wsm L3130 Workshop Manual Download Page 142 | Manualshive

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1-S55

L3130 · L3430 · L3830 · L4630 · L5030, WSM

ENGINE

Connecting Rod Alignment

NOTE

■

• Since the I.D. of the connecting rod small end bushing is the

basis of this check, check bushing for wear beforehand.

1. Install the piston pin into the connecting rod.
2. Install the connecting rod on the connecting rod alignment tool.
3. Put a gauge over the piston pin and move it against the face

plate.

4. If the gauge does not fit squarely against the face plate, measure

the space between the pin of the gauge and the face plate.

5. If the measurement exceeds the allowable limit, replace the

connecting rod.

W1032720

(D) Crankshaft

Side Clearance of Crankshaft

1. Move the crankshaft to the flywheel side.
2. Set a dial indicator to the crankshaft.
3. Measure the end play by pulling the crankshaft toward the crank

gear.

4. If the measurement exceeds the allowable limit, replace the

thrust bearing 1 and 2.

(Reference)

• Oversize dimensions of crankshaft journal

W1032880

Crankshaft Alignment

1. Support the crankshaft with V blocks on the surface plate and set

a dial indicator with its tip on the intermediate journal at right
angle.

2. Rotate the crankshaft on the V blocks and get the misalignment

(half of the measurement).

3. If the misalignment exceeds the allowable limit, replace the

crankshaft.

W1033001

Connecting rod
alignment

Allowable limit

0.05 mm
0.0020 in.

Crankshaft side
clearance

Factory
spec.

D1503-M
D1703-M
V2203-M

0.15 to 0.35 mm
0.0059 to 0.0138 in.

D1803-M
V2403-M

0.15 to 0.31 mm
0.0059 to 0.0122 in.

Allowable limit

0.5 mm
0.0197 in.

Oversize

Dimension

0.2 mm
0.008 in.

0.4 mm
0.016 in.

A

26.20 to 26.25 mm
1.0315 to 1.0335 in.

26.40 to 26.45 mm
1.0394 to 1.0413 in.

B

54.5 to 54.7 mm
2.1456 to 2.1535 in.

54.6 to 54.8 mm
2.1496 to 2.1574 in.

C

2.8 to 3.2 mm radius
0.1102 to 0.1260 in. radius

2.8 to 3.2 mm radius
0.1102 to 0.1260 in. radius

(0.8-S)
The crankshaft journal must be fine-finished to higher than

∇∇∇∇

Crankshaft alignment

Allowable limit

0.02 mm
0.00079 in.

KiSC issued 02, 2007 A

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Summary of Contents for L3130

Page 1: ...WORKSHOP MANUAL TRACTOR L3130 L3430 L3830 L4630 L5030 KiSC issued 02 2007 A ...

Page 2: ...897 01872 97897 18200 for the one which has not been described to this workshop manual Servicing The heading General includes general precautions check and maintenance and special tools Other section there are troubleshooting servicing specification lists checking and adjusting disassembling and assembling and servicing which cover procedures precautions factory specifications and allowable limits...

Page 3: ...ut this manual and on labels on the machine itself to warn of the possibility of personal injury Read these instructions carefully It is essential that you read the instructions and safety regulations before you attempt to repair or use this unit DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a potentially hazardous ...

Page 4: ...ly by a jack Always support the machine by safety stands Do not touch the rotating or hot parts while the engine is running Never remove the radiator cap while the engine is running or immediately after stopping Otherwise hot water will spout out from radiator Only remove radiator cap when cool enough to touch with bare hands Slowly loosen the cap to first stop to relieve pressure before removing ...

Page 5: ... into eyes Keep electrolyte away from eyes hands and clothing If you spill electrolyte on yourself flush with water and get medical attention immediately DISPOSE OF FLUIDS PROPERLY Do not pour fluids into the ground down a drain or into a stream pond or lake Observe relevant environmental protection regulations when disposing of oil fuel coolant electrolyte and other harmful waste PREPARE FOR EMER...

Page 6: ... SAFETY INSTRUCTIONS The following safety decals are installed on the machine If a decal becomes damaged illegible or is not on the machine replace it The decal part number is listed in the parts list SAFETY DECALS KiSC issued 02 2007 A ...

Page 7: ...5 L3130 L3430 L3830 L4630 L5030 WSM SAFETY INSTRUCTIONS KiSC issued 02 2007 A ...

Page 8: ...6 L3130 L3430 L3830 L4630 L5030 WSM SAFETY INSTRUCTIONS KiSC issued 02 2007 A ...

Page 9: ...7 L3130 L3430 L3830 L4630 L5030 WSM SAFETY INSTRUCTIONS KiSC issued 02 2007 A ...

Page 10: ...on case 42 L 11 1 U S gals 9 2 Imp gals Dimensions Overall length without 3P 3025 mm 119 1 in 3015 mm 118 7 in Overall width min tread 1430 mm 56 3 in Overall height with ROPS 2255 mm 88 8 in 2415 mm 95 1 in Wheel base 1805 mm 71 1 in Min ground clearance 370 mm 14 6 in Tread Front 1150 mm 45 3 in Rear 1110 mm 43 7 in 1205 mm 47 4 in 1300 mm 51 2 in 1385 mm 54 5 in Weight with ROPS 1480 kg 3265 lb...

Page 11: ...3 L 11 4 U S gals 9 5 Imp gals Dimensions Overall length without 3P 3075 mm 121 1 in 3170 mm 124 8 in Overall width min tread 1485 mm 58 5 in Overall height with ROPS 2420 mm 95 3 in Wheel base 1840 mm 72 4 in 1895 mm 74 6 in Min ground clearance 400 mm 15 7 in Tread Front 1145 mm 45 1 in Rear 1140 mm 44 9 in 1210 mm 47 6 in 1310 mm 51 6 in 1410 mm 55 5 in Weight with ROPS 1500 kg 3305 lbs 1520 kg...

Page 12: ... 7 7 Imp qts Transmission case 43 L 11 4 U S gals 9 5 Imp gals Dimensions Overall length without 3P 3075 mm 121 1 in 3170 mm 124 8 in Overall width min tread 1485 mm 58 5 in Overall height 2195 mm 86 4 in Wheel base 1840 mm 72 4 in 1895 mm 74 6 in Min ground clearance 400 mm 15 7 in Tread Front 1145 mm 45 1 in Rear 1140 mm 44 9 in 1210 mm 47 6 in 1310 mm 51 6 in 1410 mm 55 5 in Weight 1640 kg 3616...

Page 13: ...ssion case 45 L 11 9 U S gals 9 9 Imp gals Dimensions Overall length without 3P 3245 mm 127 8 in Overall width min tread 1470 mm 57 9 in Overall height 2275 mm 89 6 in Wheel base 1915 mm 75 4 in Min ground clearance 425 mm 16 7 in Tread Front 1135 mm 44 7 in Rear 1125 mm 44 3 in 1225 mm 48 2 in 1325 mm 52 2 in Weight 1840 kg 4057 lbs 1860 kg 4101 lbs Travelling system Standard tire size Front 9 5 ...

Page 14: ...er Main gear shift lever km h mph km h mph Forward At rated engine rpm Low 1 1 81 1 1 1 68 1 0 2 2 56 1 6 2 38 1 5 3 4 16 2 6 3 86 2 4 4 6 14 3 8 5 71 3 5 High 1 9 13 5 7 8 49 5 3 2 12 91 8 0 12 01 7 5 3 20 96 13 0 19 49 12 1 4 30 96 19 2 28 78 17 9 Reverse At rated engine rpm Low 1 1 51 0 9 1 40 0 9 2 2 13 1 3 1 98 1 2 3 3 46 2 1 3 22 2 0 4 5 11 3 2 4 76 3 0 High 1 7 61 4 7 7 07 4 4 2 10 76 6 7 1...

Page 15: ... 0 69 0 4 5 71 3 5 0 64 0 4 6 02 3 7 0 68 0 4 High 1 9 13 5 7 1 02 0 6 8 49 5 3 0 95 0 6 8 95 5 6 1 00 0 6 2 12 91 8 0 1 45 0 9 12 01 7 5 1 35 0 8 12 66 7 9 1 42 0 9 3 20 96 13 0 2 35 1 5 19 49 12 1 2 19 1 4 20 54 12 8 2 31 1 4 4 30 96 19 2 3 48 2 2 28 78 17 9 3 23 2 0 30 34 18 9 3 41 2 1 Reverse At rated engine rpm Low 1 1 51 0 9 0 17 0 1 1 40 0 9 0 16 0 1 1 48 0 9 0 17 0 1 2 2 13 1 3 0 24 0 1 1 ...

Page 16: ...75 4 2 0 76 0 5 7 12 4 4 0 80 0 5 8 8 49 5 3 0 95 0 6 8 95 5 6 1 00 0 6 9 9 55 5 9 1 07 0 7 10 07 6 3 1 13 0 7 10 12 01 7 5 1 35 0 8 12 66 7 9 1 42 0 9 11 19 49 12 1 2 19 1 4 20 54 12 8 2 31 1 4 12 28 78 17 9 3 23 2 0 30 34 18 9 3 41 2 1 Reverse At rated engine rpm 1 1 40 0 9 0 16 0 1 1 48 0 9 0 17 0 1 2 1 98 1 2 0 22 0 1 2 09 1 3 0 23 0 1 3 3 22 2 0 0 36 0 2 3 39 2 1 0 38 0 2 4 4 76 3 0 0 53 0 3 ...

Page 17: ...15 L3130 L3430 L3830 L4630 L5030 WSM DIMENSIONS DIMENSIONS L3130 L3430 L3830 KiSC issued 02 2007 A ...

Page 18: ...16 L3130 L3430 L3830 L4630 L5030 WSM DIMENSIONS L4630 L5030 KiSC issued 02 2007 A ...

Page 19: ...G GENERAL KiSC issued 02 2007 A ...

Page 20: ...ECK POINTS OF INITIAL 50 HOURS G 15 3 CHECK POINTS OF EVERY 50 HOURS G 19 4 CHECK POINTS OF EVERY 100 HOURS G 22 5 CHECK POINTS OF EVERY 200 HOURS G 27 6 CHECK POINTS OF EVERY 400 HOURS G 31 7 CHECK POINTS OF EVERY 600 HOURS G 31 8 CHECK POINTS OF EVERY 800 HOURS G 31 9 CHECK POINTS OF EVERY 1 YEAR G 32 10 CHECK POINTS OF EVERY 2 YEARS G 32 11 OTHERS G 34 8 SPECIAL TOOLS G 39 1 SPECIAL TOOLS FOR E...

Page 21: ...always specify engine serial number tractor serial number and hour meter reading W10106000 1 Tractor Identification Plate 2 CABIN Identification Plate CABIN Serial Number 3 Tractor Serial Number 4 Engine Serial Number 5 Hour Meter IntelliPanel Display 6 ROPS Identification Plate ROPS Serial Number KiSC issued 02 2007 A ...

Page 22: ...uring Use only KUBOTA genuine parts for parts replacement to maintain machine performance and to assure safety Gaskets and O rings must be replaced during reassembly Apply grease to new O rings or oil seals before assembling See the figure left side When reassembling external snap rings or internal snap rings they must be positioned so that sharp edge faces against the direction from which a force...

Page 23: ...aler to perform periodic check for a fee Do not attempt to modify or remodel any electrical parts and wiring When removing the battery cables disconnect the negative cable first When installing the battery cables connect the positive cable first W10111140 1 WIRING Securely tighten wiring terminals W10112160 Do not let wiring contact dangerous part W10113130 Securely insert grommet W10113880 1 Nega...

Page 24: ...part where sag be required W10115870 In installing a part take care not to get wiring caught by it W10116700 After installing wiring check protection of terminals and clamped condition of wiring only connect battery W10117350 1 Clamp Wind Clamp Spirally 2 Wire Harness 3 Clamp 4 Welding Dent 1 Wiring 2 Clamp A Correct B Incorrect 1 Wiring A Incorrect 1 Cover Securely Install Cover KiSC issued 02 20...

Page 25: ...f with water immediately Before recharging the battery remove it from the machine Before recharging remove cell caps Do recharging in a well ventilated place where there is no open flame nearby as hydrogen gas and oxygen are formed W10118160 3 FUSE Use fuses with specified capacity Neither too large or small capacity fuse is acceptable Never use steel or copper wire in place of fuse Do not install...

Page 26: ...ain that there is no female connector being too open W10124300 Make certain plastic cover is large enough to cover whole connector W10125190 5 HANDLING OF CIRCUIT TESTER Use tester correctly following manual provided with tester Check for polarity and range W10126840 1 Exposed Terminal 2 Deformed Terminal 3 Sandpaper 4 Rust A Correct B Incorrect 1 Cover A Correct B Incorrect KiSC issued 02 2007 A ...

Page 27: ... Imp qts 6 7 L 7 1 U S qts 5 9 Imp qts Engine oil API service classification CD CE or CF Above 25 C SAE30 77 F 10W 30 or 10W 40 0 to 25 C SAE20 32 to 77 F 10W 30 or 10W 40 Below 0 C SAE10W 32 F 10W 30 or 10W 40 4 Transmission case 42 L 11 1 U S gals 9 2 Imp gals 43 L 11 4 U S gals 9 5 Imp gals KUBOTA UDT or SUPER UDT fluid 5 Front axle case 6 5 L 6 9 U S qts 5 7 Imp qts KUBOTA UDT or SUPER UDT flu...

Page 28: ... Imp qts Engine oil API service classification CD CE or CF Above 25 C SAE30 77 F 10W 30 or 10W 40 0 to 25 C SAE20 32 to 77 F 10W 30 or 10W 40 Below 0 C SAE10W 32 F 10W 30 or 10W 40 4 Transmission case 43 L 11 4 U S gals 9 5 Imp gals 45 L 11 9 U S gals 9 9 Imp gals KUBOTA UDT or SUPER UDT fluid 5 Front axle case 6 5 L 6 9 U S qts 5 7 Imp qts 6 0 L 6 3 U S qts 5 3 Imp qts KUBOTA UDT or SUPER UDT flu...

Page 29: ...se of a low fulfur fuel on on road vehicle engines When an off orad vehicle engine runs on a high sulfur fuel it is advisable to employ the CF CD or CE lubricating oil with a high total base number If the CF 4 or CG 4 lubricating oil is used with a high sulfur fuel change the lubricating oil at shorter intervals Lubricating oil recommended when a low sulfur or high sulfur fuel is employed Recommen...

Page 30: ...o 2 0 12 3 to 14 4 23 6 to 27 4 2 4 to 2 8 17 4 to 20 2 17 7 to 20 5 1 8 to 2 1 13 1 to 15 1 29 5 to 34 3 3 0 to 3 5 21 7 to 25 3 M10 10 mm 0 39 in 39 3 to 45 1 4 0 to 4 6 29 0 to 33 2 31 4 to 34 3 3 2 to 3 5 23 2 to 25 3 48 1 to 55 8 4 9 to 5 7 35 5 to 41 2 39 3 to 44 1 4 0 to 4 5 29 0 to 32 5 60 9 to 70 6 6 2 to 7 2 44 9 to 52 0 M12 12 mm 0 47 in 62 8 to 72 5 6 4 to 7 4 46 3 to 53 5 77 5 to 90 2...

Page 31: ...0 200 250 300 350 400 450 500 1 Brake Adjust G 18 2 Engine oil Change G 15 3 Engine oil filter Replace G 15 4 Hydraulic oil filter Replace G 16 5 Transmission fluid Change G 17 6 Front axle case oil Change G 18 7 Engine start system Check G 20 21 8 Wheel bolt torque Check G 21 9 Greasing G 19 10 Battery condition Check 5 G 25 11 Air cleaner element Double type Primary element Clean 1 G 22 Replace ...

Page 32: ... 800 1 year 2 years 1 Brake Adjust G 18 2 Engine oil Change G 15 3 Engine oil filter Replace G 15 4 Hydraulic oil filter Replace G 16 5 Transmission fluid Change G 17 6 Front axle case oil Change G 18 7 Engine start system Check G 20 21 8 Wheel bolt torque Check G 21 9 Greasing G 19 10 Battery condition Check 5 G 25 11 Air cleaner element Double type Primary element Clean 1 G 22 Replace 2 G 22 Sec...

Page 33: ... pipes and hoses Check G 32 7 CABIN isolation cushion Check G 32 8 Lubricating points Check Service as required G 37 9 Washer liquid Check G 37 10 Amount of refrigerant gas Check G 38 No Period Item Indication on hour meter After purchase Important Reference page 550 600 650 700 750 800 1 year 2 years 1 Clogging of air conditioner condenser screen Clean Daily 2 Tension of air conditioner drive bel...

Page 34: ...an the radiator screen grill and oil cooler HST only 8 Check and clean the air condenser screen CABIN only 9 Check the screws and nuts of tires are tight 10 Check the number plate 11 Care of danger warning and caution labels 12 Clean around the exhaust manifold and the muffler of the engine 13 Check the fuel level 14 Check the dust indicator While sitting in the operator s seat 1 Check the brake p...

Page 35: ...engine before changing oil filter cartridge Allow engine to cool down sufficiently oil can be hot and can burn 1 Remove the oil filter cartridge with the filter wrench 2 Apply a slight coat of oil onto the new cartridge gasket 3 To install the new cartridge screw it in by hand Over tightening may cause deformation of rubber gasket 4 After the new cartridge has been replaced the engine oil normally...

Page 36: ...ting surface then tighten it by hand an additional 1 2 turn only Transmission oil filter Quickly tighten the filter until it contacts the mounting surface then with a filter wrench tighten it an additional 1 turn only 6 After the new filters have been replaced fill the transmission oil up to the upper notch on the dipstick 7 After running the engine for a few minutes stop the engine and check the ...

Page 37: ...gine for a few minutes stop it and check the oil level again if low add oil prescribed level IMPORTANT Use only multi grade transmission oil Use of other oils may damage the transmission or hydraulic system Refer to LUBRICANTS FUEL AND COOLANT See page G 7 8 Never work the tractor immediately after changing the transmission oil Keeping the engine at medium speed for a few minutes to prevents damag...

Page 38: ...W10300640 Adjuting Brake Pedal Free Travel CAUTION Stop the engine and chock the wheels before checking 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 lock nut 1 and turn the turnbuckle 2 to adjust the rod length within acceptable limits 4 Retighten...

Page 39: ...nditions lubricate grease fittings more often When apply a grease to the front axle support remove the breather plug and apply a grease until grease overflows from breather plug After greasing reinstall the plug W10308650 1 Grease Fitting Front Wheel Case Support RH LH 2 Grease Fitting Front Axle Support 3 Breather Plug 4 Grease Fitting Lift Cylinder 5 Grease Fitting Top Link 6 Grease Fitting Lift...

Page 40: ...Shift the shuttle shift lever to the forward or reverse position 3 Depress the clutch pedal fully 4 Disengage the PTO clutch control lever 5 Turn the key to START position 6 The engine must not crank Test 2 Switch for the PTO clutch control lever 1 Sit on operator s seat 2 Engage the PTO clutch control lever 3 Depress the clutch pedal fully 4 Shift the range gear shift lever to the neutral positio...

Page 41: ... 6 The engine must not crank Test 3 Switch for the clutch pedal 1 Sit on operator s seat 2 Disengage the PTO clutch control lever 3 Place the speed control pedal to the neutral position 4 Release the clutch pedal 5 Turn the key to START position 6 The engine must not crank If it cranks at the test 1 2 or 3 adjust or replace the required safety switch W10739440 Checking Wheel Mounting Screws and Nu...

Page 42: ... it is damaged or not 3 Replace air cleaner primary element Once yearly or after every six times of cleaning whichever comes first NOTE Check to see if the evacuator valve is blocked with dust IMPORTANT The air cleaner uses a dry element never apply oil Do not run the engine with filter element removed Be sure to refit the cover with the arrow on the rear of cover upright If the cover is improperl...

Page 43: ... element bowl periodically W1078193 Adjusting Fan Belt Tension CAUTION Be sure to stop the engine before checking fan belt tension 1 Stop the engine and remove the key 2 Apply moderate thumb pressure to belt between pulleys 3 If tension is incorrect loosen the alternator mounting bolts and using a lever placed between the alternator and the engine block pull the alternator out until the deflection...

Page 44: ...stem IMPORTANT When the fuel line is disconnected for change close both ends of the fuel line with a piece of clean cloth or paper to prevent dust and dirt from entering Entrance of dust and dirt causes malfunction of the fuel injection pump In addition particular care must be taken not to admit dust and dirt into the fuel pump W10342570 Adjusting Clutch Pedal Free Travel CAUTION When checking par...

Page 45: ...ou are spattered with it wash it away completely with water immediately and get medical attention Wear eye protection and rubber gloves when working around battery NOTE The factory installed battery is of non refillable type If the indicator turns white do not charge the battery but replace it with new one 1 Mishandling the battery shortens the service life and adds to maintenance costs 2 The orig...

Page 46: ...rgencies 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 early as possible Failure to do this will shorten the battery s service life 3 The battery is charged if the indicator display turns green from black 4 When exchanging an old battery into new one use battery of equal specification shown in t...

Page 47: ...en bands securely 2 Replace hoses and tighten hose clamps securely if radiator hoses are swollen hardened or cracked Replace hoses and hose clamps every 2 years or earlier if checked and found that hoses are swollen hardened or cracked Precaution 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...

Page 48: ...the measurement is not within the factory specifications adjust by changing the tie rod length Adjusting 1 Detach the snap ring 1 2 Loosen the tie rod 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 right and left tie rod joint is adjusted to the s...

Page 49: ...e sure to stop the engine before checking air conditioner belt tension 1 Stop the engine and remove the key 2 Apply 98 N 10 kgf 22 lbs pressure to the belt between the pulleys 3 If tension is incorrect adjust the belt tension 4 If belt is damaged replace it W1019789 1 HST Oil Line 2 Power Steering Pressure Hoses A HST Type Air conditioner belt tension Factory spec A deflection of between 10 to 12 ...

Page 50: ...flow NOTE If the filter is very dirty Dip the filter in lukewarm water with mild dish washing detergent Move it up and down as well as left and right to loosen dirt Rinse the filter with clean water and let it air dry IMPORTANT Do not use 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 ...

Page 51: ...CHECK POINTS OF EVERY 600 HOURS Adjust Front Axle Pivot 1 Loosen the lock nut 2 tighten the adjusting screw 1 all the way and then loosen the adjusting screw 1 by 1 6 turn 2 Retighten the lock nut 2 NOTE If the axle pivot pin adjustment is not correct front wheel vibration can occur causing vibration in the steering wheel Reference W1036668 8 CHECK POINTS OF EVERY 800 HOURS Checking Valve Clearanc...

Page 52: ...y have deteriorated W1021413 10 CHECK POINTS OF EVERY 2 YEARS Replacing Fuel Hose 1 Replace the fuel hoses and clamps if necessary Refer to Checking Fuel Line See page G 24 W1037148 Replacing Parking Brake Cable 1 Replace the cable Refer to Adjusting Parking Brake Lever See page G 27 W1037203 Replacing HST Oil Line 1 Replace the hoses and clamps Refer to Checking HST Oil Line and Power Steering Li...

Page 53: ...tor cap 1 securely 7 Fill with coolant up to FULL mark on the recovery tank 8 Start and operate the engine for few minutes 9 Stop the engine and let cool Check coolant level of recovery tank 2 and add coolant if necessary IMPORTANT Do not start engine without coolant Use clean fresh water and anti freeze to fill the radiator and recovery tank When the anti freeze is mixed with water the anti freez...

Page 54: ...ate a minimum glycol content in the concentrated anti freeze When the coolant level drops due to evaporation add water only In case of leakage add anti freeze and water in the specified mixing ratio Anti freeze absorbs moisture Keep unused anti freeze in a tightly sealed container Do not use radiator cleaning agents when anti freeze has been added to the coolant Anti freeze contains an anti corros...

Page 55: ...in plug 1 under the clutch housing After operating in rain snow or tractor has been washed water may get into the clutch housing 1 Check it by pushing in the split pin 1 2 If water enters into the clutch housing remove the plug 1 and drain the water then reinstall the plug W1039199 1 Split Pin Plug KiSC issued 02 2007 A ...

Page 56: ...fer to troubleshooting section of this manual If any of them should blow replace with a new one of the same capacity Protected Circuit W1039315 Fuse No Capacity A Protected circuit ROPS CABIN 1 25 Head lights 2 20 Flasher 3 20 Hazard 4 5 Panel 5 7 5 Alternator 6 5 Lamp relay 7 7 5 Work light 8 5 Brake lamp switch 9 5 Key stop 10 30 Starter relay 11 7 5 Position lamp 12 5 T M controller 1 GST Type ...

Page 57: ...g Washer Liquid 1 Add a proper amount of automobile washer liquid W1120170 Light Capacity ROPS CABIN Head lights 45 W 40 W Tail light 10 W Hazard and turn signal light rear 21 W Hazard and turn signal light front 21 W Side marker light 5 W Room light 10 W Work light 27 W Instrument panel light 1 1 W Brake stop light 21 W Number plate light 10 W 1 Door Hinge 2 Rear Window Hinge Tank capacity 2 0 L ...

Page 58: ... that the amount of refrigerant is extremely low inspect and charge See page 10 S21 Checking Procedure 1 Run the air conditioner in the following conditions Engine speed About 1500 min 1 rpm Temperature control lever Maximum cooling position leftmost Fan switch Highest blow HI Air conditioner switch ON 2 Look into the sight glass 1 to see if the refrigerant is flowing through its circuit IMPORTANT...

Page 59: ...linder W10241000 Piston Ring Tool Code No 07909 32121 Application Use exclusively for removing or installing the piston ring with ease W10241500 Diesel Engine Compression Tester Code No 07909 30208 Assembly 07909 31251 G 07909 30934 A to F 07909 31271 I 07909 31211 E and F 07909 31281 J 07909 31231 H Application Use to measure diesel engine compression and diagnostics of need for major overhaul W1...

Page 60: ...iator cap pressure and leaks from cooling system Remarks Adapter 1 BANZAI Code No RCT 2A 30S W10245320 Connecting Rod Alignment Tool Code No 07909 31661 Application Use to check the connecting rod alignment Applicable Connecting rod big end I D range 30 to 75 mm 1 18 to 2 95 in dia Connecting rod length 65 to 300 mm 2 56 to 11 81 in W10245830 Nozzle Tester Code No 07909 31361 Application Use to ch...

Page 61: ...eck Code No 07909 31371 Application Use to check cracks on cylinder head cylinder block etc W10249090 Crankshaft Nut Socket 46 Code No 07916 30821 Application Use exclusively for removing or installing the crankshaft nut W10443610 Socket Wrench 46 Code No 07916 30901 Application Use exclusively for removing or installing the crankshaft nut W10444600 Auxiliary Socket For Fixing Crankshaft Sleeve Co...

Page 62: ... dia K 12 5 to 12 8 mm dia 0 492 to 0 504 in dia L 8 9 to 9 1 mm 0 350 to 358 in C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in C0 3 Chamfer 0 3 mm 0 012 in A Pressure gauge full scale More than 29 4 MPa 300 kgf cm2 4267 psi B Copper gasket C Flange Material Steel D Hex nut 27 mm 1 06 in across the plat E Injection pipe F PF 1 2 G 5 mm 0 20 in H 17 mm dia 0 67 in dia I 8 mm dia 0 31 in dia ...

Page 63: ...l screw W10259480 A 162 mm 6 38 in B 35 mm 1 38 in C 27 mm 1 06 in D 35 mm dia 1 38 in dia E 27 90 to 27 95 mm dia 1 098 to 1 100 in dia F 25 00 to 25 01 mm dia 0 984 to 0 985 in dia A 175 mm 6 89 in B 40 mm 1 57 in C 38 mm 1 49 in D 45 mm dia 1 77 in dia E 41 90 to 41 95 mm dia 1 650 to 1 652 in dia F 37 95 to 37 97 mm dia 1 494 to 1 495 in dia A 200 mm 7 87 in B 20 mm 0 79 in C 30 mm 1 18 in D 8...

Page 64: ...dia A 130 mm 5 12 in B 72 mm 2 83 in C R40 mm R1 57 in D 9 mm 0 35 in E 4 mm 0 16 in F 20 mm 0 79 in G 20 mm dia 0 79 in dia H 68 mm dia 2 68 in dia I 51 8 to 51 9 mm dia 2 039 to 2 043 in dia J 56 8 to 56 9 mm dia 2 236 to 2 240 in dia A 135 mm 5 31 in B 72 mm 2 83 in C R40 mm R1 57 in D 10 mm 0 39 in E 20 mm 0 79 in F 20 mm dia 0 79 in dia G 64 8 to 64 9 mm dia 2 551 to 2 555 in dia H 59 8 to 59...

Page 65: ... N 21 947 to 21 960 mm dia 0 8641 to 0 8646 in dia D 0 52 rad 30 O 28 mm 1 10 in E 46 950 to 46 975 mm dia 1 8484 to 1 8494 in dia P 29 mm 1 14 in F 43 934 to 43 950 mm dia 1 7297 to 1 7303 in dia Q 5 mm 0 20 in G 41 mm 1 61 in R 36 mm 1 42 in H 32 5 mm 1 28 in S 195 25 to 195 75 mm 7 687 to 7 707 in I 148 5 mm 5 85 in T 145 mm 5 71 in J 46 50 to 46 75 mm dia 1 831 to 1 841 in dia U 384 75 to 385 ...

Page 66: ...a 1 38 in dia T 60 mm dia 2 36 in dia G 60 mm dia 2 36 in dia U 46 950 to 46 975 mm dia 1 8484 to 1 8494 in dia H 37 mm 1 46 in V 44 950 to 44 975 mm dia 1 7697 to 1 7707 in dia I 21 947 to 21 960 mm dia 0 8641 to 0 8646 in dia W 41 934 to 41 950 mm dia 1 6509 to 1 6516 in dia J 24 959 to 24 980 mm dia 0 9826 to 0 9835 in dia X 145 mm 5 71 in K 8 8 to 9 2 mm 0 346 to 0 362 in Y 195 25 to 195 75 mm...

Page 67: ...njector CH3 Code No 07916 52501 Application Use for injecting calcium chloride solution into and removing it from rear and 4WD type front wheel tires W10265850 Clutch Center Tool For B and L Series Tractors Application The clutch center tool can be used for all B and L series tractors with a diaphragm clutch by changing tip guides Center piece diameter is 20 mm 0 79 in W10266370 Toe in Gauge Code ...

Page 68: ...testing the hydraulic system W10313960 Power Steering Adapter Code No 07916 54021 Application Use for measuring the relief valve setting pressure for power steering W10442870 1 Gauge 07916 50322 2 Cable 07916 50331 3 Threaded Joint 07916 50401 4 Threaded Joint 07916 50341 5 Adaptor B M18 P1 5 07916 50361 6 Adaptor C PS3 8 07916 50371 7 Adaptor D PT1 8 07916 50381 8 Adaptor E PS3 8 07916 50392 9 Ad...

Page 69: ...2751 Application This offers easy measurement of relief valve setting pressure from the hydraulic coupler This is available with the relief valve setting pressure tester W10623960 NOTE The following special tools are not provided so make them referring to the figure Pinion Shaft Remover Application Use for removing a pinion shaft W10315930 A 106 mm 4 17 in B 350 mm 13 78 in C 6 mm 0 24 in D 90 mm ...

Page 70: ...in B 24 5 to 25 5 mm 0 9646 to 1 0039 in 21 5 to 22 5 mm 0 8465 to 0 8858 in C 40 mm 1 57 in 40 mm 1 57 in D 32 mm 1 26 in 30 mm 1 18 in E 49 7 to 49 9 mm 1 9567 to 1 9646 in 44 7 to 44 9 mm 1 7598 to 1 7677 in F 70 mm dia 2 76 in dia G 40 mm dia 1 57 in dia H 50 mm 1 97 in I 10 mm 0 39 in a 6 3 μm 250 μin b 6 3 μm 250 μin c 6 3 μm 250 μin d 6 3 μm 250 μin A 1045 mm 41 14 in B 1000 mm 29 37 in C 2...

Page 71: ...r gas leak testing the air conditioning system W1013817 Vacuum Pump Code No DENSO CO 95046 00040 AC220V 95046 00050 AC240V Application Use for evacuating the air conditioning system W1013764 1 Manifold Gauge Assembly 2 Charging Hose Red HI 3 Charging Hose Blue LO 4 Charging Hose Green 5 Can Tap Valve 6 T Joint 7 Quick Coupler HI 8 Quick Coupler LO 9 Service Valve Packing 10 Charging Hose Packing 1...

Page 72: ...ication Use for loosen and tighten the magnet clutch mounting nut NOTE This special tool is not provided so make it referring to the figure A 125 mm 4 92 in H 4 52 rad 120 B 40 mm dia 1 57 in dia I Radius 27 mm Radius 1 06 in C Radius 33 mm Radius 1 30 in J Radius 50 mm Radius 1 97 in D 16 mm 0 63 in K Weld all around E 120 mm dia 4 72 in dia L 20 mm 0 78 in F 12 mm dia 0 47 in dia M Radius 41 mm ...

Page 73: ...r measuring the system pressure of shuttle valve W1039227 A 24 mm 0 94 in B 27 7 mm 1 09 in C PS1 4 D 11 mm 0 43 in E 15 mm 0 59 in F 40 mm 1 57 in G 60 mm 2 36 in H 15 mm 0 59 in I PT1 8 J 4 mm dia 0 15 in dia C1 Chamfer 1 mm 0 039 in C2 Chamfer 2 mm 0 079 in KiSC issued 02 2007 A ...

Page 74: ...m size A to size R are same size as adaptor 61 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 71 in dia N 37 mm 1 46 in E 12 mm dia 0 47 in dia O 61 5 mm 2 42 in F 1 7 to 1 9 mm 0 067 to 0 075 in P 24 mm 0 94 in G 30 mm Round 1 18 in Round Q 27 7 mm 1 09 in H 10 mm dia 0 39 in dia R 0 244 rad 14 I G 3 8 S 40 ...

Page 75: ...nflate as necessary NOTE Maintain the maximum pressure in front tires if using a front loader or when equipped with a full load of front weights W10440050 Tire sizes Inflation Pressure Rear 11 2 24 4PR 120 kPa 1 2 kgf cm2 17 psi 12 4 24 4PR 100 kPa 1 0 kgf cm2 14 psi 13 6 24 4PR 100 kPa 1 0 kgf cm2 14 psi 13 6 26 4PR 100 kPa 1 0 kgf cm2 14 psi 13 6 28 6PR 140 kPa 1 4 kgf cm2 20 psi 355 80 D20 4PR ...

Page 76: ...stable 1 Tread W10527070 2 Rear Wheels Rear tread can be adjusted in 6 steps depending on the model To change the tread 1 Lift the rear tires off the ground 2 Follow the illustrations below to get the desired tread width IMPORTANT If not attached as illustrated transmission parts may be damaged When re fitting or adjusting a wheel tighten the bolts to the following torques then recheck after drivi...

Page 77: ...4 5 in 1220 mm 48 0 in 1320 mm 52 0 in 1400 mm 55 1 in L3830 L4630 13 6 24 Farm 1140 mm 44 9 in 1210 mm 47 6 in 1310 mm 51 6 in 1410 mm 55 5 in L3830 L4630 13 6 26 Farm 1140 mm 44 9 in 1210 mm 47 6 in 1310 mm 51 6 in 1335 mm 52 6 in L5030 13 6 28 Farm 1125 mm 44 3 in 1225 mm 48 2 in 1325 mm 52 2 in Models L3130 L3430 355 80 D20 Turf 1125 mm 44 3 in 1190 mm 46 9 in L3830 L4630 355 80 D20 Turf 1140 ...

Page 78: ...ng a calcium chloride solution do not pour water over calcium chloride since this results in chemical reaction which will cause high temperature Instead add a small amount of calcium chloride to the water at a time until the desired solution is achieved W10330830 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 a...

Page 79: ... C 22 F Approx 1 kg 2 lbs CaCl2 per 4 L 1 gals 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 gals of water 108 kg 238 lbs 125 kg 276 lbs 160 kg 353 lbs Slush free at 47 C 53 F Solid at 52 C 62 F Approx 2 25 kg 5 lbs CaCl2 per 4 L 1 gals of water 115 kg 254 lbs 133 kg 293 lbs 170 kg 375 lbs Tire sizes 13 6 26 1...

Page 80: ...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 direct compressed air into the tire to force out the liquid through the injector s vent W10451670 1 Injector 2 Hose 3 Vent A Compressed Air KiSC issued 02 2007 A ...

Page 81: ...1 ENGINE KiSC issued 02 2007 A ...

Page 82: ...CONTENTS MECHANISM 1 FEATURES 1 M1 2 FUEL SYSTEM 1 M2 3 LUBRICATING SYSTEM 1 M3 4 COOLING SYSTEM 1 M4 KiSC issued 02 2007 A ...

Page 83: ...RES The engine model shown in the table below is adopted in the L30 series tractor These are 03 M series engine W1012642 Tractor Model Engine Model L3130 D1503 MA E L3430 D1703 MA E L3830 D1803 MA E L4630 V2203 MA E L5030 V2403 MA E KiSC issued 02 2007 A ...

Page 84: ... 6 by the fuel feed pump 8 after passing through the fuel filter 7 The fuel camshaft actuates the injection pump and force feeds fuel to the injection nozzle 2 through the injection pipe 3 Fuel is then sprayed through the nozzle into the combustion chamber The fuel discharged after lubricating and cooling the injection nozzle is returned to the fuel tank 4 automatically through the overflow pipe 1...

Page 85: ...s down to the oil filter cartridge where it is further filtered Then the oil is forced to crankshaft 7 connecting rods 16 idle gear 6 governor shaft 5 camshaft 14 and rocker arm shaft 3 to lubricate each part through the oil gallery 1 Rocker Arm 2 Oil Pressure Switch 3 Rocker Arm Shaft 4 Valve 5 Governor Shaft 6 Idle Gear 7 Crankshaft 8 Oil Pump 9 Oil Strainer 10 Relief Valve 11 Oil Filter Cartrid...

Page 86: ... from the cylinder head and force it into the cylinder block The thermostat 3 opens or closes according to the water temperature When the water temperature is high the thermostat 3 opens to allow the water to flow from the cylinder head to the radiator 1 When the water temperature is low the thermostat close to flow the water only to the water pump 4 The opening temperature of the thermostat 3 is ...

Page 87: ... 1 S12 1 SEPARATING ENGINE FROM TRACTOR 1 S12 2 ENGINE BODY 1 S26 1 Checking and Adjusting 1 S26 2 Disassembling and Assembling 1 S28 3 Servicing 1 S44 3 LUBRICATING SYSTEM 1 S61 1 Checking 1 S61 2 Servicing 1 S61 4 COOLING SYSTEM 1 S62 1 Checking and Adjusting 1 S62 5 FUEL SYSTEM 1 S64 1 Checking and Adjusting 1 S64 KiSC issued 02 2007 A ...

Page 88: ...orrect or replace timing gear Replace Adjust G 7 8 G 34 G 31 G 7 8 G 7 8 1 S29 1 S64 1 S37 1 S32 1 S37 S39 S42 1 S29 S30 1 S36 1 S39 1 S27 Starter Does Not Run Battery discharged Starter malfunctioning Main switch malfunctioning Safety switches improperly adjusted or defective Starter relay defective Wiring disconnected Electronic instrument panel connector disconnected Charge Repair or replace Re...

Page 89: ... worn Oil leaking due to defective seals or packing Shift ring gap direction Replace Replace the piston Replace Replace 1 S40 1 S40 1 S39 S40 1 S31 Fuel Mixed Into Lubricant Oil Injection pump s plunger worn Deficient nozzle injection Injection pump broken Replace pump element or pump Repair or replace the nozzle Replace 1 S32 1 S29 S65 1 S32 Water Mixed Into Lubricant Oil Head gasket defective Cy...

Page 90: ...net and radiator fin clogged with dust Inside of radiator corroded Coolant flow route corroded Radiator cap defective Overload running Head gasket defective Incorrect injection timing Unsuitable fuel used Replenish Change or adjust Replenish Clean Clean or replace Clean or replace Replace Loosen the load Replace Adjust Use the specified fuel G 7 8 G 23 G 27 1 S63 1 S30 1 S64 G 7 8 KiSC issued 02 2...

Page 91: ...pm 10 or less Top Clearance 0 55 to 0 70 mm 0 0217 to 0 0276 in Valve Clearance When Cold 0 18 to 0 22 mm 0 0071 to 0 0087 in Valve Seat Width Intake Width Exhaust 2 12 mm 0 0835 in 2 12 mm 0 0835 in Valve Seat Angle Intake Angle Exhaust 1 047 rad 60 0 785 rad 45 Valve Face Angle Intake Angle Exhaust 1 047 rad 60 0 785 rad 45 Valve Stem to Valve Guide Valve Stem Valve Guide Clearance O D I D 0 040...

Page 92: ...ing Free Length Setting Load Setting Length Tilt 41 7 to 42 2 mm 1 6417 to 1 6614 in 117 6 N 35 0 mm 12 0 kgf 35 0 mm 26 4 lbs 1 3780 in 41 2 mm 1 6220 in 100 0 N 35 0 mm 10 2 kgf 35 0 mm 22 5 lbs 1 3780 in 1 0 mm 0 039 in Rocker Arm Shaft to Rocker Arm Rocker Arm Shaft Rocker Arm Clearance O D I D 0 016 to 0 045 mm 0 00063 to 0 00177 in 13 973 to 13 984 mm 0 55012 to 0 55055 in 14 000 to 14 018 m...

Page 93: ... Gear Bushing Idle Gear Shaft Idle Gear Bushing Clearance O D I D 0 025 to 0 066 mm 0 00098 to 0 00260 in 37 959 to 37 975 mm 1 49445 to 1 49508 in 38 000 to 38 025 mm 1 49606 to 1 49704 in 0 1 mm 0 0039 in Camshaft Side Clearance 0 07 to 0 22 mm 0 0028 to 0 0087 in 0 3 mm 0 0118 in Camshaft Alignment 0 01 mm 0 0004 in Cam Height Intake Exhaust 33 90 mm 1 3346 in 33 85 mm 1 3327 in Camshaft Journa...

Page 94: ...476 in 25 05 mm 0 9862 in Second Ring to Ring Groove D1503 M D1703 M D1803 M V2203 M V2403 M Clearance 0 093 to 0 120 mm 0 0037 to 0 0047 in 0 093 to 0 128 mm 0 0037 to 0 0050 in 0 2 mm 0 0079 in 0 2 mm 0 0079 in Oil Ring to Ring Groove Clearance 0 020 to 0 060 mm 0 0008 to 0 0021 in 0 15 mm 0 0059 in Top Ring D1503 M D1703 M D1803 M V2203 M V2403 M Ring Gap 0 20to 0 35 mm 0 0079 to 0 0138 in 0 20...

Page 95: ...nkshaft Bearing 2 D1503 M D1703 M V2203 M D1803 M V2403 M D1503 M D1703 M V2203 M D1803 M V2403 M Oil Clearance O D I D 0 040 to 0 104 mm 0 00157 to 0 00409 in 51 921 to 51 940 mm 2 04413 to 2 04488 in 59 921 to 59 940 mm 2 35909 to 2 35984 in 51 980 to 52 025 mm 2 04646 to 2 04823 in 59 980 to 60 025 mm 2 36142 to 2 36318 in 0 2 mm 0 0079 in Crankpin to Crankpin Bearing Crankpin Crankpin Bearing ...

Page 96: ...0 in 0 15 mm 0 0059 in 0 15 mm 0 0059 in 0 15 mm 0 0059 in 0 15 mm 0 0059 in Engine Oil Pressure At Idle Speed At Rated Speed 98 kPa or more 1 0 kgf cm2 or more 14 psi or more 294 to 441 kPa 3 0 to 4 5 kgf cm2 43 to 64 psi 49 kPa 0 5 kgf cm2 7 psi 245 kPa 2 5 kgf cm2 36 psi Engine Oil Pressure Switch Working Pressure 49 kPa 0 5 kgf cm2 7 psi Inner Rotor to Outer Rotor Clearance 0 03 to 0 14 mm 0 0...

Page 97: ...ure falling from 88 to 59 kPa from 0 9 to 0 6 kgf cm2 from 13 to 9 psi Injection Pump Injection Timing 0 297 to 0 331 rad 17 to 19 before T D C Pump Element Fuel Tightness 14 7 MPa 150 kgf cm2 2133 psi Delivery Valve Fuel Tightness 10 seconds or more for pressure falling from 14 7 to 13 7 MPa from 150 to 140 kgf cm2 from 2133 to 1990 psi 5 seconds for pressure falling from 14 7 to 13 7 MPa from 15...

Page 98: ... 27 5 26 5 to 31 0 10 5 to 12 0 14 0 to 15 0 17 0 to 20 0 12 6 to 15 0 20 to 23 2 5 to 3 0 3 2 to 3 8 12 6 to 15 0 5 0 to 7 0 3 5 to 4 0 3 5 to 4 0 7 9 to 9 2 4 0 to 5 0 4 0 to 5 0 5 0 to 6 0 7 9 to 9 2 10 5 to 12 0 4 0 to 4 5 1 8 to 2 1 2 4 to 2 8 192 to 224 75 9 to 86 8 102 to 108 123 to 145 91 1 to 108 145 to 166 18 1 to 21 7 23 1 to 27 5 91 1 to 108 36 1 to 50 6 25 3 to 28 9 25 3 to 28 9 57 1 ...

Page 99: ...ing Fill the engine oil up to the upper line on the dipstick 2 IMPORTANT Never mix two different type of oil Use the proper SAE Engine Oil according to ambient temperature Refer to LUBRICANTS FUEL AND COOLANT See page G 7 8 W1013940 Engine oil capacity L3130 L3430 5 7 L 6 0 U S qts 5 0 Imp qts L3830 6 7 L 7 1 U S qts 5 9 Imp qts L4630 L5030 8 2 L 8 7 U S qts 7 2 Imp qts 1 Drain Plug 2 Dipstick 3 O...

Page 100: ...utes 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 hydraulic system Refer to LUBRICANTS FUEL AND COOLANT See page G 7 8 Do not mix different brands of fluid together W1014221 Transmission fluid capacity L3130 L3430 42 L 11 1 U S gals 9 2 Imp gals L3830 L46...

Page 101: ...ighten all screws until most components are attached W1031307 Battery Front Grill Skirt and Bonnet 1 Open the bonnet and disconnect the battery negative cable 2 Disconnect the head light connector and remove the front grill 4 3 Remove the left and right side skirts 3 4 Disconnect window washer hoses 2 Cabin model only 5 Remove the bonnet 1 NOTE When disconnecting the battery cords disconnect the n...

Page 102: ...e Lower connector mounting screw 3 103 to 118 N m 10 5 to 12 0 kgf m 75 9 to 86 8 ft lbs Plate mounting screw 4 138 to 147 N m 14 0 to 15 0 kgf m 102 to 108 ft lbs Plate mounting screw 8 167 to 196 N m 17 0 to 20 0 kgf m 123 to 145 ft lbs Tightening torque Fulcrum bolt and nut 9 118 to 137 N m 12 0 to 14 0 kgf m 86 8 to 102 ft lbs 1 Upper Frame 2 Lower Connector 3 Screw M12 65 4 Screw M14 40 5 Low...

Page 103: ... disconnecting 6 Disconnect the wiring connector for window washer tank 5 and compressor 1P connector 6 Cabin model only 7 Disconnect the brake pedal rod When reassembling When accelerator wire is installed adjust the wiring length as hit both the idling speed adjusting bolt and the maximum speed adjusting bolt by lever within the stroke of the accelerator lever Set the steering joint 1 by the joi...

Page 104: ... and battery 3 Remove the clamps and ground earth of wiring harness and collect wiring harness to the step or cabin 4 Remove the clamps 7 of A C hoses 8 Cabin A C model only When reassembling Be sure to check and adjust the clutch and brake pedal free travel See page G 18 24 W1061165 1 Alternator 2 Oil Pressure Switch 3 Fuel Unit 4 Clutch Rod 5 Brake Pedal Rod 6 Starter Motor 7 Clamps 8 A C Hoses ...

Page 105: ... Differential Lock Rod Lowering Speed Adjusting Knob and PTO Speed Change Lever if equipped 1 Disconnect the differential lock rod 2 Reference As for location of differential lock rod 2 it is at right side for manual transmission and GST model and left side for HST model 2 Remove the lowering speed adjusting knob 3 3 Remove the PTO speed change lever 1 if equipped 4 Disconnect the PTO speed sensor...

Page 106: ...eed adjusting knob 4 2 Disconnect the differential lock rod 2 3 Disconnect the range gear shift lever sensor connector 3 4 Disconnect the cruise switch connector 1 5 Disconnect the HST pedal neutral switch connector 5 6 Disconnect the ground earth a W1064315 1 ECU Connector 2 GST Lever Sensor Connector 3 Wiring Harness of GST Lever Sensor 4 Pressure Switch Connector 5 Proportional Reducing Valve C...

Page 107: ...he lock nut 4 of wire and connect wire to the clutch valve lever and then place the wire to the hook 3 Tighten the lock nut 4 clockwise pull the wire and lock the nut just before the lever moves W1064487 Shuttle Switch Connector Manual and GST Model 1 Remove the panel cover and steering post cover 2 Disconnect the shuttle switch connector 1 W1064666 Cruise Control Release Wire HST Model 1 Disconne...

Page 108: ...he recovery tank hose 5 6 Disconnect the radiator upper hose 3 7 Remove the oil cooler mounting screw HST model only 8 Remove the battery 10 9 Remove the battery stay mounting bolt 10 Take out the compressor 1 condenser 11 receiver 12 hoses 13 battery stay 9 and etc as a unit When reassembling After reassembling the compressor be sure to adjust the air conditioner belt tension See page G 29 W10153...

Page 109: ...e 1 2 2 Remove the PTO delivery pipe 3 Manual and GST model 3 Disconnect the suction hose 1 from hydraulic pump 4 Remove the joint bolt 4 of oil cooler pipe 5 HST model When reassembling W1067766 Tightening torque Cabin mounting bolt and nut 124 to 147 N m 12 6 to 15 0 kgf m 91 1 to 108 ft lbs 1 Nylon Straps 2 Bolt 3 Plate 4 Mount Rubber 5 Collar 6 Plain Washer M14 7 Washer 8 Spring Washer 9 Nut F...

Page 110: ...flywheel housing and clutch housing W1069132 Fuel Tank 1 Remove the muffler 5 ROPS model 2 Disconnect the overflow hoses 3 and fuel hose 8 3 Remove the reserve tank bracket 6 ROPS model 4 Remove the compressor bracket Cabin model 5 Remove the shutter plate 4 6 Remove the tank frame mounting bolt and remove the fuel tank 2 with frame 1 When reassembling W1015605 1 Coupling 2 Spring Pin 3 Propeller ...

Page 111: ...ing screws 3 Separate the front axle frame 1 from engine When reassembling W1016162 1 Battery 2 Oil Cooler HST Model Only 3 Air Cleaner Hose 4 Battery Stay 5 Radiator Upper Hose 6 Radiator 7 Radiator Lower Hose Tightening torque Joint bolt for power steering delivery pipe 39 2 to 49 0 N m 4 0 to 5 0 kgf m 28 9 to 36 2 ft lbs Cap nut of power steering delivery pipe 49 0 to 58 8 N m 5 0 to 6 0 kgf m...

Page 112: ...nt to the splines of clutch disc boss Install the pressure plate nothing the position of straight pins IMPORTANT Align the center of disc and flywheel by inserting the clutch center tool See page G 47 NOTE Do not allow grease and oil on the clutch disc facing W10171850 Tightening torque Alternator mounting screw M10 39 2 to 44 1 N m 4 0 to 4 5 kgf m 28 9 to 32 5 ft lbs Tension adjusting screw M8 1...

Page 113: ...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 pressure is still less than the allowable limit check the top clearance valve and cylinder head 10 If the compression pressure increases after applying oil check the cylinder wall and piston rings NO...

Page 114: ...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 The piston is at the compression top dead center when both the IN and EX valves do not move it is at the overlap position when both the valves move Finally turn the flywheel 6 28 rad 360 and align the TC marking line and t...

Page 115: ... bearing and between the piston pin and bushing W1020190 2 Disassembling and Assembling A Cylinder Head and Valves Cylinder Head Cover 1 Remove the lead 1 2 Remove the breather hose 2 3 Remove the head cover screws 3 4 Remove the cylinder head cover 4 When reassembling Check to see if the cylinder head cover gasket is not defective W1060460 Top clearance Factory spec 0 55 to 0 70 mm 0 0217 to 0 02...

Page 116: ...heat seal hole 2 Turn screw driver three or four times each way 3 While turning the screw driver slowly pull the heat seal 4 out together with the copper gasket 3 4 If the heat seal drops repeat the above procedure When reassembling Heat seal and copper gasket must be changed when the injection nozzle is removed for cleaning or for service W1021255 Tightening torque Injection pipe retaining nut 24...

Page 117: ...d 3 to detach 4 Remove the cylinder head gasket 4 When reassembling Replace the cylinder head gasket with a new one Tighten the cylinder head screws after applying sufficient oil Tighten the cylinder head screws in diagonal sequence starting from the center in the order of a to n or r Tighten them uniformly or the head may deform in the long run W1021755 Tightening torque Rocker arm bracket nut 23...

Page 118: ...move the valve spring collet 3 pushing the valve spring retainer 4 by valve spring replacer 1 3 Remove the valve spring retainer 4 valve spring 5 and valve stem 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 proper fit with a plastic hammer IMPORTANT Do...

Page 119: ...ion Replace the hi idling body gasket 6 with a new one Before fitting the stop lever to the gear case install the solenoid guide first into position Then attach the stop lever and use it to see if it functions well Before fitting the idling limiter in place attach the solenoid guide and the engine stop lever in their respective positions When installing the stop solenoid be careful to keep the O r...

Page 120: ... nuts and bolts 3 Using the specific tool 1 undo the large governor spring 2 from the fork lever 3 4 Using the specific tool 1 undo the small governor spring 4 from the fork lever 3 5 Set the speed control lever 5 as the figure 6 Take out the speed control plate 6 with care not to let the large 2 and small 4 governor springs come off this plate and fall in to the gear case W1148604 1 Specific Tool...

Page 121: ...too long because otherwise it may get deformed permanently Using the specific tool 1 hook the large governor spring 2 onto the fork lever 3 Make sure both the governor springs 2 4 are tight on the fork lever 3 Apply and tighten up the two bolts and two nuts on the speed control plate 6 Check that the speed control lever 5 positions low idle after assembling governor springs Check that the speed co...

Page 122: ... both side of hour meter gear 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 gasket apply a non drying adhesive W1024531 Crankshaft Oil Slinger 1 Remove the feather key 2 Remove the crankshaft collar 3 3 Remove the O ring 2 4 Detach the crankshaft oi...

Page 123: ...with its aligning mark Idle gear 2 and crank gear 5 cam gear 3 and balancer gear 4 Cam gear 3 and idle gear 2 Idle gear 2 and injection pump gear 1 Idle gear 2 and balancer gear 7 W1024941 Camshaft for D1503 M D1703 M and D1803 M 1 Remove the camshaft set bolts 2 and draw out the camshaft 1 When reassembling When installing the idle gear be sure to align the alignment marks on gears W1046059 1 Inj...

Page 124: ...fork 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 2 4 are fixed to the fork lever shaft and that they can turn smoothly in the holder 7 W1025309 Oil Pump 1 Remove the nut 2 Draw out the oil pump drive gear 1 with gear puller 2 3 Remove the four oi...

Page 125: ... the oil strainer 3 and O ring 4 When reassembling After cleaning the oil strainer 3 check to see that the filter mesh in clean and install it Visually check the O ring 4 apply engine oil and install it Securely fit the O ring 4 to the oil strainer 3 Apply a liquid gasket Three Bond 1215 or equivalent to the oil pan side of the oil pan gasket 2 To avoid uneven tightening tighten oil pan mounting s...

Page 126: ...mple mark 1 on the No 1 piston Place the piston rings with their gaps at 0 79 rad 45 from the piston pin s direction as shown in the figure Carefully insert the pistons using a piston ring compressor When inserting the piston in place be careful not to get the molybdenum disulfide coating torn off its skirt This coating is useful in minimizing the clearance with the cylinder liner Just after the p...

Page 127: ...site side of the oil ring gap 11 Apply engine oil to the piston pin When installing the connecting rod 7 to the piston 2 immerse the piston 2 in 80 C 176 F oil for 10 to 15 minutes and insert the piston pin 1 to the piston 2 NOTE When installing the connecting rod 7 to the piston 2 align the mark 8 on the connecting rod 7 to the fan shaped concave 9 Mark the same number on the connecting rod 7 and...

Page 128: ...case cover 5 to remove it IMPORTANT The length of inside screws and outside screws are different Do not take a mistake using inside screws and outside screws When reassembling Fit the bearing case gasket 1 and the bearing case cover gasket 2 with correct directions Install the bearing case cover 5 to position the casting mark UP on it upward Apply engine oil to the oil seal lip and take care that ...

Page 129: ...r of the third cylinder 4 Repeat the above steps to draw out all the crankshaft 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 holding the crank pins to the horizontal directions Right or Left When reassembling IMPORTANT Install the crankshaft sub assembl...

Page 130: ...s 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 main bearing case 1 and 2 face the mark FLYWHEEL to the flywheel Install the thrust bearing with its oil groove facing 7 outward Confirm that the main bearing case moves smoothly after tightening the mai...

Page 131: ...with the detergent 2 5 Spray the cylinder head surface with white developer 3 6 If flawed it can be identified as red marks W1076542 Valve Recessing 1 Clean the cylinder head surface valve face and valve seat 2 Insert the valve into the valve guide 3 Measure the valve recessing with a depth gauge 4 If the measurement exceeds the allowable limit replace the valve 5 If it still exceeds the allowable...

Page 132: ...ool When installing 1 Clean a new valve guide and valve guide bore and apply engine oil to them 2 Press in a new valve guide using a valve guide replacing tool 3 Ream precisely the I D of the valve guide to the specified dimension IMPORTANT Do not hit the valve guide with a hammer during replacement W1027889 Clearance between valve stem and guide Factory spec 0 040 to 0 070 mm 0 00157 to 0 00276 i...

Page 133: ...r 2 Correcting Valve Seat 1 Slightly correct the seat surface with a 1 047 rad 60 intake valve or 0 785 rad 45 exhaust valve seat cutter Code No 07909 33102 2 Resurface the seat surface with a 0 523 rad 30 valve seat cutter to intake valve seat and with a 0 262 rad 15 valve seat cutter to exhaust valve seat so that the width is close to specified valve seat width 2 12 mm 0 0835 in 3 After resurfac...

Page 134: ...he allowable limit replace it 2 Put the valve spring on a surface plate place a square on the side of the valve spring 3 Check to see if the entire side is in contact with the square Rotate the valve spring and measure the maximum tilt B Check the entire surface of the valve spring for scratches If there is any defect replace it W1028935 Valve Spring Setting Load 1 Place the valve spring on a test...

Page 135: ...appet O D with an outside micrometer 2 Measure the I D of the tappet guide bore with a cylinder gauge and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit or the tappet is damaged replace the tappet W1028249 Oil clearance between rocker arm and rocker arm shaft Factory spec 0 016 to 0 045 mm 0 00063 to 0 00177 in Allowable limit 0 10 mm 0 0039 in Rocker arm shaft O D ...

Page 136: ...r Factory spec 0 0415 to 0 1122 mm 0 00163 to 0 00442 in Allowable limit 0 15 mm 0 0059 in Backlash between idle gear and cam gear Factory spec 0 0415 to 0 1154 mm 0 00163 to 0 00454 in Allowable limit 0 15 mm 0 0059 in Backlash between idle gear and injection pump gear Factory spec 0 0415 to 0 1154 mm 0 00163 to 0 00454 in Allowable limit 0 15 mm 0 0059 in Backlash between crank gear and oil pump...

Page 137: ...Side 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 the allowable limit replace the balancer shaft W1030111 Camshaft side clearance Factory spec 0 07 to 0 22 mm 0 0028 to 0 0087 in Allowable limit 0 30 mm 0 0118 in Side clearance of balancer shaft Fa...

Page 138: ...Balancer shaft bearing 1 I D Factory spec 43 980 to 44 045 mm 1 73149 to 1 73405 in Oil clearance of balancer shaft journal 2 Factory spec 0 030 to 0 111 mm 0 00118 to 0 00437 in Allowable limit 0 2 mm 0 0079 in Balancer shaft journal 2 O D Factory spec 41 934 to 41 950 mm 1 65094 to 1 65157 in Balancer shaft bearing 2 I D Factory spec 41 980 to 42 045 mm 1 65275 to 1 65531 in Oil clearance of bal...

Page 139: ... on the surface plate at both end journals 2 Set a dial indicator with its tip on the intermediate journal 3 Measure the camshaft alignment 4 If the measurement exceeds the allowable limit replace the camshaft W1031413 Cam Height 1 Measure the height of the cam at its highest point with an outside micrometer 2 If the measurement is less than the allowable limit replace the camshaft W1031532 Camsha...

Page 140: ...ll end bushing I D with an inside micrometer and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit replace the bushing If it still exceeds the allowable limit replace the piston pin W1031982 Oil clearance of camshaft journal Factory spec 0 050 to 0 091 mm 0 00197 to 0 00358 in Allowable limit 0 15 mm 0 0059 in Camshaft journal O D Factory spec 39 934 to 39 950 mm 1 572...

Page 141: ...arance between the ring and the groove with a feeler gauge 3 If the clearance exceeds allowable limit replace the ring since compression leak and oil shortage result 4 if the clearance still exceeds the allowable limit after replacing the ring replace the piston W1032489 Top ring Factory spec D1503 M 0 20 to 0 35 mm 0 0079 to 0 0138 in D1703 M D1803 M V2203 M V2403 M 0 20 to 0 40 mm 0 0079 to 0 01...

Page 142: ...nce Oversize dimensions of crankshaft journal W1032880 Crankshaft Alignment 1 Support the crankshaft with V blocks on the surface plate and set a dial indicator with its tip on the intermediate journal at right angle 2 Rotate the crankshaft on the V blocks and get the misalignment half of the measurement 3 If the misalignment exceeds the allowable limit replace the crankshaft W1033001 Connecting r...

Page 143: ...Never insert the plastigage into the crankpin oil hole Be sure not to move the crankshaft while the connecting rod screws are tightened Reference Undersize dimensions of crankpin W1033106 Oil clearance between crankpin and crankpin bearing Factory spec 0 025 to 0 087 mm 0 00098 to 0 00343 in Allowable limit 0 2 mm 0 0079 in Crankpin O D Factory spec 46 959 to 46 975 mm 1 84878 to 1 84941 in Crankp...

Page 144: ...old side W1033946 Oil clearance between crankshaft journal and crankshaft bearing 1 Factory spec 0 040 to 0 118 mm 0 00157 to 0 00409 in Allowable limit 0 2 mm 0 0079 in Crankshaft journal O D Factory spec D1503 M V1703 M V2203 M 51 921 to 51 940 mm 2 0441 to 2 0449 in D1803 M V2403 M 59 921 to 59 940 mm 2 35909 to 2 35984 in Crankshaft bearing 1 I D Factory spec D1503 M V1703 M V2203 M 51 980 to ...

Page 145: ... crankshaft sleeve W1033354 Oil clearance between crankshaft and crankshaft bearing 2 Factory spec 0 040 to 0 104 mm 0 00157 to 0 00409 in Allowable limit 0 20 mm 0 0079 in Crankshaft O D Factory spec D1503 M V1703 M V2203 M 51 921 to 51 940 mm 2 0441 to 2 0449 in D1803 M V2403 M 59 921 to 59 940 mm 2 35909 to 2 35984 in Crankshaft bearing 2 I D Factory spec D1503 M V1703 M V2203 M 51 980 to 52 02...

Page 146: ...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 limit bore and hone to the oversize dimension Refer to Correcting Cylinder 4 Visually check the cylinder wall for scratches If deep scratches are found the cylinder should be bores Refer to Correcting Cylinder W1034389 1 Stopper 2 Sl...

Page 147: ...n beyond the allowable limit replace the cylinder block with a new one W1034448 Oversize cylinder I D Factory spec D1503 M 83 250 to 83 272 mm 3 2776 to 3 2784 in D1703 M D1803 M V2203 M V2403 M 87 250 to 87 272 mm 3 43503 to 3 43590 in Maximum wear Allowable limit D1503 M 0 15 mm 0 0059 in D1703 M D1803 M V2203 M V2403 M 0 15 mm 0 0059 in Finishing Hone to 2 2 to 3 0 mm μR max 0 00087 to 0 00118 ...

Page 148: ...the engine oil pressure switch to the specified torque W1034952 2 Servicing Rotor Lobe Clearance 1 Measure the clearance between lobes of the inner rotor and the outer rotor with a feeler gauge 2 Measure the clearance between the outer rotor and the pump body with a feeler gauge 3 If the clearance exceeds the factory specifications replace the oil pump rotor assembly W1035296 Engine oil pressure A...

Page 149: ...sing the belt halfway between the fan drive pulley and alternator pulley at specified force 98 N 10 kgf 22 lbs 2 If the measurement is not within the factory specifications loosen the alternator mounting screws and relocate the alternator to adjust W1035667 Fan Belt Damage and Wear 1 Check the fan belt for damage 2 If the fan belt is damaged replace it 3 Check if the fan belt is worn and sunk in t...

Page 150: ...9 kgf cm2 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 W1036090 Radiator Water Leakage 1 Pour a specified amount of water into the radiator 2 Set a radiator tester Code No 07909 31551 with an adapter BANZAI Code No RCT 2A 30S and raise the water pressure to the specified pressur...

Page 151: ...ery 0 087 rad 5 of crank angle from 0 175 rad 10 to 0 436 rad 25 before mark 1TC Calculate the angle which the center of the window points out If the calculation differs from specified injection timing add or remove the shim to adjust Injection Timing 0 297 to 0 331 rad 17 to 19 B T D C NOTE The sealant is applied to both sides of the soft metal gasket shim The liquid gasket is not required for as...

Page 152: ...ctory specifications replace the injection nozzle assembly W1037197 Nozzle Spraying Condition 1 Set the injection nozzle to a nozzle tester Code No 07909 31361 and check the nozzle spraying condition 2 If the spraying condition is defective replace the injection nozzle assembly W1037394 Valve Seat Tightness 1 Set the injection nozzle to a nozzle tester Code No 07909 31361 2 Raise the fuel pressure...

Page 153: ...2 CLUTCH KiSC issued 02 2007 A ...

Page 154: ...CONTENTS MECHANISM 1 FEATURE 2 M1 KiSC issued 02 2007 A ...

Page 155: ...dal and the pedal 5 and release fork 3 have been linked as shown in figure W1012642 1 Clutch Disc 2 Pressure Plate Assembly 3 Release Fork 4 Clutch Pedal Rod 5 Clutch Pedal 6 Release Bearing 7 Release Hub 8 Clutch Lever Shaft 9 Flywheel 10 Pressure Plate 11 Diaphragm Spring 12 Main Shaft 13 Clutch Cover 14 PTO Shaft A Manual Transmission and GST Model B HST Model KiSC issued 02 2007 A ...

Page 156: ...ATIONS 2 S2 3 TIGHTENING TORQUES 2 S3 4 CHECKING DISASSEMBLING AND SERVICING 2 S4 1 CHECKING AND ADJUSTING 2 S4 2 DISASSEMBLING AND ASSEMBLING 2 S5 1 Separating Clutch Housing and Engine 2 S5 2 Removing Clutch Assembly 2 S14 3 SERVICING 2 S15 KiSC issued 02 2007 A ...

Page 157: ...Pressure Plate assembly 2 S4 2 S14 2 S14 2 S14 2 S14 2 S14 Chattering Grease or oil on clutch disc facing Clutch disc or pressure plate warped Clutch disc boss spline worn or rusted Gear shaft bent Pressure plate or flywheel face cracked or scored Clutch disc boss spline and gear shaft spline worn Diaphragm spring strength uneven or diaphragm spring broken Replace Replace Replace or remove rust Re...

Page 158: ...lay 20 to 30 mm 0 78 to 1 18 in Clutch Stopper Bolt Height 18 to 22 mm 0 70 to 0 87 in Clutch Disc Disc Surface to Rivet Top Depth 0 3 mm 0 012 in Clutch Disc Boss to Gear Shaft Backlash Displacement Around Disc Edge 2 0 mm 0 079 in Pressure Plate Flatness 0 2 mm 0 008 in Diaphragm Spring Mutual Difference 0 5 mm 0 020 in KiSC issued 02 2007 A ...

Page 159: ...bolt for oil cooler pipe Clutch mounting screw Release fork setting screw Engine and clutch housing mounting screw and nut Engine and clutch housing mounting stud bolt 260 to 304 103 to 118 138 to 147 167 to 196 124 to 147 196 to 225 24 5 to 29 4 31 4 to 37 2 124 to 147 49 to 69 34 to 39 34 to 39 23 5 to 27 5 23 5 to 27 5 77 5 to 90 2 39 2 to 49 0 26 5 to 31 0 10 5 to 12 0 14 0 to 15 0 17 0 to 20 ...

Page 160: ...he clutch 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 within acceptable limits 3 Retighten the lock nut 2 and split the cotter pin 4 W1018185 Clutch pedal free travel L on top of clutch pedal Factory spec 20 to 30 mm 0 78 to 1 18 in 1 Clutch Pedal Rod 2 ...

Page 161: ...ls may damage the transmission or hydraulic system Refer to LUBRICANTS FUEL AND COOLANT See page G 7 8 Do not mix different brands of fluid together W1018004 ROPS Center ROPS Type 1 Remove the upper frame 1 from ROPS lower frame 2 2 Disconect the light connectors 3 Remove the shields 3 4 Remove the lower frames 2 When reassembling NOTE Do not firmly tighten all screws until most components are att...

Page 162: ...emove the upper frame 1 from ROPS lower frame 5 When reassembling NOTE Do not firmly tighten all screws until most components are attached Reference W1015970 1 Bonnet 2 Window Washer Hose 3 Skirt 4 Front Grill Tightening torque Lower connector mounting screw 3 103 to 118 N m 10 5 to 12 0 kgf m 75 9 to 86 8 ft lbs Plate mounting screw 4 138 to 147 N m 14 0 to 15 0 kgf m 102 to 108 ft lbs Plate moun...

Page 163: ...mark to the each heater hose before disconnecting 6 Disconnect the wiring connector for window washer tank 5 and compressor 1P connector 6 Cabin model only 7 Disconnect the brake pedal rod When reassembling When accelerator wire is installed adjust the wiring length as hit both the idling speed adjusting bolt and the maximum speed adjusting bolt by lever within the stroke of the accelerator lever ...

Page 164: ... and battery 3 Remove the clamps and ground earth of wiring harness and collect wiring harness to the step or cabin 4 Remove the clamps 7 of A C hoses 8 Cabin A C model only When reassembling Be sure to check and adjust the clutch and brake pedal free travel See page G 18 24 W1019114 1 Alternator 2 Oil Pressure Switch 3 Fuel Unit 4 Clutch Rod 5 Brake Pedal Rod 6 Starter Motor 7 Clamps 8 A C Hoses ...

Page 165: ...Differential Lock Rod Lowering Speed Adjusting Knob and PTO Speed Change Lever if equipped 1 Disconnect the differential lock rod 2 Reference As for location of differential lock rod 2 it is at right side for manual transmission and GST model and left side for HST model 2 Remove the lowering speed adjusting knob 3 3 Remove the PTO speed change lever 1 if equipped 4 Disconnect the PTO speed sensor ...

Page 166: ...PTO shift wire 2 at the PTO clutch valve lever 4 2 Disconnect the traveling speed sensor connector 1 When reassembling When connecting the PTO shift wire 2 to the lever 4 be sure to adjust the length of wire as follows 1 Set the PTO shift lever to OFF Neutral position 2 Loosen the lock nut 3 of wire and connect wire to the clutch valve lever 4 and then place the wire to the hook 3 Tighten the lock...

Page 167: ...r checking whether there is forgetting to disconnect wiring When reassembling Be sure to set the washers and rubber plates of the floor seat and step mounting bolt at an original positions as shown in figure Before mounting the floor seat and step be sure to set both the shuttle lever rod and the shuttle arm to the neutral position and then connect the shuttle lever rod securely Manual and GST mod...

Page 168: ...nd nuts 9 4 Dismounting the cabin from tractor body NOTE Lift the cabin while making sure it does not catch on anything When reassembling Be sure to install the washers and mount rubbers etc in their original positions Before mounting the cabin be sure to set both the shuttle lever rod and the shuttle arm to the neutral position and then connect the shuttle lever rod securely GST model W1021215 Ti...

Page 169: ... shaft with covers 4 8 When reassembling Apply grease to the splines of propeller shaft 1 3 W1021671 Tightening torque Joint bolt for main delivery pipe 1 to front hydraulic block 49 to 69 N m 5 0 to 7 0 kgf m 36 1 to 50 6 ft lbs Joint bolt for PTO delivery pipe 34 to 39 N m 3 5 to 4 0 kgf m 25 3 to 28 9 ft lbs Joint bolt for oil cooler pipe 34 to 39 N m 3 5 to 4 0 kgf m 25 3 to 28 9 ft lbs 1 Suct...

Page 170: ...he clutch from the flywheel When reassembling 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 noting the position of straight pins IMPORTANT Align the center of disc and flywheel by inserting the clutch center tool See page G 47 NOTE Do not allow grease and oil...

Page 171: ...2 Check for abnormal wear on contact surface 3 Hold bearing inner race and rotate outer race while applying pressure to it 4 If the bearing rotation is rough or noisy replace the bearing NOTE Do not depress outer race while installing thrust ball bearing W1017028 Clutch Disc Wear 1 Measure the depth from clutch disc surface to the top of rivet at least 10 points with a depth gauge 2 If the depth i...

Page 172: ...damage As these parts are invisible from outside shake pressure plate assembly up and down to listen for chattering noise or lightly hammer on rivets for a slightly cracked noise Any of these noises indicates need of replace as a complete assembly W1017284 Pressure Plate Flatness 1 Place a straight edge on the pressure plate and measure clearance with a feeler gauge at several points 2 If the clea...

Page 173: ...3 TRANSMISSION KiSC issued 02 2007 A ...

Page 174: ...ROL SYSTEM 3 M11 1 Construction and Function of Components 3 M11 2 Electrical Control 3 M14 5 HYDRAULIC CONTROL SYSTEM 3 M15 1 Hydraulic Circuit and System Outline 3 M15 2 Construction and Function of Components 3 M17 6 SHIFT LINKAGE MECHANISM 3 M24 3 HYDROSTATIC TRANSMISSION HST MODEL 3 M25 1 STRUCTURE 3 M25 2 POWER TRAIN 3 M26 1 Hydrostatic Transmission HST 3 M26 2 Range Gear Shift Section 3 M36...

Page 175: ...UAL TRANSMISSION MODEL 1 STRUCTURE Standard Type with Creep Speed 1 Main Gear Shift Section 2 PTO Clutch Section 3 Shuttle Shift Section 4 Range Gear and Creep Gear Shift Section 5 PTO Gear Shift Section 6 Front Wheel Drive Shift Section KiSC issued 02 2007 A ...

Page 176: ...ION Ground PTO Type without Creep Speed 1 Main Gear Shift Section 2 PTO Clutch Section 3 Shuttle Shift Section 4 Range Gear Shift Section 5 PTO Gear Shift Section 6 Front Wheel Drive Shift Section 7 Ground PTO Gear SHift Section KiSC issued 02 2007 A ...

Page 177: ... synchromesh is characterized by its light operating force and durability because it engages with the gear in reverse rotation when the speed is changed from forward to reverse position or vice versa Two synchronizing rings 7 9 are installed on one side and the center ring 8 is provided between the synchronizing rings This construction doubles the ground contact area of the synchronizer rings 7 9 ...

Page 178: ...he differential gear case 2 wheel drive or 4 wheel drive is selected by operating the front wheel drive lever to shift the shifter gear 4 W1013518 1 Shuttle Gear Shaft 2 Gear for Low 3 Shifter 4 Gear for High 5 Range Gear Shaft 6 Counter Gear 7 Spiral Bevel Pinion L Low Speed H High Speed 1 Spiral Bevel Pinion 2 Gear 3 Front Wheel Drive Gear 4 Shifter Gear 5 Front Wheel Drive Shaft Connected to Pr...

Page 179: ...single shift lever 6 When the shift lever 6 is moved to the left the shift arm 3 is engaged with the 1 2 shift fork 1 allowing the operator to change the 1st or the 2nd speed When the shift lever 6 is moved to the right the shift arm 3 is engaged with the 3 4 shift fork 2 allowing the operator to change the 3rd or the 4th speed W1013619 1 Creep Output Gear 2 Range Gear Shaft 3 Shifter 4 Low Speed ...

Page 180: ... fork 5 is moved to the A side by means of the rod 2 sub arm 3 and shift arm 4 changing the shift arm to the Lo speed side When the shift lever 1 is moved to the B side the shift fork 5 is moved to the Hi speed side W1013899 4 Front Wheel Drive Lever The shift lever 1 is connected directly to the shift fork 2 When the shift lever 1 is moved to the A side the shift fork 2 is also moved to the A sid...

Page 181: ...lever 3 is moved to the A side the shift fork 1 is moved to the A side by means of the rod 4 sub arm 5 and shift arm 2 thereby causing the creep shift When the shift lever 3 is moved to the B side the shift fork 1 is moved to the B side to cause the normal shift W1021330 1 Shift Fork 2 Shift Arm 3 Shift Lever 4 Rod 5 Sub arm A Creep Speed Shift B Normal Speed Shift KiSC issued 02 2007 A ...

Page 182: ...M TRANSMISSION 2 GLIDE SHIFT TRANSMISSION GST MODEL 1 STRUCTURE 1 Main Gear Shift Section 2 Clutch Pack for GST 3 PTO Clutch Section 4 Shuttle Shift Section 5 Range Gear Shift Section 6 Front Wheel Drive Shift Section KiSC issued 02 2007 A ...

Page 183: ...on 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 Moreover because the selected speed and the traveling speed can be confirmed by the liquid crystal display LCD 1 of electronic instrument panel IntelliPanel 2 it can do a comfortable tractor operation And ...

Page 184: ...ttern input to the electric control unit ECU The shift pattern is shown in the table below Regarding a double cone type synchromesh system and front wheel drive section these are basically similar to manual transmission model and refer to page 3 M3 and 3 M4 Forward shift pattern Reverse shift pattern 1 Main Shift Section 2 GST Clutch Pack 3 Sub range Shift Section 4 Shuttle Shift Section 5 Main Ra...

Page 185: ...ntrol of GST system and it is equipped on the left under of the platform The ECU processes and judges the input data from various switches and sensors and send the signal to various solenoid valves solenoid valves and proportional reducing valve At the same time it also sends the communication data to display the selected speed and several messages in electronic instrument panel W1015703 1 Traveli...

Page 186: ...position from N to 12 speed is output within the range from about 0 7 to 4 2 voltages W1015847 Shuttle Switch This switch has function to detect the shuttle lever position and it is equipped on the bottom of the shuttle lever rod 2 This switch has three contact points which is Forward Neutral and Reverse and detects their position As for GST control it judges the shuttle start condition W1015891 E...

Page 187: ...tional reducing valve in accordance with the oil temperature This is used to thermistor and it has such characteristics that its resistance decreases at high temperature and increases at low temperature W1016064 Traveling Speed Sensor This sensor is to detect the traveling speed and it is equipped on the right bottom side of the differential case This sensor perceives tooth of the front wheel driv...

Page 188: ...sure switch s ON the ECU detects the present condition traveling speed 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 traveling speed engine speed and oil temperature the indicated pressure period from c to d is controlled at appropriate pressure respective...

Page 189: ... 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 Shift Check Valve 21 Shift Check Valve Sub range Shift 22 Shift Check Valve Shuttle 23 Pressure Switch 24 Clutch Valve 25 Low pass Valve 26 Proportional Reducing Valve 27 GST Clutch 28 GST Valve Assembly a To Steering...

Page 190: ...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 setting pressure for closing of low pass valve and controlled indication pressure of the proportional reducing valve Reference Setting pressure for closing of low pass valve 0 24 MPa 2 5 kgf cm2 34 1 psi 7 ...

Page 191: ...ure 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 The regulating valve 3 is provided to maintain 2 94 MPa 30 0 kgf cm2 427 psi at inlet pressure of the pressure reducing valve 5 except when the power steering is operated Thereby getting 2 45 MPa 25 0...

Page 192: ...ration 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 ball against the valve seat 11 to open the unload passage 12 and drain the oil W1019949 1 GST Valve Assembly 2 Clutch Valve 3 Low pass Valve 4 Connector for Pressure Switch 5 Proportional Reducing Valve 6 ...

Page 193: ... 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 W1020109 1 3 4 Shift Piston 2 1 2 Shift Piston 3 Main Range Shift Piston 4 Sub range Shift Piston 5 Shifter 6 Valve Body 7 Cover 8 Piston 9 Ball for Check Valve 10 Spring 11 Check Pin 12 Ball for Detent 13 Neutral Piston A Shift Piston for Main Range Shift B 1 2 and 3 4 Shif...

Page 194: ...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 the shift check valve 3 is opened and closed by the groove of the shuttle shift rod Note that the shuttle shift fork rod has a slot into which the shift fork mounting bolt is inserted Therefore when the...

Page 195: ...ry 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 IN port A passes through the low pass valve poppet 4 flows out from OUT port B and flows to the clutch valve 7 and clutch 9 When the pressure on the side of the OUT port B reaches setting pressure the p...

Page 196: ...icrocomputer 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 according to the traveling speed sensor By these instructions from microcomputer of ECU the proportional reducing valve adjusts pressure in the clutch to become a appropriate acceleration W1021268 1 Proportio...

Page 197: ...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 the oil flow to the GST clutch 6 Furthermore the oil of the GST clutch flows in from D port and is drained from E port and then the GST clutch is disengaged W1021514 1 Plug 2 Spool 3 Spring 4 Stopper...

Page 198: ... 6 The piston is pushed to the left by the oil thereby pushing the clutch discs 4 and the plates 5 to transmit the power Disengaging When the engine stop the shift levers 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 W1021896 6 SHIFT LINKAGE MECHANISM For shift linkage mechanism...

Page 199: ...3830 L4630 L5030 WSM TRANSMISSION 3 HYDROSTATIC TRANSMISSION HST MODEL 1 STRUCTURE 1 Hydrostatic Transmission Section 2 PTO Clutch Section 3 Range Gear Shift Section 4 Front Wheel Drive Shift Section KiSC issued 02 2007 A ...

Page 200: ...raulically As a result the HST pedal feels extremely light and smoother pedal operation can be done HST assembly is chiefly composed of HST case clutch housing variable displacement piston pump fixed displacement piston motor charge pump servo regulator and various valves Refer to the next page for detailed parts in the HST 1 Output Shaft Motor Shaft 2 Case Relief Valve 3 Bypass Pipe Servo Pipe 4 ...

Page 201: ...ulator Assembly 8 Port Block Cover 9 Cylinder Block Pump 10 Input Shaft Pump Shaft 11 Piston 12 Output Shaft Motor Shaft 13 Cylinder Block Motor 14 Bypass Pipe Servo Pipe 15 Case Relief Valve 16 Check and High Pressure Relief Valve 17 Charge Relief Valve A Sectional View W W B Sectional View X X C Sectional View Y Y D Sectional View Z Z KiSC issued 02 2007 A ...

Page 202: ...harge relief valve 6 flows out from d port and is sent to the suction line through the oil cooler 10 And the case relief valve 5 controls pressure in the HST case Reference Valve Setting Pressure Oil temperature 40 to 60 C 104 to 140 F Charge Relief Valve 2 25 to 2 45 MPa 23 to 25 kgf cm2 327 to 355 psi Check and High Pressure Relief Valve 33 3 to 36 3 MPa 340 to 370 kgf cm2 4836 to 5262 psi Case ...

Page 203: ...d the movement of the piston is restricted according to the amount of depressing of the HST pedal Refer to Workshop Manual of TRACTOR MECHANISM Code No 97897 18200 for the operation of the servomechanism that is the operation of regulator and servo piston Valves As for the mechanism and function of check and high pressure relief valve charge relief valve and case relief valve refer to Workshop Man...

Page 204: ...he pump pistons and they only rotate with cylinder 5 without reciprocation Since the oil is not being pumped to motor the cylinder block in the motor 20 is stationary and the output shaft 21 does not rotate 1 Transmission Case 2 Filter 3 Input Shaft 4 Charge Pump 5 Pump Cylinder 6 Variable Swashplate 7 Regulator Valve Assembly 8 Servo Piston 9 Feedback Lever 10 HST Pedal 11 Regulator Valve 12 Bypa...

Page 205: ... 20 This drives the machine forward and the angle of pump swashplate determines the output shaft speed As the motor cylinder block continues to rotate oil is forced out of motor port C at low pressure and returns to the pump port B 1 Transmission Case 2 Filter 3 Input Shaft 4 Charge Pump 5 Pump Cylinder 6 Variable Swashplate 7 Regulator Valve Assembly 8 Servo Piston 9 Feedback Lever 10 HST Pedal 1...

Page 206: ...This drives the machine rearward and the angle of pump swashplate determines the output shaft speed As the motor cylinder block continues to rotate oil is forced out of motor port D at low pressure and returns to the pump port A 1 Transmission Case 2 Filter 3 Input Shaft 4 Charge Pump 5 Pump Cylinder 6 Variable Swashplate 7 Regulator Valve Assembly 8 Servo Piston 9 Feedback Lever 10 HST Pedal 11 R...

Page 207: ...increases Then the swashplate is returned to neutral with the neutral holder arm 10 when the pedal is released The ball bearing 9 on the neutral holder 8 pulled with the neutral spring 11 seats the detent of the neutral holder arm 10 so that the neutral holder arm returns to neutral The damper 12 is connected to the HST pedal 4 through connecting shaft 6 neutral rod 7 and neutral holder arm 10 res...

Page 208: ...dal 1 are connected by the connecting shaft 11 the HST pedal is moved and HST becomes forward position On the other hand because the plate 4 and the rubber 5 are suppressed outside by the release lever 2 and the cruise spring 3 cruise lever 1 9 and cruise lever 2 6 are fixed at the position As a result cruise control lever position can be infinitely set In addition because the movement of the crui...

Page 209: ...e 10 The release lever 4 is moved along grooves 12 As a result the holding force of cruise control lever 8 is lost and the cruise control lever 8 returns to neutrality by force of the release spring 5 NOTE The cruise control will release when both brake pedals are depressed The cruise control does not release when the individual right or left brake is applied 1 Brake Pedal 2 Brake Lever 3 Bracket ...

Page 210: ... 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 W1024918 1 Counter Shaft 2 Gear for L 3 Shifter Gear for M 4 Range Gear Shaft 5 Spline Boss 6 Gear for H 7 Spiral Bevel Pinion Shaft L Low Speed Position N Neutral Position M Middle Speed Position H High Speed Position 1 Spiral Bevel Pinion Shaft 2 Front Wh...

Page 211: ...chanism of Front Wheel Drive Lever refer to page 3 M6 1 Range Gear Shift Lever The links are connected from the shift lever 3 to the shift fork 1 as shown in figure W1025045 1 Shift Fork 2 Shift Arm 3 Range Gear Shift Lever 4 Rod 5 Sub arm H High Speed M Middle Speed L Low Speed KiSC issued 02 2007 A ...

Page 212: ...YSTEM 1 STRUCTURE 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 Shaft 1 9 PTO Gear Shaft 2 A Manual Transmission Model B GST Model C HST Model KiSC issued 02 2007 A ...

Page 213: ...nto the clutch valve 2 after it is regulated to the system pressure As for the system pressure of the PTO clutch valve it is controlled by the regulating valve for GST and Manual Transmission model and it is controlled by the HST charge relief valve for HST model When the PTO lever is at the DISENGAGED position the oil does not flow through the PTO clutch valve 2 to the clutch pack When the PTO le...

Page 214: ...ol 2 is turned to b position then the oil is stopped by the spool 2 and the oil in the PTO clutch pack and accumulator is drained into the transmission case Thus the piston 4 is pushed back the brake plate 7 is also moved to contact the brake disc 6 so as to stop the rotation and the drag of the PTO shaft W1025465 1 Check Valve Except HST Model 2 Spool 3 Plate 4 Piston 5 Brake Spring 6 Brake Disc ...

Page 215: ... the tractor travelling speed W1022245 2 Shift Linkage The ground PTO can be engage only when PTO speed change lever is in the neutral position The ground PTO lever 1 is connected directly to the shift fork 4 When the ground PTO lever 1 is moved to the A side the shift fork 4 is also moved to A side then the ground PTO is Engaged When the ground PTO lever 1 is moved to the B side the ground PTO is...

Page 216: ...en 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 side the shift fork 4 is moved to the Hi speed side W1022707 1 Gear for High 2 Gear for Low 3 PTO Drive Shaft 4 Shifter 5 PTO Counter Shaft L Lo speed Shift N Neutral Position H Hi speed Shift 1 PTO Speed CHange Le...

Page 217: ...KING DISASSEMBLING AND SERVICING 3 S17 1 MANUAL TRANSMISSION MODEL 3 S17 1 Checking and Adjusting 3 S17 2 Disassembling and Assembling 3 S18 3 Servicing 3 S43 2 GLIDE SHIFT TRANSMISSION GST MODEL 3 S49 1 Checking and Adjusting 3 S49 2 Disassembling and Assembling 3 S55 3 Servicing 3 S84 3 HYDROSTATIC TRANSMISSION HST MODEL 3 S86 1 Checking and Adjusting 3 S86 2 Disassembling and Assembling 3 S92 3...

Page 218: ... shift arms rusted Synchronizer unit damaged Replace Replace Repair Repair Replace 3 S44 Gears Clash When Shifting Clutch does not release Gears worn or damaged Synchronizer unit damaged Adjust or repair Replace Replace G 24 3 S44 Differential Lock Can Not Be Set Differential lock shift fork damaged Differential lock shift fork mounting clevis pin damaged Differential lock shifter pin bent or dama...

Page 219: ...3 S2 L3130 L3430 L3830 L4630 L5030 WSM TRANSMISSION 2 GST SYSTEM Electrical Diagnosis by Electronic Instrument Panel IntelliPanel KiSC issued 02 2007 A ...

Page 220: ...e of lever sensor short circuited Check ground wire Check input voltage at ECU connector Check sensor connector 9 S27 9 S29 GST lever sensor is failed Lever sensor output terminal is out of adjustment Lever sensor output wire terminal broken or short circuited Input line broken Lever sensor defective It is possible to run at its selected speed position until engine is stopped Check sensor connecto...

Page 221: ...r of solenoid Check a resistance between solenoid and GND Replace GST valve 9 S30 S32 3 S79 Solenoid 1 failure At reverse 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 solenoid Check a resistance between solenoid and GND Replace GST valve 9 S30 S32 3 S79 Solenoid 2 failure At reverse Solenoid 3 failu...

Page 222: ...nnector of solenoid Check a resistance between solenoid and GND Replace GST valve 9 S30 S32 3 S79 Solenoid 4 failure At reverse Solenoid 6 Main range gear shift failure 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 Check a resistance between solenoid and GND Replace GST valve 9 S30 S32 3 S79 Solenoid 6 Main range g...

Page 223: ...3 S6 L3130 L3430 L3830 L4630 L5030 WSM TRANSMISSION Error Message Does not Indicate on LCD KiSC issued 02 2007 A ...

Page 224: ...3 S7 L3130 L3430 L3830 L4630 L5030 WSM TRANSMISSION KiSC issued 02 2007 A ...

Page 225: ...3 S8 L3130 L3430 L3830 L4630 L5030 WSM TRANSMISSION 3 HST SYSTEM KiSC issued 02 2007 A ...

Page 226: ...3 S9 L3130 L3430 L3830 L4630 L5030 WSM TRANSMISSION KiSC issued 02 2007 A ...

Page 227: ...3 S30 3 S32 3 S33 PTO Shaft Does Not Rotate PTO clutch malfunctioning PTO propeller shaft coupling disengaged Repair or replace Engage 3 S32 PTO Clutch Operating Pressure is Low Transmission oil improper or insufficient Relief valve malfunctioning Replenish or change Adjust or replace G 7 8 3 S17 S89 PTO Clutch Drags Brake plate excessively worn Return spring weaken or broken Accumulator valve mal...

Page 228: ... N m 0 40 to 0 65 kgf m 2 89 to 4 70 ft lbs Spiral Bevel Pinion to Spiral Bevel Gear Backlash Tooth Contact Center to Tooth Contact 0 15 to 0 30 mm 0 006 to 0 012 in More than 35 1 3 to 1 2 of the entire width from the small end Differential Case Bore Differential Case Cover Bore to Differential Side Gear Boss Differential Case Bore Differential Case Cover Bore Differential Side Gear Boss Clearanc...

Page 229: ...dling Oil Temperature 40 to 60 C 104 to 140 F Operating Pressure Manual and GST Model HST Model 2 30 to 2 50 MPa 23 5 to 25 5 kgf cm2 334 to 363 psi 2 21 to 2 40 MPa 22 5 to 24 5 kgf cm2 320 to 348 psi PTO Clutch Disc Thickness 1 70 to 1 90 mm 0 067 to 0 075 in 1 55 mm 0 061 in PTO Steel Plate Thickness 1 15 to 1 25 mm 0 045 to 0 049 in 1 10 mm 0 043 in PTO Piston Flatness 0 15 mm 0 006 in PTO Ste...

Page 230: ... or Reverse Operating Pressure 2 30 to 2 50 MPa 23 5 to 25 5 kgf cm2 334 to 363 psi GST Clutch Pressure Condition Engine Speed Idling Oil Temperature 40 to 60 C 104 to 140 F GST Lever Neutral to 12th or 8th Shuttle Lever Neutral to Forward and Reverse Operating Pressure 2 30 to 2 50 MPa 23 5 to 25 5 kgf cm2 334 to 363 psi GST Clutch Disc Thickness 2 55 to 2 65 mm 0 100 to 0 104 in 2 50 mm 0 098 in...

Page 231: ...ift Lever H Position HST Pedal Depress Forward or Reverse with Brake Setting Pressure 33 3 to 36 3 MPa 340 to 370 kgf cm2 4836 to 5262 psi Charge Relief Valve Condition Engine Speed Maximum Oil Temperature 40 to 60 C 104 to 140 F HST Pedal Neutral Setting Pressure 2 26 to 2 45 MPa 23 to 25 kgf cm2 327 to 355 psi Cruise Control Lever Operating Force Forward Direction 54 to 64 N 5 5 to 6 5 kgf 12 1 ...

Page 232: ...ase mounting screw Differential support mounting screw Differential case cover mounting screw Spiral bevel gear UBS screw Muffler mounting screw 260 to 304 103 to 118 138 to 147 167 to 196 124 to 147 196 to 225 49 to 69 49 to 69 49 to 69 34 to 39 77 5 to 90 2 39 2 to 49 0 102 9 to 117 6 77 5 to 90 2 38 2 to 45 1 23 5 to 27 5 77 5 to 90 2 102 9 to 117 6 39 2 to 49 0 23 5 to 27 4 48 1 to 55 9 9 8 to...

Page 233: ...w Hex head plug Hex head plug Regulator mounting hex head screw Servo piston and cover mounting hex head screw Joint bolt for PTO pipe to PTO clutch valve 24 5 to 29 4 124 to 147 23 5 to 27 5 9 8 to 11 3 48 1 to 55 9 34 3 to 44 1 34 to 39 12 7 to 14 7 42 2 to 48 1 48 1 to 55 9 34 3 to 44 1 34 3 to 39 2 49 0 to 68 6 39 3 to 49 0 17 6 to 20 6 49 0 to 58 8 9 8 9 8 9 8 to 10 8 6 86 to 8 33 34 to 39 39...

Page 234: ...of the regulating valve assembly 5 IMPORTANT Do not connect the universal joint of the implement to the tractor PTO shaft while testing Condition Engine speed Idling speed Oil temperature 40 to 60 C 104 to 140 F Reference Turn to clockwise direction Pressure is increased Turn to counterclockwise direction Pressure is decreased W1012774 PTO operating pressure When PTO shift lever is ENGAGED positio...

Page 235: ...damage the transmission or hydraulic system Refer to LUBRICANTS FUEL AND COOLANT See page G 7 8 Do not mix different brands of fluid together W1012748 ROPS Center ROPS Type 1 Remove the upper frame 1 from ROPS lower frame 2 2 Disconect the light connectors 3 Remove the shields 3 4 Remove the lower frames 2 When reassembling NOTE Do not firmly tighten all screws until most components are attached W...

Page 236: ...pper frame 1 from ROPS lower frame 5 When reassembling NOTE Do not firmly tighten all screws until most components are attached Reference W1051168 1 Bonnet 2 Skirt 3 Front Grill Tightening torque Lower connector mounting screw 3 103 to 118 N m 10 5 to 12 0 kgf m 75 9 to 86 8 ft lbs Plate mounting screw 4 138 to 147 N m 14 0 to 15 0 kgf m 102 to 108 ft lbs Plate mounting screw 8 167 to 196 N m 17 0...

Page 237: ...support 3 so that the steering wheel is turned lightly Be sure to check and adjust the brake pedal free travel See page G 18 W1014002 Clutch Rod Brake Pedal Rod and Electric Wiring 1 Disconnect the brake pedal rod 5 and clutch pedal rod 4 2 Disconnect the wiring connectors for alternator 1 coolant temperature sensor 7 oil pressure switch 2 fuel unit 3 starter motor 6 and battery 3 Remove the clamp...

Page 238: ...3430 L3830 L4630 L5030 WSM TRANSMISSION Shuttle Switch Connector 1 Remove the panel cover and steering post cover 2 Disconnect the shuttle switch connector 1 W1014526 1 Shuttle Switch Connector KiSC issued 02 2007 A ...

Page 239: ...TO lever 8 if equipped and PTO gear shift lever 9 if equipped 3 Disconnect the differential lock rod 10 4 Remove the lowering speed adjusting knob 11 5 Disconnect the PTO speed change connector 12 W1053470 1 Seat 2 Range Gear Shift Lever 3 Main Shift Lever 4 Front Wheel Drive Lever 5 Draft Control Lever 6 Position Control Lever 7 Auxiliary Control Lever 8 Ground PTO Lever 9 PTO Gear Shift Lever 10...

Page 240: ...case and then remove the front hydraulic block 7 with pipes and bracket as a unit 3 Remove the suction pipe 4 with oil filter 3 4 Remove the PTO delivery pipe 5 When reassembling W1015283 Tightening torque Step mounting bolt and nut 124 to 147 N m 12 6 to 15 0 kgf m 91 1 to 108 ft lbs Floor seat mounting bolt and nut 196 to 225 N m 20 to 23 kgf m 145 to 166 ft lbs 1 Panel Frame Connector 2 Floor S...

Page 241: ...s 3 Remove the engine and clutch housing mounting screws and nuts 4 Separate the engine and clutch housing while lifting up the tank frame When reassembling 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 W1015876 1 Coupling 2 Spring Pin 3 Propeller Shaft 1 4 Propeller Shaft Cover 5 Coupling 6 Spr...

Page 242: ...he main shift base 1 and main shift arm 3 as a unit When reassembling Apply liquid gasket Three Bond 1208D or equivalent to joint face of the clutch housing case and main shift base The main shift arm should be fitted on to the shift fork grooves 2 after setting the shift forks to neutral position W1016861 1 Shuttle Shift Shaft 2 Spring Pin 3 Main Shift Rod 1 4 Shuttle Shift Arm 5 Shuttle Fork Rod...

Page 243: ... mounting screws 2 Screw down the two M6 screws 1 into the shaft case 2 and pull it out 3 Take out the shaft case 2 When reassembling Apply liquid gasket Three Bond 1208D or equivalent to joint face of the shaft case and clutch housing case When replacing oil seal in shaft case Install the oil seal 3 as shown in the figure noting its direction Apply grease to the oil seal 3 W10128390 Tightening to...

Page 244: ...housing bearing holder 5 with using two jack bolts 6 NOTE Take care not to fly out the balls 3 and springs 4 when pull out the bearing holder 1 When reassembling Tap in the clutch housing bearing holder 5 with plastic hummer until contact to clutch housing case and then tighten the screws to specified torque Install the three interlock balls 2 with a small amount of grease to the clutch housing be...

Page 245: ...stall the synchronizer keys 9 in the key grooves of the synchronizer rings 6 firmly 1 External Snap Ring 2 Collar 3 Counter Shaft Assembly 4 Shift Rods 5 18T Gear Shaft Assembly 6 Idle Shaft Assembly 7 PTO Counter Shaft Assembly 8 Main Gear Shaft Assembly 1 Internal Snap Ring 2 Bearing 3 Needle Bearing 4 24T Gear 4th 5 External Snap Ring 6 Synchronizer Ring 7 Synchronizer Spring 8 Hub 9 Synchroniz...

Page 246: ...ng after removing their mounting screws When reassembling Apply liquid gasket Three Bond 1208D or equivalent to joint face of clutch housing and mid case When reassembling the shuttle shift arm 1 to the shuttle fork rod 2 be sure to install it to the groove A W1018779 1 Spring Pin 2 Main Shift Rod 3 Support 4 Main Gear Shift Lever Tightening torque Mid case and transmission case mounting screw 77 ...

Page 247: ...bearing holder 2 When reassembling Tap in the mid case bearing holder 2 with plastic hummer until contact to mid case and then tighten the screws to specified torque W1019191 Shaft Assemblies 1 Remove the external snap ring 5 2 Draw out the shaft assemblies 1 2 3 and shuttle fork rod 4 W1019826 Tightening torque PTO clutch valve mounting screw 23 5 to 27 5 N m 2 4 to 2 8 kgf m 17 4 to 20 3 ft lbs ...

Page 248: ...mly Install the protrusion portions D of the outer synchronizer rings 7 to the grooves C of the inner synchronizer rings 5 Install the external snap ring 12 to the groove of the shuttle shaft 2 firmly Install the synchronizer keys 8 in the key grooves of the outer synchronizer rings 7 firmly W1019932 1 Bearing 2 Shuttle Shaft 3 Needle Bearing 4 24T Gear Forward 5 Inner Synchronizer Ring 6 Center R...

Page 249: ...l plates Assemble the plug rubbers portion of the three steel plates 6 are same positions while assembling them Refer to figure below Apply enough transmission fluid to the discs 5 Confirm the moving of the piston 11 smoothly when pressure air at 0 29 to 0 39 MPa 3 to 4 kgf cm2 42 to 57 psi is sent to clutch pack Refer to the figure left W10159250 Accumulator Valve of PTO Clutch 1 Remove the inter...

Page 250: ...5 and be sure to install the three O rings 5 W10167880 Piston 1 Press the washer 7 lightly by the hand press using the hand made jig Refer to the figure left 2 Remove the external snap ring 3 washer 7 and spring 6 3 Draw out the piston 5 When reassembling Apply enough transmission fluid to seal rings 4 and 8 W10169240 1 External Snap Ring 2 Collar 3 Bearing Holder 4 Collar 5 Brake Disc 6 Brake Pla...

Page 251: ...ake rods 12 When reassembling Apply grease to the lower link pins and hydraulic cylinder pins W1142329 Tightening torque Rear wheel mounting screw and nut 215 N m 22 kgf m 160 ft lbs Rear wheel mounting stud bolt 98 1 to 112 8 N m 10 0 to 11 5 kgf m 72 3 to 83 2 ft lbs Tightening torque Lift arm pin mounting nut 77 5 to 90 2 N m 7 9 to 9 2 kgf m 57 1 to 66 5 ft lbs Lift arm pin lock nut 62 8 to 72...

Page 252: ...id gasket Three Bond 1208D or equivalent to joint face of the brake cae and transmission case Be sure to apply liquid gasket to A position Be sure to fix the brake cam and cam plate Before installing the brake case to the transmission case install the cam plate to the transmission case W10194530 Tightening torque Joint bolt for main delivery pipe 49 to 69 N m 5 0 to 7 0 kgf m 36 1 to 50 6 ft lbs 1...

Page 253: ...g screws 4 Take out the pinion bearing cover 4 and shims 1 When reassembling Make sure of the number of shims in the pinion bearing case Replace the lock nut 5 with a new one and stake the lock nut firmly after installing the parts on the shaft W1022792 Tightening torque Mid case and transmission case mounting screw 77 5 to 90 2 N m 7 9 to 9 2 kgf m 57 1 to 66 5 ft lbs Mid case and transmission ca...

Page 254: ...ion 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 pin 8 so that its split portion may face forward Refer to figure W1023062 Tightening torque Transmission bearing holder mounting screw 48 1 to 55 9 N m 4 9 to 5 7 kgf m 35 5 to 41 2 ft lbs 1 Transmission ...

Page 255: ...aft assembly 5 and PTO drive shaft assembly 3 3 Take out the front wheel drive shaft 2 W1024207 1 Traveling Speed Sensor 2 Front Wheel Drive Shaft 3 PTO Drive Shaft 4 Spiral Bevel Pinion Shaft 5 Range Gear Shaft 6 Shift Fork 7 Shift Fork 8 17T Gear 9 Needle Bearing 10 35T Gear 11 17T Gear 12 20T 49T Gear 13 Shifter 14 29T 32T Gear 15 24T Shifter Gear KiSC issued 02 2007 A ...

Page 256: ...out the differential lock shift fork 2 When reassembling Apply grease to the left and right oil seals on the transmission case Insert the clevis 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 W10225860 1 Differential Lock Fork Shaft 2 DIfferential Lock Shift Fork 3 Clevis Pin 4 Spring Pin a Split ...

Page 257: ...rt noting the number of left shims 2 Take out the differential gear assembly 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 number of shims as before disassembling W10245370 Tightening torque Lock nut 147 to 196 N m 15 to 20 kgf m 108 to 145 ft lbs Bearing...

Page 258: ... circumferential surface of the differential side gear boss W10247220 Spiral Bevel Gear 1 Remove the spiral bevel gear When reassembling Check the spiral bevel gear for wear or damage If it is no longer serviceable replace it Then also replace the spiral bevel pinion shaft Apply liquid lock Three Bond 1372 or equivalent to the spiral bevel gear UBS screws W10249330 Tightening torque Differential c...

Page 259: ...Three Bond 1901 or equivalent to the inner circumferential surface of the differential pinions Install the parts to their original position Install the differential pinion washer 4 noting its groove position W10250420 Differential Side Gear 1 Take out the differential side gear 2 and differential side gear washer 1 When reassembling Check the thrust and bearing surface of both differential side ge...

Page 260: ...ar Groove 1 Place for in the groove to check clearance with feeler gauge 2 If the clearance exceeds allowable limit replace W10269970 Clearance between Gear and Shaft 1 Measure the shaft O D rubbing surface 2 Measure the gear I D rubbing surface 3 Measure the O D of the two needles installed diagonally in the needle bearing 4 Calculate the clearance Clearance Gear I D 2 needle O D shaft O D 5 If t...

Page 261: ...pring for fatigue or wear on the area where the spring contacts with the keys 3 If there is any defect replace them W1021026 Side Clearance between Synchronizer Ring and Gear In Contact 1 Press the synchronizer ring against the tapered portion of the gear and measure the side clearance 2 Apply thin film of red lead to the tapered portion press the ring against it by hand rub them together a few ti...

Page 262: ...nts 3 If the gauge can be inserted replace it W1021557 Piston Return Spring Free Length 1 Measure the free length of spring with vernier calipers 2 If the measurement is less than the allowable limit replace it W1021677 Thickness of PTO clutch disc Factory spec 1 70 to 1 90 mm 0 067 to 0 075 in Allowable limit 1 55 mm 0 061 in Thickness of PTO steel plate Factory spec 1 15 to 1 25 mm 0 045 to 0 04...

Page 263: ...rning 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 turning torque 4 After getting the specified turning torque divide the thickness of shims to left and right side 5 Assemble the transmission case and adjust the backlash and tooth contact with spiral bevel pini...

Page 264: ...n 1 0 mm 0 039 in 0 5 mm 0 020 in 0 8 mm 0 031 in 1 2 mm 0 047 in 0 6 mm 0 024 in 0 9 mm 0 035 in 1 4 mm 0 055 in Thickness of shims 6 0 4 mm 0 016 in 0 8 mm 0 031 in 1 2 mm 0 047 in 0 6 mm 0 024 in 1 0 mm 0 039 in 1 6 mm 0 063 in W10279260 More than 35 red lead contact area on the gear tooth surface The center of tooth contact at 1 3 of the entire width from the small end W10187470 Replace the ad...

Page 265: ... 1 5 mm 0 059 in 1 7 mm 0 067 in 1 6 mm 0 063 in W10289200 Clearance between differential case bore and differential side gear boss Factory spec 0 050 to 0 151 mm 0 00197 to 0 00594 in Allowable limit 0 35 mm 0 0138 in Differential case bore I D Factory spec 40 500 to 40 550 mm 1 59449 to 1 59646 in Differential side gear boss O D Factory spec 40 388 to 40 450 mm 1 59008 to 1 59252 in Clearance be...

Page 266: ...ue holding switches and then turn the main switch 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 mode switch 2 for more then 2 seconds at this condition and the buzzer rings and Mode E is selected 6 LEVER is displayed b and PUSH SW is displayed c for...

Page 267: ...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 thru 12 several times Set the GST lever at the positions other than neutrl 8 STEP 05 g Set the GST lever to Neutral position 9 STEP 06 h Set shuttle lever to forward and engage clutch 10 PUSH SW i Push the display mode switch for more than three seconds ...

Page 268: ...ge 3 S49 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 shock Press the travel speed switch to reduce the number For higher shifting shock Press the display mode switch to increase the number 5 Move the tractor to confirm the shifting shock 6 Turn off the key ...

Page 269: ...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 5 Condition Engine speed Idling speed Oil temperature 40 to 60 C 104 to 140 F Reference Turn to clockwise direction Pressure is increased Turn to counterclockwise direction Pressure is decreased W1030916 GST syst...

Page 270: ...e 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 Start the engine and set the maximum speed 5 Disengage the main clutch and shift the GST lever to 1st position shuttle shift lever to Forward or Reverse position 6 Measure the pressure 7 When the pilot...

Page 271: ...e 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 check the low pass valve and proportional reducing valve IMPORTANT Do not engage the main clutch while checking Condition Engine speed Maximum Oil temperature 40 to 60 C 104 to 140 F Shifting GST lever Neutral to 1st to 12th or 8th S...

Page 272: ...the transmission or hydraulic system Refer to LUBRICANTS FUEL AND COOLANT See page G 7 8 Do not mix different brands of fluid together W1166268 Battery Front Grill Skirt and Bonnet 1 Open the bonnet and disconnect the battery negative cable 2 Disconnect the head light connector and remove the front grill 4 3 Remove the left and right side skirts 3 4 Disconnect window washer hoses 2 Cabin model onl...

Page 273: ...celerator lever Set the steering joint 1 by the joint support 6 so that the steering wheel is turned lightly Be sure to check and adjust the brake pedal free travel See page G 18 W1033546 Clutch Rod Brake Pedal Rod and Electric Wiring 1 Disconnect the brake pedal rod 6 and clutch rod 4 2 Disconnect the wiring connectors for alternator 1 coolant temperature sensor 9 oil pressure switch 2 fuel unit ...

Page 274: ...s a unit When reassembling After reassembling the compressor be sure to adjust the air conditioner belt tension See page G 29 W1034133 Shuttle Switch Connector 1 Remove the panel cover and steering post cover 2 Disconnect the shuttle switch connector 1 W1172874 Tightening torque Compressor mounting screw 24 5 to 29 4 N m 2 5 to 3 0 kgf m 18 1 to 21 7 ft lbs Muffler mounting screw 31 4 to 37 2 N m ...

Page 275: ...O clutch valve 4 2 Disconnect the traveling speed sensor connector 1 When reassembling When connecting the PTO shift wire 2 to the clutch valve 4 be sure to adjust the length of wire as follows 1 Set the PTO shift lever to OFF Neutral position 2 Loosen the lock nut 3 of wire and connect wire to the clutch valve lever and then place the wire to the hook 3 Tighten the lock nut 3 clockwise pull the w...

Page 276: ...ipes and bracket as a unit 3 Remove the suction pipe 8 with oil filter 7 4 Remove the PTO delivery pipe 9 and GST pipe 6 as a unit When reassembling W1047928 Tightening torque Cabin mounting bolt and nut 124 to 147 N m 12 6 to 15 0 kgf m 91 1 to 108 ft lbs 1 Nylon Straps 2 Bolt 3 Plate 4 Mount Rubber 5 Collar 6 Plain Washer M14 7 Washer 8 Spring Washer 9 Nut F Front Side R Rear Side Tightening tor...

Page 277: ...to joint face of the flywheel housing and clutch housing W1048295 Clutch Lever Release Fork and Release Bearing 1 Remove the release fork mounting screws 2 2 Draw out the clutch lever 3 to remove the release fork 1 3 Remove the release bearing and release hub 4 together When reassembling Apply grease to the sliding surface of the clutch release hub Apply grease to the clutch lever W11766950 1 Coup...

Page 278: ...then tighten the screws Do not use the hummer Replace the pipe 8 with new one if damaged W1048476 Separating Clutch Housing and Mid Case 1 Remove the clutch housing and mid case mounting screws and nuts 2 Separate the clutch housing and mid case When reassembling Apply liquid gasket Three Bond 1208D or equivalent to joint face of the clutch housing and mid case W10489710 Tightening torque Shift pi...

Page 279: ...ng its direction Apply grease to the oil seal 3 W11776010 23T 24T Gear Shaft and 27T 26T Gear 1 Remove the 23T 24T gear shaft 1 2 Remove the external snap ring 3 and 27T 26T gear 2 When reassembling Install the oil seal 4 on the 18T gear shaft 6 noting the direction of the oil seal 4 as shown in the figure Direct the boss side of the gear 2 to the bearing side Apply small amount of the grease to t...

Page 280: ...nd rods 3 Pull out the front axle drive shaft 8 to the rear side When reassembling Install the front axle drive shaft 8 from front side after assembling the clutch housing case 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 W1050076 Tightening torque Clutch housing bearing holder mounting screw 48 1 to 55 9 N m 4 9 to...

Page 281: ...of the synchronizer rings 6 or 20 firmly Be sure to install the synchronizer rings 18 19 20 with referring to page 3 S31 W1050447 1 Internal Snap Ring 2 Bearing 3 Needle Bearing 4 24T Gear 4th 5 External Snap Ring 6 Synchronizer Ring 7 Synchronizer Spring 8 Hub 9 Synchronizer Key 10 Shifter 11 29T Gear 3rd 12 Counter Shaft 13 34T Gear 2nd 14 Needle Bearing 15 37T Gear 1st 16 Bearing 17 Bearing Hol...

Page 282: ... Replace the pipe 5 with new one if damaged W1050592 Separating Mid Case and Transmission Case 1 Separate the mid case and transmission case after removing their mounting screws When reassembling Confirm to insert the PTO shaft to PTO clutch firmly turning the PTO shaft Apply liquid gasket Three Bond 1208D or equivalent to joint face of the mid case and transmission case W1050879 Tightening torque...

Page 283: ...n 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 pipe 1 with new one W1180630 Tightening torque Clutch housing and mid case mounting screw 77 5 to 90 2 N m 7 9 to 9 2 kgf m 57 1 to 66 5 ft lbs Clutch housing and mid case mounting nut 102 9 to 117 6 N m 10 5 to 12 0 kgf m 75 9 to 86 8 ft lbs Clutch housing and...

Page 284: ... of the piston smoothly when pressure air at 0 29 to 0 39 MPa 3 to 4 kgf cm2 42 to 57 psi is sent to clutch pack Air must be sent from hole A W1180845 Shaft Assemblies 1 Pull out the sub range shift rod 4 and remove the shift fork 3 2 Remove the external snap ring 2 which is located at rear side of the mid case 3 Draw out the shaft assemblies 1 5 6 and shuttle fork rod 7 W1183161 Disassembling PTO...

Page 285: ...ng as shown in the figure W1051729 Clutch Case and GST Clutch Piston 1 Remove the external snap ring 1 while pushing the spring retainer 2 by hand press 2 Take out the spring retainer 2 springs 3 and piston 4 When reassembling Apply small amount of the grease to the seal rings 8 when assemble the clutch case 7 Apply enough transmission fluid to the O ring 6 and D ring 5 W1052192 1 Clutch Case 2 Cl...

Page 286: ... external snap 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 grooves of the synchronizer rings Install the synchronizer rings 26 securely referring to page 3 S44 Direct the groove side of the hub 8 and shuttle forward shaft 14 as shown in figure W11866...

Page 287: ...ve the hydraulic cylinders 4 7 Disconnect the brake rods When reassembling Apply grease to the lower link pins and hydraulic cylinder pins W1189095 Tightening torque Rear wheel mounting screw and nut 215 N m 22 kgf m 160 ft lbs Rear wheel mounting stud bolt 98 1 to 112 8 N m 10 0 to 11 5 kgf m 72 3 to 83 2 ft lbs Tightening torque Lift arm pin mounting nut 77 5 to 90 2 N m 7 9 to 9 2 kgf m 57 1 to...

Page 288: ...se When reassembling Apply liquid gasket Three Bond 1208D or equivalent to joint face of the rear axle and brake case W1054206 Tightening torque Joint bolt for main delivery pipe to rear hydraulic block 49 to 69 N m 5 0 to 7 0 kgf m 36 1 to 50 6 ft lbs Joint bolt for GST delivery pipe 34 to 39 N m 3 5 to 4 0 kgf m 25 3 to 28 9 ft lbs 1 Rear Hydraulic Block 2 Cover 3 Lift Arm Support Tightening tor...

Page 289: ...embling Place the 1 2 1 and 3 4 2 shift pins at neutral position sub range shift pin 5 at Hi position rearward and main range shift pin 4 at L position forward and then assemble the GST valve Be sure to match the each shift pin and shift piston Install the GST valve by hand and then tighten the screws Do not use the hummer Apply liquid gasket Three Bond 1208D or equivalent to joint face of the GST...

Page 290: ...ut the pinion bearing cover 4 and shims 1 When reassembling Make sure of the number of shims in the pinion bearing case Replace the lock nut 5 with a new one and stake the lock nut firmly after installing the parts on the shaft W1054717 Tightening torque Mid case and transmission case mounting screw 77 5 to 90 2 N m 7 9 to 9 2 kgf m 57 1 to 66 5 ft lbs Mid case and transmission case mounting nut 1...

Page 291: ... to the rear 3 Take out the range gear shaft assembly 8 with the shift fork rod 9 4 Take out the creep shaft assembly 4 and spiral bevel pinion shaft assembly 7 with shift fork 10 and shift fork rod 11 5 Take out the PTO drive shaft assembly 6 and front wheel drive shaft assembly 5 W1198652 Tightening torque Transmission bearing holder mounting screw 48 1 to 55 9 N m 4 9 to 5 7 kgf m 35 5 to 41 2 ...

Page 292: ...als on the transmission case Insert the clevis 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 W12034180 1 49T 19T 20T Gear 2 Range Gear Shaft 3 17T Gear 4 35T Gear 5 50T Gear 6 18T Gear L4630 17T Gear L5030 7 Spiral Bevel Pinion Shaft 8 44T Gear 9 Shifter for Creep Shift 10 Creep Shaft 11 29T 30T ...

Page 293: ...of left shims 2 Take out the differential gear assembly 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 number of shims as before disassembling W12055450 Disassembling Differential Gears 1 See page 3 S41 S42 W1056552 Tightening torque Lock nut 147 to 196 N ...

Page 294: ...ng hydraulic pump 7 When reassembling Install the copper washers firmly Apply grease to the O ring 6 and take care not to damage it W1056783 1 Bonnet 2 Skirt RH 3 Front Grille Tightening torque Joint bolt for GST delivery pipe 3 and regulating valve 34 3 to 39 2 N m 3 5 to 4 0 kgf m 25 3 to 28 9 ft lbs Joint bolt for power steering delivery hose 2 and regulating valve 49 0 to 68 6 N m 5 0 to 7 0 k...

Page 295: ... torques 2 Be sure to clean the disassembled parts and dry them up with compressed air 3 Do not wear any gloves other than rubber ones not use waste cloth This is important for keeping the parts clean and free from rust 4 Be careful not to drop the parts on the floor or workbench Check any part if dropped for hit mark scratch and burr 5 Be sure to use a rubber or plastic hammer for reassembling 6 ...

Page 296: ...noid Valve 1 Remove the cover 7 2 Disconnect the connector 8 and remove the solenoid valves When reassembling Be sure to install the each solenoid valve to their original positions as shown in the photo and table below W1058270 Tightening torque GST valve assembly mounting screw 42 2 to 48 1 N m 4 3 to 4 9 kgf m 31 1 to 35 4 ft lbs Joint bolt for GST delivery pipe to GST valve 34 3 to 39 2 N m 3 5...

Page 297: ... the springs 13 balls 12 and filter 14 from upper body 2 When reassembling Take care so that only the main range shift check pin 6 is short length W1058592 Tightening torque Lower body mounting hex socket head cap screw 9 8 to 10 8 N m 1 0 to 1 1 kgf m 7 2 to 8 0 ft lbs 1 Hex Socket Head Cap Screw 2 Upper Body 3 Plate 4 Lower Body 5 Ball 6 Main Range Shift Check Pin 7 Sub range Shift Check Pin 8 S...

Page 298: ...iston 4 Remove the internal snap ring 12 and cover 8 and then take out the shift piston 7 11 For main range and sub range shift piston When reassembling Take care not to damage the O ring 13 and piston seal 14 W1059069 1 Internal Snap Ring 2 Cover 3 Neutral Piston 4 3 4 Shift Piston 5 Shifter 6 Spring Pin 7 Sub range Shift Piston 8 Cover 9 1 2 Shift Piston 10 Lower Body 11 Main Range Shift Piston ...

Page 299: ...80 2 Remove the plug 5 3 Remove the stopper plate 6 and remove the low pass poppet 4 and spring 3 W1059505 Clutch Valve 1 Separate the upper body and lower body See page 3 S80 2 Remove the stopper plate 4 while pushing the plug 1 3 Take out the spool 2 and spring 3 When reassembling Be careful about the direction of the spool 2 and the plugs 1 referring to the figure W1059735 1 Lock Nut 2 Adjustor...

Page 300: ...ng W1059897 Check Valve Oil Temperature Sensor Orifice and Filter 1 Remove the oil temperature sensor 3 and take out the spring 2 and ball 1 2 Remove the plug 6 and take out the spring 5 and orifice plug 4 with filter 7 When reassembling Be careful about the direction of the orifice support 4 and filter 7 W1060139 1 Hex Socket Head Cap Screw 2 Proportional Reducing Valve 3 Plug 4 Orifice Support 5...

Page 301: ...urface plate 2 Check it unable to insert a feeler gauge allowable limit size underneath it at least four points 3 If the gauge can be inserted replace it W1061290 Piston Return Spring Free Length 1 Measure the free length of spring with vernier calipers 2 If the measurement is less than the allowable limit replace it W1060662 Thickness of GST clutch disc Factory spec 2 55 to 2 65 mm 0 100 to 0 104...

Page 302: ...1 Measure the thickness of seal rings 1 with an outside micrometer 2 If the measurement is less than the allowable limit replace it W1061536 Thickness of seal ring Factory spec 2 45 to 2 50 mm 0 096 to 0 098 in Allowable limit 2 0 mm 0 0079 in 1 Seal Ring KiSC issued 02 2007 A ...

Page 303: ...release the switches 4 Press the display mode switch 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 the existing symbol setting is flashing 7 Press the display mode switch 2 to move the flashing part and flash the H of the HST model 8 Hold down the displ...

Page 304: ...n order 5 Check to see that parking brake is applied 6 Run the engine at maximum speed 7 Place the range gear shift lever in H position 8 Depress the HST pedal and measure the check and high pressure relief valve pressure 9 If the measurement is not within the factory specification check the check and high relief valve assembly See page 3 S103 IMPORTANT Measure quickly so that the relief valve may...

Page 305: ...lever in neutral 6 Run the engine at maximum 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 3 See page 3 S103 or adjust with adjusting shim NOTE Adjusting shim is located on between spring guide 6 and plug 7 Reference Thickness of adjusting shim 0 5 mm 0 02 in Pressure change pe...

Page 306: ...im 0 5 mm 0 02 in Pressure change per 0 5 mm 0 02 in of shim Approx 61 8 kPa 0 68 kgf cm2 8 97 psi W1224108 C HST Linkages Checking Neutral 1 Disengage the front wheel drive lever Drive only rear wheels 2 Lift the rear of the tractor so that the rear wheels are off the ground and run the engine at low idling and drive only rear wheels 3 Depress the one end of speed control pedal and release and do...

Page 307: ...pecified torque W1011601 Cruise Lever Operating Force 1 Push the cruise control lever 1 into maximum tied position After that pull it 50 mm 2 in back 2 Measure the force needed to move the cruise control lever back into the maximum position at the top of the lever grip 2 3 If the force is not within the factory specifications loosen the lock nut 4 and adjust the tension of cruise spring 3 4 Retigh...

Page 308: ...l Fully depressed forward 4 Set the cruise control lever to fully forward Maximum position HST pedal also tilts 5 Measure the clearance b of between bottom of HST pedal and tip of pedal stopper bolt F 3 6 If the measurement is not within factory specification adjust by the cruise adjusting rod 5 Cruise Linkage Adjustment 7 Shorten the pedal stopper bolt R 2 to the position where the length of the ...

Page 309: ...ng and Assembling A Separating Clutch Housing and Engine Draining the Transmission Fluid 1 Place oil pans underneath the transmission case 2 Remove the drain plugs 1 3 Drain the transmission fluid 4 Reinstall the drain plugs 1 When refilling Fill up from filling port after removing the filling plug 2 until reaching the upper notch on the dipstick 3 After running the engine for few minutes stop it ...

Page 310: ...r sensor 9 and glow plug 5 Disconnect the heater hoses 4 and then reconnect their hoses to make loop NOTE Put a mark to the each heater hose before disconnecting 6 Disconnect the wiring connector for window washer tank 5 and compressor 1P connector 6 7 Disconnect the brake pedal rod When reassembling When accelerator wire is installed adjust the wiring length as hit both the idling speed adjusting...

Page 311: ...hose 8 5 Disconnect the recovery tank hose 5 6 Disconnect the radiator upper hose 3 7 Remvoe the oil cooler mounting screw 8 Remove the battery 10 9 Remove the battery stay mounting bolt 10 Take out the compressor 1 condenser 11 receiver 12 hoses 13 battery stay 9 and etc as a unit When reassembling After reassembling the compressor be sure to adjust the air conditioner belt tension See page G 29 ...

Page 312: ...lectric Connector for HST 1 Remove the lowering speed adjusting knob 4 2 Disconnect the differential lock rod 2 3 Disconnect the range gear shift lever sensor connector 3 4 Disconnect the cruise switch connector 1 5 Disconnect the HST pedal neutral switch connector 5 6 Disconnect the ground earth a W1066282 1 Cruise Control Release Wire 1 Seat Bracket 2 Position Control Lever 3 Seat Switch Connect...

Page 313: ...nut just before the lever moves W1066431 Cabin Assembly 1 Remove the outer roof of cabin 2 Support the cabin with nylon straps 1 and hoists 3 Loosen and remove the cabin mounting bolts 2 and nuts 9 4 Dismounting the cabin from tractor body NOTE Lift the cabin while making sure it does not catch on anything When reassembling Be sure to install the washers and mount rubbers etc in their original pos...

Page 314: ... with covers 4 8 When reassembling Apply grease to the splines of propeller shaft 1 3 W1254425 Tightening torque Joint bolt for main delivery pipe 1 to front hydraulic block 49 to 69 N m 5 0 to 7 0 kgf m 36 1 to 50 6 ft lbs Joint bolt for main delivery pipe 2 to rear hydraulic block 49 to 69 N m 5 0 to 7 0 kgf m 36 1 to 50 6 ft lbs Cap nut for return pipe to mid case 49 to 69 N m 5 0 to 7 0 kgf m ...

Page 315: ...3 3 Remove the joint bolt 4 and disconnect the charge delivery pipe 2 5 at the HST side When reassembling Be sure to adjust the HST neutral position See page 3 S90 Install the copper washer securely W1067625 Tightening torque Engine and clutch housing mounting screw and nut 77 5 to 90 2 N m 7 9 to 9 2 kgf m 57 1 to 66 5 ft lbs Engine and clutch housing mounting stud bolt 39 2 to 49 0 N m 4 0 to 5 ...

Page 316: ...se fork 1 3 Remove the release bearing and release hub 4 together When reassembling Apply grease to the sliding surface of the clutch release hub Apply grease to the clutch lever W12561710 Tightening torque Clutch housing and mid case mounting nut 102 9 to 117 6 N m 10 5 to 12 0 kgf m 75 9 to 86 8 ft lbs Clutch housing and mid case mounting screw 77 5 to 90 2 N m 7 9 to 9 2 kgf m 57 1 to 66 5 ft l...

Page 317: ...nstall the oil seal 5 as shown in the figure noting its direction Apply grease to the oil seal 5 Install the front axle drive shaft 1 from front side after assembling the clutch housing case HST unit and mid case Then install the bearing 8 sleeve 9 collar 10 oil seal 7 internal snap ring 6 O ring 11 and spacer 12 in order W10682690 HST Servo Pipe Bypass Pipe 1 Remove the servo pipe 1 W1257288 1 Fr...

Page 318: ...ot interchange pistons between pump and motor cylinder block W1018501 Motor Shaft 1 Remove the motor swashplate setting hex head screw 1 2 Remove the motor swashplate 3 and motor shaft 4 When reassembling Be sure to install the thrust plate to swashplate 3 When installing the swashplate to clutch housing HST body be sure to align the hole 2 of swashplate and straight pin 5 Apply clean transmission...

Page 319: ... bearing W1018971 Charge Pump 1 Remove the charge pump mounting hex head screws and remove the charge pump cover 3 2 Tap out the rotors 1 2 with soft hummer slightly and take out the rotors When reassembling NOTE Align the each alignment mark of rotors Alignment mark should be rear side W1017976 Tightening torque Cradle bearing bracket mounting hex head screw 28 to 35 N m 2 9 to 3 6 kgf m 21 to 26...

Page 320: ...ting hex head screw 2 Remove the servo regulator assembly 1 When reassembling Place a new gasket on the housing Install the servo regulator assembly to the housing align the feedback lever 2 of regulator and groove of servo piston NOTE Do not disassemble the regulator assembly since it has been factory adjusted W1019454 Tightening torque Hex head plug 30 to 37 N m 3 1 to 3 8 kgf m 22 4 to 27 5 ft ...

Page 321: ...he low and high HST charge pressures Place 5 MPa 50 kgf cm2 725 psi gauges on the two spots in the photo 6 Lift 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 servo piston adjusting screw 1 8 Start the engine and measure the low and high charge pressures No...

Page 322: ...tening torque Joint bolt for main delivery pipe 1 to front hydraulic block 49 to 69 N m 5 0 to 7 0 kgf m 36 1 to 50 6 ft lbs Joint bolt for main delivery pipe 2 to rear hydraulic block 49 to 69 N m 5 0 to 7 0 kgf m 36 1 to 50 6 ft lbs Cap nut for return pipe to mid case 49 to 69 N m 5 0 to 7 0 kgf m 36 1 to 50 6 ft lbs Joint bolt for charge delivery pipes to filter bracket 39 to 49 N m 4 0 to 5 0 ...

Page 323: ...o joint face of the mid case and transmission case W1071622 Separating Mid Case 1 Separate the mid case from the clutch housing after removing their mounting screws When reassembling Apply liquid gasket Three Bond 1208D or equivalent to joint face of clutch housing and mid case Be sure to install the gasket W1071785 1 Cruise Release Wire 2 Connecting Shaft 3 Cruise Adjusting Rod 4 Lock Nut 5 Neutr...

Page 324: ...ocedure from Draining the Transmission Fluid to Step and Floor Seat or Cabin Assembly refer to page 3 S92 to 3 S96 Rear Wheel 1 Place disassembling stand under the transmission case and support it with a jack 2 Remove the rear wheels 3 After removing the rear wheels support it at both sides of rear axle by stands When reassembling W1261766 Tightening torque PTO clutch valve mounting screw 23 5 to ...

Page 325: ... to 9 2 kgf m 57 1 to 66 5 ft lbs Lift arm pin lock nut 62 8 to 72 6 N m 6 4 to 7 4 kgf m 46 3 to 53 5 ft lbs Drawbar frame mounting screw M12 77 5 to 90 2 N m 7 9 to 9 2 kgf m 57 1 to 66 5 ft lbs Drawbar frame mounting screw M14 167 to 196 N m 17 0 to 20 0 kgf m 123 to 145 ft lbs Hydraulic cylinder hose 34 3 to 48 1 N m 3 5 to 4 9 kgf m 25 3 to 35 4 ft lbs 1 Check Chain 2 Lift Rod 3 Hydraulic Cyl...

Page 326: ...7 and release spring 8 2 Remove the cruise assembly mounting screws Three screws and remove the cruise assembly 1 3 Remove the range gear shift lever rod and remove the range gear shift lever sensor 2 with stay 4 Remove the external snap ring and remove the range gear shift lever 5 and cruise control lever 4 5 Remove the rear hydraulic block 3 cover and lift arm support 6 as a unit When reassembli...

Page 327: ...ure to apply liquid gasket to A position Be sure to fix the brake cam and cam plate Before installing the brake case to the transmission case install the cam plate to the transmission case W12666170 Tightening torque Rear axle case mounting screw and nut M10 screw and nut 7T 48 1 to 55 9 N m 4 9 to 5 7 kgf m 35 4 to 41 2 ft lbs Stud bolt 24 5 to 31 4 N m 2 5 to 3 2 kgf m 18 1 to 23 1 ft lbs M10 nu...

Page 328: ...ut the pinion bearing cover 4 and shims 1 When reassembling Make sure of the number of shims in the pinion bearing case Replace the lock nut 5 with a new one and stake the lock nut firmly after installing the parts on the shaft W1267146 Tightening torque Mid case and transmission case mounting screw 77 5 to 90 2 N m 7 9 to 9 2 kgf m 57 1 to 66 5 ft lbs Mid case and transmission case mounting nut 1...

Page 329: ...ion 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 pin 8 so that its split portion may face forward Refer to figure W1267434 Tightening torque Transmission bearing holder mounting screw 48 1 to 55 9 N m 4 9 to 5 7 kgf m 35 5 to 41 2 ft lbs 1 Transmission ...

Page 330: ...ssembly 3 3 Take out the front wheel drive shaft 2 When reassembling Apply transmission fluid to needle bearings 12 W1268230 1 Traveling Speed Sensor 2 19T 24T 31T Gear Shaft 3 Needle Bearing 4 17T Gear 5 Spiral Bevel Pinion Shaft 6 49T Gear 7 Needle Bearing 8 32T Gear 9 Spline Boss 10 17T Gear 11 11T Gear 12 PTO Drive Shaft 13 29T 32T Gear 14 Front Wheel Drive Shaft 15 24T Shifter Gear 16 Needle ...

Page 331: ...fter replacing be sure to stake it firmly Install the slinger 7 firmly Apply grease to the oil seal 4 and install it noting its direction W12700450 Differential Gear Assembly 1 Remove the differential support noting the number of left shims 2 Take out the differential gear assembly noting the number of right shims When reassembling Check the spiral bevel gear for wear or damage If it is no longer ...

Page 332: ...r plate 1 2 Check the pistons for their free movement in the cylinder block bores 3 If the piston or the cylinder block bore is scored replace cylinder block assembly IMPORTANT Do not interchange pistons between pump and motor cylinder block W1026142 Piston Slipper 1 Check the slipper 1 for flatness 2 If rounded replace 3 Measure the thickness of piston slipper 4 If the measurement is less than th...

Page 333: ...t interchangeable W1026799 Thrust Plate Swashplate and Cradle Bearing 1 Check the thrust plate 1 for scratches and excessive wear 2 If worn or scored replace 3 Check the piston contact face of swashplate 2 for scratched and excessive wear and check the holes 3 of swashplate 2 for clogged 4 If worn or scored replace and if holes are clogged clean them 5 Check the surface of cradle bearings 4 for sc...

Page 334: ...hes breakage and damage 2 If anything unusual replace NOTE When re installing the charge relief valve never change the number of shims If replace with new one be sure to check and adjust the setting pressure See page 3 S88 W1027404 Servo Piston 1 Check the surface of servo piston for scratches and excessive wear 2 If worn or scored replace the servo piston assembly W1027526 1 Valve Plug 2 Spring 3...

Page 335: ...4 REAR AXLE KiSC issued 02 2007 A ...

Page 336: ...CONTENTS MECHANISM 1 STRUCTURE 4 M1 KiSC issued 02 2007 A ...

Page 337: ... the rear 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 load besides transmitting power to the rear wheel The rear axles also support the weight of the tractor 1 Ball Bearing 2 Rear Axle 3 Rear Axle Case 4 Differential Gear Shaft 5 Brake Case 6 Bra...

Page 338: ... 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 Differential Lock Shifter 12 Differential Case 13 Differential Side Gear KiSC issued 02 2007 A ...

Page 339: ...UBLESHOOTING 4 S1 2 TIGHTENING TORQUES 4 S2 3 CHECKING DISASSEMBLING AND SERVICING 4 S3 1 DISASSEMBLING AND ASSEMBLING 4 S3 1 Separating Rear Axle Case from Brake Case 4 S3 2 Disassembling Rear Axle 4 S6 KiSC issued 02 2007 A ...

Page 340: ...cessive or Unusual Noise at All Time Improper backlash between differential gear shaft and final gear Bearing worn Insufficient or improper type of transmission fluid used Replace Replace Replenish or change 4 S6 G 7 8 Noise while Turning Differential gear shaft and final gear worn or damaged Replace 4 S6 KiSC issued 02 2007 A ...

Page 341: ...ut Cabin mount bracket mounting screw Rear axle case mounting screw M10 Rear axle case mounting nut M10 9T Rear axle case mounting screw M12 Rear axle case mounting stud bolt Rear axle lock nut 215 98 1 to 112 8 166 7 to 196 1 124 to 147 166 7 to 196 1 48 1 to 55 9 60 8 to 70 5 77 5 to 90 2 24 5 to 31 4 196 to 245 22 10 0 to 11 5 17 to 20 13 0 to 15 0 17 to 20 4 9 to 5 7 6 2 to 7 2 7 9 to 9 2 2 5 ...

Page 342: ...tch on the dipstick 3 After running the 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 transmission or hydraulic system Refer to LUBRICANTS FUEL AND COOLANT See page G 7 8 Do not mix different brands of fluid together W1012666 Transmission fluid capa...

Page 343: ... bracket mounting bolt 8 and nut When reassembling Be sure to install the washers plate and mount rubbers etc in their original positions W1011906 Tightening torque Rear wheel mounting screw and nut 215 N m 22 kgf m 160 ft lbs Rear wheel mounting stud bolt 98 1 to 112 8 N m 10 0 to 11 5 kgf m 72 3 to 83 2 ft lbs ROPS lower frame mounting screw 166 7 to 196 1 N m 17 to 20 kgf m 123 to 144 ft lbs 1 ...

Page 344: ...208D or equivalent to joint face of the rear axle case and brake case W10113490 Tightening torque Cabin mount bracket mounting screw 166 7 to 196 1 N m 17 to 20 kgf m 123 to 144 ft lbs 1 Cabin Mount Bracket 2 Screw M14 30 Tightening torque Rear axle case mounting screw and nut M10 screw 48 1 to 55 9 N m 4 9 to 5 7 kgf m 35 4 to 41 2 ft lbs M10 nut 9T Except L3130 L3430 60 8 to 70 5 N m 6 2 to 7 2 ...

Page 345: ...30 only When 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 direction See figure W10116810 1 Rear Axle 2 Oil Seal 3 Internal Snap Ring 4 Ball Bearing 5 Spacer 6 Rear Axle Case 7 Gear 8 Lock Nut 9 Ball Bearing 10 Ball Bearing 11 Rear Axle Cover 12 O ring A L...

Page 346: ...5 BRAKES KiSC issued 02 2007 A ...

Page 347: ...CONTENTS MECHANISM 1 LINKAGE 5 M1 2 OPERATION 5 M2 KiSC issued 02 2007 A ...

Page 348: ...30 WSM BRAKES 1 LINKAGE 1 Brake Pedal Turnbuckle Rod 2 Brake Pedal 3 Brake Rod 4 Brake Cam Lever 5 Parking Brake Turnbuckle Rod 6 Brake Disc 7 Brake Plate 8 Cam Plate 9 Parking Brake Cable 10 Parking Brake Lever KiSC issued 02 2007 A ...

Page 349: ...two 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 5 to move in the direction of allow through the brake rod At the same time the brake cam 7 spline couples with the brake cam lever also moves Due to this force cam plate 3 moves in the direction of...

Page 350: ...5 S2 3 TIGHTENING TORQUES 5 S3 4 CHECKING DISASSEMBLING AND SERVICING 5 S4 1 BRAKE PEDAL 5 S4 1 Checking and Adjusting 5 S4 2 Disassembling and Assembling 5 S4 3 Servicing 5 S7 2 BRAKE CASE 5 S7 1 Disassembling and Assembling 5 S7 2 Servicing 5 S11 KiSC issued 02 2007 A ...

Page 351: ...e 5 S4 5 S11 5 S11 Brake Drags Brake pedal play too small Ball holes of cam plate for uneven wear Brake pedal return spring weaken or broken Brake cam rusted Adjust Replace Replace Repair 5 S4 5 S11 5 S6 5 S11 Poor Braking Force Brake pedal play excessive Brake disc worn Cam plate warped Brake cam or lever damaged Transmission fluid improper Adjust Replace Replace Replace Change 5 S4 5 S11 5 S11 5...

Page 352: ...e Lever Link Bushing Clearance O D I D 0 12 to 0 25 mm 0 0047 to 0 0098 in 19 90 to 19 98 mm 0 7835 to 0 7866 in 20 10 to 20 15 mm 0 7913 to 0 7933 in 1 0 mm 0 039 in Cam Plate Flatness 0 3 mm 0 012 in Cam Plate and Ball Height 20 9 to 21 1 mm 0 823 to 0 831 in 20 5 mm 0 8071 in Brake Disc Thickness 4 6 to 4 8 mm 0 181 to 0 189 in 4 2 mm 0 165 in Plate Thickness 2 54 to 2 66 mm 0 1000 to 0 1047 in...

Page 353: ... axle case mounting screw M12 Rear axle case mounting stud bolt Brake case mounting screw and nut Floor seat mounting bolt and nut Brake case mounting stud bolt Brake cam lever mounting nut 215 98 1 to 112 8 166 7 to 196 1 124 to 147 166 7 to 196 1 48 1 to 55 9 60 8 to 70 5 77 5 to 90 2 24 5 to 31 4 77 5 to 90 2 196 to 225 38 2 to 45 1 62 8 to 72 5 22 10 0 to 11 5 17 to 20 13 0 to 15 0 17 to 20 4 ...

Page 354: ... checking parking lever 1 Release the parking brake lever 1 2 Measure the length of L 3 Confirm there is free play in a right and left parking brake rod 3 4 Adjust the parking brake rod 3 length to become the same when right and left free play is different at that time 5 Pull the parking lever 1 by one notch At that time confirm there is no free play in the parking brake rods 6 Adjust the parking ...

Page 355: ...hazard connector position light connector main switch connector 6 and mode switch connector 7 3 Remove the electronic instrument panel 2 with panel frame 1 as a unit W1017912 1 Panel Frame 2 Electronic Instrument Panel 3 Panel Connector 4 Combination Switch Connector 5 Hazard Switch 6 Main Switch Connector 7 Mode Switch Connector 8 Position Light Switch KiSC issued 02 2007 A ...

Page 356: ...p out the spring pin 7 and pull out the brake pedal shaft 10 with clutch pedal 9 6 Remove the brake pedals 5 8 and springs 6 7 Remove the parking brake lever 1 1 Parking Brake Lever 2 External Snap Ring 3 Oil Seal 4 Needle Bearing 5 Brake Pedal RH 6 Spring 7 Spring Pin 8 Brake Pedal LH 9 Clutch Pedal 10 Brake Pedal Shaft 11 Brake Pedal Rod RH 12 Brake Rod RH 13 Brake Pedal Rod LH 14 Brake Rod LH K...

Page 357: ...heck 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 system Refer to LUBRICANTS FUEL AND COOLANT See page G 7 8 Do not mix different brands of fluid together W1019291 Clearance between brake lever link shaft and brake lever link bushing Factory spec 0 12 to 0 25 mm ...

Page 358: ...bling Be sure to install the washers plate and mount rubbers etc in their original positions W1015212 Tightening torque Rear wheel mounting screw and nut 215 N m 22 kgf m 160 ft lbs Rear wheel mounting stud bolt 98 1 to 112 8 N m 10 0 to 11 5 kgf m 72 3 to 83 2 ft lbs ROPS lower frame mounting screw 166 7 to 196 1 N m 17 to 20 kgf m 123 to 144 ft lbs 1 ROPS Upper Frame 2 Top Link 3 ROPS Lower Fram...

Page 359: ...asket Three Bond 1208D or equivalent to joint face of the rear axle case and brake case Be sure to check and adjust the parking brake lever free play see page 5 S4 W10200480 Tightening torque Rear axle case mounting screw and nut M10 screw 48 1 to 55 9 N m 4 9 to 5 7 kgf m 35 4 to 41 2 ft lbs M10 nut 9T Except L3130 L3430 60 8 to 70 5 N m 6 2 to 7 2 kgf m 44 9 to 52 1 ft lbs M12 screw Except L3130...

Page 360: ... the brake cam 13 and cam plate 9 Before installing the brake case to the transmission case install the cam plate 9 to the transmission case W1015647 Brake Cam and Brake Cam Lever 1 Remove the brake cam mounting nut and remove the brake cam 2 and brake cam lever 4 When reassembling Apply grease to the O ring 3 and take care not damage the O ring W1014346 Tightening torque Brake case mounting screw...

Page 361: ...owable limit 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 W10147220 Brake Disc Wear 1 Measure the brake disc thickness with vernier calipers 2 If the measurement is less than the allowable limit replace it W10148530 Plate Wear 1 Measure the plate thickness with vernier calipers 2 If the measurement is less than the all...

Page 362: ...6 FRONT AXLE KiSC issued 02 2007 A ...

Page 363: ...CONTENTS MECHANISM 1 STRUCTURE 6 M1 KiSC issued 02 2007 A ...

Page 364: ...vel gear case 6 The revolution is greatly reduced by the bevel gears 15 4 then the power is transmitted to the axle 1 The differential system allows each wheel to rotate at a different speed to make turning easier 1 Axle 2 Collar 3 Axle Flange 4 Bevel Gear 5 Bevel Gear 6 Bevel Gear Case 7 Bevel Gear 8 Differential Side Gear 9 Differential Pinion 10 Pinion Shaft 11 Collar 12 Front Axle Bracket Fron...

Page 365: ...ear 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 Bevel Gear 17 Front Gear Case 18 Bevel Gear Shaft 19 Front Axle Case 20 Differential Yoke Shaft 21 Differential Case 22 Front Axle Bracket Rear 23 Coupling 24 Propeller Shaft KiSC issued 02 2007 A ...

Page 366: ...FICATIONS 6 S2 3 TIGHTENING TORQUES 6 S4 4 CHECKING DISASSEMBLING AND SERVICING 6 S5 1 CHECKING AND ADJUSTING 6 S5 2 DISASSEMBLING AND ASSEMBLING 6 S7 1 Separating Front Axle Assembly 6 S7 2 Disassembling Front Axle 6 S8 3 SERVICING 6 S15 KiSC issued 02 2007 A ...

Page 367: ... sucked in power steering circuit Adjust Adjust Replace Adjust Replace Tighten Bleed G 55 6 S5 6 S19 6 S6 6 S5 6 S9 7 S12 Front Wheels Can Not Be Driven Propeller shaft broken Front wheel drive gears in transmission broken Front differential gear broken Shift fork broken Coupling displaced Replace Replace Replace Replace Reassemble 6 S7 3 S38 S75 S113 6 S14 6 S7 Noise Gear backlash excessive Oil i...

Page 368: ...3 in 31 911 to 31 950 mm 1 25634 to 1 25789 in 0 20 mm 0 0079 in for L5030 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 0 114 mm 0 00197 to 0 00449 in 32 000 to 32 025 mm 1 25984 to 1 26083 in 32 000 to 32 025 mm 1 25984 to 1 26083 in 31 911 to 31 950 mm 1 25634 to 1 25789 in 0 20...

Page 369: ...6 in 0 50 mm 0 19685 in for L3130 L3430 L3830 and L4630 Front 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 01150 in 69 970 to 70 000 mm 2 75472 to 2 75590 in 70 100 to 70 262 mm 2 75984 to 2 76622 in 1 0 mm 0 03937 in for L5030 Front Axle Case Boss Rear to Bracket Bushing Front Axle Case Boss Rear Bushing Clearance O D I ...

Page 370: ...30 L5030 Axle case support mounting screw L5030 Tie rod joint to steering cylinder Differential case cover mounting screw L3130 L3430 L3830 L4630 L5030 166 7 to 196 1 19 6 to 29 4 39 2 to 58 8 58 8 to 98 1 24 5 to 29 4 60 8 to 70 6 137 77 5 to 90 1 39 2 to 45 1 156 9 to 176 5 123 to 147 166 7 to 196 1 23 6 to 27 5 29 4 to 34 3 127 to 142 166 7 to 196 1 48 0 to 58 8 60 8 to 70 6 17 0 to 20 0 2 0 to...

Page 371: ...3 2 Loosen the tie rod lock 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 rod joint is adjusted to the same length W10213280 Axial Sway of Front Wheel 1 Jack up the front side of tractor 2 Set a dial gauge on the outside of rim 3 Turn the wheel slow...

Page 372: ...n the length of stopper 3 4 Keeping the front gear case 1 contact with the bevel gear case 2 make a specified clearance A as shown in the lower table 5 After adjustment secure the stopper with the lock nut 4 6 For adjusting the left steering angle perform the same procedure as mentioned in right steering angle Reference W10126440 Tightening torque Front axle adjusting screw 19 6 to 29 4 N m 2 0 to...

Page 373: ...1035934 Power Steering Hoses 1 Disconnect the power steering hoses 1 2 from steering cylinder 2 Remove the cylinder cover When reassembling W10225690 1 Coupling 2 Spring Pin 3 Propeller Shaft 1 4 Propeller Shaft Cover 5 Coupling 6 Spring Pin 7 Screws 8 Propeller Shaft Cover Tightening torque Power steering hose retaining nut 24 5 to 29 4 N m 2 5 to 3 0 kgf m 18 1 to 21 7 ft lbs Cylinder cover moun...

Page 374: ...eath the front axle case 2 Remove the drain plug 3 both sides and filling port plug 2 to drain the oil 3 After draining reinstall the drain plugs 3 and filling port plug 2 When reassembling Remove the filling port plug 2 and right and left check plugs 1 Fill with the new oil After filling reinstall the filling port plug 2 IMPORTANT Use KUBOTA SUPER UDT fluid or SAE80 90 gear oil Refer to LUBRICANT...

Page 375: ...tter pin as shown in the figure left W10145200 Bevel Gear Case and Front Gear Case for L3130 L3430 L3830 and L4630 1 Remove the bevel gear case mounting screws 2 Remove the bevel gear case 2 and front gear case 3 as a unit from the front axle case 1 When reassembling W10227940 1 Coupling 2 Spring Pin 3 Propeller Shaft 1 4 Propeller Shaft Cover 5 Coupling 6 Spring Pin 7 Screws 8 Propeller Shaft Cov...

Page 376: ... Tighten the axle flange mounting screws and nuts diagonally in several steps W10156660 Bevel Gear and Bevel Gear Shaft 1 Remove the plug 5 2 Remove the internal snap ring 4 and shim 3 3 Tap out the bevel gear 2 with ball bearing 4 Draw out the bevel gear shaft 1 W10159240 Tightening torque Bevel gear case mounting screw 166 7 to 196 1 N m 17 0 to 20 0 kgf m 123 to 145 ft lbs 1 Front Axle Case 2 O...

Page 377: ...case noting its direction W10160540 Axle 1 Remove the bearing with a special use puller set Code No 07916 09032 2 Take out the bevel gear 2 3 Take out the collar 1 4 Tap out the axle 3 When reassembling Install the oil seal 5 of axle flange 4 noting its direction as shown in the figure below W10163910 Tightening torque Axle case support mounting screw 127 to 142 N m 13 0 to 14 5 kgf m 94 0 to 104 ...

Page 378: ... Remove the internal snap ring 4 7 Draw out the steering cylinder 5 When reassembling Apply liquid lock Three Bond 1324 or equivalent to the tie rod joint W10165600 Tightening torque Power steering hose retaining nut 24 5 to 29 4 N m 2 5 to 3 0 kgf m 18 1 to 21 7 ft lbs Cylinder cover mounting screw 60 8 to 70 6 N m 6 2 to 7 2 kgf m 44 8 to 52 1 ft lbs 1 Power Steering Hose RH with Red Tape 2 Powe...

Page 379: ...inal position Install the taper roller bearings correctly noting their direction and apply gear oil to them Tighten up the lock nut 11 until the turning force of the spiral bevel pinion shaft reaches the factory specification See page 6 S16 When press fitting an oil seal 6 observe the dimension A described in the figure IMPORTANT After adjusting the turning torque stake the lock nut 11 firmly W101...

Page 380: ...gears 12 When reassembling Apply molybdenum disulfide Three Bond 1901 or equivalent to the inner circumferential surface of the differential side gears 12 and differential pinions 4 W10174670 Tightening torque Differential case cover mounting screw L3130 L3430 L3830 L4630 48 0 to 58 8 N m 4 9 to 6 0 kgf m 35 4 to 43 4 ft lbs L5030 60 8 to 70 6 N m 6 2 to 7 2 kgf m 44 8 to 52 1 ft lbs 1 Shim 2 Diff...

Page 381: ...wable limit 0 20 mm 0 0079 in Differential case bore I D Factory spec 32 000 to 32 062 mm 1 25984 to 1 26228 in Differential case cover bore I D Factory spec 32 000 to 32 025 mm 1 25984 to 1 26083 in Differential side gear O D Factory spec 31 911 to 31 950 mm 1 25634 to 1 25789 in Clearance between differential case differential case cover and differential side gear Factory spec 0 050 to 0 114 mm ...

Page 382: ...nly 1 Install the spiral bevel pinion shaft assembly 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 torque is not able to adjust by lock nut 2 change the thickness of collar 1 and adjust with lock nut 2 again Reference Standard size of collar 1 10 0 mm 0 3...

Page 383: ...Backlash between Bevel Gear and Bevel Gear 1 Stick a strip of fuse to three spots on the bevel gear 1 with grease 2 Fix the front axle case bevel gear case and front gear case 3 Turn the axle 4 Remove the bevel gear case from front axle case and measure the thickness of the fuses with an outside micrometer 5 If the backlash is not within the factory specifications adjust with shim 3 Reference Thic...

Page 384: ...nt gear case and measure the 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 2 0 mm 0 079 in 0 5 mm 0 020 in Tooth contact More than 35 W10196490 Backlash between bevel gear 2 and bevel gear 1 Factory spec 0 2 to 0 3 mm 0 008 to 0 012 in Allowable limit 0 6 mm 0 024...

Page 385: ... case boss front O D Factory spec 49 950 to 49 975 mm 1 96653 to 1 96752 in Bracket bushing front I D Factory spec 50 095 to 50 225 mm 1 97224 to 1 97736 in Clearance between front axle case boss rear and bracket bushing rear Factory spec 0 100 to 0 292 mm 0 00394 to 0 01150 in Allowable limit 1 0 mm 0 03937 in Front axle case boss rear O D Factory spec 69 970 to 70 000 mm 2 75472 to 2 75590 in Br...

Page 386: ...calculate the clearance 3 If the clearance exceeds the allowable limit replace it W10198060 Clearance between bevel gear case boss and front axle support bushing Factory spec 0 080 to 0 232 mm 0 00315 to 0 00913 in Allowable limit 1 0 mm 0 03937 in Bevel gear case boss O D Factory spec 54 970 to 55 000 mm 2 16417 to 2 16535 in Front axle support bushing I D Factory spec 55 080 to 55 202 mm 2 16850...

Page 387: ...7 STEERING KiSC issued 02 2007 A ...

Page 388: ... 7 M1 2 HYDRAULIC CIRCUIT 7 M2 3 HYDRAULIC PUMP 7 M3 4 STEERING CONTROLLER 7 M4 1 CONTROL VALVE 7 M5 2 METERING DEVICE GEROTOR 7 M5 3 RELIEF VALVE WITH CHECK VALVE 7 M6 4 OIL FLOW 7 M7 5 STEERING CYLINDER 7 M9 KiSC issued 02 2007 A ...

Page 389: ...teering system is composed of steering wheel steering joint shafts steering controller steering cylinder and other components shown in the figure 1 Steering Wheel 2 Steering Joint Shaft 1 3 Hydraulic Pump 4 Steering Cylinder 5 Steering Controller 6 Steering Joint Shaft 3 7 Steering Joint Shaft 2 8 Steering Shaft KiSC issued 02 2007 A ...

Page 390: ...inder 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 the engine is not operating and the steering wheel is turned gerotor 1 rotates to supply oil to steering cylinder 2 Thus the machine can be steered manually W1012726 1 Gerotor 2 Steering Cylinder 3 St...

Page 391: ...nts 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 W1014335 1 Drive Gear 1 2 Coupling 3 Drive Gear 2 4 Driven Gear 1 5 Bushing 6 Bushing 7 Driven Gear 2 8 Side Plate A From Power Steering Controller B From Transmission Case C To Power Steering Controller D To Main Hydraulic Circ...

Page 392: ...ainly consists of a control valve a metering device and a relief valve with check valve The metering device comprises a set of special gear called Gerotor 1 Port Cover 2 Hex Drive Assembly 3 Rotor 4 Drive Plate 5 Relief Valve 6 Valve Plate 7 Drive Link 8 Stator 9 Upper Cover KiSC issued 02 2007 A ...

Page 393: ... of the steering wheel W1013040 2 METERING DEVICE GEROTOR All oil directed from the hydraulic pump to the steering cylinder passes through the metering device gerotor on its way This metering device is a trochoid pump As the steering wheel is turned the action is transmitted directly to stator 2 through drive plate 1 Thus the gerotor sends the amount of oil corresponding to the turn of the steerin...

Page 394: ...so if no oil is supplied from the hydraulic pump the relief valve will act as a check valve and help draw oil from the return oil line to the drain hose thus making it possible to steer the machine manually W1013357 1 Outlet Port 2 Check Valve 3 Auxiliary Port 4 Inlet Port 5 R Port 6 L Port 7 Relief Valve A Normal Condition B Relief Valve in Operation C Check Valve in Operation a From Hydraulic Pu...

Page 395: ...sponding 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 oil which has passed through gerotor 3 flows back to the control valve in which it is directed to cylinder port R to operate steering cylinder 4 Consequently the front wheels are moved to the right through the an...

Page 396: ...ft turn as well except that oil flows into and out of steering cylinder in the directions opposite to those at a right turn W1013826 1 Steering Wheel 2 Valve Plate 3 Gerotor 4 Steering Cylinder 5 Steering Controller 6 Relief Valve P Pump Port T Tank Port R Cylinder Port R L Cylinder Port L KiSC issued 02 2007 A ...

Page 397: ...ed to both knuckle arm guarantees equal steering movement to both front wheels The steering cylinder provides force in both directions Depending upon direction the steering wheel is turned pressure oil enters at one end of the cylinder to extend or the other end to retract it thereby turning front wheel of the tractor 1 Tie rod 2 Piston Rod 3 Head Cover 4 Cylinder Tube 5 Head Cover 6 Front Axle Ca...

Page 398: ... S4 1 HYDRAULIC PUMP 7 S4 1 Checking 7 S4 2 Disassembling and Assembling 7 S8 3 Servicing 7 S10 2 STEERING CONTROLLER 7 S11 1 Checking 7 S11 2 Disassembling and Assembling 7 S12 3 STEERING CYLINDER 7 S13 1 Disassembling and Assembling 7 S13 2 Servicing 7 S14 4 STEERING LINKAGE 7 S14 1 Disassembling and Assembling 7 S14 KiSC issued 02 2007 A ...

Page 399: ...eplace Replace Change or replenish Retighten Inflate Replace Replace 7 S8 S9 G 7 8 G 55 7 S12 7 S12 Steering Force Fluctuates Air sucked in pump due to leaking or missing of oil Air sucked in pump from suction circuit Replenish Repair Excessive Steering Wheel Play Steering linkage worn Replace 7 S15 Front Wheels Wander to Right or Left Air sucked in pump due to leak of oil Air sucked in pump from ...

Page 400: ...als min 4 00 Imp gals min 16 2 L min 4 28 U S gals min 3 56 Imp gals min Housing Depth of Scratch 0 09 mm 0 0035 in Bushing to Gear Shaft Gear Shaft Bushing Clearance O D I D 0 020 to 0 081 mm 0 0008 to 0 0032 in 14 970 to 14 980 mm 0 5894 to 0 5898 in 15 000 to 15 051 mm 0 5906 to 0 5926 in 0 15 mm 0 0059 in Side Plate Thickness 2 48 to 2 50 mm 0 0976 to 0 0984 in 2 40 mm 0 0945 in Relief Valve C...

Page 401: ...er steering delivery pipe retaining nut Front wheel mounting nut Tie rod end slotted nut L3130 L3430 L3830 L4630 L5030 Tie rod joint lock nut Steering wheel mounting nut Tie rod joint 39 2 to 49 0 39 2 to 49 0 49 0 to 68 6 34 3 to 39 2 17 7 to 20 6 23 5 to 27 5 39 2 to 44 1 24 5 to 29 4 49 0 to 58 8 137 3 39 2 to 45 1 156 9 to 176 5 166 7 to 196 1 48 1 to 55 9 166 7 to 196 1 4 0 to 5 0 4 0 to 5 0 ...

Page 402: ...Remove the regulator delivery pipe 7 When reassembling Install the copper washers firmly Tighten the steering joint shaft bracket mounting screw after adjusting the position of steering joint shaft bracket 5 for smooth rotation of the steering wheel W1012306 Tightening torque Regulator delivery pipe joint bolt 39 2 to 49 0 N m 4 0 to 5 0 kgf m 28 9 to 36 2 ft lbs 1 Bonnet 2 Side Skirt RH 3 Fuel Ta...

Page 403: ... C 104 F 7 Open the loading valve completely 8 Set the engine speed Refer to Condition 9 Read and note the pump delivery at no pressure 10 Slowly close the loading valve to increase pressure Rated pressure As the load is increased engine speed drops therefore reset the engine speed 11 Read and note the pump delivery at rated pressure 12 Open the loading valve completely and stop the engine 13 If t...

Page 404: ...n reassembling Install the copper washers firmly Tighten the steering joint shaft bracket mounting screw after adjusting the position of steering joint shaft bracket 8 for smooth rotation of the steering wheel W1013423 Tightening torque Power steering delivery pipe joint bolt 39 2 to 49 0 N m 4 0 to 5 0 kgf m 28 9 to 36 2 ft lbs 1 Bonnet 2 Side Skirt RH 3 Fuel Tank Frame Support 4 Power Steering D...

Page 405: ... loading valve completely 8 Set the engine speed Refer to Condition 9 Read and note the pump delivery at no pressure 10 Slowly close the loading valve to increase pressure Rated pressure As the load is increased engine speed drops therefore reset the engine speed 11 Read and note the pump delivery at rated pressure 12 Open the loading valve completely and stop the engine 13 If the pump delivery do...

Page 406: ...en the bonnet 1 2 Remove the side skirt RH 2 W1014408 Regulator Valve Manual and Glide Shift Transmission Models 1 Disconnect the power steering delivery pipe 4 and return hose 3 2 Disconnect the GST PTO delivery pipe 5 and regulator delivery pipe 1 3 Remove the regulator valve 2 When reassembling Apply grease to the O ring and take care not to damage it Install the copper washer firmly W1014496 1...

Page 407: ...ar 6 driven gear 2 and side plate 3 from the casing When reassembling Take care not to damage the gasket Align the hole of the pump cover 4 and casing 2 5 Install the side plate noting its location and direction Install the gears noting its direction W10135590 Tightening torque Power steering delivery pipe joint bolt 39 2 to 49 0 N m 4 0 to 5 0 kgf m 28 9 to 36 2 ft lbs 1 Oil Cooler Return Pipe 2 ...

Page 408: ... interior surface of the housing caused by the gear 2 If the scratch reaches more than half the area of the interior surface of the housing replace at pump assembly 3 Measure the housing I D where the interior surface is not scratched and measure the housing I D where the interior surface is scratched 4 If the values obtained in the two determinations differ by more than the allowable limit replac...

Page 409: ...t maximum speed 5 Fully turn the steering 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 or replace the steering controller assembly Condition Engine speed Maximum Oil temperature 40 to 60 C 104 to 140 F W1016736 Side plate thickness Factory spec 2 48 to 2 50 mm 0 0976...

Page 410: ...3 When reassembling Tighten the steering joint shaft bracket mounting screw after adjusting the position of steering joint shaft bracket 4 for smooth rotation of the steering wheel W1017095 Steering Controller Assembly 1 Disconnect the power steering delivery pipe 4 steering hoses 3 5 and return hose 2 2 Remove the steering controller mounting screw 6 and take out the steering controller assembly ...

Page 411: ...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 1324B or equivalent to the thread of tie rod joint 4 W1018590 Tightening torque Front wheel mounting nut 137 3 N m 14 0 kgf m 101 3 ft lbs Tie rod end slotted nut L3130 L3430 L3830 L4630 39 2 to 45 1 N m 4 0 to 4 6 kgf m 28 9 to 33 3 ft lbs L5030 156...

Page 412: ...place as a unit W10182660 4 STEERING LINKAGE 1 Disassembling and Assembling Steering Wheel and Steering Post Covers 1 Remove the steering wheel 1 2 Remove the steering post covers 2 3 When reassembling W1019416 Steering cylinder I D Factory spec 55 000 to 55 074 mm 2 16535 to 2 16827 in Allowable limit 55 100 mm 2 16929 in Clearance between rod and bushing Factory spec 0 009 to 0 127 mm 0 00035 to...

Page 413: ...ering joint shaft 2 1 When reassembling Tighten the steering joint shaft bracket mounting screw after adjusting the position of steering joint shaft bracket 2 for smooth rotation of the steering wheel W1019696 Steering Joint Shaft 1 and Steering Post 1 Remove the steering joint shaft 1 2 2 Remove the steering post 1 W1019851 1 Bonnet 2 Side Skirt RH 3 Fuel Tank Frame Support 4 Cover 1 Steering Joi...

Page 414: ...8 HYDRAULIC SYSTEM KiSC issued 02 2007 A ...

Page 415: ...HYDRAULIC PUMP 8 M8 4 FRONT HYDRAULIC BLOCK 8 M9 5 REAR HYDRAULIC BLOCK 8 M10 6 POSITION CONTROL VALVE 8 M11 7 POSITION CONTROL LINKAGE 8 M13 8 POSITION CONTROL WITH DRAFT CONTROL LINKAGE 8 M14 9 MIXED CONTROL 8 M17 10 LOWERING SPEED ADJUSTING VALVE 8 M18 11 HYDRAULIC CYLINDER 8 M19 12 AUXILIARY CONTROL VALVE 8 M20 1 DOUBLE ACTING TYPE 1 8 M20 2 DOUBLE ACTING TYPE 2 FLOATING WITH DETENT 8 M21 3 SI...

Page 416: ...d of two hydraulic pumps relief valve position control valve hydraulic cylinder oil filter and other components as shown in the figure 1 Cylinder Safety Valve 2 Check Valve 3 Rear Hydraulic Outlet 4 Lowering Speed Adjusting Valve 5 Oil Filter 6 Front Hydraulic Block 7 Regulator Valve 8 Power Steering Controller 9 Hydraulic Pump 1 10 Hydraulic Pump 2 11 Relief Valve 12 Hydraulic Cylinder KiSC issue...

Page 417: ...ion control valve hydraulic cylinder oil filters oil cooler and other components as shown in the figure 1 Oil Filter HST 2 Cylinder Safety Valve 3 Check Valve 4 Rear Hydraulic Outlet 5 Lowering Speed Adjusting Valve 6 Oil Filter 7 Front Hydraulic Block 8 Hydraulic Pump 2 9 Hydraulic Pump 1 10 Oil Cooler 11 Power Steering Controller 12 Relief Valve 13 Hydraulic Cylinder KiSC issued 02 2007 A ...

Page 418: ...Hydraulic Cylinder 4 Cylinder Safety Valve 5 Auxiliary Control Valve 6 Power Steering Controller Refer to STEERING Section 7 PTO Clutch Valve Refer to TRANSMISSION Section 8 Regulator Valve Refer to TRANSMISSION Section 9 Hydraulic Pump 2 10 Rear Hydraulic Block 11 Oil Filter 12 Hydraulic Pump 1 13 Relief Valve 14 Front Hydraulic Block KiSC issued 02 2007 A ...

Page 419: ... Control Valve 2 Lowering Speed Adjusting Valve 3 Hydraulic Cylinder 4 Cylinder Safety Valve 5 Auxiliary Control Valve 6 Power Steering Controller Refer to STEERING Section 7 PTO Clutch Valve Refer to TRANSMISSION Section 8 GST Valve Assembly Refer to TRANSMISSION Section KiSC issued 02 2007 A ...

Page 420: ...0 L4630 L5030 WSM HYDRAULIC SYSTEM 9 Regulator Valve Refer to TRANSMISSION Section 10 Hydraulic Pump 2 11 Rear Hydraulic Block 12 Oil Filter 13 Hydraulic Pump 1 14 Relief Valve 15 Front Hydraulic Block KiSC issued 02 2007 A ...

Page 421: ...ISSION 1 Position Control Valve 2 Lowering Speed Adjusting Valve 3 Hydraulic Cylinder 4 Cylinder Safety Valve 5 Auxiliary Control Valve 6 Power Steering Controller Refer to STEERING Section 7 Hydraulic Pump 2 8 Servo Regulator Refer to TRANSMISSION Section KiSC issued 02 2007 A ...

Page 422: ...YSTEM 9 PTO Clutch Valve Refer to TRANSMISSION Section 10 Hydrostatic Transmission HST Refer to TRANSMISSION Section 11 Oil Cooler 12 Rear Hydraulic Block 13 Oil Filter 14 Hydraulic Pump 1 15 Relief Valve 16 Front Hydraulic Block KiSC issued 02 2007 A ...

Page 423: ...ponents 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 W1013488 1 Drive Gear 1 2 Coupling 3 Drive Gear 2 4 Driven Gear 1 5 Bushing 6 Bushing 7 Driven Gear 2 8 Side Plate A From Power Steering Controller B From Transmission Case C To Power Steering Controller D To Main Hydraulic ...

Page 424: ...the tractor to operate the hydraulic cylinders on the implement such as front end loader front blade and so on 1 Cap 2 Front Hydraulic Block 3 Relief Valve A To Implement Control Valve B From Implement Control Valve C To Position Control Valve P From Hydraulic Pump T1 To Transmission Case T2 From Implement Control Valve KiSC issued 02 2007 A ...

Page 425: ...lic outlet port The hydraulic outlet port is located top of the rear hydraulic block to take power out from the tractor to operate the hydraulic cylinders on the implement 1 Cylinder Safety Valve 2 Lowering Speed Adjusting Valve 3 Position Control Valve 4 Cover Rear Hydraulic Outlet Port 5 Check Valve A From Hydraulic Pump B To or From Hydraulic Cylinder C To or From Hydraulic Cylinder KiSC issued...

Page 426: ...e kept at a steady height W1013891 Lifting When the control lever is moved to LIFT position spool 1 is pushed by the spool operating lever forming a circuit with the P port and chamber A The pressurized oil thus flows into the chamber A and closes unload poppet 1 2 The oil from C1 port flows into hydraulic cylinder through check valve in the rear hydraulic block to lift the implement W1014132 1 Po...

Page 427: ...Lowering When the control lever is moved to DOWN position spool 2 moves to arrow mark direction and pushes the poppet 2 1 It forms a circuit with the C2 port and T2 port The oil in the hydraulic cylinder is forced out by the weight of the implement and returns to the tank through the C2 port and T2 port lowering the implement The pressurized oil at the P port pushes open unload poppet 1 3 and retu...

Page 428: ... rotated 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 position Down 1 When the position control lever is moved to the DOWN position the control arm shaft 2 rotates to the arrow Therefore the spool drive lever 3 moves around the fulcrum P and pull the spool...

Page 429: ...ssively The setting traction load can be adjusted by changing the position of the draft control lever The draft control system uses the same control valve as the position control system Therefore it is possible to use the mixed control The traction load applied to the tractor is sensed and is fed back to the control valve by means of the other linkage mechanism 1 Position Control Lever 2 Draft Con...

Page 430: ... lift circuit and the lift arm goes up Down b 1 When the position control lever 3 is moved to the DOWN side the position control link 2 is also rotated 2 By this action the arm 2 5 and the arm 1 1 are returned by the return spring 4 3 The position control valve becomes the down circuit and the lift arm is lowered Reference For the feedback mechanism of the position control refer to Position Contro...

Page 431: ...o push the arm 1 5 3 At the same time the arm 2 11 is moved the connected position control valve becomes the lift circuit and the lift arm goes up Movement of the Link Under Decreased Load b 1 When the lift arm goes up the traction load is decreased and the draft control rod 1 is returned 2 At the same time the arm 2 11 arm 1 5 and draft control link 1 4 are returned by the return spring 8 3 The p...

Page 432: ... the lift arms implement lower to the height set by the position control only when traction load increases slippage or engine stop may occur unless the implement is raised With the draft control only plowing depth cannot be kept constant if soil hardness changes greatly The mixed control serves to eliminate such disadvantages W1017580 A Position Controlled B Draft Controlled C Not Deep Even in Sof...

Page 433: ...ases 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 hydraulic cylinder and rotor 4 W1015173 1 Holder 2 Rotor Shaft 3 Pin 4 Rotor 5 Position Control Valve A Closed Position B Open Position C Cylinder Port T Tank Port KiSC issued 02 2007 A ...

Page 434: ... 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 W1015282 1 Cylinder Tube 2 Rod 3 Wiper 4 Snap Ring 5 O ring 6 Head 7 Bushing 8 Snap Ring 9 Bearing Ring 10 Backup Ring 11 Seal 12 Piston A To Transmission Case B To or From Position Control Valve KiSC issued 02 2007 A ...

Page 435: ...mission case through T port W1015571 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 cylinder via A port Return oil from the implement cylinder flows from the B port to the transmission case through T port W1015748 1 Check Valve 2 Spool A A Port Implement Cylinder B B Port Implement Cylinder P Pump P...

Page 436: ...he arrow the pressure fed oil in the P port opens the check valve 2 and flows to the implement cylinder via B port Return oil from the implement cylinder flows from the A port to the transmission case through T port 1 Spool 2 Check Valve 3 Detent Ball 4 Detent Sleeve A A Port Implement Cylinder B B Port Implement Cylinder P Pump Port N Neutral Port T Tank Port 1 Spool 2 Check Valve A A Port Implem...

Page 437: ...etent sleeve 4 hold the spool 1 at the floating position as shown in the figure The pressure fed oil from the hydraulic pump flows to position control valve via N port And the A port and B port lead to the T port along the notched sections of the spool 1 This result in the attached implement to follow the contour of the terrain 1 Spool 2 Check Valve A A Port Implement Cylinder B B Port Implement C...

Page 438: ...rol valve via N port Lift 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 cylinder via A port 1 Check Valve 2 Spool A A Port Implement Cylinder P Pump Port N Neutral Port T Tank Port 1 Check Valve 2 Spool A A Port Implement Cylinder P Pump Port N Neutral Port T Tank Port KiSC issued 02 2007 A ...

Page 439: ...AULIC SYSTEM Down When the spool 2 is moved in the direction of the arrow return oil from the implement cylinder flows from the A port 1 Check Valve 2 Spool A A Port Implement Cylinder P Pump Port N Neutral Port T Tank Port KiSC issued 02 2007 A ...

Page 440: ...assembling and Assembling 8 S7 3 Servicing 8 S9 2 RELIEF VALVE 8 S11 1 Checking and Adjusting 8 S11 2 Disassembling and Assembling 8 S11 3 REAR HYDRAULIC BLOCK AND VALVES 8 S12 1 Checking and Adjusting 8 S12 2 Disassembling and Assembling 8 S14 3 Servicing 8 S18 4 LIFT ARM SUPPORT AND HYDRAULIC CYLINDER 8 S18 1 Disassembling and Assembling 8 S18 2 Servicing 8 S21 KiSC issued 02 2007 A ...

Page 441: ...ydraulic arm shaft lift arm improperly assembled 3 point link improperly set Adjust Adjust Adjust Adjust 8 S12 8 S20 Implement Does Not Lower Position control valve malfunctioning Spool damaged Poppet 2 push rod improperly adjusted Replace Adjust 8 S17 8 S17 Implement Drops by Weight Hydraulic cylinder worn or damaged Safety valve damaged Hydraulic piston and O ring worn or damaged Lowering speed ...

Page 442: ... 14 Imp gals min Above 30 9 L min 8 16 U S gals min 6 80 Imp gals min Above 36 3 L min 9 59 U S gals min 7 99 Imp gals min 27 6 L min 7 29 U S gals min 6 07 Imp gals min 32 4 L min 8 56 U S gals min 7 13 Imp gals min Housing Bore Depth of Scratch 0 09 mm 0 0035 in Bushing to Gear Shaft Gear Shaft Bushing Clearance O D I D 0 020 to 0 081 mm 0 0008 to 0 0032 in 14 970 to 14 980 mm 0 5894 to 0 5898 i...

Page 443: ...FT ARM SUPPORT AND HYDRAULIC CYLINDER W10118710 Item Factory Specification Allowable Limit Cylinder Safety Valve Operating Pressure 19 6 to 22 6 MPa 200 to 230 kgf cm2 2845 to 3271 psi Hydraulic Cylinder I D 55 000 to 55 074 mm 2 16535 to 2 16827 in 55 100 mm 2 16929 in KiSC issued 02 2007 A ...

Page 444: ...t arm pin mounting nut Lift arm pin lock nut Drawbar frame mounting screw M14 M12 Top link holder mounting screw 49 0 to 68 6 49 0 to 68 6 34 3 to 39 2 39 2 to 49 0 17 7 to 20 6 39 2 to 49 0 23 5 to 27 5 39 2 to 44 1 49 0 to 68 6 34 3 to 48 1 49 0 to 68 6 39 2 to 49 0 58 8 to 78 5 39 2 to 58 8 39 2 to 58 8 39 2 to 58 8 77 5 to 90 2 62 8 to 72 6 166 7 to 196 1 77 5 to 90 2 77 5 to 90 2 5 0 to 7 0 5...

Page 445: ...ng Flow meter Preparation 1 Open the bonnet 1 2 Remove the side skirt RH 2 3 Remove the main delivery pipe 3 When reassembling Install the copper washers firmly W1012121 Tightening torque Main delivery pipe joint bolt 49 0 to 68 6 N m 5 0 to 7 0 kgf m 36 2 to 50 6 ft lbs 1 Bonnet 2 Side Skirt RH 3 Main Delivery Pipe KiSC issued 02 2007 A ...

Page 446: ... 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 Condition 9 Read and note the pump delivery at no pressure 10 Slowly close the loading valve to increase Rated pressure As the load is increased engine speed drops therefore reset the engine speed 11 Read and note ...

Page 447: ...eassembly be sure to perform break in operation and ensure that there is nothing abnormal with the hydraulic pump A Removing Hydraulic Pump Assembly Bonnet and Side Skirt RH 1 Open the bonnet 1 2 Remove the side skirt RH 2 W1014408 Hydraulic pump delivery at no pressure Factory spec Above 31 5 L min 8 32 U S gals min 6 93 Imp gals min Hydraulic pump delivery at rated pressure Factory spec Above 30...

Page 448: ...assembly 2 When reassembling Apply grease to the O ring and take care not to damage it W1014977 Tightening torque Power steering delivery pipe joint bolt 49 0 to 68 6 N m 5 0 to 7 0 kgf m 36 2 to 50 6 ft lbs GST PTO delivery pipe joint bolt 34 3 to 39 2 N m 3 5 to 4 0 kgf m 25 3 to 28 9 ft lbs Regulator delivery pipe joint bolt 39 2 to 49 0 N m 4 0 to 5 0 kgf m 28 9 to 36 2 ft lbs Regulator valve ...

Page 449: ...th the hydraulic pump applied with 2 94 MPa 30 kgf cm2 427 psi to 4 90 MPa 50 kgf cm2 711 psi pressure operate it for approx 15 minutes 4 With the engine set to maximum speed fully turn the steering wheel to the left or right then actuate the relief valve five times for 25 seconds one time 5 seconds W10145360 3 Servicing Housing Bore Depth of Scratch 1 Check for the scratch on the interior surface...

Page 450: ... W1015746 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 W10134960 Clearance between bushing and gear shaft Factory spec 0 020 to 0 081 mm 0 0008 to 0 0032 in Allowable limit 0 15 mm 0 0059 in Gear shaft O D Factory spec 14 970 to 14 980 mm 0 5894 to 0 5898 in Bushing I D Factory spec 15 000 to 15 05...

Page 451: ...f shims 4 0 1 mm 0 0039 in 0 2 mm 0 0079 in 0 4 mm 0 0157 in Pressure change per 0 1 mm 0 0039 in shim Approx 264 8 kPa 2 7 kgf cm2 38 4 psi W1014806 2 Disassembling and Assembling Relief Valve 1 Remove the plug 9 and draw out the spring 5 and the poppet 4 2 Take out the valve seat 3 When reassembling Take care not to damage the O ring IMPORTANT After disassembling and assembling the relief valve ...

Page 452: ... counterclockwise by 2 turns 6 Tighten the lock nut 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 to the uppermost position then move the lift arm to the upper end by hand and measure the free play 10 If the measurement is not within the factory ...

Page 453: ...tween 4 and 5 4 Set the draft control lever 1 between lever guide 1 and 2 5 Lift the test bar 5 upward until the top link bracket 4 comes in contact with the stopper 6 Confirm that the lower link begin to rise 7 If the specified play is not obtained adjust the feedback rod 3 to A or B position W1017519 1 Draft Control Lever 2 Position Control Lever 3 Feedback Rod 4 Top Link Bracket 5 Test Bar A In...

Page 454: ...r 6 Confirm the lower link does not rise 7 Set the draft control lever 4 to 7 position of the lever guide Refer to figure B 8 Lift the test bar 2 9 Confirm the lower links 3 must rise before the top link bracket 1 contact the stopper 10 If the specified play is not obtained readjust the feedback rod Refer Adjusting Draft Control Position Section W1018582 2 Disassembling and Assembling Seat Seat Br...

Page 455: ... 8 S12 W1016371 Lowering Speed Adjusting Valve 1 Draw out the spring pin 4 2 Remove the holder 5 3 Draw out the lowering speed adjusting shaft 3 dowel pin 6 and rotor 2 When reassembling Take care not to damage the O rings W1016653 Check Valves 1 Remove the plug 3 2 Draw out the spring 2 and poppet 1 When reassembling Take care not to damage the O ring W1016889 Tightening torque Hydraulic cylinder...

Page 456: ...linder safety valve assembly be sure to check the operating pressure W1017017 Position Control Valve 1 Remove the position control valve 1 from rear hydraulic block 2 When reassembling Take care not to damage the O rings W1017276 Tightening torque Cylinder safety valve assembly 39 2 to 49 0 N m 4 0 to 5 0 kgf m 28 9 to 36 2 ft lbs Cylinder safety valve lock nut 58 8 to 78 5 N m 6 0 to 8 0 kgf m 43...

Page 457: ...to set the dimension A to 0 2 mm 0 0079 in When reassembling Take care not to damage the backup ring and O rings W1017707 1 Nut 2 External Snap Ring 3 Unload Plug 4 Spring 5 Unload Poppet 6 Valve Body 7 Unload Poppet 2 8 Spring 9 Plug 2 10 Spool 11 Spring 12 Plain Washer 13 External Snap Ring 14 Spool Joint 15 External Snap Ring 16 Plug 1 17 Poppet 2 18 O ring 19 Backup Ring 20 Sleeve 21 O ring 22...

Page 458: ... W10205610 4 LIFT ARM SUPPORT AND HYDRAULIC CYLINDER 1 Disassembling and Assembling Top Link Lift Rod and PTO Cover 1 Remove the top link 1 and PTO cover 3 2 Disconnect the lift rods 2 4 from lift arm When reassembling W1018168 Cylinder safety valve operating pressure Factory spec 19 6 to 22 6 MPa 200 to 230 kgf cm2 2845 to 3271 psi Tightening torque Cylinder safety valve lock nut 58 8 to 78 5 N m...

Page 459: ...rt this action by pushing from the outside of the cylinder tube with another small screwdriver or similar tool 5 Draw out the rod 6 and head 5 6 Inject the compressed air through the oil inlet port of the cylinder tube 3 and remove the piston 2 7 Remove the external snap ring 7 and remove the head 5 When reassembling Apply transmission fluid to the piston 2 head 5 and cylinder tube 3 Take care not...

Page 460: ... Arm and Lift Arm Shaft 1 Remove the external snap ring 5 2 Remove the lift arm RH 6 3 Draw out the lift arm shaft 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 arm support and O rings Take care not to damage the O rings W1019375 Tightening torque...

Page 461: ...auge 2 If the cylinder I D exceed the allowable limit replace the cylinder tube W1019902 Lift Arm Support Bushing 1 Visually inspect the DX bushings for signs of wear or damage The DX bushing tends to show concentrated wear 2 If the DX bushing is worn beyond the alloy portion A replace it Reference W1020043 Hydraulic cylinder rod bushing Alloy thickness A 0 57 mm 0 0224 in Hydraulic cylinder I D F...

Page 462: ...ng 1 Visually inspect the DX bushings for signs of wear or damage The DX bushing tends to show concentrated wear 2 If the DX bushing is worn beyond the alloy portion A replace it Reference W1020165 Lift arm bushing Alloy thickness A 0 57 mm 0 0224 in KiSC issued 02 2007 A ...

Page 463: ...9 ELECTRICAL SYSTEM KiSC issued 02 2007 A ...

Page 464: ...UTLINE AND ELECTRICAL CIRCUIT 9 M7 1 System Outline 9 M7 2 Control Items 9 M8 2 CONSTRUCTION AND FUNCTION OF COMPONENTS 9 M9 3 CONTROL SYSTEM 9 M18 1 Basic Control System 9 M18 2 Assistant Control System 9 M25 3 STARTING SYSTEM 9 M28 1 MANUAL ROPS MODEL 9 M28 2 MANUAL CABIN MODEL 9 M1 3 GST MODEL 9 M1 4 HST MODEL 9 M31 4 CHARGING SYSTEM 9 M32 5 LIGHTING SYSTEM 9 M33 1 ROPS TYPE 9 M33 2 CABIN TYPE ...

Page 465: ...itch 0 85 R L Hazard Switch 1 25 Y R 1 25 B 1 25 Y R 0 5 R W 0 5 B W 0 5 Br Y 0 5 G L 0 5 B W 0 5 G L 0 5 B W 0 5 B 0 5 B 0 5 R L 0 5 R L 0 5 L 0 5 W 0 5 G R 0 5 G R Horn 3A 0 5 L W 0 5 B 0 5 L W Brake Lamp Switch 7 5A 1 25 W G 1 25 W G 0 5 G R 0 5 G R Rear Combination Lamp RH 1 25 G 1 25 G 1 25 G Trailer Socket 1 13 12 18 13 12 18 4 1 2 3 e d c e e d c b a OFF ON e d c a OFF ON c a d b a 1 2 3 17...

Page 466: ...nt Wiper Motor A C Compressor Window Washer Tank LH Window Washer Tank RH 2 L 2 L 2 L 0 85 R B 0 85 R B 1 25 W G Brake Lamp Switch 1 25 W G 1 25 G 1 25 G 1 25 G 0 85 R L 0 5 L 0 5 L 0 5 L 0 5 L 0 85 Lg B 0 85 Lg B 0 85 B 0 5 Lg L 0 5 Lg L 1 25 Y G 1 25 Y G 0 85 Lg 0 85 Lg 0 5 Lg R 0 5 Lg R 0 5 L 0 5 G L 0 5 B W Ciger Lighter 1 25 Y 1 25 B 2 B 2 B 1 25 Y 0 5 G R 10A 1 25 Y Trailer Socket 0 5 G R 0 ...

Page 467: ... W 0 5 R 1 25 Y 0 5 Y O 0 85 B 0 5 Lg 0 5 B Y 0 5 R G 2 W G Hazard Switch 1 25 Y R 1 25 B 1 25 Y R 0 5 R W 0 5 B W 0 5 G R 0 5 G R 0 5 Br Y 0 5 G L 0 5 B W 0 5 G L 0 5 B W 0 5 B 0 5 B 0 5 R L 0 5 R L 0 5 L 0 5 Br W 0 5 Br 0 5 㨃 0 5 G L 0 5 B W 0 5 B 0 5 B 0 5 B W 0 5 R Y 0 5 R 0 5 Br Y 0 5 L R 0 5 Br B 0 5 G W 0 5 Y 0 5 Y 0 5 Y 0 5 B Emergency Coupler Connector for Emergency Coupler 3 R 3 B W 10A ...

Page 468: ...0 5 B W Rear Combination Lamp RH Rear Combination Lamp LH 0 5 G R 0 5 G R 0 5 Br Y 0 5 G L 0 5 B W 0 5 G L 1 25 Y R 0 5 B 0 5 B 0 5 R L 0 5 R L 0 5 L 0 5 㨃 0 5 G L 0 5 B W 0 5 B 0 5 B 3 R 3 B W 7 5A 15A 10A 30A 10A 3 B R 3 B R 3 B L 3 R L 5 R 0 5 L Y 0 5 L Y 2 P L 2 P L 0 5 P 0 5 P 2 R 2 R 1 25 R W Front Wiper Motor A C Compressor Window Washer Tank LH Window Washer Tank RH 2 L 2 L 2 L 0 85 R B 0 ...

Page 469: ...5 R B 0 5 G L 0 5 G L 0 5 G R 0 5 G R 0 85 R B 0 85 R B 0 85 R W 1 25 Y 1 25 Y 0 5 L Y 0 5 L Y 1 25 L 1 25 L 0 5 P 0 5 P 0 5 P 0 5 P 2 R 2 R 1 25 R W 1 25 R W 1 25 R W 1 25 R W 0 5 Lg R 0 5 Lg R 0 5 Lg L 0 5 Lg L 0 85 Lg 0 85 Lg 0 85 Lg B 0 85 Lg B 1 25 B 0 5 Y B 0 5 Y B 0 5 Y 0 5 Y 0 5 W B 0 5 W B 0 5 W 0 5 W 0 5 B R 0 5 B R 0 5 B R 0 5 B R 0 5 L R 0 5 L R 2 L W 2 L W 2 L W 2 O 2 O 2 G 2 G 0 5 G ...

Page 470: ...W Red White W White G R Green Red R Y Red Yellow Y Yellow G W Green White W B White Black Br Brown G Y Green Yellow W G White Green Lg Light Green L B Blue Black W L White Blue Or Orange L G Blue Green W R White Red Sb Sky Blue L Or Blue Orange W Y White Yellow B G Black Green L R Blue Red Y B Yellow Black B L Black Blue L W Blue White Y G Yellow Green B P Black Pink L Y Blue Yellow Y L Yellow Blu...

Page 471: ...ta 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 for one second When the capacity of the transmission line is extremely larger than the ability of the transmission reception performed by a terminal device signals from plural terminals can be transmitted by means of time...

Page 472: ... 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 the LCD Service Interval Display Display and alert the service interval periodically on the LCD and panel Warning Display Display the fuel level warning and overheat warning on the LCD and panel Error Display...

Page 473: ...lasher Unit 12 Combination Switch 13 Main Switch 14 Cruise Switch 15 HST Range Shift Lever Sensor 16 HST Pedal Neutral Switch 17 Clutch Pedal Switch 18 Alternator 19 Engine Tachometer Sensor 20 Traveling Speed Sensor 21 Shuttle Switch 22 GST Lever Sensor 23 Oil Pressure Switch 24 Oil Temperature Sensor 25 Electronic Instrument Panel IntelliPanel 26 Electronic Control Unit ECU 27 GST Valve Solenoid...

Page 474: ...on the computer in the IntelliPanel detects the signals and determines whether the engine can be started safety W1014104 Combination Switch The illumination lamp within the IntelliPanel lights up by the operation of the headlight switch 1 interlocked with the light up of the headlight When the high beam headlight is used the monitor lamp at the panel lights up The pilot lamp at the panel lights up...

Page 475: ...itch 2 is used to switching to the traveling speed display as well as at data input and fine adjustment W1014375 Brake Lamp Switch This switch is mounted on the brake pedal When the brake pedal is depressed this switch is turned on and the brake lamp is lighting W1020505 Parking Brake Switch This switch 1 is turned on and off interlocked with the parking brake lever It is switched on when the park...

Page 476: ...oat that moves according to the quantity of fuel through the variation in resistance of the variable resistor in order to indicate the fuel level on the LCD It also sends a signal to light up the monitor lamp at the IntelliPanel when fuel becomes less than 5 L 1 3 U S gals 1 1 Imp gals W1014733 Coolant Temperature Sensor This sensor 1 is designed to detect the temperature of coolant It employs a t...

Page 477: ... cam gear teeth The engine speed is calculated from the frequency of the pulse The tachometer of the IntelliPanel is of cross coil type and analogically indicates by and after converting the frequency of the engine tachometer sensor The PTO speed is calculated by means of using the frequency detected by this sensor and operational coefficient preset from model to model W1015004 Traveling Speed Sen...

Page 478: ...e signal inlet and outlet W1015355 GST Valve Solenoid Valves and Proportional Reducing Valve for GST Model This valve 1 includes the sensors and switches and the associated necessary for GST control solenoid that actuates GST shift pin proportional reducing valve and others It sends information from sensors and the associated to ECU and then a signal from ECU actuates each solenoid valve W1015434 ...

Page 479: ...become lower than 0 34 MPa 3 5 kgf cm2 50 psi W1015635 Oil Temperature Sensor for GST Model This sensor 1 is designed to detect the temperature of transmission oil and is mounted at the side of GST valve It is provided in order to compensate the operating time and electric current of the proportional reducing valve within GST valve according to the transmission oil temperature The sensor employs t...

Page 480: ...is mounted at the bottom of the cruise lever assembly and is turned on when the lever is operated thereby sending a signal to light up the pilot lamp at the electronic instrument panel W1015910 Clutch Pedal Switch for HST Model This switch 1 is mounted close to the fulcrum of the clutch pedal and is turned on when the pedal is depressed clutch OFF It serves as a safety switch when the engine is st...

Page 481: ...ough the trouble is repaired Use of emergency connector 1 Stop the engine 2 Disconnect the ECU connector 3 3 Remove the each cap from connectors 1 2 4 Connect the connector A and B 5 Start the engine and move the tractor NOTE When connecting the emergency connectors the GST valve is set at 1st speed position even if the GST lever is at any position And the stop and the start of the tractor is oper...

Page 482: ...ter displayed 1 Let s suppose that the PTO gear shift lever is at the neutral position When you turn ON the PTO clutch control lever the PTO shaft stays off but the meter displays the rpm at the L position This is normal not a machine failure W1015278 1 IntelliPanel Electronic Instrument Panel 2 Liquid Crystal Display LCD 3 Display Mode Switch 4 Travel Speed Switch 5 Periodic Service Required Read...

Page 483: ... The safety 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 indicated When the shuttle lever is not set at a Neutral position Shift the shuttle lever to Neutral position W1017623 When the PTO shift lever is not set at a Neutral Position Shift the PTO shift...

Page 484: ...on Release the HST pedal to set the Neutral Position W1017819 When the PTO shift lever is not set at a Neutral position Shift the PTO shift lever to Neutral position W1017869 When the clutch pedal is not depressed Depress the clutch pedal W1017913 When the HST pedal and PTO shift lever are not set a Neutral position Release the HST pedal and shift the PTO shift lever to set the Neutral position W1...

Page 485: ...1018012 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 W1018064 When the HST pedal and PTO shift lever are not set a Neutral position and clutch pedal is not depressed Release the HST pedal and shift the PTO shift lever to set a Neutral position and depress the clutch pedal W101...

Page 486: ...play by pushing the display mode switch 3 Clearing Operation Keep pushing both switches 3 4 for two seconds or more while displaying the hour meter Normal Display 1 W1018218 D Warning Display or Warning Information Fuel Level Warning If the fuel in the tank goes below the prescribed level less than 5 L 1 3 U S gals 1 1 Imp gals FUEL is displayed on the LCD 1 and the warning lamp 2 in the panel wil...

Page 487: ...es 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 W1018762 Engine Oil Pressure and Electric Charging Warning If the engine oil pressure goes below the 49 kPa 0 5 kgf cm2 7 1 psi the warning lamp 1 will come on If this should happen during operation and it does not go off when the engine is accelerated to more than 700 min...

Page 488: ... 3 Glow Indicator Lamp If the main switch is turned to ON position the glow indicator lamp comes on and goes off automatically when preheating is completed 4 Rear PTO Lamp If the PTO shift lever is ON position PTO switch is turned on and monitor lamp will come on 5 High Beam Indicator Lamp If the head light switch is turned to High beam position the indicator lamp comes on 6 Shuttle Neutral Lamp M...

Page 489: ...wever put in the memory device of the IntelliPanel and can be reviewed in the Error Information Display Mode see page 9 S18 Such error information can also be deleted out of the error history by operating of Error Information Reset Mode see page 9 S15 Error Messages For All Models ERROR 00 Electronic meter in trouble ERROR 20 Communication error For GST model GST specified meter wrongly installed ...

Page 490: ...raveling speed to IntelliPanel C PTO Coefficient Number Input Mode For inputting operation coefficient number of PTO to IntelliPanel D Error Information Reset Mode For deleting the error information 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 proportiona...

Page 491: ...the 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 temperature And the supply current to the glow plug is stopped automatically when the preheating time is completed and monitor lamp on the electronic meter panel is turned off Refer to STARTING SYST...

Page 492: ... A 4 Main Switch 5 Slow Blow Fuse 50 A 6 Slow Blow Fuse 30 A 7 Key Stop Solenoid Relay 8 Fuse 5 A 9 Fuse 5 A 10 Fuse 30 A 11 Fuse 5 A 12 Key Stop Solenoid 13 PTO Switch 14 PTO Speed Change Switch 15 Shuttle Switch 16 Starter Relay 17 Starter 18 Fuse 7 5 A 19 Electronic Instrument Panel IntelliPanel 20 Glow Relay 21 Glow Plug KiSC issued 02 2007 A ...

Page 493: ... 4 Main Switch 5 Slow Blow Fuse 60 A 6 Slow Blow Fuse 30 A 7 Key Stop Solenoid Relay 8 Fuse 5 A 9 Fuse 5 A 10 Fuse 30 A 11 Key Stop Solenoid 12 PTO Switch 13 PTO Speed Change Switch 14 Shuttle Switch 15 Starter Relay 16 Starter 17 Fuse 7 5 A 18 Electronic Instrument Panel IntelliPanel 19 Glow Relay 20 Glow Plug KiSC issued 02 2007 A ...

Page 494: ...ow Blow Fuse 60 A 6 Slow Blow Fuse 30 A 7 Key Stop Solenoid Relay 8 Key Stop Solenoid 9 Fuse 5 A 10 Fuse 5 A 11 Fuse 30 A 12 Fuse 10 A 13 Fuse 5 A 14 PTO Switch 15 Shuttle Switch 16 Starter Relay 17 Starter 18 Fuse 7 5 A 19 Electronic Instrument Panel IntelliPanel 20 Glow Relay 21 Glow Plug 22 Electronic Control Unit ECU KiSC issued 02 2007 A ...

Page 495: ...ch 5 Slow Blow Fuse 60 A 6 Slow Blow Fuse 30 A 7 Key Stop Solenoid Relay 8 Key Stop Solenoid 9 Fuse 5 A 10 Fuse 5 A 11 Fuse 30 A 12 PTO Switch 13 HST Pedal Switch 14 Main Clutch Switch 15 Cruise Switch 16 Starter Relay 17 Starter 18 Fuse 7 5 A 19 Glow Relay 20 Glow Plug 21 Electronic Instrument Panel IntelliPanel KiSC issued 02 2007 A ...

Page 496: ...CAL SYSTEM 4 CHARGING SYSTEM 1 Battery 2 Slow Blow Fuse ROPS 60 A Cabin 80 A 3 Main Switch for ROPS 4 Main Switch for Cabin 5 Engine Tachometer Sensor 6 Electronic Instrument Panel IntelliPanel 7 ECU GST Model Only 8 Alternator KiSC issued 02 2007 A ...

Page 497: ... Switch 10 Turn Signal Switch 11 Hazard Switch 12 Flasher Unit 13 Head Light 14 Front Combination Lamp RH 15 Rear Combination Lamp RH 16 Front Combination Lamp LH 17 Rear Combination Lamp LH 18 Electronic Instrument Panel IntelliPanel 19 Position Switch 20 License Plate Lamp 21 Brake Lamp Switch 22 Trailer Socket 23 Lamp Relay 24 Fuse 45 A 25 Horn 26 Alternator 27 Fuse 5 A 28 Fuse 20 A KiSC issued...

Page 498: ... Horn 18 Rear Combination Lamp RH 19 Rear Combination Lamp LH 20 Turn Signal Light RH 21 Turn Signal Light LH 22 Patrol Lamp Switch 23 Positin Switch 24 Fuse 10 A 25 Room Lamp 26 Door Switch 27 Fuse 15 A 28 Working Light Switch Front 29 Working Light Switch Rear 30 Working Light Front 31 Working Light Rear 32 Electronic Instrument Panel IntelliPanel 33 License Plate Lamp 34 Position Light 35 Lamp ...

Page 499: ...el IntelliPanel 9 S12 2 Checking Electrical Control System 9 S20 3 Checking GST Electric Control System GST Model Only 9 S27 3 STARTING SYSTEM 9 S33 1 Checking 9 S33 2 Disassembling and Assembling 9 S41 3 Servicing 9 S41 4 CHARGING SYSTEM 9 S44 1 Checking 9 S44 2 Disassembling and Assembling 9 S45 3 Servicing 9 S47 5 LIGHTING SYSTEM 9 S49 1 Checking 9 S49 6 WARNING LAMPS 9 S53 1 Checking 9 S53 7 M...

Page 500: ...Does Not Operate Battery discharged or defective Slow blow fuse blown Safety switch improperly adjusted or defective Wiring harness disconnected or improperly connected between main switch terminal and safety switches between safety switches and starter motor between battery positive terminal and starter motor Starter motor defective Main switch defective Connector A for electronic instrument pane...

Page 501: ...t Replace Replace Repair or replace G 36 G 37 Hazard Light Does Not Light Fuse blown Bulb blown Wiring harness disconnected or improperly connected Flasher unit defective Hazard switch defective Replace Replace Repair or replace Replace Replace G 36 G 37 9 S52 9 S51 Position Light Does Not Light Fuse blown Bulb blown Wiring harness disconnected or improperly connected Flasher unit defective Positi...

Page 502: ...s below 7 V Slow blow fuse blown IntelliPanel connector disconnect IntelliPanel defective Recharge or replace Replace Connect Replace G 25 9 S10 9 S23 9 S23 Indication on LCD Does Not Change When Pushing the Display Mode Switch Display mode switch defective Wiring harness disconnected Replace Repair 9 S26 Traveling Speed is Not Indicating Wiring harness disconnected Traveling speed sensor defectiv...

Page 503: ...sor voltage by Test mode Mode A Check sensor voltage by connector Check sensor resistance Replace lever sensor 9 S24 9 S13 9 S24 9 S26 9 S26 Wrong setting of IntelliPanel Manual Transmission and HST model GST specified IntelliPanel installed wrong on HST or Manual transmission model Input appropriate transmission model by Transmission model Input Mode Mode I 9 S19 Communication error between ECU a...

Page 504: ...short circuited Input line broken Lever sensor defective It is possible to run at its selected speed position until engine is stopped Check sensor connector Check sensor voltage by Test mode Mode A Check lever sensor wire connector voltage or check sensor resistance Replace lever sensor 9 S13 9 S29 S31 9 M15 Proportional reducing valve failure GST model Output voltage of proportional reducing valv...

Page 505: ...oid Check a resistance between solenoid and GND Replace GST valve 9 S30 S32 3 S79 Solenoid 1 failure At reverse GST model Solenoid 2 failure At forward or neutral GST model Able to travel at speeds other than 2 9 and 10 Forward or 2 and 6 Reverse Check the wiring connector of solenoid Check a resistance between solenoid and GND Replace GST valve 9 S30 S32 9 S79 Solenoid 2 failure At reverse GST mo...

Page 506: ...or of solenoid Check a resistance between solenoid and GND Replace GST valve 9 S30 S32 3 S79 Solenoid 4 failure At reverse GST model Solenoid 6 Main range gear shift failure At forward or neutral GST model Able to travel at speeds other than 1 to 6 Forward or 1 to 4 Reverse Check the wiring connector of solenoid Check a resistance between solenoid and GND Replace GST valve 9 S30 S32 3 S79 Solenoid...

Page 507: ...Float at Upper most Position Float at Lower most Position Resistance Resistance 1 0 to 5 0 Ω 103 to 117 Ω Coolant Temperature Sensor at 130 C 266 F at 105 C 221 F at 80 C 176 F at 50 C 122 F Resistance Resistance Resistance Resistance Approx 12 2 Ω Approx 23 6 Ω Approx 51 9 Ω Approx 153 9 Ω Alternator Stator Rotor Slip Ring Brush No load voltage Resistance Resistance O D Length More than 14 V Less...

Page 508: ...ues of screws bolts and nuts on the table below are especially specified For general use screws bolts and nuts See page G 10 W10127360 Item N m kgf m ft lbs Alternator pulley nut Starter terminal nut 58 3 to 78 9 5 9 to 11 8 5 95 to 8 05 0 6 to 1 2 43 0 to 58 2 4 3 to 8 7 KiSC issued 02 2007 A ...

Page 509: ...ery If this advice is disregarded damage to alternator and regulator may result 1 BATTERY 1 Checking Battery Voltage 1 Stop the engine and turn the main switch off 2 Connect the COM lead of the voltmeter to the battery s negative 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...

Page 510: ...ly and hold the hydrometer at eye level The hydrometer reading must be taken at the highest electrolyte level Reference Specific gravity slightly varies with temperature To be exact the specific gravity decreases by 0 0007 with an increase of 1 C 0 0004 with an increase of 1 F in temperature and increases by 0 0007 with a decreases of 1 C 0 0004 with a decrease of 1 F Therefore using 20 C 68 F as ...

Page 511: ...switch 2 until the buzzer rings When a setting has been saved or an adjustment mode in any mode be sure to turn off the main switch to end the procedure W1010725 W1083952 1 Liquid Crystal Display LCD 2 Display Mode Switch 3 Travel Speed Switch A Mode Selection Display for HST and Manual Transmission Model B Mode Selection Display for GST Model Symbol Mode Necessary Situation A Test Mode When the c...

Page 512: ...ts Condition Value unit Availability M G H T1 Engine revolution Idling to Max 700 to Max min 1 rpm T2 Coolant temperature sensor voltage 20 60 100 C 4 140 212 F 4 76 to 4 81 2 80 to 3 0 0 77 to 0 83 V T3 Fuel sensor voltage F to E Below 0 31 to above 3 24 V T4 Battery Voltage More than 12 V T5 HST range gear shift lever sensor voltage L N M N H 3 55 to 4 45 2 95 to 3 85 2 05 to 2 95 1 15 to 2 05 0...

Page 513: ...isplay mode switch is pressed the flashing number shifts Press the travel speed switch to change the number 4 Hold down the display mode switch for more than 2 seconds to preserve the code in the panel s memory 5 OK is displayed c The code has been input correctly NG is displayed d Incorrect input Repeat the procedure 6 Turn off the main switch to end the mode B W1012066 Tractor Model Rear wheel t...

Page 514: ... input correctly Repeat the procedure 6 Turn off the main switch to end the mode C W1013003 Error Information Reset Mode Mode D Delete the error information from the IntelliPanel 1 Select the mode D See page 9 S12 Mode Selection 2 CLEAR is displayed b and PUSH SW is displayed e for 2 seconds 3 Hold down the display mode switch for more than 2 seconds and the error information is deleted 4 OK is di...

Page 515: ...5 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 If NG is displayed f it means the preserving has not been made correctly 4 Turn off the main switch and repeat the procedure 6 If LEVER is displayed b first and then ERROR 70 shows up e it means the lever sensor voltage is out of specification In this case Check to see ...

Page 516: ...s follows disengaged the clutch select forward with the shuttle lever and shift the GST lever from 1 through 12 several times Set the GST lever at the positions other than neutral 8 STEP 05 g Set the GST lever to Neutral position 9 STEP 06 h Set shuttle lever to forward and engage clutch 10 PUSH SW i Push the display mode switch for more than 3 seconds 11 STEP 07 j To preform this function the ope...

Page 517: ...he key Then setting 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 W1020862 Error Information Display Mode Mode H Confirming or Reviewing the Error Information 1 Select mode H See page 9 S12 Mode Selection 2 If there is not error information in memory NO ERROR is displayed b If there is error information in memory its info...

Page 518: ...odel has not been input correctly Repeat the procedure 5 Turn off the main switch to end the mode I W1014885 Adjustment of HST range gear shift lever sensor for HST Model NOTE When the IntelliPanel or range gear shift sensor was replaced this adjustment is required 1 Set the range gear shift lever to the M position 2 Select mode I and then select H of the HST model according to above procedure 3 O...

Page 519: ...nding line first check by the test function of IntelliPanel next and check the connectors of panel or electronic control unit If any defect is found there check individual sensors switches or solenoids to see whether the defect exists at the sensor switch and solenoid side or at the wire harness side When the normal function is restored as the result of replacement of the part which is suspected t...

Page 520: ...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 defective parts are found repair or replace them IMPORTANT Connect connectors surely after checked W1035253 1 Grounding Wire A Located at Left Side of Front Axle Frame B Located at Left Side of Transmission Case 1 ...

Page 521: ...w beam 5 Red White Black Yellow Main switch ON HST pedal neutral switch 6 Black Red PTO switch output 7 Black Yellow PTO switch input 8 Black Yellow Shuttle switch Clutch switch 9 Red Black Green White PTO speed change switch input 10 11 Blue Oil switch 12 13 White Red Charge 14 Violet Trailer indicator 15 Violet White Cruise switch 16 Blue White PTO speed change switch output 17 Black White Main ...

Page 522: ...ly 12 V 2 Black GND for circuit line 3 Black Yellow GND for sensor 4 Brown White Check connector ECU RS485 Check connector 5 Brown Check connector ECU RS485 Check connector 6 Yellow HST lever sensor 7 White Coolant temperature sensor 8 Yellow Blue Fuel unit 9 Red Blue Main switch ON 10 Red Yellow HST lever sensor 11 Black GND for circuit line 12 Green Red Parking brake switch 13 14 Orange Travelin...

Page 523: ...is not indicated as table below wire harness or fuse is faulty Sensor Voltage 1 Turn on the main switch 2 Measure the voltage between the terminal 6 and terminal 3 of the connector B while shifting the range gear shift lever 3 If the voltage is not indicated as table below wire harness or lever sensor is faulty W1045520 Voltage Terminal 1 to 11 Approx battery voltage A Connector B 16P of Wire Harn...

Page 524: ...inal 2 of connector A and chassis 4 It is OK if the battery voltage 12 V is indicated while pushing the display mode switch Travel Speed Switch 3 Measure the voltage with voltmeter between terminal 3 of connector A and chassis 4 It is OK if the battery voltage 12 V is indicated while pushing the travel speed switch W1046806 Checking Engine Tachometer Sensor 1 Connect the panel connectors to the In...

Page 525: ... Switch and Travel Speed Switch 1 Check the resistance between the terminal a and terminal c while pushing the display made switch 1 2 It is OK if 0 Ω is indicated 3 Check the resistance between the terminal b and terminal c while pushing the travel speed switch 2 4 It it OK if 0 Ω is indicated W1048960 HST Range Gear Shift Lever Sensor Resistance 1 Measure the resistance between the terminal a an...

Page 526: ...me capacity W1058136 Checking Grounding Wire 1 Check the whether the grounding wire 1 is connected securely to the tractor chassis 2 If the grounding wire is broken or disconnected replace it W1058245 Checking 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 def...

Page 527: ...tput terminal for 3rd shift solenoid 8 Red Yellow 12 V power source from main switch 30 Brown Green Output terminal for 4th shift solenoid 9 31 Red 12 V power source from battery 10 Black White GND ground for oil temp sensor 32 Blue Red Return line terminal for proportional reducing valve 11 Black White GND ground for check connector 33 Black White GND ground for sensor 12 34 Red White 5 V power s...

Page 528: ...oltage between terminal 34 and terminal 33 3 It is OK if the voltage is approx 5 V W1039947 GST Lever Sensor Voltage 1 Turn on the main switch Do not start engine 2 Measure the voltage between terminal 42 and terminal 34 3 It is OK if the voltage comes to show in the table below W1040168 1 Seat Bracket 2 Seat Suspension 3 ECU Electric Control Unit 4 ECU Connector Voltage Terminal 31 to 7 Approx ba...

Page 529: ... Reducing Valve Solenoid Valve Resistance 1 Measure the resistance between each value terminal and terminal 32 2 It is OK if the resistance value approximates to the value shown in the table below W1041158 Voltage between terminal 35 to 7 GST lever at Neutral 0 V GST lever at Shifting Above 12 V A Connector of wire harness side Voltage between terminal 19 to 33 Reference value Approx 4 7 V at 30 C...

Page 530: ...oyed W1041711 Pressure Switch Resistance 1 Disconnect the pressure switch connector 1 2 Connect the circuit tester pins to each terminal of pressure switch 2 3 Start the engine and depress the clutch pedal 4 Check the resistance at time when shuttle lever or GST lever is shifted 5 It is OK if the resistance comes to have shown in the table below CAUTION Be sure to depress the clutch pedal so that ...

Page 531: ...o have shown in the table below W1042539 Shift Solenoid Resistance 1 Measure the resistance between each connector terminal and each valve body 2 It is OK if the resistance comes to have shown in the table below W1042693 Resistance Reference value 16 4 to 21 1 kΩ at 20 C 4 F 1 04 to 1 23 kΩ at 40 C 104 F 0 15 to 0 16 kΩ at 100 C 212 F 1 Oil Temperature Sensor Resistance Reference value 8 to 9 Ω Me...

Page 532: ...ion switch 2 Remove the panel cover 3 Disconnect the main switch connector 4 Perform the following checking W1013848 Connector Voltage 1 Measure the voltage between the terminal B and chassis 2 If the voltage differs from the battery voltage 11 to 14 V the wiring harness is faulty W1014366 Resistance between connecter terminals When brake pedal is released Infinity When brake pedal is depressed 0 ...

Page 533: ...CABIN Type Connector Voltage 1 Measure the voltage between the terminal B and chassis 2 If the voltage differs from the battery voltage 11 to 14 V the wiring harness is faulty W1014732 Main Switch at ACC Position 1 Turn the main switch ACC position 2 Measure the resistance between the terminal B and the terminal ACC 3 If 0 Ω is not indicated renew the main switch W1014824 Resistance Terminal B Ter...

Page 534: ... is not indicated renew the main switch W1015222 C Safety Switch PTO Switch Continuity 1 Disconnect the PTO switch connector 1 2 Measure the resistance between connector terminal as shown in table below 3 If the switch is defective replace it W1044513 Resistance Terminal B Terminal ACC 0 Ω Terminal B Terminal IG1 0 Ω Terminal B Terminal IG2 0 Ω A Main Switch Side Connector 6G Resistance Terminal B...

Page 535: ...der cover 2 Disconnected the shuttle switch connector 1 3 Measure the resistance across four terminal referring to the table below 4 If 0 Ω is not indicated the shuttle switch is faulty Reference There are only terminal N1 and COM1 for manual transmission model W1044817 Resistance between connector terminal When switch spring is pushed Neutral 0 Ω When switch spring is Released Infinity 1 PTO Spee...

Page 536: ...tch pedal switch connector 2 3 Measure the resistance between connector terminals while pushing the clutch pedal switch 4 If 0 Ω is not indicated switch is faulty W1045306 D Starter and Starter Relay Starter Motor B Terminal Voltage 1 Measure the voltage between the B terminal and chassis 2 If the voltage differs from the battery voltage check the battery s cable W1016256 Resistance while pushing ...

Page 537: ...ter housing 2 Prepare a 12 V battery for the test 3 Connect jumper leads from the battery negative terminal to the housing and the starter C terminal 4 The plunger should be attached and the pinion gear should pop out when a jumper lead is connected from the battery positive terminal to the S terminal It s a correct 5 Disconnect the jumper lead to the starter C terminal Then the pinion gear should...

Page 538: ... glow plug is faulty W10151150 Glow Relay 1 Connector Voltage 1 Turn the main switch off 2 Disconnect the 4P connector from glow relay 3 Measure the voltage across the terminal 3 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 Measure the voltage across the terminal 1 Positive and chassis Negative 7 If the vol...

Page 539: ...re the voltage between the terminal 3 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 Measure the voltage between the terminal 1 Positive and chassis Negative 7 If the voltage differs from the battery voltage the wiring harness is faulty 2 Engine Stop Solenoid Relay 1 Remove the engine stop solenoid relay 2 Ap...

Page 540: ... teeth of the gears 5 and overrunning clutch 2 and ball 3 W10167280 Plunger 1 Remove the end cover 1 2 Take out the plunger 2 W10168830 3 Servicing Overrunning Clutch 1 Inspect the pinion for wear or damage 2 If there is any defect replace the overrunning clutch assembly 3 Check that the pinion turns freely and smoothly in the overrunning direction and does not slip in the cranking direction 4 If ...

Page 541: ... face of the brush is dirty or dusty clean it with emery paper 2 Measure the brush length A with vernier calipers 3 If the length is less than the allowable limit replace the yoke assembly and brush holder W10175440 Brush Holder 1 Check the continuity across the brush holder and the holder support with an ohmmeter 2 If there is continuity replace the brush holder W10176720 Commutator O D Factory s...

Page 542: ...e continuity across the segments of the commutator with an ohmmeter 4 If there is continuity replace the armature W10177670 Field Coil 1 Check the continuity of the lead 1 and brush 2 with an ohmmeter 2 If it does not conduct replace the yoke assembly 3 Check the continuity of the brush 2 and yoke 3 with an ohmmeter 4 If it conducts replace the yoke assembly W10180150 1 Lead 2 Brush 3 Yoke KiSC is...

Page 543: ...onnect the negative cable from the battery 5 Measure the voltage between the terminal B 2 and the chassis 6 If the measurement is less than the factory specification disassemble the alternator and check the IC regulator Reference Once the engine has started the alternator temperature rises quickly up to an ambient temperature of 70 to 90 C 158 to 194 F As the temperature goes higher than 50 C 122 ...

Page 544: ... and the B terminal nut and remove the rear end cover W10189820 Brush Holder 1 Unscrew the two screws holding the brush holder 1 and remove the brush holder 1 W10190540 IC Regulator 1 Unscrew the three screws holding the IC regulator 1 and remove the IC regulator 1 W10191230 Rectifier 1 Remove the four screws holding the rectifier 1 and the stator lead wires 2 Remove the rectifier 1 W10191920 Tigh...

Page 545: ...ring or fan etc W10194380 Retainer Plate 1 Unscrew the four screws holding the retainer plate 1 and remove the retainer plate 1 W10195420 Bearing on Drive End Side 1 Press out the bearing from drive end frame 3 with a press and jig 1 W10196110 Bearing at Slip Ring Side 1 Lightly secure the rotor 1 with a vise to prevent damage and remove the bearing 2 with a puller 3 W10197010 1 Rear End Frame 1 R...

Page 546: ...ck the continuity of the slip ring and core with an ohmmeter 4 If infinity is not indicated replace it W10200940 Slip Ring 1 Check the slip ring for score 2 If scored correct with an emery paper or on a lathe 3 Measure the O D of slip ring with vernier calipers 4 If the measurement is less than the allowable limit replace it W10202080 Brush Wear 1 Measure the brush length with vernier calipers 2 I...

Page 547: ...uto digital multimeter Because it s very hard to check the continuity of rectifier by using it W10204520 IC Regulator 1 Check the continuity of the terminal B and the terminal F of IC regulator with an analog ohmmeter Conduct the test in the R 1 setting 2 The IC regulator is normal if the IC regulator conducts in one direction and does not conduct in the reverse direction IMPORTANT Do not use a 50...

Page 548: ...main switch is OFF position 3 If the voltage differs from 0 V the wiring harness is faulty W1073019 2 Light Switch Continuity when Setting Switch at OFF Position 1 Disconnect the combination switch connector 2 Set the light switch to the OFF position 3 Measure the resistance between the terminal B1 and the terminal T the terminal 1 the terminal 2 4 If infinity is not indicated the head light switc...

Page 549: ...witch is faulty W1044501 6 Turn Signal Light Switch when Setting Switch Knob at R Position 1 Set the turn signal light switch to the R position 2 Measure the resistance between the terminal B2 and the terminal R 3 If 0 Ω is not indicated the turn signal light switch is faulty W1044955 7 Turn Signal Light Switch when Setting Switch Knob at L Position 1 Set the turn signal light switch to the L posi...

Page 550: ...hassis 2 If the voltage differ from the battery voltage the wiring harness is faulty W1060059 2 Hazard Switch Continuity 1 Measure the resistance with ohmmeter across the terminal a and terminal c and across the terminal d and terminal e 2 If the measurement is not following below the hazard switch or the bulb are faulty W1060293 Resistance Horn switch is pushed B1 terminal H terminal 0 Ω 1 Hazard...

Page 551: ...een the terminal d and terminal e 2 If the measurement is not following below the position switch or the bulb are faulty W1047271 Flasher Unit 1 Disconnect the connector from the flasher unit 2 Turn the main switch at ON position 3 Measure the voltage between the terminal 12 and chassis 4 If the voltage differ from the battery voltage the wiring harness is faulty W1047788 1 Position Switch Voltage...

Page 552: ...rd and Wiring Harness 1 Disconnect the lead 2 from the engine oil pressure switch after turning the main switch OFF 2 Turn the main switch ON and connect a jumper lead from the lead to the chassis 3 If the engine oil pressure indicator lamp does not light the panel circuit or the wiring harness is faulty W10259540 Engine Oil Pressure Switch Continuity 1 Measure the resistance across the switch ter...

Page 553: ...1 after turning the main switch OFF 2 Measure the resistance between the two terminals 3 If infinity is not indicated the switch is faulty W1026390 Parking Brake Switch Panel and Wiring Harness 1 Disconnect the connector from the parking brake switch after turning the main switch OFF 2 Turn the main switch ON and connect a jumper lead between the connector terminals of wiring harness 3 If the park...

Page 554: ...e Switch Panel and Wiring Harness 1 Disconnect the connector from the cruise switch after turning the main switch OFF 2 Turn the main switch ON and connect a jumper lead between the connector terminals of wiring harness 3 If the cruise indicator lamp does not light the panel circuit or wiring harness is faulty W1076155 Resistance Across switch terminals In normal state Infinity 1 Cruise Switch Con...

Page 555: ...248650 B Coolant Temperature Sensor Coolant Temperature Sensor Continuity 1 Measure the resistance across the sensor terminal and the chassis 2 If the measurement is not indicated the sensor is faulty W1022725 Resistance Sensor terminal its body Reference value Float at upper most position 1 to 5 Ω Float at lower most position 103 to 117 Ω Resistance Sensor terminal Chassis Factory spec Approx 16 ...

Page 556: ...10 CABIN KiSC issued 02 2007 A ...

Page 557: ...M 10 M1 1 A C Model 10 M1 2 Heater Model 10 M3 2 SYSTEM CONTROL 10 M4 1 A C Model 10 M4 2 Heater Model 10 M5 3 ELECTRICAL SYSTEM 10 M6 1 Electrical Circuit 10 M6 2 Air Conditioner Relay Blower Relays and Compressor Relay 10 M7 3 Air Conditioner Blower Switch 10 M8 KiSC issued 02 2007 A ...

Page 558: ...odel 1 Heater Hose Out Side 2 Heater Hose In Side 3 Control Panel 4 Water Valve 5 Outside Air Filter 6 Inner Roof 7 Inside Air Filter 8 Side Air Outlet 9 Front Air Outlet 10 High Pressure Pipe 11 Low Pressure Pipe 12 Pressure Switch 13 Air Conditioner Unit 14 Compressor 15 Receiver 16 Condensor KiSC issued 02 2007 A ...

Page 559: ...r Oil The compressor oil dissolves in 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 through the cycle and the lifespan of the compressor is considerably shortened It is still essential to ensure that the correct refrigerant oil is used R12 systems ...

Page 560: ...10 M3 L3130 L3430 L3830 L4630 L5030 WSM CABIN 2 Heater Model W1016479 1 Heater Hose From Cabin 2 Heater Hose To Cabin 3 Water Valve 4 Heater Unit KiSC issued 02 2007 A ...

Page 561: ...en water valve The air flows to door D3 12 side passing through the heater core 3 Outlet air flow is controlled by door D3 Moving the air mode lever 1 opens and shuts door D3 and establishes the air passage according to the lever position DEF FACE By moving the mode lever to DEF FACE position the door D3 12 is moved to establish the air passages to outlets O1 and O2 Air comes out from both outlets...

Page 562: ... moved to open water valve The air flows to door D3 10 side passing through the heater core 3 Outlet air flow is controlled by door D3 Moving the air mode lever 1 opens and shuts door D3 and establishes the air passage according to the lever position DEF FACE By moving the mode lever to DEF FACE position the door D3 10 is moved to establish the air passages to outlets O1 and O2 Air comes out from ...

Page 563: ...ch 7 ON the thermostat temperature is more than 4 C 39 2 F Pressure Switch 8 ON if refrigerant pressure is between 0 21 MPa 2 1 kgf cm2 30 psi and 2 65 MPa 27 kgf cm2 384 psi Magnetic Clutch of Compressor 7 Engaged 1 Battery 2 Slow Blow Fuse 3 Main Switch 4 Diode 5 Joint Connector 6 Compressor Relay 7 Compressor 8 Pressure Switch 9 Thermostat 10 A C Blower Switch 11 Diode 12 A C Blower Relay 13 A ...

Page 564: ...ed directly from the battery 3 forgetting to turn off the blower motor 7 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 the contact close to supply the power from the battery 3 By employing these relays the current flowing through the main switch 5 has been decreased as only a ...

Page 565: ...r Relay Contact 12 Blower Motor 13 Blower Resistor 14 A C Blower Switch 10 LO Position Ground Medium Position Battery 1 Slow Blow Fuse 2 Main Switch 3 Fuse A C Blower Relay Contact 12 Blower Motor 13 Blower Resistor 14 A C Blower Switch 10 ME Position Ground High Position Battery 1 Slow Blow Fuse 2 Main Switch 3 Fuse A C Blower Relay Contact 12 A C Blower Motor 13 A C Blower Switch 10 HI Position ...

Page 566: ...13 1 CHECKING WITH MANIFOLD GAUGE 10 S13 2 DISCHARGING EVACUATING AND CHARGING 10 S17 1 Discharging the System 10 S17 2 Evacuating the System 10 S17 3 Charging the System 10 S19 4 Checking Charge Refrigerant Amount 10 S21 6 CHECKING DISASSEMBLING AND SERVICING 10 S22 1 SEPARATING CABIN FROM TRACTOR BODY 10 S22 2 COMPRESSOR 10 S28 1 Checking 10 S28 2 Disassembling and Assembling 10 S28 3 Servicing ...

Page 567: ...ed or improperly connected Fuse blown Magnetic clutch defective A C switch defective Pressure switch defective Belt slipping Insufficient refrigerant Expansion valve defective Compressor defective Replace Repair or replace Replace Replace Replace Repair Replace Repair or replace Replace Replace Adjust or replace Check with manifold gauge Replace Replace G 36 10 S31 10 S31 10 S33 10 S32 G 36 10 S28...

Page 568: ...Magnetic clutch defective Compressor defective Thermostat defective Water valve defective Condenser fin clogged with dust Expansion valve defective Adjust or replace Repair or replace Replace Replace Replace Clean Replace G 29 10 S28 10 S29 G 30 Insufficient Heating Water valve defective Air mix door malfunctioning Insufficient coolant Replace Adjust control cable Replenish 10 S40 S46 G 7 8 KiSC i...

Page 569: ...10 S3 L3130 L3430 L3830 L4630 L5030 WSM CABIN AIR CONDITIONING SYSTEM Continued KiSC issued 02 2007 A ...

Page 570: ...10 S4 L3130 L3430 L3830 L4630 L5030 WSM CABIN KiSC issued 02 2007 A ...

Page 571: ...dshield Wiper Operating Speed Is Too Low Wiper motor defective Short circuit of motor armature worn motor brush or seized motor shaft Low battery voltage Humming occurs on motor in arm operating cycle due to seized arm shaft Wiper switch contact improper Replace Recharge or replace Lubricate or replace Replace 10 S42 G 25 10 S36 Windshield Wiper Does Not Stop Correctly Wiper motor defective Contam...

Page 572: ...to 2 0 kgf cm2 21 to 28 psi 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 MPa 2 0 kgf cm2 28 4 psi More than approx 3 14 MPa 32 kgf cm2 455 psi Air Conditioner Drive Belt Tension 10 to 12 mm 0 39 to 0 47 in deflection at 98 N 10 kgf 22 lbs of fo...

Page 573: ...ut condenser side High pressure pipe 2 retaining nut Low pressure pipe mounting screw compressor side Low pressure pipe retaining nut Heater unit mounting screw M6 Heater unit mounting screw M8 24 5 to 29 4 31 4 to 37 2 124 to 147 7 9 to 11 8 10 8 to 16 2 3 9 to 6 9 9 8 to 15 7 29 4 to 34 3 11 8 to 14 7 6 37 to 9 32 2 5 to 3 4 4 9 to 6 9 4 90 to 5 88 7 8 to 11 8 19 6 to 24 5 11 8 to 14 7 7 9 to 11...

Page 574: ...r IMPORTANT If the refrigerant O rings etc for R12 are used in the R134a air conditioner system problems such as refrigerant leakage or cloudiness in the sight glass may occur Therefore in order to prevent charging of refrigerant or erroneous connections the shapes of the piping joint as well as the shapes of the service valve and the service tools have been changed Always keep the working place c...

Page 575: ... must be opened W1013376 When LO Valve is Opened and HI Valve is Closed Two circuits are established Port C LO pressure gauge 1 Port B Port D Port A HI pressure gauge 2 NOTE Schrader valve D must be opened W1013454 When LO Valve is Closed and HI Valve is Opened Two circuits are established Port C HI pressure gauge 2 Port B Port D Schrader valve must be opened Port A LO pressure gauge 1 NOTE Schrad...

Page 576: ...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 remains in the charging hose at the time of connections it may be difficult to connect the quick link connector In this case perform the operation after removing any residual pressure in the hose Remo...

Page 577: ...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 the reaction with chlorine within the refrigerant is used to detect gas leaks R134a which contains no chlorine cannot be detected W1014905 5 Can Tap Valve The can tap valve that is used to charge the r...

Page 578: ...rant Recovery and Recycling Machine When there is necessity of discharging the refrigerant on repairing the tractor it should use recovery and recycling machine Don t release the refrigerant into the atmosphere IMPORTANT Use only R134a refrigerant recovery and recycling machine eliminate mixing R134a equipment refrigerant and refrigerant oils with R12 systems to prevent compressor damage W1015488 ...

Page 579: ... 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 the A C switch and set the temperature control lever to maximum cooling position 5 Set the blower switch to HI position W1015662 Normal Operating If the refrigerating cycle is operating normally the re...

Page 580: ... cause Overcharging refrigerant into cycle Condenser cooling faulty 3 Solution Clean condenser See page G 31 Adjust air conditioner belt to proper tension See page G 29 If the above two items are in normal condition check refrigerant quantity See page 10 S21 NOTE If excessive refrigerant is to be discharged loosen manifold gauge LO pressure side valve and vent out slowly W1016402 Air Entered in th...

Page 581: ...pressure is vacuum and HI pressure side 2 is low pressure LO pressure side 1 Vacuum HI pressure side 2 0 49 to 0 59 MPa 5 to 6 kgf cm2 71 2 to 85 3 psi Frost or dew formed on piping at front and rear sides of expansion valve or receiver 2 Probable cause Refrigerant flow obstructed by moisture or dirt in the refrigerating cycle freezing or sticking on the expansion valve orifice 3 Solution Allow to...

Page 582: ...ow adjustment not properly done 3 Solution Check installed condition of heat sensitizing tube If installation of heat sensitizing tube is correct replace the expansion valve W1017612 Faulty Compression of Compressor 1 Symptoms seen in refrigerating cycle LO pressure side 1 pressure too high 0 39 to 0 59 MPa 4 to 6 kgf cm2 56 9 to 85 3 psi HI pressure side 2 pressure too low 0 69 to 0 98 MPa 7 to 1...

Page 583: ... charging valve 3 on the compressor 1 Connect high pressure side hose red to HI pressure side charging valve 2 on the compressor 1 2 Follow the manufacturers instructions and discharge the system IMPORTANT Use only R134a refrigerant recovery and recycling machine Eliminate mixing R134a equipment refrigerant and refrigerant oils with R12 systems to prevent compressor damage CAUTION Protect fingers ...

Page 584: ...e refrigerant cycle For approx 15 minutes 5 When LO pressure gauge 10 reading is more than 750 mmHg 299 in Hg stop the vacuum pump 8 and close both valves 6 10 of manifold gauge fully 6 Wait for over 5 minutes with the HI and LO pressure side valves 6 10 of gauge manifold closed and then check that gauge indicator does not return to 0 7 If the gauge indicator is going to approach to 0 check whethe...

Page 585: ...m is evacuated completely 2 Connect the center charging hose 2 to the can tap valve 7 fitting and then loosen the center charging hose at the center fitting of manifold gauge until hiss can be heard Allow the air to escape for few seconds and tighten the nut 3 Open the HI pressure side valve 5 fully and keep the container upside down to charge the refrigerant in the liquid state from the HI pressu...

Page 586: ...switch Set the temperature control lever to maximum cooling position and the blower switch to HI position 4 Open the LO pressure valve 6 of manifold gauge and the can tap valve 1 on refrigerant container and charge the refrigerant until air bubbles in the sight glass of the receiver vanish 5 After charging the specified amount of refrigerant into the system close the LO pressure valve 6 of manifol...

Page 587: ...ht 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 is over 99 0 kPa 1 01 kgf cm2 14 4 psi In this case charge the refrigerant from the LO pressure side B Properly refrigerant charge Air bubbles pass through the sight glass continuously when pressure on the LO ...

Page 588: ...e drain plug 2 When refilling Fill the coolant between the FULL and LOW marks of recovery tank 1 W10590830 Battery Front Grill Skirt and Bonnet 1 Open the bonnet and disconnect the battery negative cable 2 Disconnect the head light connector and remove the front grill 4 3 Remove the left and right side skirts 3 4 Disconnect window washer hoses 2 5 Remove the bonnet 1 NOTE When disconnecting the ba...

Page 589: ... within the stroke of the accelerator lever Set the steering joint 1 by the joint support 6 so that the steering wheel is turned lightly Be sure to check and adjust the brake pedal free travel See page G 18 W1060784 Clutch Rod Brake Pedal Rod and Electric Wiring 1 Disconnect the brake pedal rod 6 and clutch rod 4 2 Disconnect the wiring connectors for alternator 1 coolant temperature sensor 9 oil ...

Page 590: ...er 2 and cruise control lever 9 W1027110 Differential Lock Rod Lowering Speed Adjusting Knob and PTO Speed Change Lever if equipped Manual and GST Model 1 Disconnect the differential lock rod 2 2 Remove the lowering speed adjusting knob 3 3 Remove the PTO speed change lever 1 if equipped 4 Disconnect the PTO speed sensor 4 if equipped W1027485 1 Seat 2 Range Gear Shift Lever 3 Main Gear Shift Leve...

Page 591: ...tial lock rod 2 3 Disconnect the range gear shift lever sensor connector 3 4 Disconnect the cruise switch connector 1 5 Disconnect the HST pedal neutral switch connector 5 6 Disconnect the ground earth a W1062242 1 ECU Connector 2 GST Lever Sensor Connector 3 Wiring Harness of GST Lever Sensor 4 Pressure Switch Connector 5 Proportional Reducing Valve Connector 6 Solenoid Valve Connector 7 Ground C...

Page 592: ...he lock nut 4 of wire and connect wire to the clutch valve lever and then place the wire to the hook 3 Tighten the lock nut 4 clockwise pull the wire and lock the nut just before the lever moves W1027788 Shuttle Switch Connector Manual and GST Model 1 Remove the panel cover and steering post cover 2 Disconnect the shuttle switch connector 1 W1062664 Cruise Control Release Wire HST Model 1 Disconne...

Page 593: ...nuts 9 4 Dismounting the cabin from tractor body NOTE Lift the cabin while making sure it does not catch on anything When reassembling Be sure to install the washers and mount rubbers etc in their original positions Before mounting the cabin be sure to set both the shuttle lever rod and the shuttle arm to the neutral position and then connect the shuttle lever rod securely GST model W1063848 Tight...

Page 594: ... the stator coil W1014331 Checking Air gap 1 Measure the air gap with a feeler gauge 2 If the measurement is not within the factory specification adjust the air gap shim see page 10 S31 W1028014 2 Disassembling and Assembling Battery Front Grill Skirt and Bonnet 1 Open the bonnet and disconnect the battery negative cable 2 Disconnect the head light connector and remove the front grill 4 3 Remove t...

Page 595: ...ponding to the shape of compressor See page G 52 2 The stopper magnet clutch 2 is hung on hub plate 3 and it is fixed that the compressor rotates 3 Remove the magnet clutch mounting screw or nut 4 Remove the hub plate 3 Compressor is used remover magnet clutch 4 See page G 52 5 Remove the shims When reassembling Do not apply grease or oil on the hub plate facing Do not use the screw or nut again I...

Page 596: ...om compressor body 2 Remove the external circlip 1 3 Remove the stator 2 When reassembling Do not use the cir clip again Assemble the cir clip for the tapered side to become outside of front housing The width of expanding of cir clip 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 W1059953 Type of compressor Code No for circ...

Page 597: ...nal 4 and chassis should be approx battery voltage 2 When turning the main switch ON and A C blower switch to LO position the voltage between the terminal 2 and chassis should be approx battery voltage b Compressor Relay 1 The voltage between the terminal 4 and chassis should be 0 V 2 When turning the main switch ON A C blower switch to LO and A C switch ON the voltage between the terminal 2 and c...

Page 598: ...s 1 and 2 W1017559 1 Connector Voltage 1 Turn the main switch ON 2 Measure the voltage with a voltmeter between the connector terminal 4 and terminal 3 3 If the voltage differs from the battery voltage the wiring harness A C relay fuse or main switch is faulty 2 A C Blower Switch 1 Check the continuity through the switch with an ohmmeter 2 If the continuity specified below are not indicated the sw...

Page 599: ...f 2 Disconnect the 4P connector 1 for A C blower resistor 2 3 Measure the resistance with an ohmmeter across the terminal Me and terminal Hi and across the terminal Lo and terminal Hi 4 If the factory specifications are not indicated A C blower resistor is faulty W1019107 A C Switch 1 Remove the outer roof and disconnect the A C switch connector 2 2 Perform the following checkings 1 and 2 W1019584...

Page 600: ...ry voltage the wiring harness A C relay or fuse is faulty 2 A C Switch 1 Check the continuity through the switch with an ohmmeter 2 If the continuity specified below is not indicated the switch is faulty 1 Push the A C switch button to ON position 2 Push again the A C switch button to OFF position W1019763 Terminal Position 7 6 5 A C switch OFF 2 ON 1 1 A C Switch 2 A C Switch Connector KiSC issue...

Page 601: ... setting pressure replace the pressure switch with a new one 2 LO Pressure Side 1 Disconnect 2P connector of pressure switch 2 Measure the resistance with an ohmmeter across the connector terminals 3 If 0 ohm is not indicated at normal condition there is no refrigerant in the refrigerating cycle because gas leaks or pressure switch is defective Reference The resistance of pressure switch is 0 ohm ...

Page 602: ...eter between the terminal W and chassis 3 If the voltage differs from the 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 switch is faulty Reference WASH Ι OFF side of the wiper switch remains pushed in WASH ΙΙ ON side remains pushed in after the wip...

Page 603: ... and chassis 3 If the voltage differs from the 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 switch is faulty Reference WASH Ι OFF side of the wiper switch remains pushed in WASH ΙΙ ON side remains pushed in after the wiper switch is switched ON an...

Page 604: ...t Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely 1 Stop the engine and let cool down 2 Loosen the drain plug 2 to drain the coolant 3 Remove the radiator cap to completely drain the coolant 4 After all coolant is drained retighten the drain plug 2 When refilling Fill the coolant between the FULL and LOW marks of recovery tank 1 W10646580 Discharg...

Page 605: ...d reconnect the cable 1 Set the control at MAX COOL position Fit the inner cable in position and press and fix the outer cable by the cable clip 2 in the direction of arrow A as shown at left Move the temperature control lever several times to make sure the water valve is fully closed at MAX COOL position Do not allow the water valve cable to bend just away from the control nor to get caught by th...

Page 606: ...connect the air conditioner mode door control cable 3 from the defrosting DEF position control lever 1 of A C control panel side When reassembling Set the air conditioner unit to DEF mode position and reconnect the cable 3 Set the control at DEF position Fit the inner cable in position and press and fix the outer cable by the cable clip 2 in the direction of arrow A as shown at left Move the mode ...

Page 607: ...h 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 W1025169 Tightening torque A C unit mounting screw M6 3 92 to 6 86 N m 0 40 to 0 70 kgf m 2 89 to 5 06 ft lbs A C unit mounting screw M8 9 8 to 11 68 N m 1 00 to 1 19 kgf m 7 23 to 8 6 ft lbs Low pressure pipe Cooler pipe suction retaining nut 29 4 to 34 3 N m 3 0 to 3 5 k...

Page 608: ...t the rear wiper motor 3P connector 5 2 Remove the wiper arm mounting nut 7 and wiper arm 1 3 Remove the wiper link cap 6 4 Remove the rear wiper motor 3 W1034169 Tightening torque Wiper arm mounting nut 7 6 37 to 9 32 N m 0 65 to 0 95 kgf m 4 7 to 6 9 ft lbs Wiper motor mounting nut 4 2 5 to 3 4 N m 0 25 to 0 35 kgf m 1 9 to 2 5 ft lbs Distance A Factory spec 90 to 110 mm 3 5 to 4 3 in 1 Wiper Ar...

Page 609: ... take care not to damage them W1026502 Hose Clamp 1 Remove the hose clamp 4 2 Disconnect the high pressure pipe 1 5 from the receiver 1 and low pressure pipe 3 from the compressor then cap the open fittings immediately to keep moisture out of the system When reassembling Apply compressor oil DENSO CO ND OIL 8 or equivalent to the O rings and take care not to damage them W1026689 1 Bonnet 2 Window ...

Page 610: ...ant temperature is well below its boiling point Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely 1 Stop the engine and let cool down 2 Loosen the drain plug 2 to drain the coolant 3 Remove the radiator cap to completely drain the coolant 4 After all coolant is drained retighten the drain plug 2 When refilling Fill the coolant between the FULL and L...

Page 611: ...d reconnect the cable 1 Set the control at MAX COOL position Fit the inner cable in position and press and fix the outer cable by the cable clip 2 in the direction of arrow A as shown at left Move the temperature control lever several times to make sure the water valve is fully closed at MAX COOL position Do not allow the water valve cable to bend just away from the control nor to get caught by th...

Page 612: ...connect the air conditioner mode door control cable 3 from the defrosting DEF position control lever 1 of control panel side When reassembling Set the air conditioner unit to DEF mode position and reconnect the cable 3 Set the control at DEF position Fit the inner cable in position and press and fix the outer cable by the cable clip 2 in the direction of arrow A as shown at left Move the mode leve...

Page 613: ...tor cap until coolant temperature is well below its boiling point Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely 1 Stop the engine and let cool down 2 Loosen the drain plug 2 to drain the coolant 3 Remove the radiator cap to completely drain the coolant 4 After all coolant is drained retighten the drain plug 2 When refilling Fill the coolant betw...

Page 614: ...eassembling Connecting the heater hoses at their original position W1027385 Heater Hoses 1 Remove the outer roof NOTE Before disconnecting the heater hoses 2 put the parting marks on the hoses for marking proper reconnecting 2 Disconnect the heater hoses 2 from the hose pipes 1 3 Remove the inner covers 3 4 Pull out the heater hoses 2 from the bottom of the cabin 5 Take out the heater hoses 2 When...

Page 615: ...ht switch 1 2 Perform the following checkings 1 and 2 W1027926 1 Connector Voltage 1 Turn the main switch ON 2 Measure the voltage with a voltmeter between the terminal 5 and chassis 3 If the voltage differs from the battery voltage the wiring harness fuse or main switch is faulty 2 Working Light Switch 1 Check the continuity through the switch with an ohmmeter 2 If continuity specified below is n...

Page 616: ...cks or the 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 using cutter knife When glass is totally crushed finely 1 Insert the knife 3 into the adhered part 2 Keep the edge of knife blade square to the glass edge at the part a Slide the knife blade...

Page 617: ... 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 specified tip shape as shown in the figure left Apply it with a uniform speed to minimize unevenness Follow the instruction manual of Sika Tack Ultrafast When the gummed tape is removed the rear windshield may ...

Page 618: ...rance 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 Leave it for one hour 7 Remove the jig 8 8 Install the H rubber 7 between the lower and upper windshield 2 3 9 Apply the Shin Etsu silicon KE45 in H rubber 7 10 Apply the Shin Etsu silicon KE45 on the ...

Page 619: ...M 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 ksos pub kubota co jp Printed in Japan 2007 01 S EI EI e Code No 9Y011 13111 2003 11 S EI EI e ...

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