4 A C compressor relay damaged Replace 10 S27 5 A C blower motor damaged Replace 10 S26 Does Not Cool Compressor Does Not Rotate 1 Belt slipping Adjust or replace G 35 2 Fuse blown...

Page 620: ...4 A C compressor relay damaged Replace 10 S27 5 Brush in poor contact Replace 10 S26 Too Low Air Flow Rate Flow Rate Does Not Change in 4 Steps 1 Blower switch damaged Replace 10 S23 2 Relay damaged R...

Page 621: ...ansion valve clogged Replace 4 Evaporator frosted Clean or replace 5 Low pressure pipe in trouble Cracked or clogged Replace 10 S47 Insufficient Cooling Both Hi pressure and Low pressure Level is Too...

Page 622: ...ion Correct cause and replace 9 S35 4 Wiper switch damaged Replace 10 S29 5 Wiper motor damaged Broken armature worn motor brush or seized motor shaft Replace 10 S30 Windshield Wiper Operating Speed I...

Page 623: ...1 27 to 1 66 MPa 13 to 17 kgf cm2 185 to 242 psi Pressure Switch Dual Type When pressure switch is turned OFF Setting Pressure LO Pressure Side Setting Pressure HI Pressure Side Less than approx 0 196...

Page 624: ...5 to 3 0 18 to 21 Clutch mounting screw 12 3 to 14 1 1 25 to 1 44 9 05 to 10 4 A C unit mounting screw M6 4 0 to 6 8 0 40 to 0 70 2 9 to 5 0 A C unit mounting screw M8 9 81 to 11 6 1 00 to 1 19 7 24...

Page 625: ...the service can unless necessary When it has to be heated use warm water of 40 C 104 F or lower Do not heat using boiling water IMPORTANT If the refrigerant O rings etc for R12 are used in the R134a...

Page 626: ...0 g 1 70 to 1 91 lbs Factory specifica tion L4240 II L5040 II L5240 II L5740 II R134a 800 to 900 g 1 77 to 1 98 lbs Quantity Total Brand Name 50 to 70 cc 0 053 to 0 073 U S qts 0 044 to 0 061 Imp qts...

Page 627: ...en LO Valve is Opened and HI Valve is Closed Two circuits are established Port C LO pressure gauge 1 Port C Port B Port C Port D Port A HI pressure gauge 2 NOTE Schrader valve D must be opened 9Y12111...

Page 628: ...disconnect connector should the sleeve 7 move before the quick link connector can be connected to the charging valve move the quick sleeve to its original position and try again When some refrigerant...

Page 629: ...for R134a and cannot be used Therefore a new electric gas leak tester with greater sensitivity has been designed and can be used with both R134a and R12 Reference Leak tester with halide torch Since...

Page 630: ...efrigerant Recovery and Recycling Machine When there is necessity of discharging the refrigerant on repairing the tractor it should use recovery and recycling machine Do not release the refrigerant in...

Page 631: ...out the air in the charging hoses at the manifold gauge connection end by utilizing the refrigerant pressure in the refrigerating cycle 3 Start the engine and set at approx 1500 min 1 rpm 4 Turn on t...

Page 632: ...ive Refrigerant or Insufficient Condenser Cooling 1 Symptoms seen in refrigerating cycle Both LO and HI pressure side 1 2 pressures too high LO pressure side 1 0 20 to 0 35 MPa 2 0 to 3 5 kgf cm2 28 4...

Page 633: ...9Y1211167CAS0022US0 Moisture Entered in the Cycle 1 Symptoms seen in refrigerating cycle The air conditioner operates normally at the beginning but over time LO pressure side 1 pressure is vacuum and...

Page 634: ...ion valve Replace the receiver Evacuate and charge in proper amount of new refrigerant Refer to 3 Charging the Refrigerant in this section If caused by gas leakage in heat sensitizing tube replace the...

Page 635: ...7CAS0027US0 1 Discharging the Refrigerant Prepare for the R134a refrigerant recovery and recycling machine 9 1 Connect low pressure side hose blue 4 from the recovery and recycling machine 9 to LO pre...

Page 636: ...vacuum pump 8 to evacuate the refrigerant cycle For approx 15 minutes 5 When LO pressure gauge 3 reading is more than 750 mmHg 299 in Hg stop the vacuum pump 8 and close both valves 5 6 of manifold ga...

Page 637: ...cuated completely 2 Connect the center charging hose green 5 to the can tap valve 3 fitting and then loosen the center charging hose green 5 at the center fitting of manifold gauge until hiss can be h...

Page 638: ...et the temperature control lever to maximum cooling position and the blower switch to HI position 4 Open the LO pressure side valve 5 of manifold gauge and the can tap valve 3 on refrigerant container...

Page 639: ...h the sight glass becomes as stated below depending on refrigerant charged amount A Insufficient refrigerant charge Air bubbles pass continuously the sight glass when pressure on the LO pressure side...

Page 640: ...tions replace the stator coil 9Y1211167CAS0034US0 Air Gap 1 Check the air gap with feeler gauge 2 If the measurement is not within the factory specifications adjust it Refer to 3 SERVICING in this sec...

Page 641: ...the connector terminal a and terminal b 4 If the voltage differs from the battery voltage the wiring harness A C relay fuse or main switch is faulty 9Y1211167CAS0037US0 Blower Switch Test 1 Check the...

Page 642: ...ester 5 Press the air conditioner switch to set it at ON position indicator ON and then measure a voltage using a circuit tester 6 If a measured voltage does not comply with the values in the table be...

Page 643: ...the main switch to ON position 9 Check that an output voltage is approximately 10 V when turning the temperature control dial counterclockwise till it stops COOL position 10 If an output voltage diffe...

Page 644: ...ck the motor 9Y1211167CAS0044US0 5 Temperature Motor Temperature Motor Checking 1 Check whether the temperature control dial 2 is damaged Refer to 4 Control Panel in this section 2 Turn the main switc...

Page 645: ...1 Remove the air conditioner relay and blower relay 2 Check the resistance between terminal c 5 and terminal d 6 3 If resistance is clearly different from the table below the relay is damaged 4 Apply...

Page 646: ...s turned off At this time read the HI pressure gauge of the manifold gauge If this pressure reading differs largely with the setting pressure replace the pressure switch with a new one 2 LO Pressure S...

Page 647: ...he battery voltage the wiring harness fuse or main switch is faulty 2 Front Wiper Switch 1 Check the continuity through the switch with an ohmmeter 2 If continuity specified below is not indicated the...

Page 648: ...position 3 Push the front wiper switch to ON position 4 Count the number of wiper arm rocking per minutes 5 If the number differs from the factory specifications replace the wiper motor assembly 9Y12...

Page 649: ...efogger does not work and connector voltage is normal defogger switch or defogger is damaged 9Y1211167CAS0079US0 Defogger Relay 1 Remove the defogger relay 1 2 Check the resistance between terminal a...

Page 650: ...if necessary NOTE On cabin model machines fresh water circulates through the heater This means that one more liter or so of fresh water is required In changing fresh water pour fresh water up to the f...

Page 651: ...erator sensor 8 is equipped in HST model only 5 Disconnect the heater hoses 3 and then reconnect their hoses to make loop NOTE Put a mark to the each heater hose before disconnecting 6 Disconnect the...

Page 652: ...stay 12 NOTE The bolt mounting the ground cable 11 is different from the others When reassembling Be sure to check and adjust the clutch and brake pedal free travel Refer to 7 CHECK AND MAINTENANCE at...

Page 653: ...e gear shift lever 4 6 Remove the grip for main gear shift lever 6 7 Remove the grip for creep lever 7 8 Remove the grip for PTO speed change lever GST Model 5 Remove the grip for creep lever 7 6 Remo...

Page 654: ...temperature sensor connector 13 When reassembling IMPORTANT In installing the connector of the proportional valve pay attention to the color of the connector to ensure correct installation 9Y1211167C...

Page 655: ...sembling Adjust the front loader cables with the front loader control lever in the locked position Neutral position Lock the position cable at the center of the screw NOTE By using the window on the r...

Page 656: ...play Refer to CHEKING AND ADJUSTING at 5 BRAKES section 9Y1211167CLS0029US0 Remote Control Valve Lever Link If Equipped 1 Remove the snap pins 1 2 Disconnect the remote control valve lever link 2 9Y1...

Page 657: ...steering post cover 2 4 3 Remove the panel cover 2 4 Remove the brake rods 7 and clutch rod 5 5 Remove the universal joint bolt 6 and disconnect the steering joint shaft 1 8 9Y1211167CLS0016US0 1 Mat...

Page 658: ...m tractor body NOTE When lifting the cabin make sure that the cabin does not catch anything When reassembling Be sure to install the washers and mount rubbers etc in their original positions as shown...

Page 659: ...e O rings and be careful not to damage them S letter is marked on the compressor for connecting the low pressure pipe suction side D letter is marked on the compressor for connecting the high pressure...

Page 660: ...d after assembling and not contact with stator and hub plate Check and adjust the air gap before tight the magnet clutch mounting screw or nut to the specified torque Refer to 3 SERVICING in this sect...

Page 661: ...circlip is set is boss of shaft as a minimum Match and assemble the concave part 3 of the front housing 5 and the pin 4 of stator 9Y1211167CAS0056US0 3 Removing Air Conditioner Unit Draining Coolant R...

Page 662: ...Y1211167CAS0059US0 Wiring Harness 1 Disconnect the temperature motor connector 1 and thermostat connectors 2 2 Disconnect the mode motor connector 3 and blower resister connector 4 9Y1211167CAS0060US0...

Page 663: ...nd and finally retighten them after aligning the inner roof duct with the unit duct When connecting the heater hose with A C unit hose should be put into the A C unit pipe more than 30 mm 1 2 in 9Y121...

Page 664: ...ing positive cord first 9Y1211167CLS0007US0 High Pressure Pipe 1 1 Disconnect the high pressure pipe 1 2 from the compressor 1 and condenser 3 then cap the open fittings immediately to keep moisture o...

Page 665: ...1 then cap the open fittings immediately to keep moisture out of the system 4 Remove the inner covers 3 When reassembling Replace the rubber with a new one Apply compressor oil DENSO ND OIL 8 or equi...

Page 666: ...skirts 3 4 Disconnect window washer hose 2 5 Remove the bonnet 1 NOTE When disconnecting the battery cords disconnect the negative cord first when connecting positive cord first 9Y1211167CLS0007US0 Ho...

Page 667: ...4 Pull out the heater hoses 2 from the bottom of the cabin 5 Remove the heater hoses 2 When reassembling Connect the heater hoses at their original positions In assembling the heater hose 2 to the pi...

Page 668: ...like See the left figure 2 Pull the piano wire inward outward alternately to cut the adhered part NOTE Do not let the piano wire make sliding contact with the edge of glass plate forcibly In case of...

Page 669: ...eld 1 as shown in figure 4 Install the rear windshield 1 to the cabin and fix tit with a gummed tape 5 Leave it for one hour NOTE Apply the Sika Tack Ultrafast or equivalent with the jig having the sp...

Page 670: ...arance E approx 5 mm 0 2 in between the lower and upper windshield The level unevenness between the upper and lower windshields should be 1 to 1 mm 0 04 to 0 04 in or less at the windshield surface 6...

Page 671: ...symmetry 9Y1211167CAS0077US0 3 SERVICING Adjustment of Air Gap 1 Measure the air gap with a feeler gauge 2 When the measurement value comes off from factory specification adjustment shim 3 is added or...

Page 672: ...FARM INDUSTRIAL MACHINERY SERVICE LTD 64 ISHIZU KITAMACHI SAKAI KU SAKAI CITY OSAKA 590 0823 JAPAN PHONE 81 72 241 1129 FAX 81 72 245 2484 E mail ks_g ksos pub kubota com Printed in Japan 2015 02 S E...

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Kubota WSM L3540-II, Workshop Manual

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