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wsm M8540NARROW, Workshop Manual

The wsm M8540NARROW Workshop Manual is an essential tool for owners of this versatile agricultural tractor. This comprehensive manual provides step-by-step instructions, diagrams, and troubleshooting tips to ensure smooth operations. Download the user manual for free at manualshive.com and enhance your understanding of this exceptional product.

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CONTENTS

1. SERVICING SPECIFICATIONS ............................................................................................... N3-S1
2. TIGHTENING TORQUES......................................................................................................... N3-S3
3. CHECKING AND ADJUSTING................................................................................................. N3-S4

[1] MAIN GEAR SHIFTING...................................................................................................... N3-S4

(1) ROPS Model................................................................................................................. N3-S4
(2) CABIN Model................................................................................................................ N3-S5

[2] 4WD / BI-SPEED TURN SYSTEM ..................................................................................... N3-S6

4. DISASSEMBLING AND ASSEMBLING ................................................................................... N3-S8

[1] 4WD / BI-SPEED TURN SOLENOID VALVE..................................................................... N3-S8

(1) Removing Solenoid Valve Assembly............................................................................ N3-S8

[2] PREPARATION FOR SEPARATING EACH BLOCK......................................................... N3-S9

(1) External Parts ............................................................................................................... N3-S9

[3] SEPARATING EACH BLOCK .......................................................................................... N3-S10

(1) Clutch Housing Case.................................................................................................. N3-S10
(2) Transmission Case..................................................................................................... N3-S11

[4] HYDRAULIC SHUTTLE CLUTCH.................................................................................... N3-S12
[5] SHIFT COVER ................................................................................................................. N3-S13
[6] CLUTCH HOUSING ......................................................................................................... N3-S16

(1) Creep Gear Assembly ................................................................................................ N3-S16
(2) 1st Shaft, 2nd Shaft and 3rd Shaft ............................................................................. N3-S16
(3) 1st Shaft ..................................................................................................................... N3-S18
(4) 2nd Shaft .................................................................................................................... N3-S20
(5) 3rd Shaft ..................................................................................................................... N3-S20
(6) 4WD Propeller Shaft................................................................................................... N3-S20

[7] TRANSMISSION CASE ................................................................................................... N3-S21
[8] 4WD / Bi-SPEED TURN CLUTCH ................................................................................... N3-S22

(1) Removing 4WD / Bi-speed Turn Clutch...................................................................... N3-S22
(2) Disassembling 4WD / Bi-speed Turn Clutch Pack ..................................................... N3-S23
(3) Removing Differential Gear and Bevel Pinion Shaft................................................... N3-S26

[9] DIFFERENTIAL GEAR..................................................................................................... N3-S29
[10]PTO GEAR CASE ............................................................................................................ N3-S31
[11]GROUND PTO AND LIVE PTO ....................................................................................... N3-S32

5. SERVICING ............................................................................................................................ N3-S34

[1] BEARING, SHIFT FORK AND SYNCHRONIZER............................................................ N3-S34
[2] TRAVELING CLUTCH...................................................................................................... N3-S35
[3] 4WD / BI-SPEED TURN CLUTCH PACK ........................................................................ N3-S35
[4] SHAFT AND GEAR .......................................................................................................... N3-S36
[5] DIFFERENTIAL GEAR..................................................................................................... N3-S37

(1) Spiral Bevel Pinion Shaft ............................................................................................ N3-S37
(2) Backlash and Tooth Contact (Except ITA Model)....................................................... N3-S38
(3) Backlash and Tooth Contact (ITA Model)................................................................... N3-S40

SERVICING

KiSC issued 07, 2013 A 

Summary of Contents for M8540NARROW

Page 1: ...M8540NARROW M9540NARROW SUPPLEMENT WORKSHOP MANUAL TRACTOR KiSC issued 07 2013 A ...

Page 2: ...tructure and the function of the unit Before you continue with the subsequent sections make sure that you read this section Refer to the latest version of Workshop Manual Code No 9Y021 01870 9Y021 18200 for the diesel engine tractor mechanism that this workshop manual does not include Q Servicing This section primarily contains information below Troubleshooting Servicing Specifications Tightening ...

Page 3: ...month Main Revised Point and Corrective Measures Search word Reference Page 3 2013 07 Added M9540Narrow Cabin Model M9540 NI 10 N8 S20 etc Revised travelling speed NI 12 Revised service interval NG 16 Added tire variation tires NG 47 NG 48 NG 51 Added OPC for M9540Narrow Cabin OPC NG 20 N9 M24 N9 S19 KiSC issued 07 2013 A ...

Page 4: ...NI INFORMATION KiSC issued 07 2013 A ...

Page 5: ...CONTENTS 1 SAFETY FIRST NI 1 2 SAFETY DECALS NI 4 3 SPECIFICATIONS NI 10 4 TRAVELING SPEEDS NI 12 5 DIMENSIONS NI 13 INFORMATION KiSC issued 07 2013 A ...

Page 6: ...ons or in disengaged positions Do not start the engine when you stay on the ground Start the engine only from operator s seat WSM000001INI0015US0 SAFETY FIRST This symbol the industry s Safety Alert Symbol is used throughout 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 ...

Page 7: ...before you disconnect hydraulic or fuel lines Tighten all connections before you apply the pressure Do not open a fuel system under high pressure The fluid under high pressure that stays in fuel lines can cause serious injury Do not disconnect or repair the fuel lines sensors or any other components between the fuel pump and injectors on engines with a common rail fuel system under high pressure P...

Page 8: ... regulations when you discard oil fuel coolant electrolyte and other dangerous waste WSM000001INI0007US0 PREVENT ACID BURNS Keep electrolyte away from your eyes hands and clothing Sulfuric acid in battery electrolyte is poisonous and it can burn your skin and clothing and cause blindness If you spill electrolyte on yourself clean yourself with water and get medical aid immediately WSM000001INI0008...

Page 9: ...lowing safety decals pictorial safety labels are installed on the machine If a decal becomes damaged illegible or is not on the machine replace it The decal part number is listed in the parts list WSM000001INI0014US0 ROPS Model 9Y1210236INI0008US0 KiSC issued 07 2013 A ...

Page 10: ...INFORMATION M8540Narrow M9540Narrow WSM NI 5 9Y1210236INI0009US0 KiSC issued 07 2013 A ...

Page 11: ...INFORMATION M8540Narrow M9540Narrow WSM NI 6 9Y1210236INI0010US0 KiSC issued 07 2013 A ...

Page 12: ...INFORMATION M8540Narrow M9540Narrow WSM NI 7 CABIN Model 9Y1210236INI0006US0 KiSC issued 07 2013 A ...

Page 13: ...INFORMATION M8540Narrow M9540Narrow WSM NI 8 9Y1210236INI0007US0 KiSC issued 07 2013 A ...

Page 14: ...INFORMATION M8540Narrow M9540Narrow WSM NI 9 9Y1210236INI0001US0 KiSC issued 07 2013 A ...

Page 15: ...1 74 to 53 07 in Minimum ground clearance 370 mm 14 6 in Drawbar bracket Weight 2305 kg 5082 lbs Traveling system Standard tire size Front 280 70R18 Rear 380 70R28 Clutch Multiple wet discs Shuttle Hydraulic Number of speed F15 R15 Steering Hydraulic power steering Braking system Traveling Hydraulic wet discs mechanical Differential Front Bevel gears Rear Bevel gears with differential lock Hydraul...

Page 16: ... Front 1142 1156 mm 44 96 45 51 in Rear 1060 to 1348 mm 41 74 to 53 07 in Minimum ground clearance 370 mm 14 6 in Drawbar bracket Weight 2460 kg 5423 lbs Traveling system Standard tire size Front 280 70R18 Rear 380 70R28 Clutch Multiple wet discs Shuttle Hydraulic Number of speed F15 R15 Steering Hydraulic power steering Braking system Traveling Hydraulic wet discs mechanical Differential Front Be...

Page 17: ...le shift lever Range gear shift lever Main gear shift lever km h mph Forward CREEP 1 0 60 0 37 2 0 85 0 53 3 1 10 0 684 4 1 40 0 870 5 1 85 1 15 L 1 2 8 1 7 2 4 0 2 5 3 5 1 3 2 4 6 6 4 1 5 8 7 5 4 H 1 11 3 7 02 2 16 0 9 94 3 20 6 12 8 4 26 4 16 4 5 34 8 21 6 Reverse CREEP 1 0 59 0 37 2 0 84 0 52 3 1 09 0 677 4 1 39 0 864 5 1 83 1 14 L 1 2 7 1 7 2 3 8 2 4 3 4 9 3 0 4 6 3 3 9 5 8 3 5 2 H 1 10 7 6 65...

Page 18: ...INFORMATION M8540Narrow M9540Narrow WSM NI 13 5 DIMENSIONS ROPS MODEL 9Y1210236INI0004US0 KiSC issued 07 2013 A ...

Page 19: ...INFORMATION M8540Narrow M9540Narrow WSM NI 14 CABIN MODEL 9Y1210236INI0005US0 KiSC issued 07 2013 A ...

Page 20: ...NG GENERAL KiSC issued 07 2013 A ...

Page 21: ... NG 14 4 METRIC SCREWS BOLTS AND NUTS NG 15 5 AMERICAN STANDARD SCREWS BOLTS AND NUTS WITH UNC OR UNF THREADS NG 15 6 PLUGS NG 15 6 MAINTENANCE NG 16 7 CHECK AND MAINTENANCE NG 18 1 DAILY CHECK NG 18 2 CHECK POINTS OF INITIAL 50 HOURS NG 19 3 CHECK POINTS OF EVERY 50 HOURS NG 20 4 CHECK POINTS OF EVERY 100 HOURS NG 21 5 CHECK POINTS OF EVERY 200 HOURS NG 26 6 CHECK POINT OF EVERY 400 HOURS NG 30 7...

Page 22: ...ls NG 48 2 Rear Wheels NG 50 3 WHEEL HUB NG 51 4 FENDER NG 52 1 Adjusting Fender Height ROPS Model NG 52 10 IMPLEMENT LIMITATIONS NG 53 1 IMPLEMENT CAPACITY NG 54 2 TRAILER LOAD CAPACITY NG 55 KiSC issued 07 2013 A ...

Page 23: ...OPS Model When contacting your local KUBOTA distributor always specify engine serial number tractor serial number and hourmeter reading 9Y1210236GEG0001US0 1 Tractor Identification Plate 2 Tractor Serial Number 3 Engine Serial Number 4 ROPS Identification Plate ROPS Serial Number KiSC issued 07 2013 A ...

Page 24: ...our local KUBOTA distributor always specify engine serial number tractor serial number and hourmeter reading 9Y1210236GEG0002US0 1 Tractor Identification Plate 2 Tractor Serial Number 3 Engine Serial Number 4 CAB Identification Plate CAB Serial Number KiSC issued 07 2013 A ...

Page 25: ...anual Use of incorrect replacement parts or replacement parts from other emission level engines for example E2 engines may result in emission levels out of compliance with the original E3 design and EPA or other applicable regulations Please refer to the emission label located on the engine head cover to identify Output classification and Emission Control Information E3 engines are identified with...

Page 26: ...ing spring pins their splits must face the direction from which a force is applied See the figure left side To prevent damage to the hydraulic system use only specified fluid or equivalent Clean the parts before you measure them Tighten the fittings to the specified torque Too much torque can cause damage to the hydraulic units or the fittings Not sufficient torque can cause oil leakage When you u...

Page 27: ... not try to modify or remodel any electrical parts and wiring When removing the battery cables disconnect the negative cable first When installing the battery cables connect the positive cable first WSM000001GEG0062US0 1 WIRING Securely tighten wiring terminals WSM000001GEG0063US0 Do not let wiring contact dangerous part WSM000001GEG0064US0 Repair or change torn or aged wiring immediately WSM00000...

Page 28: ...le part where sag be required WSM000001GEG0068US0 In installing a part be careful not to get wiring caught by it WSM000001GEG0069US0 After installing wiring check protection of terminals and clamped condition of wiring WSM000001GEG0070US0 1 Grommet A Correct B Incorrect 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 C...

Page 29: ...ore you recharge the battery remove it from the machine Before you recharge remove cell caps Recharge in a well ventilated place where there is no open flame nearby as hydrogen gas and oxygen are formed WSM000001GEG0071US0 3 FUSE Use fuses with specified capacity Neither too large nor small capacity fuse is acceptable Never use steel nor copper wire in place of fuse Do not install working light ra...

Page 30: ...is no female connector being too open WSM000001GEG0076US0 Make sure that plastic cover is large enough to cover whole connector WSM000001GEG0077US0 5 HANDLING OF CIRCUIT TESTER Use tester correctly following manual provided with tester Check for polarity and range WSM000001GEG0078US0 1 Exposed Terminal 2 Deformed Terminal 3 Sandpaper 4 Rust A Correct B Incorrect 1 Cover A Correct B Incorrect KiSC ...

Page 31: ...des This symbol of shows color with stripe s An example Red stripe on white color W R WSM000001GEG0079US0 Color of wiring Color code Black B Brown Br Green G Gray Gy or Gr Blue L Light Green Lg Orange Or Pink P Purple Pu or V Red R Sky Blue Sb White W Yellow Y 1 Wire Color 2 Stripe KiSC issued 07 2013 A ...

Page 32: ...ation 1 CF or CI 4 External EGR Type Below 0 C 32 F SAE10W 10W 30 or 15W 40 0 to 25 C 32 to 77 F SAE20 10W 30 or 15W 40 Above 25 C 77 F SAE30 10W 30 or 15W 40 4 Transmission case 52 L 54 9 U S qts 46 Imp qts KUBOTA SUPER UDT fluid 2 5 Front differential case oil 5 0 L 5 3 U S qts 4 4 Imp qts KUBOTA UDT or KUBOTA SUPER UDT fluid 2 or SAE80 SAE90 gear oil 6 Front axle gear case oil one side 3 0 L 3 ...

Page 33: ...1 3 U S qts 9 4 Imp qts Engine oil API Service Classification 1 CF or CI 4 External EGR Type Below 10 C 14 F SAE10W 30 10 to 25 C 14 to 77 F SAE20 10W 30 or 15W 40 Above 25 C 77 F SAE30 10W 30 or 15W 40 5 Transmission case 52 L 54 9 U S qts 46 Imp qts KUBOAT UDT or SUPER UDT fluid 2 6 Front differential case oil 5 0 L 5 3 U S qts 4 4 Imp qts KUBOAT UDT or KUBOTA SUPER UDT fluid 2 or SAE80 SAE90 ge...

Page 34: ...e the service interval for engine oil and filter by 50 DO NOT use diesel fuel with sulfur content greater than 1 0 NEVER use diesel fuel with sulfur content greater than 0 05 500 rpm for EXTERNAL EGR type engine Diesel fuels specified to EN 590 or ASTM D975 are recommended No 2 D is a distillate fuel of lower volatility for engine in industrial and heavy mobile service SAE J313 JUN87 Transmission ...

Page 35: ... to 4 6 29 to 33 32 to 34 3 2 to 3 5 24 to 25 48 to 55 4 9 to 5 7 36 to 41 40 to 44 4 0 to 4 5 29 to 32 61 to 70 6 2 to 7 2 45 to 52 M12 63 to 72 6 4 to 7 4 47 to 53 78 to 90 7 9 to 9 2 58 to 66 63 to 72 6 4 to 7 4 47 to 53 103 to 117 10 5 to 12 0 76 0 to 86 7 M14 108 to 125 11 0 to 12 8 79 6 to 92 5 124 to 147 12 6 to 15 0 91 2 to 108 167 to 196 17 0 to 20 0 123 to 144 M16 167 to 191 17 0 to 19 5...

Page 36: ...0 to 4 00 21 7 to 28 9 ϕ10 t1 0 39 3 to 49 0 4 00 to 5 00 29 0 to 36 1 ϕ12 t1 5 49 1 to 68 6 5 00 to 7 00 36 2 to 50 6 ϕ15 t1 6 108 to 117 11 0 to 12 0 79 6 to 86 7 ϕ18 t1 6 108 to 117 11 0 to 12 0 79 6 to 86 7 Item Thread side Tightening torque N m kgf m lbf ft Fitting with O ring G 1 8 45 to 53 4 5 to 5 5 33 to 39 G 1 4 74 to 83 7 5 to 8 5 55 to 61 G 3 8 93 2 to 102 9 50 to 10 5 68 8 to 75 9 G 1...

Page 37: ... 60 8 63 to 11 5 16 3 to 19 7 1 67 to 2 00 12 0 to 14 6 5 16 23 1 to 27 7 2 36 to 2 82 17 0 to 20 5 33 to 39 3 4 to 3 9 25 to 28 3 8 48 to 56 4 9 to 5 7 36 to 41 61 to 73 6 3 to 7 4 45 to 53 1 2 110 to 130 11 3 to 13 2 81 2 to 95 8 150 to 178 15 3 to 18 1 111 to 131 9 16 150 to 178 15 3 to 18 1 111 to 131 217 to 260 22 2 to 26 5 160 to 191 5 8 204 to 244 20 8 to 24 8 151 to 179 299 to 357 30 5 to ...

Page 38: ...arking brake ROPS Model cable Adjust every 100 Hr NG 23 Replace every 2 years CABIN Model Check every 100 Hr NG 23 10 Toe in Adjust every 200 Hr NG 27 11 Fuel tank water Drain every 200 Hr NG 28 12 Power steering oil line Check every 200 Hr NG 27 Replace every 2 years NG 37 13 Radiator hose and clamp Check every 200 Hr NG 26 Replace every 2 years NG 37 14 Intake air line Check every 200 Hr NG 26 R...

Page 39: ...35 30 Coolant Change every 2 years NG 35 31 Master cylinder filter Clean every 2 years 32 Master cylinder kit Replace every 2 years 33 Equalizer kit Replace every 2 years 34 Brake seal 1 and 2 Replace every 2 years 35 Lift cylinder hose Replace every 2 years NG 37 36 Fuel system Bleed Service as re quired NG 38 37 Brake system Bleed NG 38 38 Clutch housing water Drain NG 39 39 Fuse Replace NG 41 4...

Page 40: ...Check and clean the radiator screen grill oil cooler and battery mount 12 Check and clean the air conditioner condenser screen CABIN model 13 Check the nuts of tires are tight 14 Check the number plate for damage and replace as necessary if equipped 15 Care of danger warning and caution labels pictorial safety valve 16 Clean around the exhaust manifold and the muffler of the engine While sitting i...

Page 41: ...p the engine before changing oil filter cartridge Allow engine to cool down sufficiently oil can be hot and can burn 1 Remove the oil filter 1 2 Put a film of clean engine oil on rubber seal of new filter 3 Tighten the filter quickly until it contacts the mounting surface Tighten filter by hand an additional 1 2 turn only 4 After the new filter has been replaced the engine oil normally decreases a...

Page 42: ...ver 1 to the neutral position 5 Turn the key to START position 6 The engine must not crank 7 If it cranks inspect the safety switch Q Test 3 Checking Operator Presence Control OPC System 1 Sit on the operator s seat 2 Make sure the PTO drive shift is disconnected from any attached implement 3 Start the engine 4 Engage the PTO clutch control switch The PTO should begin to rotate Disengage the PTO c...

Page 43: ...sive Wear eye protection and rubber gloves when working around battery 1 The original battery is maintenance free type battery Non refillable type When the performance becomes low inspect the battery 2 Clean the battery surface with a clean cloth Keep the terminals clean and coated with petroleum jelly 3 Check the battery condition by reading the indicator 9Y1210236GEG0017US0 Tightening torque Fro...

Page 44: ...ssed air must be under 205 kPa 2 1 kgf cm2 30 psi When carbon or oil adheres to the element soak the element in detergent for 15 minutes then wash it several times in water rinse with clean water and dry it naturally After element is fully dried inspect inside of the element with a light and check if it is damaged or not 3 Replace the primary element 2 Once a year or after every six times of clean...

Page 45: ... 1 To check and adjusting for brake pedal refer to 1 CHECKING AND ADJUSTING at N5 BRAKES section 9Y1210236GEG0021US0 Adjusting Parking Brake Lever 1 To check and adjusting for parking brake lever refer to 1 CHECKING AND ADJUSTING at N5 BRAKES section 9Y1210236GEG0022US0 Checking Fuel Line 1 Check to see that all lines and hose clamps are tight and not damaged 2 If hoses and clamps are found worn o...

Page 46: ...dy condition lubricate grease fittings more often 9Y1210236GEG0024US0 1 Battery Terminals 2 Grease Fitting Front Axle Support 3 Grease Fitting Front Axle Support 4 Grease Fitting Knuckle Shaft RH LH 5 Grease Fitting Top Link Bracket 6 Grease Fitting Lifting Rod 7 Grease Fitting Top Link 8 Grease Fitting Hydraulic Lift Cylinders Pin 9 Grease Fitting Steering Joint Shaft A CABIN Model KiSC issued 07...

Page 47: ...GENERAL M8540Narrow M9540Narrow WSM NG 25 Lubricating Points CABIN Model 9Y1210236GEG0025US0 1 Door Hinge 2 Rear Window Hinge KiSC issued 07 2013 A ...

Page 48: ...the coolant temperature be nearly or more than the boiling point what is called Overheating 1 Stop the machine operation in a safe place and keep the engine unloaded idling 2 Do not stop the engine suddenly but stop it after about 5 minutes of unloaded idling 3 Keep yourself well away from the machine for further 10 minutes or while the steam blown out 4 Checking that there gets no danger such as ...

Page 49: ...tire beads at rear of tire hub height 6 Front distance should be shorter than rear distance 7 If not adjust tie rod length Q Toe in Adjustment 1 Detach the snap ring 1 2 Loosen the tie rod nut 3 3 Turn the tie rod joint 2 to adjust until the proper toe in measurement is obtained 4 Retighten the tie rod nut 3 5 Attach the snap ring 1 of the tie rod joint 9Y1210236GEG0029US0 1 Power Steering Hose 2 ...

Page 50: ...Filter CABIN Model 1 Remove the inner filter and blow air from the direction opposite to the filter s normal air flow 2 Pressure of compressed air must be under 205 kPa 2 1 kgf cm2 30 psi Reference Detach and attach the push rivet 2 as follows Detaching procedure Push in the center rivet a and pull out the push rivet assembly b Attaching procedure Pull out the center rivet c attach the push rivet ...

Page 51: ...tioner which may cause damage and malfunction 9Y1210236GEG0032US0 Check the Air Conditioner Condenser CABIN Model 1 Remove the air conditioner condenser screen 2 2 Check the air conditioner condenser 1 to be sure it is clean of debris 9Y1210236GEG0033US0 Adjusting Air Conditioner Belt Tension CAUTION Be sure to stop the engine before checking belt tension 1 Stop the engine and remove the key 2 App...

Page 52: ... ring 2 and remove the cup 3 and rinse the inside with kerosene 3 Take out the element 5 and dip it in the kerosene to rinse 4 After cleaning reassemble the water separator keeping out dust and dirt 5 Bleed the fuel system Refer to 14 OTHERS in this section 9Y1210236GEG0038US0 1 Fuel Cock 2 Retaining Ring 3 Cup 4 O ring 5 Element 6 Spring 7 Red Float A Close A ROPS Model B CABIN Model KiSC issued ...

Page 53: ...on rubber seal of new filters 6 Tighten the filter quickly until it contacts the mounting surface Tighten filter by hand and additional 1 2 turn only 7 After the new filter has been replaced fill with the oil up to the upper notch on the dipstick 4 8 After running the engine for a few minutes stop it and check the oil level again add oil to the prescribed level 9 Make sure that the transmission fl...

Page 54: ...e drain plug 1 at the bottom of the transmission case and drain the oil completely into the oil pan 2 After draining reinstall the drain plug 3 Fill with the new KUBOTA SUPER UDT fluid up to the upper notch on the dipstick 2 4 After running the engine for a few minutes stop it and check the oil level again add oil to prescribed level IMPORTANT Do not operate the tractor immediately after changing ...

Page 55: ...plug filling port plug and check plug 9Y1210236GEG0014US0 Adjusting Engine Valve Clearance 1 Refer to 1 CHECKING AND ADJUSTING at 1 ENGINE section 9Y1210236GEG0044US0 10 CHECK POINT OF EVERY 1500 HOURS Checking Fuel Injection Nozzle Injection Pressure 1 Refer to 1 CHECKING AND ADJUSTING at 1 ENGINE section 9Y1210236GEG0045US0 11 CHECK POINTS OF EVERY 3000 HOURS Checking Turbocharger 1 Refer to 1 C...

Page 56: ...ecking Air Conditioner Pipe and Hose CABIN Model 1 Check to see that all lines and hose clamps are tight and not damaged 2 If hoses and clamps are found worn or damaged replace them 9Y1210236GEG0050US0 Checking CAB Isolation Cushion CABIN Model 1 Check the cushion for any breakage or figure 2 Replace them if they are deteriorated 9Y1210236GEG0051US0 1 Isolation Cushion F Front Side R Rear Side KiS...

Page 57: ...reeze until the coolant level is just below the radiator cap Install the radiator cap 3 securely 7 Fill with clean water and anti freeze up to the upper line of recovery tank 4 8 Start and operate the engine for few minutes 9 Stop the engine Check coolant level and add coolant if necessary 10 Properly dispose of used coolant IMPORTANT Do not start engine without coolant Use clean fresh water and a...

Page 58: ...torage let out coolant completely or mix fresh water with long life coolant and fill the radiator and reserve tank with the mixture 1 Long life coolant hereafter LLC comes in several types Use ethylene glycol EG type for this engine 2 Before employing LLC mixed coolant fill the radiator with fresh water and empty it again Repeat this procedure 2 or 3 times to clean up the inside 3 Mixing the LLC P...

Page 59: ...ant level drops due to evaporation add water only to keep the antifreeze mixing ratio less than 50 In case of leakage add antifreeze and water in the specified mixing ratio before filling in to the radiator 9Y1210236GEG0052US0 Replacing Radiator Hose Water Pipes 1 Replace the hoses and clamps Refer to 5 CHECK POINTS OF EVERY 200 HOURS in this section 9Y1210236GEG0053US0 Replacing Intake Air Line 1...

Page 60: ...lt when the knob is pumped then no air remains 3 Set the hand throttle lever at the maximum speed position turn the key switch to start the engine and then reset the throttle lever at the mid speed around 1500 min 1 rpm position If engine does not start try it several times at 30 second intervals 4 Accelerate the engine to remove the small portion of air left in the fuel system 5 If air still rema...

Page 61: ...shortage of refrigerant impairs the air conditioner performance Check the following points If it is indicated that the amount of refrigerant is extremely low inspect and charge Refer to 10 CABIN service section Q 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 b...

Page 62: ... 1 Remove the cover 1 and open the washer liquid tank cap 3 2 Add a proper amount of automobile washer liquid 9Y1210236GEG0063US0 Washer liquid tank capacity 1 0 L 1 1 U S qts 0 9 Imp qts 1 Cover 2 Knob Bolt 3 Washer Liquid Tank Cap 4 Washer Liquid Tank KiSC issued 07 2013 A ...

Page 63: ...all the head lamp assembly in the reverse order Q Other lights 1 Detach the lens and replace the bulb IMPORTANT Be sure to use a new bulb of the specified wattage Never touch the bulb surface glass with bare hands Fingerprints for example may break the bulb 9Y1210236GEG0064US0 Replacing Fuse 1 Refer to 3 CHECKING AND ADJUSTING at N9 ELECTRICAL SYSTEM section in this manual 9Y1210236GEG0065US0 ROPS...

Page 64: ...Sliding Hammer Application Use to removing the hydraulic pump drive gear pin with sliding hammer 9Y1210236GEG0066US0 Hydraulic pump drive gear pin A M8 P1 25 B 25 mm 0 98 in C 50 mm 1 97 in D 23 mm 0 91 in E 27 mm 1 06 in F M14 P1 5 1 Adaptor M6 2 Stud Bolt M8 P1 25 KiSC issued 07 2013 A ...

Page 65: ...0 52 rad 30 0 52 rad 30 E 26 0 mm dia 1 02 in dia 32 6 to 33 0 mm dia 1 28 to 1 29 in dia F Involute spline refer to below Involute spline refer to below G Chamfer 1 0 mm 0 039 in Chamfer 1 0 mm 0 039 in H 30 mm 1 18 in 30 mm 1 18 in I 5 mm 0 19 in 5 mm 0 19 in J 55 mm 2 17 in 55 mm 2 17 in K 30 mm dia 1 18 in dia 40 mm dia 1 57 in dia L 40 mm dia 1 57 in dia 50 mm dia 1 97 in dia Bevel gear for f...

Page 66: ...and PTO clutch valve relief pressure 9Y1210236GEG0069US0 A 49 85 to 49 95 mm 1 963 to 1 966 in B 15 mm 0 59 in C 50 mm 1 969 in D 30 mm 1 18 in E 44 85 to 44 95 mm 1 766 to 1 770 in F 78 mm dia 3 07 in dia G 40 mm dia 1 57 in dia H 50 mm 1 97 in I 20 mm 0 79 in a 6 3 µm 0 00025 in b 6 3 µm 0 00025 in c 6 3 µm 0 00025 in d 6 3 µm 0 00025 in A 24 mm 0 94 in B 27 7 mm 1 09 in C PS1 4 D 11 mm 0 43 in ...

Page 67: ...6GEG0070US0 A 120 mm 4 72 in B 12 mm 0 72 in C M10 P1 25 D 30 mm 1 18 in E M16 P1 5 F 10 mm 0 39 in G 20 mm 0 79 in H 36 mm 1 42 in I 64 mm 2 52 in J 45 mm 1 77 in K 20 mm 0 79 in 1 Screw M10 P1 25 L50 mm 2 in 2 Screw M16 P1 5 L50 mm 2 in 3 Rocking Restrictor KiSC issued 07 2013 A ...

Page 68: ...perator s manual IMPORTANT Do not use tires other than those approved by KUBOTA Dual tires are not approved NOTE When optional different diameter tires are fitted on the machine the travel speed display mode must be changed Otherwise the travel speed will not get correctly displayed Such mode switching is also needed when the original tires are back on the machine Refer to 4 CHECKING AND ADJUSTING...

Page 69: ...i 250 80 18 250 kPa 2 55 kgf cm2 36 3 psi 260 70R16 220 kPa 2 24 kgf cm2 31 9 psi 280 65R16 220 kPa 2 24 kgf cm2 31 9 psi 280 70R16 200 kPa 2 04 kgf cm2 29 0 psi 280 70R18 196 kPa 2 00 kgf cm2 28 4 psi 280 70R20 160 kPa 1 63 kgf cm2 23 2 psi 280 80R18 160 kPa 1 63 kgf cm2 23 2 psi Rear 12 4R24 160 kPa 1 63 kgf cm2 23 2 psi 13 6R28 160 kPa 1 63 kgf cm2 23 2 psi 14 9LR20 160 kPa 1 63 kgf cm2 23 2 ps...

Page 70: ...th 1 Remove the wheel rim and disc mounting bolts 2 Change the position of the rim and disc right and left to the desired position and tighten the bolts 3 Adjust the toe in Refer to 5 CHECK POINTS OF EVERY 200 HOURS at 7 CHECK AND MAINTENANCE in this section IMPORTANT Always attach wheels as shown in the figure If not attached as illustrated transmission parts may be damaged When re fitting or adj...

Page 71: ... 70R20 1175 mm 46 26 in 280 80R18 1183 mm 46 57 in 7 5 16 1157 mm 45 55 in 7 5R16 1071 mm 42 17 in 1227 mm 48 31 in 7 5 18 1139 mm 44 84 in 1155 mm 45 47 in 7 5R18 1205 mm 47 44 in 8 0 75 15 1210 mm 47 64 in 240 70 16 1239 mm 48 78 in 250 80 16 1121 mm 44 13 in 1177 mm 46 34 in 260 70R16 1238 mm 48 74 in 280 65R16 1238 mm 48 74 in 280 70R16 1237 mm 48 70 in a Tread KiSC issued 07 2013 A ...

Page 72: ...ure 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 driving the tractor 200 m 200 yards and thereafter according to service interval 9Y1210236GEG0075US0 Tightening torque Rear wheel mounting nut M16 259 9 to 304 0 N m 26 5 to 31 0 kgf m 191 7 to 224 2 lbf ft Rear disc mounting nut M1...

Page 73: ...n 1354 mm 53 31 in 1467 mm 57 76 in 360 70R20 1112 mm 43 78 in 1221 mm 48 07 in 1096 mm 43 15 in 1248 mm 49 13 in 1357 mm 54 43 in 380 70R24 985 mm 38 8 in 1223 mm 48 15 in 1332 mm 52 44 in 1276 mm 50 24 in 1385 mm 54 53 in 380 70R20 1112 mm 43 78 in 1221 mm 48 07 in 1096 mm 43 15 in 1248 mm 49 13 in 1357 mm 54 43 in 380 70R28 1060 mm 41 73 in 1154 mm 45 53 in 1266 mm 49 84 in 1348 mm 53 07 in 420...

Page 74: ...ounting nuts 3 and detach the hydraulic control lever guide 1 from the fender R H 3 Remove the fender mounting screws 4 4 Change the position of the fender right and left to the desired position and tighten the screws 4 5 Reinstall the hydraulic control lever guide 1 to the fender R H 6 Reinstall the rear wheels When reassembling 9Y1210236GEG0078US0 Tire size Fender position 12 4R24 380 70R24 Lowe...

Page 75: ... use with improper implements are not covered by the warranty NOTE Implement size may vary depending on soil operating conditions 9Y1210236GEG0079US0 Tread max width with farm tires Lower link end max loading weight W0 Front Rear 1139 mm 44 84 in 1348 mm 53 07 in 2300 kg 5070 lbs Actual figures Implement Weight W1 and or size Max Drawbar Load W2 Trailer loading weight W3 Max capacity As in the fol...

Page 76: ...Max Tank capacity Mid 680 L 180 U S gals 150 Imp gals Rear 3 point Hitch 680 L 180 U S gals 150 Imp gals Drawbar 4000 L 1030 U S gals 880 Imp gals 4 Rotary Tiller Max Tilling Width 2130 mm 84 in Max Weight 800 kg 1760 lbs 5 Bottom Plow Max Size 14 in 3 16 in 2 18 in 1 Max Weight 3 point Hitch Type 450 kg 1000 lbs 6 Disc harrow 3 point Hitch Type Max Size 18 in 24 Max Harrowing Width 2130 mm 84 in ...

Page 77: ...ailer loading weight max capacity W3 Unbraked towable mass 3000 kg 6614 lbs 3000 kg 6614 lbs 3000 kg 6614 lbs 3000 kg 6614 lbs 3000 kg 6614 lbs 3000 kg 6614 lbs Independently braked mass 5000 kg 11020 lbs 5000 kg 11020 lbs 5000 kg 11020 lbs 5000 kg 11020 lbs 5000 kg 11020 lbs 5000 kg 11020 lbs Inertia braked towable mass 6000 kg 13230 lbs 6000 kg 13230 lbs 6000 kg 13230 lbs 6000 kg 13230 lbs 6000 ...

Page 78: ...N2 CLUTCH KiSC issued 07 2013 A ...

Page 79: ... 1 PTO CLUTCH N2 M1 1 STRAUCTURE N2 M1 1 M8540Narrow Model N2 M1 2 M9540Narrow Cabin Model N2 M2 2 PTO CLUTCH OPERATION N2 M3 3 PTO SOLENOID VALVE RELIEF VALVE AND OIL FLOW N2 M4 MECHANISM KiSC issued 07 2013 A ...

Page 80: ...y hydraulic from PTO clutch valve tightly presses the clutch discs 6 and drive plates 7 toward the pressure plate 5 As a result the rotation of the PTO propeller shaft 1 is transmitted to the PTO propeller shaft 2 3 through the PTO clutch pack 2 The belleville washer cupped spring washer 9 reduce the engaging shock Thereby the PTO clutch is engaged very smoothly 9Y1210236CLM0001US0 1 PTO Propeller...

Page 81: ...c from PTO clutch valve tightly presses the clutch discs 6 and drive plates 7 toward the pressure plate 5 As a result the rotation of the PTO propeller shaft 1 is transmitted to the PTO propeller shaft 2 3 through the PTO clutch pack 2 The belleville washer cupped spring washer 9 reduce the engaging shock Thereby the PTO clutch is engaged very smoothly 9Y1210236CLM0004US0 1 PTO Propeller Shaft 1 2...

Page 82: ...the PTO solenoid valve 3 is operated Then the oil flows to clutch pack through the PTO solenoid valve 3 When the PTO switch is set to the A position the PTO solenoid valve 3 is not operated 9Y1210236CLM0002US0 1 PTO Switch 2 Solenoid Valve Assembly 3 PTO Solenoid Valve A Disengage B Engage KiSC issued 07 2013 A ...

Page 83: ...intains the hydraulic system pressure and supply the oil to lubricate the shuttle section synchro mesh gears PTO clutch pack and PTO brake section NOTE Hydraulic system pressure is a operating pressure for the PTO clutch pack 2WD 4WD clutch pack and Bi speed turn clutch pack 2 16 MPa 22 0 kgf cm2 313 psi 9Y1210236CLM0003US0 1 Solenoid Valve Assembly 2 Relief Valve 3 PTO Solenoid Valve 4 Connector ...

Page 84: ...SASSEMBLING AND ASSEMBLING N2 S4 1 SEPARATING CLUTCH HOUSING FROM TRANSMISSION CASE N2 S4 1 Preparation N2 S4 2 ROPS Model N2 S5 3 CABIN Model N2 S10 4 Separating Clutch Housing Case from Transmission Case N2 S12 2 REMOVING PTO CLUTCH PACK AND HOLDER N2 S13 3 REMOVING PTO CLUTCH VALVE N2 S14 SERVICING KiSC issued 07 2013 A ...

Page 85: ...CATIONS 9Y1210236CLS0001US0 Item Factory Specification Allowable Limit PTO Clutch Condition Engine Speed Approx 2600 min 1 rpm Oil temperature 45 to 55 C 113 to 131 F Operating Pressure 2 16 to 2 26 MPa 22 to 23 kgf cm2 312 91 to 327 14 psi KiSC issued 07 2013 A ...

Page 86: ...wheel mounting nut 260 to 304 26 5 to 31 0 191 8 to 224 2 Rear ROPS mounting screw M16 9T 260 to 304 26 5 to 31 0 191 8 to 224 2 Brake pipe retaining nut 16 0 to 24 0 1 6 to 2 5 11 8 to 17 7 Transmission case and clutch housing mounting screw M10 9T 60 8 to 70 5 6 2 to 7 2 44 9 to 52 1 Transmission case and clutch housing mounting screw and nut M14 9T 166 7 to 196 1 17 0 to 20 0 123 0 to 144 6 PTO...

Page 87: ...tch engaged position is low check the hydraulic PTO clutch system 9 If the measurement is not within the factory specifications measure the system pressure and adjust the system pressure with relief valve 9 if necessary Condition Engine speed Approx 2600 min 1 rpm Oil temperature 45 to 55 C 113 to 131 F Reference Turn the adjusting screw after removed lock nuts 10 and 11 Turn the adjusting screw c...

Page 88: ...sitive cable first 9Y1210236CLS0004US0 Bonnet CABIN Model 1 Open the bonnet 1 and disconnect the battery negative terminal 2 2 Disconnect the connector 4 for head lights 3 Disconnect the dampers 3 4 Remove the bonnet 1 When reassembling Be sure to assemble the dampers 3 to the original direction IMPORTANT When disconnecting the battery cables disconnect the grounding cable first When connecting po...

Page 89: ...ness cover 1 and disconnect the connectors 3 and 4 4 Remove the hydraulic lever guide from fender R H and remove the fenders 2 When reassembling Assemble the hydraulic lever guide to original position 9Y1210236CLS0008US0 Seat 1 Remove the seat 1 with seat stay 3 2 Remove the rubber sheets 2 and 5 3 Remove the rubber step 4 9Y1210236CLS0009US0 1 Front Axle Rocking Restrictor Tightening torque Rear ...

Page 90: ... Lever Side 1 Screw in the wire to the rod end fully 2 Shift the control lever forward and fix the wire with lock nuts to contact the control lever and stopper 3 Fix the wire with retaining nut center of thread Valve Side 1 Pull the valve lever 9 to a full engage position 2 Pull out the wire 3 fully and fix the wire with retaining nuts 8 to be a length L between wire end 11 and valve lever pin 10 ...

Page 91: ...6CLS0012US0 Fuel Tank R H Brake Rod and Hydraulic Pipes 1 Remove the fuel hose cover 5 and disconnect the fuel hose 4 from the lower fuel tank R H 1 2 Disconnect the fuel breather hose 3 and fuel sensor connector 2 3 Disconnect the fuel hose 6 fuel return hose 7 and remove the lower fuel tank R H 1 9Y1210236CLS0013US0 1 Main Shift Grip 2 Tilt Lever Grip 3 Shift Cover 4 Step L H 5 Select Shift Wire...

Page 92: ...g nut 3 3 Remove the mounting screw for parking brake lever 2 4 Remove the parking cable support 5 as shown photo 5 Disconnect the brake cables 7 and 8 from the stabilizer plate 6 When reassembling Adjust the parking brake lever free play Refer to the N5 BRAKE section 9Y1210236CLS0016US0 1 Fuel Breather Hose 2 Lower Fuel Tank L H 1 Rear Differential Lock Rod 2 Hose Support 3 Hydraulic Outlet Hose ...

Page 93: ...6CLS0018US0 Hydraulic Pipe and Brake Hose 1 Remove the hydraulic pipes 1 and 2 2 Disconnect the hydraulic brake pipes 3 and 4 When reassembling Be sure to bleed the air from hydraulic brake system Refer to the 5 BRAKE section 9Y1210236CLS0019US0 1 Screw 2 Connector 3 Breather Hose 1 Shield 2 Panel Board 3 Steering Post Cover 4 Panel Board Tightening torque Brake pipe retaining nut 16 0 to 24 0 N m...

Page 94: ... at N10 CABIN section 9Y1210236CLS0023US0 Brake Rod Parking 1 Refer to 2 DISASSEMBLING AND ASSEMBLING at N10 CABIN section 9Y1210236CLS0024US0 Removing Control Rods and Brake Hoses 1 Refer to 2 DISASSEMBLING AND ASSEMBLING at N10 CABIN section 9Y1210236CLS0025US0 Auxiliary Control Valve Cable and Ground Cable 1 Refer to 2 DISASSEMBLING AND ASSEMBLING at N10 CABIN section 9Y1210236CLS0026US0 Brake ...

Page 95: ...ank L H 9 5 Remove the PTO wire and disconnect the traveling speed sensor connector 10 6 Remove the parking brake rod L H 11 7 Remove the hydraulic pipe solenoid valve assembly 12 When reassembling Be sure to assemble the ground harness 13 9Y1210236CLS0029US0 1 Rear Differential Lock Rod 2 Fuel Breather Hose 3 Connector Fuel Sensor 4 Fuel Hose 5 Fuel Hose Cover 6 Protector 7 Parking Brake Rod R H ...

Page 96: ... nuts 3 Separate the transmission case from the clutch housing When reassembling Apply liquid gasket Three Bond 1206C or equivalent to joint face of transmission case and clutch housing case 9Y1210236CLS0030US0 Tightening torque Transmission case and clutch housing mounting screw M10 9T 60 8 to 70 5 N m 6 2 to 7 2 kgf m 44 9 to 52 1 lbf ft Transmission case and clutch housing mounting screw nut M1...

Page 97: ...with new one 9Y1210236CLS0031US0 Removing PTO Clutch Pack and Holder 1 Draw out the pin 2 with sliding hammer 3 2 Take out the hydraulic pump drive gear 1 3 Remove the PTO clutch holder mounting screws 4 Remove the PTO clutch 4 with holder 5 When reassembling Take care not to damage the hydraulic pipes IMPORTANT After assembling the PTO clutch assembly be sure to check the piston operation by air ...

Page 98: ...speed turn 3 5 Remove the hydraulic pipe Delivery 6 6 Remove the solenoid valve assembly 5 When reassembling Apply transmission fluid to hydraulic pipes PTO 7 Remove the two hydraulic pipes from the PTO clutch holder Insert both the hydraulic pipes into the solenoid valve assembly holes Replace the hydraulic pipes with new one 9Y1210236CLS0034US0 Tightening torque Rear wheel mounting nut 260 to 30...

Page 99: ...N3 TRANSMISSION KiSC issued 07 2013 A ...

Page 100: ... PTO MODEL ITA MODEL N3 M2 2 POWER TRAIN FOR TRAVELING GEAR N3 M3 1 BI SPEED TURN SYSTEM N3 M3 1 2WD 4WD Bi speed Turn N3 M3 2 Solenoid Valve N3 M5 3 4WD Bi speed Turn Oil Flow N3 M6 3 POWER TRAIN FOR PTO SYSTEM N3 M7 1 GROUND PTO AND LIVE PTO SECTION ITA MODEL N3 M7 MECHANISM KiSC issued 07 2013 A ...

Page 101: ... M1 1 STRUCTURE 1 F15 R15 SPEED TRANSMISSION WITH CREEP SYSTEM 1 Damper 2 Hydraulic Shuttle Clutch 3 Main Gear Shift 4 PTO Clutch 5 PTO Gear Case 6 4WD Bi speed Section 7 Creep Gear Cassette Type Section 8 Range Gear Shift KiSC issued 07 2013 A ...

Page 102: ...VE PTO GROUND PTO MODEL ITA MODEL 1 Damper 2 Hydraulic Shuttle Clutch 3 Main Gear Shift Section 4 PTO Clutch 5 Live PTO Ground PTO Section 6 PTO Gear Case 7 4WD Bi speed Section 8 Creep Gear Cassette Type 9 Range Gear Shift Section KiSC issued 07 2013 A ...

Page 103: ...s turned to 4WD The 4WD Bi speed turn solenoid valve switches and supply the hydraulic pressure to actuate the 4WD piston 4 to engage the clutch pack together with the spring 5 tension force The power is transmitted as follow 36T Gear 2 31T Gear 14 Clutch Body 6 4WD Bi speed Turn Shaft 9 DT Propeller Shaft 1 Engine stop The 4WD piston 4 engage to 4WD mode by spring 5 tension force Bi speed turn dr...

Page 104: ...ning angle exceeds approximately 0 56 rad 32 switch is ON position and current flows to 4WD Bi speed turn relay s coil and the relay contact is set to bi speed turn position by electromagnetic force Therefore current from the battery flows to bi speed turn solenoid 9Y1210236TRM0004US0 A Power B Oil C Electrical Signal a Engine b Transmission Case c 4WD Clutch d Bi speed Turn Clutch e Front Axle f ...

Page 105: ...the oil pressure from the P port to A port to 4WD clutch 4 And the oil pressure feeds the spool 4WD priority valve 2 to change the hydraulic line The spool 4WD priority valve 2 opens Bi speed turn clutch 5 and tank port to prevent the 4WD clutch 4 and Bi speed clutch 5 are not engage at the same time 9Y1210236TRM0005US0 1 4WD Solenoid Valve 2 Spool 4WD Priority Valve 3 Bi speed Solenoid Valve 4 4W...

Page 106: ...t to Bi speed turn side the 4WD priority valve 2 effect to reduce the engagement shock of clutch pack The maximum pressure against the clutch piston is regulated under approx 2 45 MPa 25 0 kgf cm2 356 psi by the relief valve of PTO clutch valve And a part of oil is used for lubricating 4WD clutch pack through the orifice 6 On the other hand the return oil is flowed to the transmission case through...

Page 107: ...PTO Gear 3 PTO Propeller Shaft 3 4 Coupling 5 PTO Gear Section Q Ground PTO Spiral Bevel Pinion Shaft 6 33T G PTO Gear 7 26T Ground PTO Gear 3 PTO Propeller Shaft 3 4 Coupling 5 PTO Gear Section NOTE The number of revolution at one rotation of rear tire 16 9R30 At 540 PTO speed 8 94 At 540E PTO speed 10 56 At 1000 PTO speed 14 47 9Y1210236TRM0007US0 1 PTO Clutch Pack 2 Propeller Shaft 2 3 26T G PT...

Page 108: ...S16 2 1st Shaft 2nd Shaft and 3rd Shaft N3 S16 3 1st Shaft N3 S18 4 2nd Shaft N3 S20 5 3rd Shaft N3 S20 6 4WD Propeller Shaft N3 S20 7 TRANSMISSION CASE N3 S21 8 4WD Bi SPEED TURN CLUTCH N3 S22 1 Removing 4WD Bi speed Turn Clutch N3 S22 2 Disassembling 4WD Bi speed Turn Clutch Pack N3 S23 3 Removing Differential Gear and Bevel Pinion Shaft N3 S26 9 DIFFERENTIAL GEAR N3 S29 10 PTO GEAR CASE N3 S31 ...

Page 109: ...re Differential Side Gear Boss Clearance I D O D 0 080 to 0 181 mm 0 004 to 0 00712 in 40 53 to 40 592 mm 1 5960 to 1 5981 in 40 411 to 40 45 mm 1 5910 to 1 592 in 0 35 mm 0 014 in 39T Bevel Gear Bore to Differential Side Gear Boss 39T Bevel Gear Bore Differential Side Gear Boss Clearance I D O D 0 09 to 0 169 mm 0 004 to 0 00665 in 40 54 to 40 58 mm 1 596 to 1 597 in 40 411 to 40 45 mm 1 591 to 1...

Page 110: ...23 kgf cm2 312 91 to 327 14 psi Clutch Disc Both 4WD Side and Bi speed Turn Side Thickness 2 1 to 2 3 mm 0 083 to 0 090 in 1 9 mm 0 090 in Steel Plate Both 4WD Side and Bi speed Turn Side Thickness 1 56 to 1 64 mm 0 0614 to 0 0646 in 1 3 mm 0 051 in Pressure Plate Both 4WD Side and Bi speed Turn Side Thickness 3 92 to 4 08 mm 0 155 to 0 160 in 3 7 mm 0 15 in Piston Both 4WD Side and Bi speed Turn ...

Page 111: ...7 7 11 0 to 12 0 79 6 to 86 8 Cylinder hose retaining nut 34 3 to 48 1 3 5 to 4 9 25 3 to 35 4 3 point hitch hydraulic block mounting screw and nut 166 7 to 196 1 17 0 to 20 0 123 0 to 144 6 Rear axle case mounting screw and nut 166 7 to 196 1 17 0 to 20 0 123 0 to 144 6 PTO gear case mounting screw 77 5 to 90 2 7 9 to 9 2 57 1 to 66 5 Shuttle case mounting screw and nut 48 1 to 55 8 4 9 to 5 7 35...

Page 112: ...t available adjust the front and or rear stopper bolt 5 and 4 4 Adjust the main shift cable 1 is fixed at the center of thread Adjust the select cable 2 retaining position L4 and L5 for the references 9Y1210236TRS0004US0 Length of front stopper bolt L1 Initial adjustment 19 mm 0 75 in Length of rear stopper bolt L2 Initial adjustment 25 mm 0 98 in Length of select shift rod L3 Factory specificatio...

Page 113: ...r position Neutral position to 3rd gear position Neutral position to 4th gear position Neutral position to 5th gear position 2 If shifting is not smooth check the length of main shift rod 1 The select cable 2 are fixed at the center of thread 9Y1210236TRS0005US0 Length of select shift rod L Factory specification 655 mm 25 8 in 1 Main Shift Rod 2 Select Cable L Select Shift Rod Length KiSC issued 0...

Page 114: ...ctory specifications measure the system pressure and adjust the system pressure with relief valve 4 if necessary Condition Engine speed Approx 2600 min 1 rpm Oil temperature 45 to 55 C 113 to 131 F WARNING Be sure to place the main gear shift lever and shuttle lever in neutral position NOTE Pressure gauge is 5 MPa 50 kgf cm2 700 psi full scale Apply Three Bond 1324N or equivalent to the plugs 1 an...

Page 115: ...lable as below 9Y1210236TRS0007US0 Factory specification Traveling speed 0 1 to 7 2 km h 0 063 to 4 4 mph with 480 65 R 24 rear tire Check the instrument panel engine rotation sensor and or traveling speed sensor Front wheel steered angle 0 56 rad 32 and more Check front wheel turning switch or adjust with adjusting shim Part No Thickness 3A481 40461 1 0 mm 0 039 in 3A481 40471 0 5 mm 0 02 in 1 Bi...

Page 116: ...G AND ASSEMBLING 1 4WD BI SPEED TURN SOLENOID VALVE 1 Removing Solenoid Valve Assembly Solenoid Valve Assembly 1 Refer to the Removing Solenoid Valve Assembly at N2 CLUTCH section in this manual 9Y1210236TRS0008US0 1 Solenoid Valve Assembly KiSC issued 07 2013 A ...

Page 117: ...Model 1 Open the bonnet 1 and disconnect the battery negative terminal 2 2 Disconnect the connector 4 for head lights 3 Disconnect the dampers 3 4 Remove the bonnet 1 When reassembling Be sure to assemble the dampers 3 to the original direction IMPORTANT When disconnecting the battery cables disconnect the grounding cable first When connecting positive cable first 9Y1210236TRS0010US0 Ground PTO Ro...

Page 118: ...IN Assembly CABIN Model 1 Refer to 2 DISASSEMBLING AND ASSEMBLING at N10 CABIN section 9Y1210236TRS0012US0 Separating Engine from Clutch Housing 1 Check the engine and clutch housing case are securely mounted on the disassembling stands 2 Remove the engine mounting screws and nuts 3 Separate the engine from the clutch housing When reassembling Apply molybdenum disulphide Three Bond 1901 or equival...

Page 119: ...screws and nuts 2 Remove the rear axle case assembly 1 When reassembling Apply liquid gaskets Three Bond 1206C or equivalent to joint face 9Y1210236TRS0016US0 Tightening torque Transmission case and clutch housing mounting screw M10 9T 60 8 to 70 5 N m 6 2 to 7 2 kgf m 44 9 to 52 1 lbf ft Transmission case and clutch housing mounting screw nut M14 9T 166 7 to 196 1 N m 17 0 to 20 0 kgf m 123 0 to ...

Page 120: ...uide screws 2 When reassembling Be sure to fit the O rings 3 and apply transmission fluid The passage hole of oil b is not closed with liquid gaskets Apply liquid gaskets Three Bond 1206C or equivalent to joint face of the shuttle case and clutch housing case 9Y1210236TRS0018US0 Tightening torque PTO gear case mounting screw 77 5 to 90 2 N m 7 9 to 9 2 kgf m 57 1 to 66 5 lbf ft 1 PTO Cover 2 PTO G...

Page 121: ... range shift forks 7 and shifters in the transmission on H side forward Apply liquid gaskets Three Bond 1206C or equivalent to joint face 9Y1210236TRS0019US0 Range Gear Shift Fork 1 Remove the roll pins 1 fork rod 3 and range shift forks 2 2 Remove the ball detent 4 and spring 5 NOTE Take care not to lose the detent ball 4 and spring 5 9Y1210236TRS0020US0 Tightening torque Shift cover mounting scr...

Page 122: ...5th fork 5 NOTE Take care not to lose the balls and springs The inner lock ball 3 uses 2 balls for each position When reassembling Be sure to assemble the detent balls 2 with springs 1 and inter lock balls 3 9Y1210236TRS0021US0 1 Spring 2 Ball Detent 3 Ball Inter Lock 4 Fork Rod 5 5th Fork 6 Roll Pin 7 3rd 4th Fork 8 Roll Pin 9 Fork Rod 10 Fork Rod 11 1st 2nd Fork 12 Roll Pin 13 Roll Pin 14 Shifte...

Page 123: ...en reassembling Replace the seal cap 5 and 13 with new one Align the center of main shift lever 1 and projection mark A at shifter cover when the shift arm 2 at neutral position Apply transmission fluid to the spline Assemble the select arm 3 and select lever 4 with spline difference them at 1 57 rad 90 as shown in the photo 9Y1210236TRS0022US0 1 Main Shift Lever 2 Main Shift Arm 3 Select Arm 4 Se...

Page 124: ... the clearance L between external circlip 2 and adjusting collar 3 If the measurement is not within the factory specification adjust with shim Reference Thickness of adjusting collar 3 3 00 mm 0 118 in Code No 3C001 28410 3 2 mm 0 126 in Code No 3C001 28420 3 4 mm 0 134 in Code No 3C001 28430 3 6 mm 0 142 in Code No 3C001 28441 9Y1210236TRS0024US0 Tightening torque Creep gear cover 48 1 to 55 8 N ...

Page 125: ...ase IMPORTANT Do not fall down the shaft when removing the shafts with gears Do not tap the bearing stop part a of clutch housing case it cause break a part of clutch housing case Be sure to tap at the inner race of bearing 4 or 2nd shaft when remove the 2nd shaft assembly 2 For easily assemble stand the clutch housing case and assemble the 1st shaft assembly 1 2nd shaft assembly 2 and 3rd shaft a...

Page 126: ...urn the without spline side E to the rearward R The inner race 21 for 37T gear 5th speed 22 turn the without spline side E to the forward F The directionality of coupling The coupling for 1 2 speed 9 turn the longer boss side D to the rearward R The coupling for 3 4 speed 16 turn the longer boss side D to the forward F The coupling for 5th speed 23 turn the shift end side G to the rearward R Apply...

Page 127: ...oupling 1 2 Speed 10 Synchronizer Key 11 Shifter 12 Inner Race 13 24T Gear 14 Thrust Collar 15 28T Gear 16 Coupling 3 4 Speed 17 Inner Race 18 32T Gear 19 Thrust Collar 20 1st Shaft 21 Inner Race 22 37T Gear 5 speed 23 Coupling 5 speed 24 Needle Stopper 25 External Circlip 26 Bearing 27 Without Teeth 28 Teeth E Without Spline Side D Longer Boss F Forward G Shift End R Rearward KiSC issued 07 2013 ...

Page 128: ...d internal circlip 4 3 Tap out the DT propeller shaft 1 to the forward When reassembling Replace the oil seal 3 with new one 9Y1210236TRS0030US0 1 Bearing 2 46T Gear 3 41T Gear 4 41T Gear 5 46T Gear 6 External Circlip 7 29T Gear 8 2nd Shaft 9 Bearing 1 Bearing 2 Collar 3 Thrust Collar 4 Inner Race 5 27T Gear 6 Spline Boss 7 Shifter 8 44T Gear Creep 9 Bearing 10 Collar 11 16T Gear Shaft 2nd Shaft 1...

Page 129: ...very 6 6 Remove the solenoid valve assembly 5 When reassembling Apply transmission fluid to hydraulic pipes PTO 7 Remove the two hydraulic pipes from the PTO clutch holder Insert both the hydraulic pipes into the solenoid valve assembly holes Replace the hydraulic pipes with new one 9Y1210236TRS0031US0 1 Hydraulic Pipe 2WD 2 Hydraulic Pipe 4WD 3 Hydraulic Pipe Bi speed Turn 4 Connector 5 Solenoid ...

Page 130: ...pply grease to the seal rings 3 when assembling 9Y1210236TRS0032US0 Clutch Holder 1 Draw out the three pipes 5 using the M6 P1 0 screw 6 as shown photo 2 Remove the clutch holder 7 When reassembling Apply oil to the O rings 4 9Y1210236TRS0033US0 1 4WD Bi speed Turn Clutch 2 Bi speed Turn Gear and Shaft Assembly 3 Seal Ring 1 Hydraulic Pipe 2WD 2 Hydraulic Pipe 4WD 3 Hydraulic Pipe Bi speed Turn 4 ...

Page 131: ...he neutral cover 6 6 Tap out the 26T gear 8 from 4WD Bi speed turn shaft 7 When reassembling Install the 26T gear 8 to the clutch discs Align the key 9 and key groove 11 when install the 4WD Bi speed turn shaft 7 Apply oil to the O ring 10 and 12 when assemble the neutral cover 6 9Y1210236TRS0034US0 1 Bearing 2 31T Gear 3 Clutch Body 4 Thrust Collar 5 External Circlip 6 Neutral Cover 7 4WD Bi spee...

Page 132: ...types of steel plates The steel plate with plug rubbers 7 and without rubbers 6 Two steel plates match the position of rubber 8 from the piston side and one remaining steel plate is not matched Do not confuse the pressure plates 4 and steel plate 6 The pressure plate 4 is thicker than the steel plate When installing the internal circlip 3 to the clutch case 1 align its split portion to the notched...

Page 133: ...tch discs 2 and steel plate 5 7 mutually Apply enough transmission fluid to the discs 2 Do not confuse the two types of steel plates The steel plate with rubbers 5 and without rubbers 7 Do not confuse the pressure plates 3 and steel plate 7 The pressure plate 3 is thicker than the steel plate Put the rubber positions that consecutively set up not to come in touch with each rubber 6 directly as sho...

Page 134: ...ure to check the piston operation by air pressure 9Y1210236TRS0037US0 3 Removing Differential Gear and Bevel Pinion Shaft Brake Cam Plate 1 Remove the return spring 1 2 Remove the brake cam plate 2 When reassembling Apply grease to the brake ball seats Do not apply excessively Be sure to assemble the brake cam plate 2 to the original side refer to the I D mark R and L 9Y1210236TRS0038US0 Tightenin...

Page 135: ...d plug 1 2 Draw out the differential lock shaft 5 3 Take out the differential lock shift fork 2 and spring 4 When reassembling Apply grease to the oil seal 9Y1210236TRS0039US0 1 Plug 2 Differential Lock Shift Fork 3 Clevis Pin 4 Spring 5 Differential Lock Shaft 6 Shim 7 Oil Seal KiSC issued 07 2013 A ...

Page 136: ... photo Be sure to adjust the turning torque of spiral bevel pinion shaft refer to 6 SERVICING in this section Be sure to adjust the backlash and tooth contact between the spiral bevel gear and spiral bevel pinion shaft refer to 6 SERVICING in this section 9Y1210236TRS0040US0 Tightening torque Differential bearing support mounting screw 48 1 to 55 8 N m 4 9 to 5 7 kgf m 35 4 to 41 2 lbf ft 1 Differ...

Page 137: ...ut after installing the differential gear assembly 9Y1210236TRS0041US0 9 DIFFERENTIAL GEAR Spiral Bevel Gear 1 Remove the spiral bevel gear 1 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 1324N or equivalent to the spiral bevel gear mounting UBS screws 9Y1210236...

Page 138: ...on Apply molybdenum disulfide Three Bond 1901 or equivalent to the inner circumferential surface of the differential pinions Install the parts to their original position Install the differential pinion washer 4 noting its groove position a 9Y1210236TRS0043US0 Differential Side Gear 1 Take out the differential side gear 2 and differential side gear washer 1 When reassembling Check the thrust and be...

Page 139: ...tightening Apply molybdenum disulfide Three Bond 1901 or equivalent to the inner rings 13 and 17 Apply grease to the oil seal 22 and O ring 30 Do not loose the ball 24 and 28 Tighten the reamer screw 8 first at original position when assemble the PTO gear case cover 9Y1210236TRS0046US0 1 PTO Gear Case Cover Screw 2 PTO Gear Case Cover 3 Internal Circlip 4 Ball Bearing 5 PTO Gear Shaft 6 Ball Beari...

Page 140: ...1 Remove the roll pin 1 and ground PTO lever 2 2 Remove the retainer plate 3 3 Pull the arm 4 to disconnect the ground PTO shift fork 6 When reassembling Be sure to assemble the O ring 5 properly Be sure to assemble the arm 4 to the ground PTO shift fork 6 9Y1210236TRS0067US0 Tightening torque Top cover mounting screw and nut 166 7 to 196 1 N m 17 0 to 20 0 kgf m 123 0 to 144 0 lbf ft PTO gear cas...

Page 141: ... When assemble the 26T ground PTO gear 5 toward the groove for the shift fork 3 to the rearward 9Y1210236TRS0069US0 60T Coupling Gear and Propeller Shaft 2 1 Remove the 60T coupling gear 1 with propeller shaft 2 2 2 Remove the external circlip bearing 3 and 60T coupling gear 1 When reassembling When assemble the 60T coupling gear 1 toward the stopper portion a to the forward 9Y1210236TRS0070US0 1 ...

Page 142: ... is any doubt as to the condition of a taper roller bearing replace it 9Y1210236TRS0049US0 Clearance between Shift Fork and Shifter Groove 1 Measure the width of shift fork 2 Measure the shifter groove width and calculate the clearance 3 If the clearance exceeds the allowable limit replace them 9Y1210236TRS0050US0 Checking Contact between Coupling and Shifter 1 Check to see if there is flaw or wea...

Page 143: ...ch Disc Wear Both 4WD Side and Bi speed Turn Side 1 Measure the thickness of clutch disc with vernier calipers 2 If the thickness is less than the allowable limit replace it 9Y1210236TRS0054US0 Steel Plate and Pressure Plate Wear Both 4WD Side and Bi speed Turn Side 1 Measure the thickness of steel plate and pressure plate with vernier calipers 2 If the thickness is less than the allowable limit r...

Page 144: ...l circlip 1 and adjusting collar 2 2 If clearance L exceeds the factory specification adjust the clearance using adjusting collar 2 Reference Thickness of adjusting collar 2 3 00 mm 0 118 in Code No 3C001 28410 3 2 mm 0 126 in Code No 3C001 28420 3 4 mm 0 134 in Code No 3C001 28430 3 6 mm 0 142 in Code No 3C001 28441 9Y1210236TRS0058US0 Flatness of piston Allowable limit 0 15 mm 0 006 in Flatness ...

Page 145: ...ing nut 1 with locking wrench and turning wrench 2 After tapping the bevel pinion shaft to the front and rear retighten the staking nut 1 to specified torque 3 Measure the turning torque of spiral bevel pinion shaft 4 If the measurement is not within the factory specifications adjust the tightening torque of staking nut 1 NOTE Stake the staking nut after performing adjustment described in the foll...

Page 146: ...ver several teeth at three positions equally spaced on the spiral bevel gear 6 Turn the spiral bevel pinion shaft while pressing a wooden piece against the periphery on the spiral bevel gear 7 Check the tooth contact If not proper adjust according to the instructions next page Reference Thickness of adjusting shim 4 0 3 mm 0 012 in 1 0 mm 0 039 in 1 2 mm 0 047 in 1 4 mm 0 055 in 1 6 mm 0 063 in Th...

Page 147: ... spiral bevel gear rightward Repeat above until the proper tooth contact and backlash are achieved Deep or Toe Contact Replace the adjusting collar 2 with a thinner one to move the spiral bevel pinion shaft forward And increase the shim 4 to move the spiral bevel gear leftward Repeat above until the proper tooth contact and backlash are achieved 9Y1210236TRS0060US0 1 Spiral Bevel Pinion Shaft 2 Ad...

Page 148: ...clearance is smaller than factory specification When reassembling Assemble the adjusting collar 1 6 and 2 7 direction as shown figure Reference Thickness of adjusting shim 4 0 1 mm 0 004 in Code No 3C081 32130 0 3 mm 0 012 in Code No 3C081 32140 0 5 mm 0 020 in Code No 3C081 32150 Thickness of adjusting collar 6 and 7 2 8 mm 0 11 in Code No 36200 32621 3 0 mm 0 12 in Code No 36200 32631 3 20 mm 0 ...

Page 149: ...nce is smaller than factory specification And reduce the shim 4 to move the spiral bevel gear rightward Repeat above until the proper tooth contact and backlash are achieved Deep or Toe Contact Change the combination of adjusting collar 1 6 and 2 7 with a thinner one to move the spiral bevel pinon shaft forward And increase the shim 4 to move the spiral bevel gear leftward Repeat above until the p...

Page 150: ...mm 0 004 to 0 00712 in Allowable limit 0 35 mm 0 014 in Differential case bore I D Factory specification 40 53 to 40 592 mm 1 5960 to 1 5981 in Differential side gear boss O D Factory specification 40 411 to 40 45 mm 1 5910 to 1 592 in Clearance between 39T bevel gear bore and differential side gear boss Factory specification 0 09 to 0 169 mm 0 004 to 0 00665 in Allowable limit 0 35 mm 0 014 in 39...

Page 151: ...in 2 0 mm 0 078 in 9Y1210236TRS0063US0 Clearance of Differential Lock Shifter 1 Measure the clearance L between differential lock shifter and differential case when the differential lock pedal OFF position 2 If the measurement is not within the factory specifications adjust with adjusting shim 2 Reference Thickness of adjusting shim 0 5 mm 0 020 in 1 0 mm 0 039 in 9Y1210236TRS0064US0 Backlash betw...

Page 152: ...N4 REAR AXLE KiSC issued 07 2013 A ...

Page 153: ...CONTENTS 1 STRUCTURE N4 M1 MECHANISM KiSC issued 07 2013 A ...

Page 154: ...les The rear axles 1 are semi floating type with the ball bearing between the rear axle 1 and rear axle case 2 which support the rear wheel load as well as transmitting power to the rear wheel They withstand all the forces caused by tire rotation and side skidding 9Y1210236RAM0001US0 1 Rear Axle 2 Rear Axle Case 3 Planetary Gear Support 4 Differential Gear 5 39T Bevel Gear 6 Brake Shaft 12T Gear 7...

Page 155: ...NING TORQUES N4 S2 3 DISASSEMBLING AND SERVICING N4 S3 1 PREPARATION N4 S3 2 SEPARATING REAR AXLE FROM TRANSMISSION CASE N4 S3 1 ROPS Model N4 S3 2 CABIN Model N4 S5 3 DISASSEMBLING REAR AXLE CASE N4 S6 4 SERVICING N4 S7 SERVICING KiSC issued 07 2013 A ...

Page 156: ...0157 in 0 5 mm 0 020 in Thrust Collar Thickness 1 55 to 1 65 mm 0 0610 to 0 0650 in 1 2 mm 0 047 in Planetary Gear to Planetary Gear Shaft Planetary Gear Shaft Planetary Gear Needle Clearance O D I D O D 0 009 to 0 046 mm 0 00035 to 0 00180 in 29 991 to 30 000 mm 1 18075 to 1 18110 in 38 009 to 38 025 mm 1 4965 to 1 4970 in 3 994 to 4 000 mm 0 1573 to 0 1574 in 0 30 mm 0 0118 in KiSC issued 07 201...

Page 157: ... 26 5 to 31 0 192 to 224 Stabilizer bracket mounting nut M16 7T 197 to 225 20 0 to 23 0 145 to 166 Rear wheel mounting nut 260 to 304 26 5 to 31 0 192 to 224 Rear ROPS mounting screw M16 9T 260 to 304 26 5 to 31 0 192 to 224 Rear axle case mounting screw and nut 166 to 196 17 0 to 20 0 123 to 144 Cabin mounting bolt and nut M14 9T 124 to 147 12 6 to 15 0 91 2 to 108 Rear axle case mounting screw a...

Page 158: ...h sides refer to 8 SPECIAL TOOLS at NG GENERAL section 3 Remove the both rear wheels 9Y1210236RAS0019US0 2 SEPARATING REAR AXLE FROM TRANSMISSION CASE 1 ROPS Model Fender 1 Remove the harness cover 2 for both side and disconnect the connectors 2 Remove the 3 point hydraulic lever guide from the fender R H 4 3 Remove the fender 1 and 4 9Y1210236RAS0006US0 Tightening torque Stabilizer bracket mounti...

Page 159: ...2 Remove the rear axle case mounting screws and nuts 3 Remove the rear axle assembly 1 When reassembling Apply liquid gaskets Three Bond 1206C or equivalent to joint face Bleed the air from hydraulic brake system Align the brake cam 3 and groove a of brake cam plate 2 9Y1210236RAS0008US0 Tightening torque Rear ROPS mounting screw M16 9T 260 to 304 N m 26 5 to 31 0 kgf m 192 to 224 lbf ft 1 Upper F...

Page 160: ...the rear axle under neath as shown photo When reassembling Apply liquid gasket Three Bond 1206C or equivalent to joint face of the rear axle case and transmission case after eliminate the water oil and stuck liquid gasket Align the brake cam 6 and groove a of brake cam plate 5 Be sure to assemble the cabin mount as shown figure Be sure to bleed the air from the hydraulic brake system 9Y1210236RAS0...

Page 161: ... roll pin 1 into the planetary gear shaft 3 2 Draw out the planetary gear shaft 3 and remove the planetary gear 2 3 Tap out the roll pin from the planetary gear shaft When reassembling Apply transmission fluid to the inner surface of planetary gear 2 Tap in the roll pin 1 as shown in the figure 9Y1210236RAS0011US0 Tightening torque Retainer plate mounting screw 60 8 to 70 6 N m 6 2 to 7 2 kgf m 44...

Page 162: ...l when insert the rear axle to rear axle case 9Y1210236RAS0012US0 4 SERVICING Ball Bearing 1 Hold the inner race and push and pull the outer race in all directions to check for wear and roughness 2 Apply transmission fluid to the bearing and hold the inner race Then turn the outer race to check rotation 3 If there is any defect replace it 9Y1210236TRS0047US0 Needle Bearing 1 Check the needle beari...

Page 163: ...f the two needles installed diagonally in the needle bearing 4 Calculate the clearance 5 Clearance Planetary gear I D 2 Needle O D Planetary gear shaft O D 6 If the clearance exceeds the allowable limit replace them 9Y1210236RAS0017US0 Backlash between internal gear and planetary gear Factory specification 0 2 to 0 4 mm 0 0078 to 0 0157 in Allowable limit 0 5 mm 0 020 in Thrust collar thickness Fa...

Page 164: ...N5 BRAKES KiSC issued 07 2013 A ...

Page 165: ...CONTENTS 1 PARKING BRAKE N5 M1 1 STRUCTURE N5 M1 1 ROPS Model N5 M1 2 CABIN Model N5 M2 MECHANISM KiSC issued 07 2013 A ...

Page 166: ...utomatically adjust the operating forces for both R H and L H side of parking cable 12 and 13 While the machine is parked with the engine off the hydraulic 4WD clutch is kept disengaged But the clutch disc is held pressed by the spring which means that the 4WD mechanism is still on When the parking brake is applied therefore all the 4 wheels are put on brakes to provide for greater braking effect ...

Page 167: ...ke plates 1 to brake the brake shaft 6 While the machine is parked with the engine off the hydraulic 4WD clutch is kept disengaged But the clutch disc is held pressed by the spring which means that the 4WD mechanism is still on When the parking brake is applied therefore all the 4 wheels are put on brakes to provide for greater braking effect 9Y1210236BRM0002US0 1 Brake Plate 2 Brake Disc 3 Steel ...

Page 168: ... 1 Traveling Brake N5 S3 2 Parking Brake N5 S5 2 DISASSEMBLING AND ASSEMBLING N5 S5 1 Preparation N5 S5 2 Separating Rear Axle Case from Transmission Case N5 S6 3 Brake Piston N5 S7 4 Differential Support and Cam Plate Support N5 S8 5 Removing Brake Disc and Plate N5 S8 3 SERVICING N5 S9 1 Travelling Brake N5 S9 SERVICING KiSC issued 07 2013 A ...

Page 169: ...0 3 mm 0 012 in Cam Plate and Ball Height 25 45 to 25 55 mm 1 002 to 1 0059 in 25 00 mm 0 9843 in Brake Piston Flatness 0 3 mm 0 012 in Brake Disc Thickness 4 15 to 4 35 mm 0 1634 to 0 1713 in 3 3 mm 0 130 in Brake Plate Thickness 2 1 to 2 5 mm 0 0827 to 0 0984 in 1 5 mm 0 059 in Item Factory Specification Allowable Limit Parking Brake Lever ROPS Model CABIN Model Free Travel Free Travel 2 notches...

Page 170: ...Brake rod turn backle lock nut 29 4 to 34 3 3 00 to 3 49 21 7 to 25 2 Breeder 6 4 to 6 9 0 66 to 0 70 4 8 to 5 0 Rear wheel mounting nut 260 to 304 26 5 to 31 0 192 to 224 Rear ROPS mounting screw M16 9T 260 to 304 26 5 to 31 0 192 to 224 Rear axle case mounting screw and nut 166 to 196 17 0 to 20 0 123 to 144 Stabilizer bracket mounting screw M16 9T 260 to 304 26 5 to 31 0 192 to 224 Stabilizer b...

Page 171: ... depress the brake pedals and measure free travel at the top of pedal stroke 3 If the measurement is not within the factory specifications adjust the free travel by the turn buckle 2 or push rod 3 4 After adjustment tighten the lock nut firmly IMPORTANT Keep the free travel in the right and left brake pedals equal 9Y1210236BRS0004US0 Brake pedal free travel L Factory specification 7 to 14 mm 0 28 ...

Page 172: ...g release the finger Repeat this operation several times Prepare the oil can 3 After bleeding the master cylinder install the front brake pipes 4 After installing the vinyl pipe 4 to the bleeder 3 loosen the bleeder two turns 5 Move the brake pedal up and down Repeat this motion until air bubble in brake oil disappears After bleeding tighten the bleeders firmly Reference Importance of Bleeding If ...

Page 173: ...e parking position while counting the ratchet sound made by the parking brake lever 1 2 If the free travel is not within factory specifications adjust the turnbuckle rod 2 3 Set the parking brake lever at 2nd notches position and adjust the turnbuckle rod 2 by hand to zero free play position both right and left side evenly 4 Retighten the lock nut 3 NOTE Make sure the parking brake indicator lamp ...

Page 174: ... section 3 Remove the both rear wheels 9Y1210236RAS0005US0 2 Separating Rear Axle Case from Transmission Case Rear Axle 1 Remove the rear axle assembly 1 refer to the 3 DISASSEMBLING AND SERVICING at N4 REAR AXLE section 9Y1210236BRS0011US0 Tightening torque Stabilizer bracket mounting screw M16 9T 260 to 304 N m 26 5 to 31 0 kgf m 191 8 to 224 2 lbf ft Stabilizer bracket mounting nut M16 7T 197 t...

Page 175: ...air from bleeder hole 1 When reassembling Replace the brake seal 1 and 2 with new one Install the brake seal so as not to twist Take care not to enter the foreign matter into the seal groove of inside brake case When installing the brake piston apply silicon grease to the brake seals and tap it in evenly and lightly using a soft hammer Install the brake piston toward the flat surface A side to the...

Page 176: ...0 5 Removing Brake Disc and Plate Brake Shaft Brake Disc and Brake Plate 1 Draw out the brake shaft 5 with brake disc 1 and steel plate 3 2 Remove the external circlip 4 3 Remove the brake plate 2 collars 7 and pins 8 When reassembling Place the brake discs 1 so that the hole a of the second disc should be overlapped 9Y1210236BRS0015US0 1 Mark 2 Cam Plate Support L H 3 Differential Support R H 1 B...

Page 177: ...ate and Ball 1 Measure the dimensions of the cam plate with the ball installed 2 If the measurement is less than the allowable 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 9Y1210236BRS0018US0 Brake Disc Wear 1 Measure the brake disc thickness with vernier calipers 2 If the measurement is less than the allowable l...

Page 178: ...ine if a 0 3 mm 0 012 in feeler gauge will fit underneath 2 Check this at four points on a diagonal line 3 If it will fit grind in a circular motion with sandpaper or replace it 4 Inspect the sliding portion of the brake piston and brake case interior If damage or wear is found replace it 9Y1210236BRS0021US0 Brake plate wear Factory specification 2 1 to 2 5 mm 0 0827 to 0 0984 in Allowable limit 1...

Page 179: ...N6 FRONT AXLE KiSC issued 07 2013 A ...

Page 180: ...CONTENTS 1 STRUCTURE N6 M1 MECHANISM KiSC issued 07 2013 A ...

Page 181: ...evel Gear 4 Front Axle Case Cover 5 Front Axle 6 10T Bevel Gear 7 Bevel Gear Shaft 8 Bevel Gear Case 9 20T Bevel Gear 10 11T Bevel Gear 11 Differential Yoke Shaft 12 Differential Gear Assembly 13 Bracket Rear 14 Propeller Shaft 15 10T Bevel Pinion Shaft 16 23T Bevel Gear 17 Front Axle Case 18 Shutter Plate 19 Bracket Front KiSC issued 07 2013 A ...

Page 182: ...CKING DISASSEMBLING AND SERVICING N6 S3 1 CHECKING AND ADJUSTING N6 S3 2 DISASSEMBLING AND ASSEMBLING N6 S3 1 Turning Angle Inspection Switch N6 S3 2 Disassembling Front Axle Case N6 S4 3 Disassembling Differential Gear N6 S4 3 SERVICING N6 S5 SERVICING KiSC issued 07 2013 A ...

Page 183: ...Spiral Bevel Pinion Shaft Pinion Shaft Only Turning Torque 1 43 to 1 56 N m 0 145 to 0 16 kgf m 1 05 to 1 15 lbf ft Front Bracket to Rear Bracket Bushing Rear Differential Case Boss Front Differential Case Boss Alloy Thickness O D O D 0 57 mm 0 0224 in 89 965 to 90 000 mm 3 5420 to 3 5433 in 59 97 to 60 000 mm 2 3611 to 2 3622 in Front Wheel Case Bushing Bevel Gear Case Alloy Thickness O D 0 57 mm...

Page 184: ... bolts and nuts on the table below are especially specified For general use screws bolts and nuts Refer to 5 TIGHTENING TORQUES at NG GENERAL section 9Y1210236FAS0002US0 Item N m kgf m lbf ft Differential case cover mounting screw M8 9T 29 4 to 34 3 3 0 to 3 5 21 7 to 25 3 KiSC issued 07 2013 A ...

Page 185: ... 9Y1210236FAS0003US0 2 DISASSEMBLING AND ASSEMBLING 1 Turning Angle Inspection Switch Turning Angle Inspection Switch 1 Remove the cover 2 2 Remove the turning angle inspection switch 1 When reassembling Adjust the turning angle inspection switch operating angle with adjusting shim 3 Shim 3 0 5 mm 0 02 in 3A481 40470 1 0 mm 0 039 in 3A481 40460 NOTE Remove the turning angle inspection switch to ex...

Page 186: ...inion gears 10 differential side gear 11 and shim When reassembling Replace the external circlip 6 with new one Check the differential pinion gears 10 pinion shaft 13 for excessive wear If these parts are damaged or excessively worn replace the parts they mesh with or are sliding on Apply molybdenum disulfide Three Bond 1901 or equivalent to inner circumferential surface of differential pinions si...

Page 187: ... 2 and 4 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 L replace it 9Y1210236FAS0008US0 Turning torque of spiral bevel pinion shaft Factory specification 1 43 to 1 56 N m 0 145 to 0 160 kgf m 1 05 to 1 15 lbf ft 1 Lock Nut Front bracket and rear bracket bushing Alloy thickness L 0 57 mm 0 0224 in Rear differential ca...

Page 188: ...s 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 L replace it 9Y1210236FAS0009US0 Front wheel case bushing Alloy thickness L 0 57 mm 0 0224 in Bevel gear case O D Factory specification 54 97 to 55 00 mm 2 1642 to 2 1653 in KiSC issued 07 2013 A ...

Page 189: ...N7 STEERING KiSC issued 07 2013 A ...

Page 190: ...NING TORQUES N7 S2 3 CHECKING DISASSEMBLING AND SERVICING N7 S3 1 CHECKING AND ADJUSTING N7 S3 1 Hydraulic Pump N7 S3 2 DISASSEMBLING AND ASSEMBLING N7 S4 1 Removing Power Steering Hydraulic Pump N7 S4 3 SERVICING N7 S5 SERVICING KiSC issued 07 2013 A ...

Page 191: ...y Above 21 4 L min Above 5 65 U S gals min Above 4 71 Imp gals min 18 0 L min 4 76 U S gals min 3 96 Imp gals min Hydraulic Pump Condition Engine Speed 2600 min 1 rpm No pressure Oil Temperature 50 to 60 C 122 to 140 F Delivery Above 21 8 L min Above 5 76 U S gals min Above 4 80 Imp gals min Item Factory Specification Allowable Limit Steering Cylinder I D 50 000 to 50 062 mm 1 9686 to 1 9709 in 50...

Page 192: ...w are especially specified For general use screws bolts and nuts Refer to 5 TIGHTENING TORQUES at NG GENERAL section 9Y1210236STS0002US0 Item N m kgf m lbf ft Rear wheel mounting nut 260 to 304 26 5 to 31 0 191 8 to 224 2 3 point hitch delivery pipe retaining nut 107 9 to 117 7 11 0 to 12 0 79 6 to 86 8 KiSC issued 07 2013 A ...

Page 193: ...ump 3 and flowmeter 4 inlet port 8 Connect the other hydraulic test hose 1 to the flowmeter outlet insert the hydraulic test hose other end to transmission oil filling port at PTO case 9 Open the flowmeter loading valve completely Turn counterclockwise 10 Start the engine and set the engine speed at 2000 to 2200 min 1 rpm 11 Slowly close the loading valve to generator pressure approx 9 8 MPa 100 k...

Page 194: ...3 point hitch delivery pipe 3 6 Disconnect the suction pipe 5 7 Remove the hydraulic pump 4 When reassembling 9Y1210236STS0004US0 Hydraulic pump delivery at no pressure Factory specification Above 21 8 L min 5 76 U S gals min 4 80 Imp gals min Hydraulic pump delivery at rated pressure Factory specification 21 4 L min 5 65 U S gals min 4 71 Imp gals min Allowable limit 18 0 L min 4 76 U S gals min ...

Page 195: ...re the bushing I D with a cylinder gauge 2 Measure the rod O D with an outside micrometer and calculate the clearance 3 If the clearance exceeds the allowable limit replace as a unit 9Y1210236STS0006US0 Steering cylinder I D Factory specification 50 000 to 50 062 mm 1 9686 to 1 9709 in Allowable limit 50 100 mm 1 97244 in Clearance between rod and bushing Factory specification 0 009 to 0 127 mm 0 ...

Page 196: ...N8 HYDRAULIC SYSTEM KiSC issued 07 2013 A ...

Page 197: ... 1 STRUCTURE N8 M1 2 HYDRAULIC CIRCUIT N8 M2 1 TOTAL HYDRAULIC CIRCUIT M8540NARROW N8 M2 2 FLOW PRIORITY VALVE M8540NARROW N8 M3 3 TOTAL HYDRAULIC CIRCUIT M9540NARROW CABIN N8 M4 MECHANISM KiSC issued 07 2013 A ...

Page 198: ...ssembly PTO 4WD and Bi speed Turn 5 Shuttle Valve 6 Relief Valve for 3 point Hitch 7 Safety Valve for 3 point Hitch 8 Top Cover 3 point Hitch Hydraulic Block 9 Flow Priority Valve M8540Narrow Valve Cover M9540Narrow Cabin 10 Auxiliary Control Valve 11 Brake Master Cylinder 12 Hydraulic Front Outlet 13 Oil Filter Cartridge 14 Hydraulic Cylinder for 3 point Hitch 15 Hydraulic Pump for 3 point Hitch ...

Page 199: ...oller 12 Steering Cylinder 13 Cylinder Safety Valve 14 Exterior Hydraulic Cylinder 15 Brake Master Cylinder 16 Brake Piston 17 PTO Clutch Pack 18 4WD Clutch Pack 19 Solenoid Valve Assembly 20 Bi speed Turn Clutch Pack 21 Solenoid Valve Bi speed Turn 22 Priority Valve 23 Solenoid Valve 4WD 24 Solenoid Valve PTO 25 Relief Valve for System 26 Relief Valve for Lubricating Line 27 Oil Cooler 28 Oil Coo...

Page 200: ...min to flow to the 3P control valve from the hydraulic pump 2 The oil flows from P port to N port through the orifice 4 3 The pressure is generated when oil passes the orifice 4 This pressure and spring 1 balance and control the oil amount 9Y1210236HYM0003US0 1 Spring 2 Spool 3 Groove 4 Orifice P Pressure Port N Neutral Port T Tank Port KiSC issued 07 2013 A ...

Page 201: ...eering Cylinder 13 Cylinder Safety Valve 14 Exterior Hydraulic Cylinder 15 Brake Master Cylinder 16 Brake Piston 17 PTO Clutch Pack 18 4WD Clutch Pack 19 Solenoid Valve Assembly 20 Bi speed Turn Clutch Pack 21 Solenoid Valve Bi speed Turn 22 Priority Valve 23 Solenoid Valve 4WD 24 Solenoid Valve PTO 25 Relief Valve for System 26 Relief Valve for Lubricating Line 27 Oil Cooler 28 Oil Cooler Check V...

Page 202: ...MBLING AND ASSEMBLING N8 S15 1 HYDRAULIC PUMP N8 S15 1 Removing Hydraulic Pump N8 S15 2 HYDRAULIC BLOCK N8 S15 1 Preparation N8 S15 2 ROPS Model N8 S15 3 CABIN Model N8 S17 3 CONTROL VALVE N8 S18 1 M8540Narrow Model N8 S18 2 M9540Narrow Cabin Model N8 S20 4 RELIEF VALVE N8 S22 5 SAFETY VALVE N8 S22 6 LIFT ARM AND LIFT ARM SHAFT N8 S23 7 LOWERING SPEED ADJUSTING VALVE N8 S23 SERVICING KiSC issued 0...

Page 203: ...a 195 kgf cm2 2770 psi Oil temperature 50 to 60 C 122 to 140 F Delivery Above 61 0 L min 16 1 U S gals min 13 4 Imp gals min 51 5 L min 13 6 U S gals min 11 3 Imp gals min Item Factory Specification Allowable Limit Relief Valve Setting Pressure 18 2 to 19 1 MPa 185 to 195 kgf cm2 2640 to 2770 psi Safety Valve Opening Pressure 23 1 to 24 5 MPa 235 to 250 kgf cm2 3342 to 3556 psi Item Factory Specif...

Page 204: ...HYDRAULIC SYSTEM M8540Narrow M9540Narrow WSM N8 S2 CONTROL VALVE 9Y1210236HYS0001US0 Item Factory Specification Allowable Limit Spool Joint Length 24 5 to 25 0 mm 0 965 to 0 984 in KiSC issued 07 2013 A ...

Page 205: ... 0 191 8 to 224 2 Cylinder hose retaining nut 45 1 to 53 0 4 6 to 5 4 33 3 to 39 1 3 point hitch hydraulic block mounting screw 166 7 to 196 1 17 0 to 20 0 123 0 to 144 7 3 point hitch hydraulic block mounting nut 123 6 to 147 1 12 6 to 15 0 91 1 to 108 5 Control valve mounting screw 19 6 to 23 5 2 0 to 2 4 14 5 to 17 4 Seat plug 1 Control valve 39 2 to 58 8 4 0 to 6 0 28 9 to 43 4 Seat plug 2 Con...

Page 206: ...8 Connect the other hydraulic test hose 1 to the flowmeter outlet insert the hydraulic test hose other end to transmission oil filling port at PTO case 9 Open the flowmeter loading valve completely Turn counterclockwise 10 Start the engine and set the engine speed at 2000 to 2200 min 1 rpm 11 Slowly close the loading valve to generator pressure approx 9 8 MPa 100 kgf cm2 1422 psi Hold in this cond...

Page 207: ...ydraulic pump delivery at no pressure Factory specification Above 21 8 L min 5 76 U S gals min 4 80 Imp gals min Hydraulic pump delivery at rated pressure Factory specification 21 3 L min 5 63 U S gals min 4 69 Imp gals min Allowable limit 18 0 L min 4 76 U S gals min 3 96 Imp gals min Hydraulic pump delivery at no pressure Factory specification Above 63 0 L min 16 64 U S gals min 13 86 Imp gals m...

Page 208: ...control valve operation lever to the UP position and read the pressure gauge when the relief valve is actuated 4 If the pressure is not within the factory specification adjust the relief valve adjuster 3 Condition Engine speed Approx 2600 min 1 rpm Oil temperature 45 to 55 C 113 to 131 F 9Y1210236HYS0004US0 Tightening torque Relief valve assembly 34 3 to 39 2 N m 3 5 to 4 0 kgf m 25 3 to 28 9 lbf ...

Page 209: ...When reassembling Install the safety valve to the hydraulic cylinder block taking care not to damage the O ring and apply transmission fluid NOTE Use specified transmission fluid refer to 4 LUBRICANTS FUEL AND COOLANT at G GENERAL section to test the operating pressure of the cylinder safety valve 9Y1210236HYS0005US0 Tightening torque Safety valve assembly 39 2 to 49 0 N m 4 0 to 5 0 kgf m 28 9 to...

Page 210: ...ol rod 1 length L1 and or draft control rod 4 length L2 ROPS Model CABIN Model 9Y1210236HYS0006US0 Position control rod length L1 Factory specification Approx 180 mm 7 09 in Draft control rod length L2 Factory specification Approx 170 mm 6 69 in Position control rod length L1 Factory specification Approx 262 mm 10 31 in Draft control rod length L2 Factory specification Approx 235 mm 9 25 in 1 Posi...

Page 211: ...ion turn the turnbuckle 5 1 5 turns to shorten the position feedback rod 3 7 Tighten the lock nut 4 8 Move the position control lever 2 to the lowest position to check the cylinder goes to lowest position 9 Set the position control lever 2 to the lowest position then slowly shift the lift arm to the upper until the lift arm begins to operated Check the floating range L guide end and position contr...

Page 212: ...he distance L1 between cylinder body end and cylinder rod end 5 Raise the lift arm 3 to the top dead center by hand 6 Measure the distance L2 and calculate the cylinder free play 7 If the cylinder free play is not within the factory specifications adjust the position feedback rod 2 9Y1210236HYS0008US0 Cylinder free play L2 L1 Factory specification 5 to 8 mm 0 197 to 0 315 in 1 Hydraulic Cylinder 2...

Page 213: ...lengthen the draft feedback rod 3 and check the point where the lift arms begin to rise 5 When the lift arms begin to rise turn the turnbuckle 4 1 turn to shorten the draft feedback rod 3 6 Move the position control lever 1 and draft control lever 2 to uppermost position to make sure the relief does not operate 7 If the relief valve operate adjust the draft feedback rod 3 8 Tighten the lock nuts s...

Page 214: ...contact with the body 6 Slowly shift the draft control lever 5 upward until the lift arms begin to rise C1 Then slowly shift the draft control lever 5 downward until the lift arms begin to down C2 Calculate the free range L of the draft control lever 5 on the lever guide 9Y1210236HYS0010US0 Free range L1 L2 Factory specification Less than 25 0 mm 0 984 in 1 Test Bar 2 Weight 3 Top Link Bracket 4 P...

Page 215: ...h the body 6 Slowly shift the draft control lever 5 upward until the lift arms begin to rise Then slowly shift the draft control lever 5 downward until the lift arms begin to down measure the floating range L of the draft control lever 5 from the end of the lever guide 6 7 If floating range L is not within the factory specification adjust the draft control rod 9Y1210236HYS0011US0 Floating range L ...

Page 216: ...ver 4 and stopper 3 Fix the wire 2 with retaining nut 1 center of thread Valve Side 1 Pull the auxiliary valve lever 7 to a full engage position 2 Pull out the wire 2 fully and fix the wire with retaining nuts 6 to be a length L between wire end 9 and valve lever pin 8 as shown photo 9Y1210236HYS0013US0 Operating force for position and draft control lever Factory specification 20 to 40 N 2 0 to 4 ...

Page 217: ... 1 Preparation Draining Fuel and Transmission Fluid 1 Refer to 3 CHECK AND MAINTENANCE and 2 LUBRICANTS FUEL AND COOLANT at NG GENERAL section 9Y1210236CLS0006US0 Front Axle Rocking Restrictor 1 Install the front axle rocking restrictor 1 refer to 8 SPECIAL TOOLS at NG GENERAL section to the front axle bracket on both sides 9Y1210236HYS0016US0 2 ROPS Model Rear ROPS 1 Remove the rear ROPS 2 with u...

Page 218: ...n hoses 5 2 Remove the cylinders 1 3 Disconnect the ground harness 3 4 Remove the hydraulic hose 2 NOTE Take care not to damage the grease nipple when remove the hydraulic cylinder pin When reassembling Apply grease to the grease nipples Take care not to damage the grease nipples when reassemble the hydraulic cylinder 9Y1210236HYS0019US0 1 Remote Control Lever Cover 2 Remote Valve Wire 3 Remote Va...

Page 219: ...oving 3 point Hitch Hydraulic Block Assembly 1 Remove the 3 point hitch hydraulic block mounting screws and nuts 2 Remove the 3 point hitch hydraulic block assembly When reassembling Apply liquid gasket Three Bond 1206C or equivalent to joint face of transmission case and cylinder block 9Y1210236HYS0023US0 Tightening torque 3 point hitch hydraulic block mounting screw 166 7 to 196 1 N m 17 0 to 20...

Page 220: ...L2 to the factory specification neutral state with operate the draft feedback lever 10 and position link lever 11 3 Check the gap G between the lowering poppet and adjusting screw 7 4 If the gap G is not within the reference value recheck length L2 at the neutral state of spool If necessary to adjust the gap G loosen the lock nut 8 and adjust by the adjusting screw 9Y1210236HYS0024US0 Tightening t...

Page 221: ...ate 4 5 Draw out the spool 12 6 Remove the sleeve 8 and spring 9 7 Remove the seat plug 2 11 When reassembling Install the plug noting O ring 9Y1210236HYS0025US0 Tightening torque Seat plug 1 39 2 to 58 8 N m 4 0 to 6 0 kgf m 28 9 to 43 4 lbf ft Seat plug 2 39 2 to 58 8 N m 4 0 to 6 0 kgf m 28 9 to 43 4 lbf ft 1 Seat Plug 1 2 Spring 3 Poppet 4 Plate 5 Screw 6 Spring Plate 7 Spring 8 Sleeve 9 Sprin...

Page 222: ...ue 2 Set the length L2 to the factory specification neutral state with operate the draft feedback lever 4 and position link lever 3 3 Check the gap G between the lowering poppet and adjusting screw 8 4 If the gap G is not within the reference valve recheck the length L2 at the neutral state of spool If necessary to adjust the gap G loosen the lock nut 9 and adjust by the adjusting screw 8 9Y121023...

Page 223: ...the spool 6 unless necessary When reassembling Install the poppet valve noting O ring and backup ring 9Y1210236HYS0032US0 Check Valve 1 Remove the seat plug 3 2 Draw out the spring 2 and check valve 1 When reassembling Install the plug noting O ring 9Y1210236HYS0033US0 Tightening torque Seat plug 1 40 to 58 N m 4 0 to 6 0 kgf m 29 to 43 lbf ft Seat plug 2 40 to 58 N m 4 0 to 6 0 kgf m 29 to 43 lbf...

Page 224: ...e 1 Remove the safety valve assembly 1 2 Secure the safety valve assembly in a vise 3 Loosen the lock nut 3 and remove the adjust screw 2 4 Draw out the spring 4 seat 5 and ball 6 When reassembling Install the safety valve to the hydraulic cylinder block taking care not to damage the O ring 9Y1210236HYS0027US0 Tightening torque Relief valve 34 3 to 39 2 N m 3 5 to 4 0 kgf m 25 3 to 28 9 lbf ft 1 R...

Page 225: ...ot to damage the O rings 9Y1210236HYS0028US0 7 LOWERING SPEED ADJUSTING VALVE Disassembling Lowering Speed Adjusting Valve 1 Remove the plate 1 2 Tap out the roll pin 2 using a vice grip pliers 3 Remove the lowering speed adjusting valve assembly 3 When reassembling Check the lowering speed adjusting valve turns smoothly 9Y1210236HYS0029US0 1 Lift Arm L H 2 Lift Arm R H 3 Lift Arm Shaft 4 O ring 5...

Page 226: ...N9 ELECTRICAL SYSTEM KiSC issued 07 2013 A ...

Page 227: ...rol System N9 M11 5 Instrument Panel Board Meter Panel Except ITA Model N9 M12 6 Instrument Panel Board Meter Panel ITA Model N9 M13 2 CABIN MODEL N9 M14 1 Starting System and Charging Except ITA Model N9 M14 2 Starting System and Charging ITA Model N9 M15 3 Lighting System N9 M16 4 4WD Bi speed Turn T M Control System N9 M17 5 Instrument Panel Board Meter Panel Except ITA Model N9 M18 6 Instrumen...

Page 228: ...ELECTRICAL SYSTEM M8540Narrow M9540Narrow WSM N9 M1 1 WIRING DIAGRAM 1 ROPS MODEL 1 Except ITA Model KiSC issued 07 2013 A ...

Page 229: ...ELECTRICAL SYSTEM M8540Narrow M9540Narrow WSM N9 M2 2 ITA Model KiSC issued 07 2013 A ...

Page 230: ...ELECTRICAL SYSTEM M8540Narrow M9540Narrow WSM N9 M3 2 CABIN MODEL 1 Main Harness Except ITA Model KiSC issued 07 2013 A ...

Page 231: ...ELECTRICAL SYSTEM M8540Narrow M9540Narrow WSM N9 M4 2 Main Harness ITA Model KiSC issued 07 2013 A ...

Page 232: ...ELECTRICAL SYSTEM M8540Narrow M9540Narrow WSM N9 M5 3 Engine Harness KiSC issued 07 2013 A ...

Page 233: ...ELECTRICAL SYSTEM M8540Narrow M9540Narrow WSM N9 M6 4 Cabin Harness KiSC issued 07 2013 A ...

Page 234: ...ELECTRICAL SYSTEM M8540Narrow M9540Narrow WSM N9 M7 5 Body Harness KiSC issued 07 2013 A ...

Page 235: ...lay 21 Working Lamp L H 12 V 35 W Option 22 Working Lamp R H 12 V 35 W Option 23 Working Lamp Front Side Switch 14 V 1 4 W 24 Working Lamp Front Side L H 12 V 21 W 25 Working Lamp Front Side R H 12 V 21 W 26 Auxiliary Power Connector 27 Auxiliary Power Socket A Fuel Work Light B Key Light C Key IG a To Meter Panel b Fuse Starter Relay c Fuse Alternator Engine PTO d Fuse Meter Panel e Fuse Turn Sig...

Page 236: ...Working Lamp R H 12 V 35 W Option 23 Working Lamp Front Side Switch 14 V 1 4 W 24 Working Lamp Front Side L H 12 V 21 W 25 Working Lamp Front Side R H 12 V 21 W 26 Auxiliary Power Connector 27 Auxiliary Power Socket A Fuel Work Light B Key Light C Key IG a To Meter Panel b Fuse Starter Relay c Fuse Alternator Engine PTO d Fuse Meter Panel e Fuse Turn Signal f Fuse Position Lamp Number Lamp g Fuse ...

Page 237: ...ight R H H4 12 V 55 60 W 14 Front Combination Lamp L H 15 Position Lamp 10 W 16 Turn Lamp 21 W 17 Rear Combination Lamp L H 18 Rear Combination Lamp R H 19 Tail Lamp 10 W 20 Stop Lamp 21 W 20 Stop Lamp 21 W 21 Front Combination Lamp R H 22 License Lamp 10 W 23 Trailer Socket Assembly A Key Light B Key IG a Fuse Flasher Hazard b Fuse Turn Signal c Fuse Horn d Fuse Position Lamp Number Lamp e Fuse H...

Page 238: ...speed Switch 12 V 7 W 2 Brake Switch L H 3 Diode 4WD Brake 4 Relay Bi speed 5 DT Valve Solenoid 6 Bi speed Valve Solenoid 7 Diode DT 8 Diode Bi speed 9 Front Turning Switch A Key IG a Fuse T M Control b To Brake Switch R H c To Meter Panel d To Brake Lamp Front Rear Combi Trailer KiSC issued 07 2013 A ...

Page 239: ...9 Bi speed Turn Indicator 20 Back Light 21 LCD Back Light 22 Meter Panel 23 Traveling Speed Sensor 24 Engine Rotation Sensor 25 Fuel Sensor 26 Engine Coolant Temperature Sensor 27 Engine Oil Pressure Switch 28 Parking Switch 29 Air Cleaner Indicator 30 Air Cleaner Switch 31 Meter Panel Wire Harness Side 32 Meter Panel Side A Key Light B Key IG a To Front Steer Turning Angle b To Main Key Start c T...

Page 240: ...n Indicator 20 Back Light 21 LCD Back Light 22 Meter Panel 23 Traveling Speed Sensor 24 Engine Rotation Sensor 25 Fuel Sensor 26 Engine Coolant Temperature Sensor 27 Engine Oil Pressure Switch 28 Parking Switch 29 Air Cleaner Indicator 30 Air Cleaner Switch 31 Meter Panel Wire Harness Side 32 Meter Panel Side 33 Ground PTO Switch A Key Light B Key IG a To Front Steer Turning Angle b To Main Key St...

Page 241: ...25 Working Light Relay 26 Auxiliary Power Connector 27 Auxiliary Power Socket A Head Light B Blower Motor C Auxiliary Power D ACC E Key ACC F Key IG a Fuse Meter Panel b Fuse Turn Signal c Fuse Radio d Fuse Air Conditioner Control e Fuse Wiper f Fuse Meter Back Up Radio g Fuse Head Light Tail Lamp h Fuse Flasher Hazard i Fuse Quarter Window Defogger j Fuse Rear Window Defogger k Fuse Auxiliary Pow...

Page 242: ...uxiliary Power Connector 27 Auxiliary Power Socket A Head Light B Blower Motor C Auxiliary Power D ACC E Key ACC F Key IG a Fuse Meter Panel b Fuse Turn Signal c Fuse Radio d Fuse Air Conditioner Control e Fuse Wiper f Fuse Meter Back Up Radio g Fuse Head Light Tail Lamp h Fuse Flasher Hazard i Fuse Quarter Window Defogger j Fuse Rear Window Defogger k Fuse Auxiliary Power l Fuse Stop Lamp m Fuse ...

Page 243: ... Door Switch R H 15 Licence Lamp 10 W 16 Front Combination Lamp L H 17 Position Lamp 5 W 18 Turn Lamp 21 W 19 Rear Combination Lamp L H 20 Rear Combination Lamp R H 21 Stop Tail Lamp 21 10 W 22 Front Combination Lamp R H 23 Trailer Socket Assembly a Fuse Flasher Hazard b Fuse Turn Signal c Fuse Position Lamp Number Lamp Head Light d Fuse Stop Lamp e Fuse Horn f To Meter Panel g To Air Conditioner ...

Page 244: ...trol System 1 4WD Bi speed Switch 12 V 7 W 2 Brake Switch L H 3 Diode 4WD Brake 4 Relay Bi speed 5 DT Valve Solenoid 6 Bi speed Valve Solenoid 7 Diode DT 8 Diode Bi speed 9 Front Turning Switch A Key IG a Fuse T M Control b To Brake Switch R H c To Meter Panel KiSC issued 07 2013 A ...

Page 245: ...Meter Panel 23 Traveling Speed Sensor 24 Engine Rotation Sensor 25 Fuel Sensor 26 Engine Coolant Temperature Sensor 27 Engine Oil Pressure Switch 28 Parking Switch 29 Air Cleaner Indicator 30 Air Cleaner Switch 31 Meter Panel Wire Harness Side 32 Meter Panel Side 33 Seat Switch M9540Narrow Cabin Model 34 OPC Buzzer M9540Narrow Cabin Model A Key Light B Key IG a To Front Steer Turning Angle b To Ma...

Page 246: ... Traveling Speed Sensor 24 Engine Rotation Sensor 25 Fuel Sensor 26 Engine Coolant Temperature Sensor 27 Engine Oil Pressure Switch 28 Parking Switch 29 Air Cleaner Indicator 30 Air Cleaner Switch 31 Meter Panel Wire Harness Side 32 Meter Panel Side 33 Ground PTO Switch 34 Seat Switch M9540Narrow Cabin Model 35 OPC Buzzer M9540Narrow Cabin Model A Key Light B Key IG a To Front Steer Turning Angle ...

Page 247: ...ing Light Switch 14 V 0 91 W 11 Rear Working Lamp L H 12 V 55 W 12 Rear Working Lamp R H 12 V 5 5W 13 Cigarette Lighter 14 Antenna 15 Radio CD Unit 16 Speaker R H 17 Speaker L H 18 Defogger Switch 19 Timer Circuit 20 Defogger Relay Rear Window 21 Defogger Relay Quarter Window 22 Rear Window Defogger 23 Quarter Window Defogger L H 24 Quarter Window Defogger R H A Light DEF B Blower Motor C ACC D Ke...

Page 248: ...witch 6 A C Indicator 7 A C Switch 8 A C Control Panel 9 Thermostat 10 Dual Pressure Switch 11 Compressor Relay 12 Diode Compressor 13 Magnetic Clutch Compressor 14 Blower Relay 15 Blower Motor 16 Blower Motor Resistor 17 Switch Blower Motor A C Control Panel A Blower Motor B Key ACC a To Light Switch b Fuse Air Con Control c Fuse Air Con Compressor d Fuse Air Con Fan Motor KiSC issued 07 2013 A ...

Page 249: ...rrow M9540Narrow WSM N9 M22 9 Wiper System 1 Front Wiper Motor 2 Front Wiper Switch 14 V 0 9 W 3 Washer Motor 4 Rear Wiper Motor Option 5 Rear Wiper Switch Option A Key ACC a Fuse Wiper b To Position Lamp KiSC issued 07 2013 A ...

Page 250: ...dicator 5 Liquid Crystal Display 6 Electrical Charge Indicator 7 Engine Oil Pressure Indicator 8 Tachometer 9 4WD Indicator 10 Heater Indicator 11 Air Cleaner Indicator 12 Rear Wheel Differential Lock Indicator 13 Parking Brake Indicator 14 Fuel Level Indicator 15 Fuel Gauge 16 Coolant Temperature Gauge 17 PTO Hour Meter Select Switch 18 Travel Speed Select Switch 19 Bi speed Turn Indicator KiSC i...

Page 251: ...and buzzer 5 Q Electric Circuit 1 When sitting on the seat in the state at engine running the battery voltage passes the seat switch 3 and the CPU 2 2 The CPU 2 detect the seat switch 3 PTO switch 4 position and engine running through the L terminal of alternator 3 When standing from the operators seat while shifting the PTO clutch lever at ON position the CPU 2 turn on the transistor 6 and buzzer...

Page 252: ...ficient N9 S5 2 Checking Meter Panel PTO Hour Meter Select Switch and Travelling Speed Select Switch N9 S9 3 SWITCHES N9 S12 1 4WD Bi speed Turn System N9 S12 2 Parking Brake Switch N9 S14 3 Ground PTO Switch N9 S14 4 RELAYS N9 S15 1 Starter Relay and Heater Relay N9 S15 2 ROPS Model N9 S16 3 CABIN Model N9 S17 5 SOLENOID VALVE N9 S18 6 OPC SYSTEM M9540NARROW CABIN MODEL N9 S19 SERVICING KiSC issu...

Page 253: ... is defective Repair or Replace N9 S12 Turning angle inspection switch or wiring harness is defective Repair or Replace N9 S13 4WD Bi speed turn relay defective Replace N9 S16 Bi speed turn solenoid valve defective Replace N9 S18 Symptom Probable Cause Solution Reference Page Bi speed Turn Indicator Lamp Does Not Lights Up When Under the Bi speed Condition 4WD Bi speed turn switch defective Replac...

Page 254: ...SM N9 S2 2 SERVICING SPECIFICATIONS 4WD BI SPEED TURN SOLENOID VALVE 9Y1210236ELS0002US0 Item Factory Specification Allowable Limit 4WD Solenoid Valve Resistance 10 to 12 Ω Bi speed Turn Solenoid Valve Resistance 10 to 12 Ω KiSC issued 07 2013 A ...

Page 255: ... terminal of battery If this advice is disregarded damage to alternator and regulator may result 9Y1210236ELS0003US0 1 FUSE 1 ROPS Model Fuse ROPS Model 1 When inspect the circuit line check the related fuses 2 If any of the fuse is blown replace with a new one of the same capacity IMPORTANT If a fuse is blown check the cause and be sure to replace it with a new one of the same capacity Q Protecte...

Page 256: ...ed Turn d 10 4WD brake e 15 Work Light Rear f 15 Work Light Front g 15 Cigarette Lighter h 20 Air Conditioner Fan Motor i 10 Air Conditioner Compressor j 15 Work Light Front Side k 15 Auxiliary Power l 5 Starter Relay m 5 Radio n 5 Air Conditioner Control o 15 Wiper p 5 Alternator Engine PTO Heater q 5 Meter Panel OPC r 10 Turn Signal Stop Lamp s 10 Meter Radio Back Up t 20 Head Light Position Lam...

Page 257: ... 1 PTO Hour meter select switch 3 and traveling speed select switch 2 1 Setting Mode Input the various dates PTO speed display mode switching entering the traveling speed coefficient and model select to the meter panel 2 Checking Mode Check a voltage of various sensor fuel unit sensor coolant temperature sensor and monitor voltage battery voltage or rotation of engine 9Y1210236ELS0006US0 1 LCD Mon...

Page 258: ...meter select switch 1 longer than 2 seconds The setting is put in memory and the LCD monitor 2 goes back to the PTO speed display mode 4 Turn the key switch to OFF position to exit NOTE The setting will be cancelled if the key switch is turned OFF halfway in the procedure 9Y1210236ELS0007US0 Numerical code PTO speed min 1 rpm 1 540 Single speed 540 540E 2 speed PTO gear shift type 2 540 1000 2 spe...

Page 259: ...or 3 goes back to the hour meter mode 7 Turn the key switch to OFF position to exit NOTE The setting will be cancelled if the key switch is turned OFF halfway in the procedure Tire circumference chart reference 9Y1210236ELS0030US0 Rear tire size Entry Rear tire size Entry 12 4R24 3612 mm 142 2 in 360 70R28 3914 mm 154 1 in 13 6R28 4109 mm 161 8 in 380 70R20 3399 mm 133 8 in 14 9LR20 3418 mm 134 6 ...

Page 260: ...select switch 2 longer than 2 seconds The setting is put in memory and the LCD monitor 3 goes back to the PTO speed display or hour meter display mode 4 Turn the key switch to OFF position to exit NOTE The setting will be cancelled if the key switch is turned OFF halfway in the procedure 9Y1210236ELS0009US0 Numerical code Tractor model 1 M8540 M9540 LP 2 M6040 N M7040 N M8540 N M9540 N 3 Void 1 PT...

Page 261: ...f checking be sure to turn OFF the main switch before hand Moreover pay attention not to allow the terminal to come in contact with other terminal or chassis while checking When applying the test pin of the tester to the connector terminals use care not to damage to the connector terminal Checking Connector Voltage Sensor Resistance and Switch Continuity 1 Remove the panel cover refer to 1 CLUTCH ...

Page 262: ...witch at high beam position T16 G B Turn signal switch L H Battery voltage and 0 V alternately Main switch at ON and turn signal switch L H ON T17 W R Coolant temperature switch Approx 117 Ω at 120 C 248 F to 5 88 kΩ at 0 C 32 F Main switch at OFF T18 Y Fuel unit sensor Approx 3 0 F to 112 Ω E Main switch at OFF T19 V W PTO change switch Battery voltage Main switch at ON and PTO speed lever shifte...

Page 263: ...ge Main switch at ON T35 T36 Y L Engine tachometer sensor Battery voltage Main switch at ON T37 R G Main switch ON position Battery voltage Main switch at ON T38 R B Main voltage battery Battery voltage T39 T40 B GND Terminal No Color of wiring Terminal Name Measuring across T40 Ground Condition KiSC issued 07 2013 A ...

Page 264: ... harness is faulty 9Y1210236ELS0013US0 4WD Bi speed Turn Switch 1 Check the continuity through switch with an ohmmeter 2 If continuity specified below are not indicated the switch is faulty 9Y1210236ELS0014US0 1 4WD Bi speed Turn Switch A ROPS Model B CABIN Model Voltage R G terminal Chassis Battery voltage 11 to 14 V 1 4WD Bi speed Turn Switch 2 4WD Bi speed Turn Switch Connector Switch Side 3 4W...

Page 265: ...wo 1P connectors while pushing the push rod of switch 4 If 0 ohm is not indicated the turning angle inspection switch is faulty IMPORTANT After reassembling the Bi speed turn sensor be sure to check its operation 1 When the front wheels are straight ahead the resistance value of the turn angle inspection switch is infinity 2 When the turning angle exceeds approximately 0 57 rad 32 the resistance v...

Page 266: ... sure to not indicate the parking brake indictor when parking brake lever at off position Adjust the parking brake switch position 9Y1210236ELS0018US0 3 Ground PTO Switch Ground PTO Switch 1 Ground PTO Switch Continuity 1 Check the continuity with an ohmmeter across the switch connector 2 2 If it does not conduct or any value is indicated when the switch is pushed the switch is faulty 3 If infinit...

Page 267: ...re are used same ones so that these are interchangeable 1 Apply battery voltage across the terminals c and d and check for continuity across the terminals a and b 2 If continuity is not established across the terminals a and b replace it 9Y1210236ELS0020US0 Starter relay ROPS and CABIN Terminal d Chassis Approx battery voltage Heater relay ROPS Terminal c Chassis Approx battery voltage CABIN Termi...

Page 268: ... PTO safety relay main switch at ON position and PTO lever OFF position Terminal c Chassis Approx battery voltage 3 Work light relay front main switch at OFF position Terminal e Chassis Approx battery voltage 4 Key stop relay main switch at OFF position Terminal e Chassis Approx battery voltage 5 Head light relay low main switch at OFF position Terminal d Chassis Approx battery voltage 6 Head ligh...

Page 269: ...inal d Chassis Approx battery voltage 3 Key stop relay main switch at OFF position Terminal e Chassis Approx battery voltage 4 Work light relay front main switch at OFF position Terminal e Chassis Approx battery voltage 5 Engine stop relay main switch at ON position Terminal c Chassis Approx battery voltage 6 4WD Bi speed turn relay main switch at ON 4WD Bi speed turn switch at bi speed position a...

Page 270: ...s faulty 2 Solenoid Valve 1 Disconnect the wire harness connector 2 2 Measure the resistance with an ohmmeter across the each terminal 4 on the connector 2 and chassis 3 If infinity is indicated the solenoid valve is faulty 9Y1210236ELS0025US0 Voltage Terminal 4 Chassis Approx battery voltage Resistance Solenoid valve 4 terminal to chassis 10 to 12 Ω 1 Solenoid Valve Assembly 2 Connector 3 Termina...

Page 271: ... 2 Check the continuity with an ohmmeter across the switch terminals 3 If it does not conduct or any value is indicated when the switch is pushed ON seat the switch is faulty 4 If infinity is not indicated when the switch is released OFF seat the switch is faulty 9Y1210236ELS0028US0 Buzzer 1 Remove the buzzer 1 2 Connect the jumper lead across the battery positive terminal and terminal 1 of connec...

Page 272: ...N10 CABIN KiSC issued 07 2013 A ...

Page 273: ...IONER SYSTEM N10 M1 1 OUTLINE OF AIR CONDITIONING SYSTEM N10 M1 2 SYSTEM CONTROL N10 M2 3 ELECTRICAL SYSTEM N10 M3 1 Electrical Circuit N10 M3 2 Air Conditioner Relay and Blower Relays N10 M4 MECHANISM KiSC issued 07 2013 A ...

Page 274: ...perature and humidity The front air outlet 9 can be opened and closed using the center knob of each port The side air outlet 8 are opened and closed using the mode lever on the control panel 4 With these ports open or closed you can feel your head cool and your feet warm NOTE As for the mechanism and function of each component part refer to Workshop Manual of MECHANISM 9Y1210236CAM0001US0 1 Heater...

Page 275: ... flows to door D3 12 side passing through the heater core 3 Outlet air flow is controlled by door D3 Moving the mode switch 2 opens and shuts door D3 12 and establishes the air passage according to the lever position Q 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 Q DEF Moving the mo...

Page 276: ...l Circuit 9Y1210236CAM0003US0 1 Battery 2 Slow Blow Fuse 3 Main Switch 4 Blower Relay 5 Blower Motor 6 Blower Resistor 7 Blower Switch 8 Compressor Relay 9 Compressor 10 Pressure Switch 11 Thermostat 12 Mode Motor 13 Temperature Motor 14 Control Panel KiSC issued 07 2013 A ...

Page 277: ... blower motor 6 could result in a discharged battery 3 To protect against such trouble relays have been provided These relays have been made so that when current flows through its coil 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 small current is required to actuate the relay Thus there...

Page 278: ...ature Motor N10 S6 5 Mode Motor N10 S7 6 Air Conditioner Relay and Blower Relay N10 S7 7 Pressure Switch N10 S8 8 Front Wiper Switch N10 S9 9 Front Wiper Motor N10 S9 2 DISASSEMBLING AND ASSEMBLING N10 S10 1 Preparation for Separating Cabin from Tractor N10 S10 2 Dismounting Cabin N10 S17 3 Removing and Disassembling Compressor Assembly N10 S17 4 Removing Air Conditioner Unit N10 S18 5 Removing Ai...

Page 279: ...Pressure LO Pressure Side Pressure HI Pressure Side 0 15 to 0 20 MPa 1 5 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 KiSC issued 07 2013 A ...

Page 280: ... 2 Compressor bracket mounting screw M10 to ordiness parts 48 1 to 55 8 4 9 to 5 7 35 5 to 41 2 A C unit mounting screw M6 4 0 to 6 8 0 40 to 0 70 2 9 to 5 0 A C unit mounting screw M8 9 81 to 11 6 1 00 to 1 19 7 24 to 8 60 Low pressure pipe Cooler pipe suction retaining nut 30 to 34 3 0 to 3 5 22 to 25 High pressure pipe Cooler pipe liquid retaining nut 12 to 14 1 2 to 1 5 8 7 to 10 High pressure...

Page 281: ...ure the voltage with a voltmeter across the connector terminal a and terminal b 5 If the voltage differs from the battery voltage the wiring harness A C relay fuse or main switch is faulty 9Y1210236CAS0003US0 Blower Switch Test 1 Check the continuity through the switch with an ohmmeter 2 If the continuity specified below are not indicated the switch is faulty 9Y1210236CAS0004US0 Voltage Terminal a...

Page 282: ...a circuit tester 5 Press the air conditioner switch to set it at ON position indicator ON and then measure a voltage using a circuit tester 6 If a measured voltage does not comply with the values in the table below the control panel wiring harness or fuse is faulty 9Y1210236CAS0006US0 Mode Control Dial Checking 1 Disconnect the 16P connector from control panel switch 2 Check the continuity through...

Page 283: ...itch to ON position 9 Check that an output voltage is approximately 10 V when turning the temperature control dial counterclockwise till it stops COOL position 10 If an output voltage differs from approximately 10 V the control panel wiring harness of fuse is faulty 9Y1210236CAS0008US0 2 Blower Resistor A C Blower Resistor 1 Remove the outer roof 2 Disconnect the 4P connector 1 for A C blower resi...

Page 284: ...9Y1210236CAS0010US0 4 Temperature Motor Temperature Motor Checking 1 Confirm whether the temperature control dial 2 is defective Refer to 1 Control Panel in this section 2 Turn the main switch to ON position 3 Turn the blower switch 3 at 1 position 4 Turn the temperature control dial from COOL position A to WARM position B At the time confirm the motor is operating 5 If the motor does not operate ...

Page 285: ...0236CAS0012US0 6 Air Conditioner Relay and Blower Relay Blower Relay and Compressor Relay 1 Remove the blower relay 1 and compressor relay 2 2 Apply battery voltage across terminals 3 and 4 and check for continuity across terminals 1 and 2 3 If continuity is not established renew the relay 9Y1210236CAS0013US0 1 Mode Motor 2 Mode Switch 3 Blower Switch a Air is blown from only the defroster air out...

Page 286: ...ned off At this time read the HI pressure gauge of the manifold gauge If this pressure reading differs largely with the setting pressure replace the pressure switch with a new one 2 LO Pressure Side 1 Disconnect 2P connector of pressure switch 6 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 re...

Page 287: ...OFF side of the wiper switch remains pushed in WASH II ON side remains pushed in after the wiper switch is switched ON and remains switched ON 9Y1210236CAS0016US0 9 Front Wiper Motor Front Wiper Motor 1 Raise up the front wiper arm 2 Turn the main switch to ON position 3 Push the front wiper switch to ON position 4 Count the number of wiper arm rocking per minutes 5 If the number differs from the ...

Page 288: ...estrictor 1 Install the front axle rocking restrictor 1 to the front axle bracket on both sides 9Y1210236CAS0019US0 Rear Wheel 1 Set the disassembling stand under the transmission case secure 2 Remove the both rear wheels 1 When reassembling 9Y1210236CAS0020US0 Tightening torque Drain plug 196 2 to 225 5 N m 20 0 to 23 0 kgf m 144 7 to 166 3 lbf ft 1 Fuel Tank 2 Drain Plug 1 Front Axle Rocking Res...

Page 289: ...NT When disconnecting the battery cords disconnect the negative cord first when connecting positive cord first 9Y1210236CAS0021US0 Side Panel and Air Cleaner Hose 1 Remove the both side cover guides 3 2 Remove the both side panels 1 3 Remove the air cleaner hose 2 9Y1210236CAS0022US0 1 Bonnet 2 Battery Negative Cable 3 Side Skirt 4 Bonnet Cylinder 5 Head Light Connector 1 Side Panel 2 Air Cleaner ...

Page 290: ...elt 1 4 Remove the hose clamps 3 5 Remove the slow blow fuse boxes 4 and relays 5 6 Disconnect 1P connector 6 of magnetic clutch 7 Remove the compressor bracket 7 mounting screw 2 from engine 8 Slide out the condenser 9 after remove the hose retainer 8 To be continued 1 A C Drive Belt 2 Screw 3 Hose Clamp 4 Slow Blow Fuse Box 5 Relay 6 1P Connector Magnetic Clutch 7 Compressor Bracket 8 Hose Retai...

Page 291: ...om steering joint When reassembling Be sure to fix the heater hose to the original position Note the inlet hose and outlet hoses 9Y1210236CAS0024US0 Tightening torque Front wheel mounting nut 259 9 to 304 0 N m 26 5 to 31 0 kgf m 191 7 to 224 2 lbf ft Compressor bracket mounting screw M8 to aluminum parts 17 7 to 20 5 N m 1 8 to 2 1 kgf m 13 1 to 15 1 lbf ft Compressor bracket mounting screw M8 to...

Page 292: ...nnector 3 and remove the connector 3 from the cabin 9Y1210236CAS0025US0 Parking Brake Rod 1 Remove the parking brake rod R H 1 When reassembling Replace the cotter pins with the new one Divide the cotter pin as shown in this figure 9Y1210236CAS0026US0 1 Floor Mat 2 Panel Cover 3 Connector 1 Parking Brake Rod R H 2 Cotter Pin KiSC issued 07 2013 A ...

Page 293: ...o bleed the air from hydraulic brake system Refer to the N5 BRAKE section 9Y1210236CAS0027US0 Auxiliary Control Valve Cable and Ground Cable 1 Remove the auxiliary control valve cable 1 2 Disconnect the ground harness 2 9Y1210236CAS0028US0 Reference Hi Lo rod length L1 300 mm 11 8 in Main shift rod length L2 655 mm 25 8 in Position control rod length L3 262 mm 10 3 in Draft control rod length L4 2...

Page 294: ... clutch cable 2 from the shuttle valve 2 Remove the brake rod L H 3 When reassembling Replace the cotter pins with the new one Divide the cotter pins as shown in this figure 9Y1210236CAS0030US0 Ground PTO Rod 1 Remove the ground PTO rod 1 and spring 2 When reassembling Be sure to assemble the ground PTO rod 1 to the hole a 9Y1210236CAS0045US0 1 Connector 2 Connector 3 Fuel Hose 4 Fuel Hose 5 Fuel ...

Page 295: ...nstall the washers and mount rubbers etc in there original positions 9Y1210236CAS0031US0 3 Removing and Disassembling Compressor Assembly Refer to the 10 CABIN section 9Y1210236CAS0032US0 Tightening torque Outer roof mounting screw 3 5 to 4 0 N m 0 36 to 0 40 kgf m 2 6 to 2 9 lbf ft Cabin mounting bolt and nut M14 9T 124 to 147 N m 12 6 to 15 0 kgf m 91 2 to 108 4 lbf ft Cabin mounting bolt and nu...

Page 296: ...the mode motor connector 3 and blower resister connector 4 9Y1210236CAS0034US0 Tightening torque Outer roof mounting screw 3 5 to 4 0 N m 0 36 to 0 40 kgf m 2 6 to 2 9 lbf ft Cabin mounting bolt and nut M14 9T 124 to 147 N m 12 6 to 15 0 kgf m 91 2 to 108 4 lbf ft Cabin mounting bolt and nut M12 7T 77 5 to 90 2 N m 7 9 to 9 2 kgf m 57 2 to 66 5 lbf ft 1 Outer Roof 2 Ground cable 3 Stay 1 Temperatu...

Page 297: ...and and finally retighten them after aligning the inner roof duct with the unit duct When connecting the heater hose with A C unit hose should be put into the A C unit pipe more than 30 mm 1 2 in 9Y1210236CAS0036US0 1 Water Cable 2 Motor Screw L 6 mm 0 2 in Tightening torque A C unit mounting screw M6 4 0 to 6 8 N m 0 40 to 0 70 kgf m 2 9 to 5 0 lbf ft A C unit mounting screw M8 9 81 to 11 6 N m 1...

Page 298: ...connect the negative cord first when connecting positive cord first 9Y1210236CAS0038US0 High Pressure Hose 1 1 Disconnect the high pressure hose 1 2 from the compressor 1 and condenser 3 then cap the open fittings immediately to keep moisture out of the system When reassembling Apply compressor oil DENSO ND OIL 8 or equivalent to the O rings and take care not to damage them 9Y1210236CAS0039US0 1 B...

Page 299: ...tely to keep moisture out of the system 4 Remove the inner covers 3 When reassembling Replace the rubber with a new one Apply compressor oil DENSO ND OIL 8 or equivalent to the O rings and take care not to damage them 9Y1210236CAS0041US0 Tightening torque Low pressure pipe mounting screw Compressor side 7 95 to 11 7 N m 0 810 to 1 20 kgf m 5 86 to 8 67 lbf ft Hose clamp screw 48 1 to 55 9 N m 4 9 ...

Page 300: ...t the heater hoses 2 from the bottom of the cabin 5 Take out the heater hoses 2 When reassembling Connect the heater hoses at their original positions In assembling the heater hose 2 to the pipe 1 connect the heater hose with identification mark white paint to upper side of the hose pipe 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 ...

Page 301: ...hing the wiper arm 6 to the wiper motor 4 assemble so that the dimensions are as given in the photo on the left After doing so check if the wiper wipes symmetrically on the left and right bilateral symmetry 9Y1210236CAS0043US0 Tightening torque Wiper motor mounting nut 4 6 4 to 9 3 N m 0 65 to 0 95 kgf m 4 7 to 6 8 lbf ft Distance A Factory specification 90 to 110 mm 3 5 to 4 3 in 1 Steering Post ...

Page 302: ...CABIN M8540Narrow M9540Narrow WSM N10 S24 3 SERVICING Adjustment of Air Gap 1 Refer to the 6 CHECKING DISASSEMBLING AND SERVICING at 10 CABIN section 9Y1210236CAS0044US0 KiSC issued 07 2013 A ...

Page 303: ...CHINERY 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 2008 12 S EI EI engusa Code No 9Y121 00000 Printed in Japan 2013 07 S EI EI engusa Code No 9Y111 02363 ...

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