Kubota L3540 Workshop Manual Download

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L3540,L4240,L5040,

L5240,L5740

WORKSHOP MANUAL

TRACTOR

KiSC issued 04, 2010 A

Summary of Contents for L3540

Page 1: ...L3540 L4240 L5040 L5240 L5740 WORKSHOP MANUAL TRACTOR KiSC issued 04 2010 A ...

Page 2: ...ng with troubleshooting disassembling and servicing Refer to Diesel Engine Tractor Mechanism Workshop Manual Code No 9Y021 01874 9Y021 18201 for the one which has not been described to this workshop manual Q Servicing Information on the troubleshooting servicing specification lists tightening torque checking and adjusting disassembling and assembling and servicing which cover procedures precaution...

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

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

Page 5: ... engine must be running to do some work make sure the area is well ventilated Never run the engine in a closed area The exhaust gas contains poisonous carbon monoxide PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin clothing and cause blindness if splashed into eyes Keep electrolyte away from eyes hands and clothing If you spill electrolyte on y...

Page 6: ...WSM SAFETY INSTRUCTIONS PREPARE FOR EMERGENCIES Keep a first aid kit and fire extinguisher handy at all times Keep emergency numbers for doctors ambulance service hospital and fire department near your telephone KiSC issued 04 2010 A ...

Page 7: ... SAFETY INSTRUCTIONS The following safety decals are installed on the machine If a decal becomes damaged illegible or is not on the machine replace it The decal part number is listed in the parts list SAFETY DECALS KiSC issued 04 2010 A ...

Page 8: ...6 L3540 L4240 L5040 L5240 L5740 WSM SAFETY INSTRUCTIONS KiSC issued 04 2010 A ...

Page 9: ...7 L3540 L4240 L5040 L5240 L5740 WSM SAFETY INSTRUCTIONS KiSC issued 04 2010 A ...

Page 10: ...p gals Dimensions Overall length without 3P 3015 mm 118 7 in Overall width min tread 1430 mm 56 30 in Overall height 2415 mm 95 08 in 2265 mm 89 17 in Wheel base 1805 mm 71 06 in Min ground clearance 360 mm 14 2 in 380 mm 15 0 in Tread Front 1150 mm 45 28 in Rear 1110 mm 43 70 in 1205 mm 47 44 in 1300 mm 51 18 in 1385 mm 54 53 in Weight 1470 kg 3241 lbs Travelling system Standard tire size Front 7...

Page 11: ...0 mm 124 8 in Overall width min tread 1485 mm 58 5 in Overall height 2450 mm 96 46 in 2375 mm 93 50 in 2265 mm 89 17 in Wheel base 1895 mm 74 6 in Min ground clearance 390 mm 15 4 in 380 mm 15 0 in 390 mm 15 4 in Tread Front 1145 mm 45 1 in Rear 1140 mm 44 9 in 1210 mm 47 6 in 1310 mm 51 6 in 1410 mm 55 5 in Weight 1560 kg 3439 lbs 1700 kg 3748 lbs 1735 kg 3825 lbs Travelling system Standard tire ...

Page 12: ...ength without 3P 3245 mm 127 8 in Overall width min tread 1470 mm 57 9 in Overall height 2385 mm 93 90 in 2375 mm 93 50 in Wheel base 1915 mm 75 55 in Min ground clearance 370 mm 14 6 in 400 mm 15 7 in Tread Front 1135 mm 44 7 in Rear 1125 mm 44 3 in 1225 mm 48 2 in 1325 mm 52 2 in Weight 1730 kg 3814 lbs 1885 kg 4156 lbs Travelling system Standard tire size Front 9 5 16 Rear 13 6 28 Clutch Dry ty...

Page 13: ...ssion case 45 L 11 9 U S gals 9 9 Imp gals Dimensions Overall length without 3P 3245 mm 127 8 in Overall width min tread 1470 mm 57 87 in Overall height 2550 mm 100 4 in 2375 mm 93 5 in Wheel base 1915 mm 75 55 in Min ground clearance 400 mm 15 7 in Tread Front 1135 mm 44 7 in Rear 1125 mm 44 3 in 1225 mm 48 2 in 1325 mm 52 2 in Weight 1765 kg 3891 lbs 1920 kg 4233 lbs Travelling system Standard t...

Page 14: ...p qts Transmission case 45 L 11 9 U S gals 9 9 Imp gals Dimensions Overall length without 3P 3245 mm 127 8 in Overall width min tread 1470 mm 56 3 in Overall height 2375 mm 93 5 in Wheel base 1915 mm 75 55 in Min ground clearance 400 mm 15 7 in Tread Front 1135 mm 44 7 in Rear 1125 mm 44 3 in 1225 mm 48 2 in 1325 mm 52 2 in Weight 1920 kg 4233 lbs Travelling system Standard tire size Front 9 5 16 ...

Page 15: ... 6 02 3 74 0 68 0 42 High 1 9 13 5 67 1 02 0 634 8 49 5 28 0 95 0 59 8 95 5 56 1 00 0 621 2 12 91 8 022 1 45 0 901 12 01 7 463 1 35 0 839 12 66 7 867 1 42 0 882 3 20 96 13 02 2 35 1 46 19 49 12 11 2 19 1 36 20 54 12 76 2 31 1 44 4 30 96 19 24 3 48 2 16 28 78 17 89 3 23 2 01 30 34 18 85 3 41 2 12 Reverse At rated engine rpm Low 1 1 51 0 938 0 17 0 11 1 40 0 87 0 16 0 099 1 48 0 920 0 17 0 11 2 2 13...

Page 16: ... 10 0 20 0 12 2 2 51 1 56 0 28 0 17 3 3 24 2 01 0 36 0 22 4 4 07 2 53 0 46 0 29 5 4 78 2 97 0 54 0 34 6 6 02 3 74 0 68 0 42 7 7 12 4 42 0 80 0 50 8 8 95 5 56 1 00 0 621 9 10 07 6 257 1 13 0 702 10 12 66 7 867 1 42 0 882 11 20 54 12 76 2 31 1 44 12 30 34 18 85 3 41 2 12 Reverse At rated engine rpm 1 1 48 0 920 0 17 0 11 2 2 09 1 30 0 23 0 14 3 3 39 2 11 0 38 0 24 4 5 01 3 11 0 56 0 35 5 7 45 4 63 0...

Page 17: ...ever Range gear shift lever km h mph Forward L L 3 5 2 2 3 4 2 1 3 6 2 2 M 7 1 4 4 7 0 4 3 7 3 4 5 H 17 9 11 1 17 7 11 0 18 4 11 4 H L 5 8 3 6 5 8 3 6 6 0 3 7 M 11 9 7 39 11 8 7 33 12 2 7 58 H 29 9 18 6 29 5 18 3 30 7 19 1 Forward L L 3 1 1 9 3 1 1 9 3 2 2 0 M 6 4 4 0 6 3 3 9 6 6 4 1 H 16 1 10 0 15 9 9 88 16 5 10 3 H L 5 2 3 2 5 2 3 2 5 4 3 4 M 10 7 6 65 10 6 6 59 11 0 6 84 H 26 9 16 7 26 6 16 5 2...

Page 18: ...16 L3540 L4240 L5040 L5240 L5740 WSM DIMENSIONS DIMENSIONS Rear ROPS Model L3540 L4240 and L5240 KiSC issued 04 2010 A ...

Page 19: ...17 L3540 L4240 L5040 L5240 L5740 WSM DIMENSIONS Center ROPS Model L3540 L4240 and L5040 KiSC issued 04 2010 A ...

Page 20: ...18 L3540 L4240 L5040 L5240 L5740 WSM DIMENSIONS CABIN Model L4240 L5040 L5240 and L5740 KiSC issued 04 2010 A ...

Page 21: ...G GENERAL KiSC issued 04 2010 A ...

Page 22: ... DAILY CHECK G 17 2 CHECK POINTS OF INITIAL 50 HOURS G 21 3 CHECK POINTS OF EVERY 50 HOURS G 24 4 CHECK POINTS OF EVERY 100 HOURS G 27 5 CHECK POINTS OF EVERY 200 HOURS G 33 6 CHECK POINTS OF EVERY 400 HOURS G 37 7 CHECK POINT OF EVERY 600 HOURS G 39 8 CHECK POINT OF EVERY 800 HOURS G 40 9 CHECK POINT OF EVERY 1500 HOURS G 40 10 CHECK POINTS OF EVERY 3000 HOURS G 40 11 CHECK POINTS OF EVERY 1 YEAR...

Page 23: ...ibutor always specify engine serial number tractor serial number and hour meter reading W10106000 1 Tractor Identification Plate 2 ROPS Identification Plate ROPS Serial Number 3 CABIN Identification Plate CABIN Serial Number 4 Tractor Serial Number 5 Engine Serial Number A Rear ROPS Model B Center ROPS Model C Cabin Model KiSC issued 04 2010 A ...

Page 24: ...er Year Alphabet or Number Year 1 2001 F 2015 2 2002 G 2016 3 2003 H 2017 4 2004 J 2018 5 2005 K 2019 6 2006 L 2020 7 2007 M 2021 8 2008 N 2022 9 2009 P 2023 A 2010 R 2024 B 2011 S 2025 C 2012 T 2026 D 2013 V 2027 E 2014 Month Engine Serial Number 0001 9999 10000 January A0001 A9999 B0001 February C0001 C9999 D0001 March E0001 E9999 F0001 April G0001 G9999 H0001 May J0001 J9999 K0001 June L0001 L9...

Page 25: ...specific emission regulations designated by the appropriate Kubota Parts List and perform all maintenance services listed in the appropriate Kubota Operator s manual or in the appropriate Kubota Workshop Manual Make sure the Emission Control Information with the label put on the cylinder head cover All the tractors listed below meet with EU regulation STAGE IIIA W1084033 Tractor Model Engine Model...

Page 26: ...uring Use only KUBOTA genuine parts for parts replacement to maintain machine performance and to assure safety Gaskets and O rings must be replaced during reassembly Apply grease to new O rings or oil seals before assembling See the figure left side When reassembling external snap rings or internal snap rings they must be positioned so that sharp edge faces against the direction from which a force...

Page 27: ...ealer to perform periodic check for a fee Do not attempt to modify or remodel any electrical parts and wiring When removing the battery cables disconnect the negative cable first When installing the battery cables connect the positive cable first W10111140 1 WIRING Securely tighten wiring terminals W10112160 Do not let wiring contact dangerous part W10113130 Securely insert grommet W10113880 1 Neg...

Page 28: ...part where sag be required W10115870 In installing a part take care not to get wiring caught by it W10116700 After installing wiring check protection of terminals and clamped condition of wiring only connect battery W10117350 1 Clamp Wind Clamp Spirally 2 Wire Harness 3 Clamp 4 Welding Dent 1 Wiring 2 Clamp A Correct B Incorrect 1 Wiring A Incorrect 1 Cover Securely Install Cover KiSC issued 04 20...

Page 29: ...f with water immediately Before recharging the battery remove it from the machine Before recharging remove cell caps Do recharging in a well ventilated place where there is no open flame nearby as hydrogen gas and oxygen are formed W10118160 3 FUSE Use fuses with specified capacity Neither too large or small capacity fuse is acceptable Never use steel or copper wire in place of fuse Do not install...

Page 30: ...ain that there is no female connector being too open W10124300 Make certain plastic cover is large enough to cover whole connector W10125190 5 HANDLING OF CIRCUIT TESTER Use tester correctly following manual provided with tester Check for polarity and range W10126840 1 Exposed Terminal 2 Deformed Terminal 3 Sandpaper 4 Rust A Correct B Incorrect 1 Cover A Correct B Incorrect KiSC issued 04 2010 A ...

Page 31: ...S qts 7 2 Imp qts Engine oil API service classification CF or better Above 25 C 77 F SAE30 10W 30 or 15W 40 0 to 25 C 32 to 77 F SAE20 10W 30 or 15W 40 Below 0 C 32 F SAE10W 10W 30 or 15W 40 4 Transmission case 42 0 L 11 1 U S gals 9 2 Imp gals 43 0 L 11 4 U S gals 9 5 Imp gals KUBOTA UDT or SUPER UDT fluid 5 Front axle case 4WD 6 5 L 6 9 U S qts 5 7 Imp qts KUBOTA UDT or SUPER UDT fluid or SAE80 ...

Page 32: ...I service classification CF or better Above 25 C 77 F SAE30 10W 30 or 15W 40 0 to 25 C 32 to 77 F SAE20 10W 30 or 15W 40 Below 0 C 32 F SAE10W 10W 30 or 15W 40 4 Transmission case 45 0 L 11 9 U S gals 9 90 Imp gals KUBOTA UDT or SUPER UDT fluid 5 Front axle case 4WD 6 0 L 6 3 U S qts 5 3 Imp qts KUBOTA UDT or SUPER UDT fluid or SAE80 90 gear oil Greasing Place No of greasing point Capacity Type of...

Page 33: ... No 2 D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service SAE J313 JUN87 Since this engine adopts EPA Tier 4 and Interim Tier 4 standards the use of low sulfur fuel or ultra low sulfur fuel is mandatory in EPA regulated area North America Therefore please use No 2 D S500 or S15 diesel fuel as an alternative to No 2 D or use No 1 D S500 or S15 diesel fuel a...

Page 34: ...o 5 7 36 to 41 40 to 44 4 0 to 4 5 29 to 32 61 to 70 6 2 to 7 2 45 to 52 M12 12 mm 0 47 in 63 to 72 6 4 to 7 4 47 to 53 78 to 90 7 9 to 9 2 58 to 66 63 to 72 6 4 to 7 4 47 to 53 103 to 117 10 5 to 12 0 76 0 to 86 7 M14 14 mm 0 55 in 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 16 mm 0 63 in 167 to 191 17 0 to 19 5 123 to 141 197 to...

Page 35: ... 21 1 3 to 2 2 9 4 to 15 13 to 21 1 3 to 2 0 9 4 to 15 R1 4 25 to 44 2 5 to 4 5 18 to 32 25 to 34 2 5 to 3 5 18 to 25 R3 8 49 to 88 5 0 to 9 0 37 to 65 49 0 to 58 5 0 to 6 0 37 to 43 R1 2 59 to 107 6 0 to 11 0 44 to 79 5 59 to 78 6 0 to 8 0 44 to 57 Straight screw G1 4 25 to 34 2 5 to 3 5 18 to 25 G3 8 62 to 82 6 3 to 8 4 46 to 60 G1 2 49 to 88 5 0 to 9 0 37 to 65 KiSC issued 04 2010 A ...

Page 36: ...Hr G 28 1 Replace every 1 year G 40 2 Secondary element Replace every 1 year G 40 9 Fuel line Check every 100 Hr G 29 Replace every 2 years G 41 10 Fuel filter element Clean every 100 Hr G 28 Replace every 400 Hr G 37 11 Parking brake cable Adjust every 100 Hr G 32 Replace every 2 year G 41 12 Engine oil change every 200 Hr G 21 13 Engine oil filter Replace every 200 Hr G 21 14 Transmission oil fi...

Page 37: ...heck every 200 Hr G 34 Replace every 2 years G 41 20 Hydraulic oil filter Replace every 400 Hr G 38 21 Transmission fluid Change every 400 Hr G 38 22 Front axle case oil Change every 400 Hr G 39 23 Front axle pivot Adjust every 600 Hr G 39 24 Engine valve clearance Adjust every 800 Hr G 40 25 Fuel injection nozzle injection pressure Check every 1500 Hr G 40 26 Injection pump Check every 3000 Hr G ...

Page 38: ...r annually W1025390 No Item Service Interval Interval Refe rence page 50 100 150 200 250 300 350 400 450 500 550 600 650 700 1 Air conditioner condenser screen Clean Daily G 19 2 Tension of air conditioner drive belt Adjust every 200 Hr G 35 3 Inner air filter Clean every 200 Hr G 36 4 Fresh air filter Clean every 200 Hr G 36 5 Air conditioner condenser Check every 200 Hr G 37 6 Air conditioner pi...

Page 39: ... temperatures below 10 C 14 F IMPORTANT Q Do not permit dirt or trash to get into the fuel system Be careful not to let the fuel tank become empty otherwise air will enter the fuel system necessitating bleeding before next engine start Be careful not to spill during refueling If should spill wipe it off at once or it may cause a fire To prevent condensation water accumulation in the fuel tank fill...

Page 40: ...it out again Check to see that the oil level lies between the two notches If the level is too low add new oil to the prescribed level at the oil inlet See page G 9 IMPORTANT Q If oil level is low do not run engine W1034473 Checking Coolant Level CAUTION Do not remove radiator cap while coolant is hot When cool slowly rotate cap to the first stop and allow sufficient time for excess pressure to esc...

Page 41: ...ls IMPORTANT Q Grille and screen must be clean from debris to prevent engine from overheating and to allow good air intake for the air cleaner W1035250 Checking Dust Indicator There is a dust indicator on the air cleaner body If the red signal on the dust indicator is visible clean the element immediately see page G 28 Reset the red signal by pushing a RESET button after cleaning W1035421 Checking...

Page 42: ...t the cotter pin W1032993 Checking Brake Pedal Free Travel CAUTION Stop the engine and chock the wheels before checking brake pedal 1 Release the parking brake 2 Slightly depress the brake pedals and measure free travel L at top of pedal stroke 3 If the measurement is not within the factory specifications loosen the lock nut 1 and turn the turnbuckle 2 to adjust the rod length within acceptable li...

Page 43: ...ne to cool down sufficiently oil can be hot and can burn 1 Remove the oil filter 2 Put a film of clean engine oil on the rubber seal of the 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 little Make sure that the engine oil does not leak th...

Page 44: ...ompletely into the oil pan 2 After draining reinstall the drain plugs 3 Remove the oil filter 4 Put a film of clean transmission oil on the rubber seal of the new filter 5 Quickly tighten the filter until it contacts the mounting surface then with a filter wrench tighten it an additional 1 turn only 6 After the new filters have been replaced fill the transmission oil up to the upper notch on the d...

Page 45: ...surface then tighten it by hand an additional 1 2 turn only 7 Fill with the new KUBOTA SUPER UDT fluid up to the upper notch on the dipstick See page G 9 8 After running the engine for a few minutes stop the engine and check the oil level again add oil to the prescribed level 9 Make sure that the transmission fluid does not leak past the seal on the filter IMPORTANT Q To prevent serious damage to ...

Page 46: ...tle shift lever to the forward or reverse position 3 Depress the clutch pedal fully 4 Disengage the PTO clutch control lever 5 Turn the key to START position 6 The engine must not crank Q Test 2 Switch for the PTO clutch control lever 1 Sit on operator s seat 2 Engage the PTO clutch control lever 3 Depress the clutch pedal fully 4 Shift the shuttle shift lever to the neutral position 5 Turn the ke...

Page 47: ... s seat 2 Engage the PTO clutch control lever 3 Depress the clutch pedal fully 4 Place the speed control pedal to the neutral position 5 Turn the key to START position 6 The engine must not crank Q Test 3 Switch for the clutch pedal 1 Sit on operator s seat 2 Disengage the PTO clutch control lever 3 Place the speed control pedal to the neutral position 4 Release the clutch pedal 5 Turn the key to ...

Page 48: ...ten 2 When apply a grease to forward front axle support remove the breather plug and apply a grease until grease overflows from breather plug port After greasing reinstall the breather plug W10308650 1 Grease Fitting Front Wheel Case Support RH LH 2 Grease Fitting Front Axle Support 3 Breather Plug 4 Grease Fitting Lift Cylinder 5 Grease Fitting Top Link 7 Grease Fitting Lifting Rod RH 7 Grease Fi...

Page 49: ... and foot throttle cable 2 CAUTION Be sure to stop the engine and remove the key before oiling W1072984 4 CHECK POINTS OF EVERY 100 HOURS Adjusting Clutch Pedal Free Travel 1 See page G 20 W1075566 Adjusting Brake Pedal Free Travel 1 See page G 20 W1068081 1 Hand Throttle Cable 2 Foot Throttle Cable KiSC issued 04 2010 A ...

Page 50: ... cover upright If the cover is improperly fitted evacuator valve will not function and dust will adhere to the element Do not touch the secondary element except in cases where replacing is required Q Evacuator Valve Open the evacuator valve 4 once a week under ordinary conditions or daily when used in a dusty place to get rid of large particles of dust and dirt W1076669 Cleaning Fuel Filter This j...

Page 51: ...rn or damaged replace or repair them at once 3 The fuel line is made of rubber and ages regardless of period of service Replace the fuel pipe together with the clamp every two years and securely tighten 4 However if the fuel pipe and clamp are found damaged or deteriorated earlier than two years then change or remedy 5 After the fuel line and clamp have been changed bleed the fuel system IMPORTANT...

Page 52: ...If you are spattered with it wash it away completely with water immediately and get medical attention Wear eye protection and rubber gloves when working around battery NOTE Q The factory installed battery is of non refillable type If the indicator turns white do not charge the battery but replace it with new one 1 Mishandling the battery shortens the service life and adds to maintenance costs 2 Th...

Page 53: ... A boost charge is only for emergencies It will partially charge the battery at a high rate and in a short time When using a boost charged battery it is necessary to recharge the battery as early as possible Failure to do this will shorten the battery s service life 3 The battery is charged if the indicator display turns green from black 4 When exchanging an old battery into new one use battery of...

Page 54: ...parking position while counting the ratchet sound made by the parking brake lever 2 If adjustment is needed loosen the lock nut and adjust the parking brake cable length with in acceptable limit 3 Retighten the lock nut W1073312 Proper parking brake lever free travel 2 notches Ratchet sound 2 1 Parking Brake Lever 2 Release Button 3 Parking Brake Cable 4 Lock Nut A PULL KiSC issued 04 2010 A ...

Page 55: ...and hose clamps every 2 years or earlier if checked and found that hoses are swollen hardened or cracked Q Precaution at Overheating Take the following actions in the event the coolant temperature be nearly or more than the boiling point what is called Overheating 1 Stop the machine operation in a safe place and keep the engine unloaded idling 2 Don t stop the engine suddenly but stop it after abo...

Page 56: ...the tie rod nut 2 and turn the tie rod joint 3 to adjust the tie rod length until the proper toe in measurement is obtained 3 Retighten the tie rod nut 2 4 Attach the snap ring 1 of the tie rod joint IMPORTANT Q A right and left tie rod joint is adjusted to the same length W1082751 Checking HST Oil Line HST Model Checking Power Steering Line 1 Check to see that all lines and hose clamps are tight ...

Page 57: ...he engine before checking air conditioner belt tension 1 Stop the engine and remove the key 2 Apply 98 N 10 kgf 22 lbf pressure to the belt between the pulleys 3 If tension is incorrect adjust the belt tension 4 If belt is damaged replace it W1019789 1 Hose 2 Hose Clamp A L3540 L4240 B L5040 L5240 L5740 Air conditioner belt tension Factory spec A deflection of between 10 to 12 mm 0 39 to 0 47 in w...

Page 58: ...ir flow Pressure of compressed air must be under 205 kPa 2 1 kgf cm2 30 psi NOTE Q If the filter is very dirty Dip the filter in lukewarm water with mild dish washing detergent Move it up and down as well as left and right to loosen dirt Rinse the filter with clean water and let it air dry IMPORTANT Q Do not use gasoline thinner or similar chemicals to clean the filter as damage to the filter may ...

Page 59: ... the air conditioner condenser 1 2 If dust and dirt wash off all dirt and dust from the condenser 1 with a soft brush use care not to damage or bend the fins W1019699 6 CHECK POINTS OF EVERY 400 HOURS Replacing Fuel Filter Element 1 See page G 28 W1085936 1 Air Conditioner Condenser KiSC issued 04 2010 A ...

Page 60: ...ll with the new KUBOTA SUPER UDT fluid up to the upper notch on the dipstick See page G 9 8 After running the engine for a few minutes stop the engine and check the oil level again add oil to the prescribed level 9 Make sure that the transmission fluid does not leak past the seal on the filter IMPORTANT Q To prevent serious damage to the hydraulic system use only a KUBOTA genuine filter Do not ope...

Page 61: ...OLANT See page G 9 5 Reinstall the filling plug 2 and check plug 1 W10300640 7 CHECK POINT OF EVERY 600 HOURS Adjust Front Axle Pivot 1 Loosen the lock nut 2 tighten the adjusting screw 1 until seated then tighten the adjusting screw 1 with an additional 1 6 turn 2 Retighten the lock nut 2 NOTE Q If the axle pivot pin adjustment is not correct front wheel vibration can occur causing vibration in t...

Page 62: ...rvicing section W1044584 11 CHECK POINTS OF EVERY 1 YEAR Replacing Air Cleaner Primary Element and Secondary Element 1 Replace the both primary and secondary elements Refer to Cleaning Air Cleaner Primary Element See page G 28 W1037077 Checking Air Conditioner Pipes and Hoses 1 Check to see that all lines and hose clamps are tight and not damaged 2 If hoses 1 and clamps are found worn or damaged r...

Page 63: ...eplacing HST Oil Line 1 Replace the hoses and clamps Refer to Checking HST Oil Line and Power Steering Line See page G 34 W1037296 Replacing Power Steering Hose 1 Replace the hoses and clamps Refer to Checking HST Oil Line and Power Steering Line See page G 34 W1037361 Replacing Radiator Hose Water Pipes 1 Replace the hoses and clamps Refer to Checking Radiator Hose and Hose Clamp See page G 33 W1...

Page 64: ...ssary NOTE Q On cabin type machines fresh water circulates through the heater This means that one more liter or so of fresh water is required In changing fresh water pour fresh water up to the filter port of the recovery tank Turn ON the heater shift the temperature control lever toward WARM and run the engine for a while in order to warm fresh water Then stop the engine When fresh water has coole...

Page 65: ...814c 4 Mix the anti freeze with water and ten fill in to the radiator At 760 mmHg pressure atmospheric A higher boiling points is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system NOTE Q The above data represent industry standards that necessitate a minimum glycol content in the concentrated anti freeze When the coolant level drops due to...

Page 66: ...nd then stop the engine 4 Close the air vent cock IMPORTANT Q Always close the air vent cock except for bleeding fuel lines Otherwise engine runs irregularly or stalls frequently W1039026 Draining Clutch Housing Water NOTE Q The tractor is equipped with split pin plug 1 under the clutch housing After operating in rain snow or tractor has been washed water may get into the clutch housing 1 Check it...

Page 67: ...er to troubleshooting section of this manual If any of them should blow replace with a new one of the same capacity Q Protected Circuit W1039315 Fuse No Capacity A Protected circuit ROPS CABIN 1 25 Head light 2 20 Flasher 3 20 Hazard 4 5 Panel 5 5 T M controller 1 GST HST type 6 7 5 Alternator 7 5 Lamp relay 8 10 Patrol lamp 9 7 5 Work light 10 5 Brake lamp switch 11 10 T M controller 2 GST HST ty...

Page 68: ...g Washer Liquid CABIN Model 1 Add a proper amount of automobile washer liquid W1120170 Light Capacity ROPS CABIN Head lights 45 W 40 W Tail light 10 W Hazard and turn signal light rear 21 W Hazard and turn signal light front 21 W Side marker light 8 W Room light 10 W Work light 35 W Instrument panel light 1 1 W Brake stop light 21 W Number plate light 10 W 1 Door Hinge 2 Rear Window Hinge Tank cap...

Page 69: ... 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 blow HI Air conditioner switch ON 2 Look into the sight glass 1 to see if the refrigerant is flowing through its ci...

Page 70: ...linder W10241000 Piston Ring Tool Code No 07909 32121 Application Use exclusively for removing or installing the piston ring with ease W10241500 Diesel Engine Compression Tester Code No 07909 30208 Assembly 07909 31251 G 07909 30934 A to F 07909 31271 I 07909 31211 E and F 07909 31281 J 07909 31231 H Application Use to measure diesel engine compression and diagnostics of need for major overhaul W1...

Page 71: ... cap pressure and leaks from cooling system Remarks Adapter 1 BANZAI Code No RCT 2A 30S W10245320 Connecting Rod Alignment Tool Code No 07909 31661 Application Use to check the connecting rod alignment Applicable Connecting rod big end I D range 30 to 75 mm 1 18 to 2 95 in dia Connecting rod length 65 to 300 mm 2 56 to 11 81 in W10245830 Nozzle Tester Code No 07909 31361 Application Use to check t...

Page 72: ... 08 in D 10 8 to 11 2 mm 0 426 to 0 440 in E 40 mm 1 6 in F 20 mm 0 79 in G 39 mm 1 5 in H 20 mm Hole 0 79 in Hole I 8 50 to 8 80 mm Drilled hole 0 335 to 0 346 in Drilled hole J 20 mm Spot faced hole 1 mm deep 0 79 in Spot faced hole 0 04 in deep K 20 mm 0 79 in L 140 mm 5 51 in M 15 mm 0 59 in N 175 mm 6 89 in C10 Chamfer 10 mm 0 39 in R9 Radius 9 0 mm 0 35 in R10 Radius 10 mm 0 39 in KiSC issue...

Page 73: ...371 Application Use to check cracks on cylinder head cylinder block etc W10550780 A 217 mm 8 54 in B 140 mm 5 51 in C 49 mm 1 9 in D 44 mm 1 7 in E 20 mm Hole 0 79 in Hole F 30 mm 1 2 in G 71 mm 2 8 in H 10 mm 0 39 in I 85 mm 3 3 in J 0 52 rad 30 K 9 0 mm 0 35 in L 120 mm 4 72 in M 10 mm 0 39 in N 139 mm 5 12 in O 10 mm 0 39 in P 44 7 to 45 3 mm 1 76 to 1 78 in Q 10 mm 0 39 in R 65 mm 2 6 in S 2 8...

Page 74: ... fix the crankshaft sleeve of the diesel engine W1027695 A 100 mm 3 94 in B 25 0 mm 0 98 in C 27 0 mm 1 06 in D 45 0 mm dia 1 77 in dia E 35 0 mm dia 1 38 in dia F 62 5 mm dia 2 46 in dia G 46 0 mm 1 81 in A 80 0 mm 3 1496 in B 60 1 to 60 3 mm 2 3661 to 2 3740 in C 80 0 mm dia 3 1496 in dia D 85 0 mm dia 3 3465 in dia E 60 1 to 60 3 mm dia 2 3661 to 2 3740 in dia F 26 3 to 26 4 mm 1 0354 to 1 0394...

Page 75: ...dia 3 1417 to 3 1437 in dia V 10 0 mm 0 3937 in W 0 04 mm dia 0 0016 in dia X 140 mm 5 5118 in Y 120 mm 4 7244 in Z 110 mm 4 3307 in a 50 0 mm 1 9685 in b 39 9 to 40 0 mm 1 5709 to 1 5748 in c 25 0 mm 0 9843 in d 90 0 mm dia 3 5433 in dia e 81 0 mm dia 3 1890 in dia f 80 10 to 80 15 mm dia 3 1535 to 3 1555 in dia g 30 0 mm dia 1 1811 in dia h 5 0 mm dia 0 1969 in dia i 70 0 mm 2 7559 in j 50 0 mm ...

Page 76: ...87 in dia K 12 5 to 12 8 mm dia 0 492 to 0 504 in dia L 8 9 to 9 1 mm 0 350 to 358 in C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in C0 3 Chamfer 0 3 mm 0 012 in A Pressure gauge full scale More than 29 4 MPa 300 kgf cm2 4267 psi B Copper gasket C Flange Material Steel D Hex nut 27 mm 1 06 in across the plat E Injection pipe F PF 1 2 G 5 mm 0 20 in H 17 mm dia 0 67 in dia I 8 mm dia 0 31 in...

Page 77: ...1 mm dia 0 984 to 0 985 in dia A 175 mm 6 89 in B 40 mm 1 57 in C 38 mm 1 49 in D 45 mm dia 1 77 in dia E 41 90 to 41 95 mm dia 1 650 to 1 652 in dia F 37 95 to 37 97 mm dia 1 494 to 1 495 in dia A 200 mm 7 87 in B 20 mm 0 79 in C 30 mm 1 18 in D 8 mm 0 31 in E 10 mm dia 0 39 in dia A 135 mm 5 31 in B 72 mm 2 83 in C 40 mm radius 1 57 in radius D 10 mm 0 39 in E 20 mm 0 79 in F 20 mm dia 0 79 in d...

Page 78: ...in N 21 947 to 21 960 mm dia 0 8641 to 0 8646 in dia D 0 52 rad 30 O 28 mm 1 10 in E 46 950 to 46 975 mm dia 1 8484 to 1 8494 in dia P 29 mm 1 14 in F 43 934 to 43 950 mm dia 1 7297 to 1 7303 in dia Q 5 mm 0 20 in G 41 mm 1 61 in R 36 mm 1 42 in H 32 5 mm 1 28 in S 195 25 to 195 75 mm 7 687 to 7 707 in I 148 5 mm 5 85 in T 145 mm 5 71 in J 46 50 to 46 75 mm dia 1 831 to 1 841 in dia U 384 75 to 38...

Page 79: ...a 1 38 in dia T 60 mm dia 2 36 in dia G 60 mm dia 2 36 in dia U 46 950 to 46 975 mm dia 1 8484 to 1 8494 in dia H 37 mm 1 46 in V 44 950 to 44 975 mm dia 1 7697 to 1 7707 in dia I 21 947 to 21 960 mm dia 0 8641 to 0 8646 in dia W 41 934 to 41 950 mm dia 1 6509 to 1 6516 in dia J 24 959 to 24 980 mm dia 0 9826 to 0 9835 in dia X 145 mm 5 71 in K 8 8 to 9 2 mm 0 346 to 0 362 in Y 195 25 to 195 75 mm...

Page 80: ... W10265330 Injector CH3 Code No 07916 52501 Application Use for injecting calcium chloride solution into and removing it from rear wheel W10265850 Clutch Center Tool For B and L Series Tractors Application The clutch center tool can be used for all B and L series tractors with a diaphragm clutch by changing tip guides Center piece diameter is 20 mm 0 79 in W10266370 Toe in Gauge Code No 07909 3168...

Page 81: ...on Use for testing the hydraulic system W10313960 Power Steering Adapter Code No 07916 54021 Application Use for measuring the relief valve setting pressure for power steering W10442870 1 Gauge 07916 50322 2 Cable 07916 50331 3 Threaded Joint 07916 50401 4 Threaded Joint 07916 50341 5 Adaptor B M18 P1 5 07916 50361 6 Adaptor C PS3 8 07916 50371 7 Adaptor D PT1 8 07916 50381 8 Adaptor E PS3 8 07916...

Page 82: ...751 Application This offers easy measurement of relief valve setting pressure from the hydraulic coupler This is available with the relief valve setting pressure tester W10623960 NOTE Q The following special tools are not provided so make them referring to the figure Pinion Shaft Remover Application Use for removing a pinion shaft W10315930 A 106 mm 4 17 in B 350 mm 13 78 in C 6 mm 0 24 in D 90 mm...

Page 83: ... mm 0 87 in I 67 mm 2 6 in J 31 mm 1 2 in K 10 mm 0 39 in 1 Screw M8 x P1 25 x L50 mm 2 in 2 Screw M14 x P1 5 x L50 mm 2 in 3 Rocking Restrictor Right Left A 54 7 to 54 9 mm 2 1535 to 2 1614 in 49 7 to 49 9 mm 1 9567 to 1 9646 in B 24 5 to 25 5 mm 0 9646 to 1 0039 in 21 5 to 22 5 mm 0 8465 to 0 8858 in C 40 mm 1 57 in 40 mm 1 57 in D 32 mm 1 26 in 30 mm 1 18 in E 49 7 to 49 9 mm 1 9567 to 1 9646 i...

Page 84: ... range and floating range of hydraulic draft control W10625190 A 1045 mm 41 14 in B 1000 mm 29 37 in C 20 mm dia 0 79 in dia D 30 mm dia 1 18 in dia E 90 mm 3 54 in F 30 mm 1 18 in G 30 mm 1 18 in H 15 mm 0 59 in I 20 mm dia 0 79 in dia J Weld all around K Weld all around L 20 mm 0 79 in KiSC issued 04 2010 A ...

Page 85: ...as leak testing the air conditioning system W1013817 Vacuum Pump Code No DENSO 95046 00040 AC220V 95046 00050 AC240V Application Use for evacuating the air conditioning system W1013764 1 Manifold Gauge Assembly 2 Charging Hose Red HI 3 Charging Hose Blue LO 4 Charging Hose Green 5 Can Tap Valve 6 T Joint 7 Quick Coupler HI 8 Quick Coupler LO 9 Service Valve Packing 10 Charging Hose Packing 11 Tool...

Page 86: ...en and tighten the magnet clutch mounting nut Use radius C NOTE Q This special tool is not provided so make it referring to the figure A 125 mm 4 92 in H 4 52 rad 120 B 40 mm dia 1 57 in dia I Radius 27 mm Radius 1 06 in C Radius 33 mm Radius 1 30 in J Radius 50 mm Radius 1 97 in D 16 mm 0 63 in K Weld all around E 120 mm dia 4 72 in dia L 20 mm 0 78 in F 12 mm dia 0 47 in dia M Radius 41 mm Radiu...

Page 87: ...erring to the figure W1066199 Valve Adaptor Application Use for measuring the system pressure of shuttle valve W1039227 A 12 mm 0 47 in E 5 5 mm dia 0 22 in dia B 35 mm 1 38 in F 6 5 mm dia 0 26 in dia C 7 mm 0 28 in G 0 52 rad 30 D 0 4 mm 0 016 in H M8 P1 25 A 12 mm 0 47 in B 55 mm 2 16 in C 20 mm 0 79 in D 5 mm dia 0 20 in dia E M8 P1 25 A 24 mm 0 94 in B 27 7 mm 1 09 in C PS1 4 D 11 mm 0 43 in ...

Page 88: ...om size A to size R are same size as adaptor 61 A 22 mm 0 872 in K 135 mm 5 31 in B 11 mm 0 437 in L 7 mm dia 0 28 in dia C 24 mm dia 0 94 in dia M 8 5 mm dia 0 33 in dia D 18 mm dia 0 71 in dia N 37 mm 1 46 in E 12 mm dia 0 47 in dia O 61 5 mm 2 42 in F 1 7 to 1 9 mm 0 067 to 0 075 in P 24 mm 0 94 in G 30 mm Round 1 18 in Round Q 27 7 mm 1 09 in H 10 mm dia 0 39 in dia R 0 244 rad 14 I G 3 8 S 40...

Page 89: ...if using a front loader or when equipped with a full load of front weights W10440050 Tire sizes Inflation Pressure Rear 11 2 24 4PR 120 kPa 1 2 kgf cm2 17 psi 12 4 24 4PR 100 kPa 1 0 kgf cm2 14 psi 13 6 24 4PR 100 kPa 1 0 kgf cm2 14 psi 13 6 26 4PR 100 kPa 1 0 kgf cm2 14 psi 13 6 28 6PR 140 kPa 1 4 kgf cm2 20 psi 355 80 D20 4PR 100 kPa 1 0 kgf cm2 14 psi 475 65 D20 4PR 80 kPa 0 8 kgf cm2 10 psi 36...

Page 90: ...eck after driving the tractor 200 m 200 yards and thereafter according to service interval Refer to G 24 1 Front Wheels Front axle is not adjustable 1 Tread W10527070 2 Rear Wheels Rear tread can be adjusted as shown with standard equipped tires To change the tread 1 Lift the rear tires off the ground 2 Follow the illustrations below to get the desired tread width IMPORTANT Q If not attached as il...

Page 91: ...m 48 0 in 1320 mm 52 0 in 1400 mm 55 1 in 13 6 24 Farm 1140 mm 44 9 in 1210 mm 47 6 in 1310 mm 51 6 in 1410 mm 55 5 in 13 6 26 Farm 1140 mm 44 9 in 1210 mm 47 6 in 1310 mm 51 6 in 1335 mm 52 56 in 440 65R24 Farm 1285 mm 50 59 in L5040 L5240 L5740 13 6 28 Farm 1125 mm 44 3 in 1225 mm 48 23 in 1325 mm 52 17 in 440 65R24 Farm 1180 mm 46 46 in 1285 mm 50 59 in Models L3540 355 80 D20 Turf 1125 mm 44 3...

Page 92: ...ing a calcium chloride solution do not pour water over calcium chloride since this results in chemical reaction which will cause high temperature Instead add a small amount of calcium chloride to the water at a time until the desired solution is achieved W10330830 Attaching Injector 1 Lift the rear tires off the ground 2 Turn the tire so that the air valve is at the top 3 Remove the air valve and ...

Page 93: ...t 30 C 22 F Approx 1 kg 2 lbs CaCl2 per 4 L 1 gal of water 103 kg 227 lbs 117 kg 258 lbs 153 kg 337 lbs Slush free at 24 C 11 F Solid at 47 C 53 F Approx 1 5 kg 3 5 lbs CaCl2 per 4 L 1 gal of water 108 kg 238 lbs 125 kg 276 lbs 160 kg 353 lbs Slush free at 47 C 53 F Solid at 52 C 62 F Approx 2 25 kg 5 lbs CaCl2 per 4 L 1 gal of water 115 kg 254 lbs 133 kg 293 lbs 170 kg 375 lbs Tire sizes 13 6 26 ...

Page 94: ...the bottom 3 Remove the air valve and drain liquid liquid can only be drained to the level of the valve and liquid under that level remains inside 4 To drain liquid completely use the injector and direct compressed air into the tire to force out the liquid through the injector s vent W10451670 1 Injector 2 Hose 3 Vent A Compressed Air KiSC issued 04 2010 A ...

Page 95: ...1 ENGINE KiSC issued 04 2010 A ...

Page 96: ...CONTENTS MECHANISM 1 FEATURES 1 M1 2 EGR EXHAUST GAS RECIRCULATION SYSTEM IF EQUIPPED 1 M2 1 EGR VALVE 1 M3 2 EGR COOLER 1 M3 KiSC issued 04 2010 A ...

Page 97: ...er to meet with the strict emission regulations Kubota has adapted the Exhaust Gas Recirculation EGR system on the V2403 M TE3 for L5240 and L5740 W1012642 Tractor Model Engine Model L3540 D1803 M E2 EU1 L4240 Manual Transmission GST Model V2203 M E2 EU2 L4240 HST Model V2203 M E2 EU1 L5040 V2403 M TE3 EU1 L5240 V2403 M TE3 EU2 L5740 V2403 M TE3 EU3 KiSC issued 04 2010 A ...

Page 98: ...n system is used to lower the combustion temperature and efficiently cool EGR gas with the aim of reducing the Nox that is in the exhaust gas of diesel engine 1 Boost Compensator 2 Thermo Valve 3 Exhaust Manifold 4 Crankcase 5 EGR Cooler 6 EGR Valve 7 Water Flange 8 Inlet Manifold A Boost Pressure B EGR Gas C Coolant KiSC issued 04 2010 A ...

Page 99: ...rns the cooled exhaust gas to the engine suction side The EGR cooler 1 has resistance to clogging up compact and efficient tubes 3 internally W1014264 1 Thermo Valve 2 Diaphragm Cover 3 Retainer 4 Diaphragm Plate 5 Diaphragm 6 Diaphragm Stay 7 Valve Spring 8 Diaphragm Plate 9 Plate 10 Plate 11 Insulator 12 Valve Shaft Bush 13 Filter 14 Shaft 15 Sheet 16 Valve 17 Housing A Boost Pressure from Boost...

Page 100: ...l 1 S25 2 Dismounting Cabin from Tractor Cabin Model 1 S32 3 Engine Separating Cabin Model 1 S32 3 SEPARATING ENGINE FROM TRACTOR ROPS AND CABIN MODEL 1 S34 6 DISASSEMBLING AND ASSEMBLING 1 S36 1 OUTER PARTS 1 S36 2 EGR VALVE AND EGR COOLER IF EQUIPPED 1 S37 3 CYLINDER HEAD AND VALVES 1 S38 4 TIMING GEARS CAMSHAFT AND FUEL CAMSHAFT 1 S42 5 PISTON AND CONNECTING ROD 1 S50 6 CRANKSHAFT 1 S53 7 SERVI...

Page 101: ... S53 Compression leak from cylinder Replace head gasket tighten cylinder head screw glow plug and nozzle holder 1 S39 S40 Improper valve timing Correct or replace timing gear 1 S47 Piston ring and cylinder worn Replace 1 S52 Excessive valve clearance Adjust 1 S13 Starter Does Not Run Battery discharged Charge G 31 Starter malfunctioning Repair or replace 9 S68 Main switch malfunctioning Repair or ...

Page 102: ...em to be seizing Repair or replace Uneven fuel injection Repair or replace the injection pump 1 S42 Deficient nozzle injection Repair or replace the nozzle 1 S39 Compression leak Replace head gasket tighten cylinder head bolt glow plug and nozzle holder 1 S39 S40 Excessive Lubricant Oil Consumption Piston ring s gap facing the same direction Shift ring gap direction 1 S51 Oil ring worn or stuck Re...

Page 103: ...of oil Use the specified type of oil G 9 Oil Pump defective Repair or replace 1 S48 High Oil Pressure Difference type oil Use the specified type of oil G 9 Relief valve defective Replace Engine Overheated Engine oil insufficient Replenish G 9 Fan belt broken or elongated Change or adjust G 29 Coolant insufficient Replenish Radiator net and radiator fin clogged with dust Clean Inside of radiator co...

Page 104: ...e Recessing Protrusion Recessing 0 05 mm 0 0020 in 0 15 mm 0 0059 in 0 4 mm 0 0157 in Valve Stem to Valve Guide Valve Stem Valve Guide Clearance O D I D 0 040 to 0 070 mm 0 0016 to 0 0027 in 7 960 to 7 975 mm 0 3134 to 0 3139 in 8 015 to 8 030 mm 0 3156 to 0 3161 in 0 1 mm 0 004 in Valve Face Angle Intake Angle Exhaust 1 0 rad 60 0 79 rad 45 Valve Seat Angle Intake Angle Exhaust 1 0 rad 60 0 79 ra...

Page 105: ...r Idle Gear to Injection Pump Gear Crank Gear to Oil Pump Gear Idle Gear to Balancer Gear Balancer Model Only Backlash Backlash Backlash Backlash Backlash Intake side Backlash Exhaust side 0 04150 to 0 1122 mm 0 001634 to 0 004417 in 0 04150 to 0 1154 mm 0 001634 to 0 004543 in 0 04150 to 0 1154 mm 0 001634 to 0 004543 in 0 0415 to 0 109 mm 0 00163 to 0 00429 in 0 0350 to 0 116 mm 0 00138 to 0 004...

Page 106: ...haft Journal 3 Balancer Shaft Bearing 3 Clearance O D I D 0 020 to 0 094 mm 0 00079 to 0 0037 in 21 947 to 21 960 mm 0 86406 to 0 86456 in 21 980 to 22 041 mm 0 86536 to 0 86775 in 0 20 mm 0 0079 in Idle Gear Shaft to Idle Gear Bushing Idle Gear Shaft Idle Gear Bushing Clearance O D I D 0 025 to 0 066 mm 0 00099 to 0 0025 in 37 959 to 37 975 mm 1 4945 to 1 4950 in 38 000 to 38 025 mm 1 4961 to 1 4...

Page 107: ...0 15 mm 0 0059 in Top Ring Ring Gap 0 25 to 0 40 mm 0 0099 to 0 015 in 1 25 mm 0 0492 in Second Ring Ring Gap 0 30 to 0 45 mm 0 012 to 0 017 in 1 25 mm 0 0492 in Oil Ring Ring Gap 0 25 to 0 45 mm 0 0099 to 0 017 in 1 25 mm 0 0492 in Second Ring to Ring Groove Clearance 0 093 to 0 128 mm 0 00367 to 0 00503 in 0 200 mm 0 00787 in Oil Ring to Ring Groove Clearance 0 020 to 0 060 mm 0 00079 to 0 0023 ...

Page 108: ...2 Oil Clearance O D I D 0 0400 to 0 104 mm 0 00158 to 0 00409 in 59 921 to 59 940 mm 2 3591 to 2 3598 in 59 980 to 60 025 mm 2 3615 to 2 3631 in 0 2 mm 0 0079 in Crankshaft Sleeve Wear 0 10 mm 0 0039 in Cylinder Bore Standard Oversize I D I D 87 000 to 87 022 mm 3 4252 to 3 4260 in 87 250 to 87 272 mm 3 4351 to 3 4359 in 0 15 mm 0 0059 in 0 15 mm 0 0059 in Item Factory Specification Allowable Limi...

Page 109: ... 10 kgf 22 lbf of force Radiator Cap Pressure Falling Time 10 seconds or more for pressure falling from 88 to 59 kPa from 0 9 to 0 6 kgf cm2 from 13 to 9 psi Radiator Water Tightness No leaks at 137 kPa 1 4 kgf cm2 20 psi Thermostat Valve Opening Temperature At Beginning Valve Opening Temperature Opened Completely 69 5 to 72 5 C 157 1 to 162 5 F 85 C 185 F KiSC issued 04 2010 A ...

Page 110: ... to 10 before T D C Pump Element Fuel Tightness 13 7 MPa 140 kgf cm2 1991 psi Delivery Valve Fuel Tightness 10 seconds or more for pressure falling from 13 7 to 12 8 MPa from 140 to 130 kgf cm2 from 1990 to 1850 psi 5 seconds for pressure falling from 13 7 to 12 8 MPa from 140 to 130 kgf cm2 from 1990 to 1850 psi Injection Nozzle Injection Pressure 13 8 to 14 7 MPa 140 to 150 kgf cm2 2000 to 2130 ...

Page 111: ...36 Retaining nut of power steering delivery pipe 49 to 58 5 0 to 6 0 37 to 43 Front axle frame mounting screw 7T 78 to 90 7 9 to 9 2 58 to 66 Front axle frame mounting screw 9T 103 to 117 10 5 to 12 0 76 0 to 86 7 Item Size x Pitch N m kgf m lbf ft Clutch mounting screw 24 to 27 2 4 to 2 8 18 to 20 Oil Pressure switch PT 1 8 15 to 20 1 5 to 2 0 11 to 14 Cylinder head cover screw M6 1 0 9 81 to 11 ...

Page 112: ...r each cylinder 8 If the measurement is below the allowable limit apply a small amount of oil to the cylinder wall through the nozzle hole and measure the compression pressure again 9 If the compression pressure is still less than the allowable limit check the top clearance valve and cylinder head 10 If the compression pressure increases after applying oil check the cylinder wall and piston rings ...

Page 113: ...26 rad 15 clockwise and counterclockwise to see if the piston is at the compression top dead center or the overlap position Now referring to the table below readjust the valve clearance A The piston is at the compression top dead center when both the IN and EX valves do not move it is at the overlap position when both the valves move Finally turn the flywheel 6 28 rad 360 and align the 1TC mark li...

Page 114: ...ctive Oil strainer clogged Oil filter cartridge clogged Oil gallery clogged Excessive oil clearance Foreign matter in the relief valve When reassembling After checking the engine oil pressure tighten the engine oil pressure switch to the specified torque W1034952 Engine oil pressure At idle speed Factory spec More than 98 kPa 1 0 kgf cm2 14 psi Allowable limit 50 kPa 0 5 kgf cm2 7 psi At rated spe...

Page 115: ...factory specifications loosen the alternator mounting screws and relocate the alternator to adjust W10356670 Fan Belt Damage and Wear 1 Check the fan belt for damage 2 If the fan belt is damaged replace it 3 Check if the fan belt is worn and sunk in the pulley groove 4 If the fan belt is nearly worn out and deeply sunk in the pulley groove replace it W1020602 Deflection A Factory spec 7 0 to 9 0 m...

Page 116: ...ak from the pinhole replace the radiator or repair with the radiator cement When water leak is excessive replace the radiator W10389070 Thermostat Valve Opening Temperature 1 Suspend the thermostat in the water by a string with its end inserted between the valve and seat 2 Heating the water gradually read the temperature when the valve opens and leaves the string 3 Continue heating and read the te...

Page 117: ...eel further and stop turning when the fuel begins to flow over to get the present injection timing 6 The flywheel has mark 1TC and four lines indicating every 0 087 rad 5 of crank angle from 0 175 rad 10 to 0 436 rad 25 before mark 1TC Calculate the angle which the center of the window points out If the calculation differs from specified injection timing add or remove the shim to adjust Injection ...

Page 118: ...bine these shims for adjustments Because only the back of shim 0 175 mm 1 is coated do not install the shim 0 175 mm 1 on top of combined shims Addition or reduction of shim 0 05 mm 0 0020 in delays or advances the injection timing by approx 0 0087 rad 0 5 In disassembling and replacing be sure to use the same number of new gasket shims with the same thickness W1083313 1 Shim 0 175 mm 2 Shim 0 20 ...

Page 119: ...ease the pressure 6 Stop the starter when the fuel jets from the injection nozzle After that turn the flywheel by the hand and raise the pressure to approx 13 7 MPa 140 kgf cm2 1991 psi 7 Now turn the flywheel back about half a turn to keep the plunger free Maintain the flywheel at this position and clock the time taken for the pressure to drop from 13 7 to 12 8 MPa from 140 to 130 kgf cm2 from 19...

Page 120: ...andle to measure the pressure at which fuel begins jetting out from the nozzle 3 If the measurement is not within the factory specifications replace the adjusting washer 1 in the nozzle holder to adjust it Reference Pressure variation with 0 025 mm 0 0010 in difference of adjusting washer thickness Approx 590 kPa 6 0 kgf cm2 85 psi W10476390 Valve Seat Tightness 1 Set the injection nozzle to a noz...

Page 121: ...61270 Compressor Side 1 Check the inlet pipe 1 1 of the compressor cover 3 to see if there is no air leak 2 Check for loose connections or cracks in the suction side of the intake pipe 3 If any air leak is found change the clamp 2 and or inlet pipes W10863400 Radial Clearance 1 If the wheel contacts to the housing replace the turbocharger assembly with new one W1077353 1 Exhaust Port 2 Gasket 3 Tu...

Page 122: ...l can be drained out easily when the engine is still warm 2 After draining reinstall the drain plug 3 3 Fill with the new oil up to the upper notch on the dipstick 2 IMPORTANT Q Refer to 4 LUBRICANTS FUEL AND COOLANT at G GENERAL section W1036028 Engine oil capacity with filter L3540 D1803 M E2 6 7 L 7 1 U S qts 5 9 Imp qts L4240 V2203 M E2 8 2 L 8 7 U S qts 7 2 Imp qts L5040 V2403 M TE3 L5240 V24...

Page 123: ...more liter or so of fresh water is required In changing fresh water pour fresh water up to the filter port of the recovery tank Turn ON the heater shift the temperature control lever toward WARM and run the engine for a while in order to warm fresh water Then stop the engine When fresh water has cooled down some of the fresh water in the recovery tank is sucked Now the recovery tank is appropriate...

Page 124: ...ngine for few minutes stop it and check the oil level again add the fluid to prescribed level if it is not correct level IMPORTANT Q Use only KUBOTA SUPER UDT fluid Use of other oils may damage the transmission or hydraulic system Refer to 4 LUBRICANTS FUEL AND COOLANT at G GENERAL section Do not mix different brands of fluid together W1014221 Transmission fluid capacity L3540 42 L 11 1 U S gals 9...

Page 125: ... attached W1031307 Battery Front Grille Skirt and Bonnet 1 Open the bonnet and disconnect the battery negative cable 2 Disconnect the head light connector and remove the front grille 3 3 Remove the left and right side skirts 2 4 Remove the bonnet 1 NOTE Q When disconnecting the battery cords disconnect the negative cord first when connecting positive cord first W1057856 Tightening torque Lower fra...

Page 126: ...he wiring connector for throttle sensor HST model only When reassembling Tighten the steering joint shaft support mounting screw after adjusting the position of steering joint shaft support 4 for smooth rotation of the steering wheel When the accelerator wire is installed adjust the wiring length as hit both the idling speed adjusting bolt and the maximum speed adjusting bolt by lever within the s...

Page 127: ...ness 4 Remove the harness bracket with wiring harness W1122986 Panel Cover 1 Remove the floor mat 2 Remove the steering post cover 2 3 and disconnect the shuttle switch connector 4 3 Remove the steering post cover 1 2 and panel cover 1 W1019247 1 Alternator 2 Fuel Sensor 3 Shield LH 4 Oil Pressure Switch 5 Starter Motor 6 Battery 7 Coolant Temperature Sensor 8 Ground Cable 1 Panel Cover 2 Steering...

Page 128: ...t the meter panel connectors 13 and remove the meter panel 12 7 Remove the relays 14 and flasher unit 15 8 Remove the wiring harnesses from the panel frame When reassembling Be sure to check and adjust the clutch and brake pedal free travel Refer to 7 4 CHECK POINTS OF EVERY 100 HOURS at G GENERAL section W1124128 1 Clutch Rod 2 Brake Rod LH 3 Fuse Box 4 Harness Cover 5 Multi Function Switch 6 Bea...

Page 129: ...0 L5740 WSM ENGINE Panel Frame 1 Remove the universal joint bolt 1 and disconnect the steering joint shaft 1 2 2 Remove the panel frame 3 W1125342 1 Universal Joint Bolt 2 Steering Joint Shaft 1 3 Panel Frame KiSC issued 04 2010 A ...

Page 130: ...ve the pipe clamp 6 For HST Model 5 Remove the oil cooler return pipe joint screw 8 When reassembling W1126364 Tightening torque Joint screw for PTO delivery pipe 35 to 39 N m 3 5 to 4 0 kgf m 26 to 28 lbf ft Joint screw for oil cooler return pipe 88 3 to 98 0 N m 9 00 to 10 0 kgf m 65 1 to 72 3 lbf ft 1 Suction Hose 2 Hydraulic Pump 3 PTO Delivery Pipe 4 Delivery Pipe 1 5 Power Steering Delivery ...

Page 131: ... clutch housing mounting screws and nuts 4 Separate the engine and clutch housing When reassembling Install the O rings 2 4 and collar 3 on the propeller shaft 2 5 as shown in the figure Apply grease to the spline of clutch shaft Apply liquid gasket Three Bond 1211 or equivalent to joint face of the flywheel housing and clutch housing W1127495 1 Coupling 2 Spring Pin 3 Propeller Shaft 1 4 Propelle...

Page 132: ...ank 9 with stay for HST Model 8 Remove the oil cooler return pipe joint screw 11 When reassembling W10392350 Tightening torque Joint screw for delivery pipe 2 40 to 49 N m 4 0 to 5 0 kgf m 29 to 36 lbf ft Retaining nut of power steering delivery pipe 49 to 58 N m 5 0 to 6 0 kgf m 37 to 43 lbf ft Joint screw for oil cooler pipe HST 88 3 to 98 0 N m 9 00 to 10 0 kgf m 65 1 to 72 3 lbf ft Joint screw...

Page 133: ... clutch housing mounting screws and nuts 4 Separate the engine and clutch housing When reassembling Install the O rings 2 4 and collar 3 on the propeller shaft 2 5 as shown in the figure Apply grease to the spline of clutch shaft Apply liquid gasket Three Bond 1211 or equivalent to joint face of the flywheel housing and clutch housing W1061438 1 Coupling 2 Spring Pin 3 Propeller Shaft 1 4 Propelle...

Page 134: ...steering return hose 6 7 Remove the fuel filter 8 with fuel filter bracket 7 8 Remove the oil return pipe 11 HST Model When reassembling W1021885 Tightening torque Muffler mounting screw 32 to 37 N m 3 2 to 3 8 kgf m 24 to 27 lbf ft 1 Radiator Hose Upper 2 Air Cleaner Hose 3 Muffler 4 Radiator Hose Lower 5 Radiator Assembly 6 Battery Stay Tightening torque Joint screw for power steering delivery p...

Page 135: ...ne by the chain at the engine hook 6 Remove the dipstick stay mounting screw and front axle frame mounting screws 7 Separate the front axle frame 4 from engine 3 When reassembling W1016162 Tightening torque Front axle frame mounting screw 7T 78 to 90 N m 7 9 to 9 2 kgf m 58 to 66 lbf ft Front axle frame mounting screw 9T 103 to 117 N m 10 5 to 12 0 kgf m 76 0 to 86 7 lbf ft 1 Engine Hook 2 Engine ...

Page 136: ...189 Clutch Assembly 1 Remove the clutch from the flywheel When reassembling Direct the shorter end of the clutch disc boss toward the flywheel Apply molybdenum disulphide Three Bond 1901 or equivalent to the splines of clutch disc boss Install the pressure plate nothing the position of straight pins IMPORTANT Q Align the center of disc and flywheel by inserting the clutch center tool Refer to 8 SP...

Page 137: ... EGR valve 1 and A side of thermo valve 4 When connecting the air tube 2 5 to the inlet manifold boost compensator 6 and B side of thermo valve 4 Replace the gasket with new one W10623940 EGR Cooler CAUTION While the engine is running and or just after it stops the EGR cooler is hot be careful not to touch the EGR cooler 1 Remove the hose 2 and 3 2 Remove the EGR cooler 1 When reassembling Replace...

Page 138: ...jection Pipes 1 Loosen the screws on the pipe clamps 1 2 Detach the injection pipes 2 When reassembling Blow out dust inside the pipes W1060970 Tightening torque Cylinder head cover screw 9 81 to 11 2 N m 1 00 to 1 15 kgf m 7 23 to 8 31 lbf ft 1 Lead 2 Breather Hose 3 Head Cover Screw 4 Cylinder Head Cover 5 Cylinder Head Cover Gasket 6 Breather Valve 7 Plate Tightening torque Injection pipe retai...

Page 139: ... seal and copper gasket must be changed when the injection nozzle is removed for cleaning or for service W1021255 Rocker Arm and Push Rod 1 Remove the rocker arm bracket nuts 2 Detach the rocker arm assembly 1 3 Remove the push rods 2 When reassembling When putting the push rods 2 onto the tappets 3 check to see if their ends are properly engaged with the grooves IMPORTANT Q After installing the r...

Page 140: ...rder of a to n or r Tighten them uniformly or the head may deform in the long run W1021755 Tappets 1 Remove the tappets 1 from the crankcase When reassembling Visually check the contact between tappets and cams for proper rotation If defect is found replace tappets Before installing the tappets apply engine oil thinly around them IMPORTANT Q Do not change the combination of tappet and tappet guide...

Page 141: ...seal 6 4 Remove the valve 7 When reassembling Wash the valve stem and valve guide hole and apply engine oil sufficiently After installing the valve spring collets lightly tap the stem to assure proper fit with a plastic hammer IMPORTANT Q Don t change the combination of valve and valve guide W1022102 1 Valve Spring Replacer 2 Valve Cap 3 Valve Spring Collet 4 Valve Spring Retainer 5 Valve Spring 6...

Page 142: ...jection pump first into position Replace the hi idling body gasket 5 with a new one Before fitting the stop lever 3 to the gear case install the stop solenoid guide 6 first into position Then attach the stop lever and use it to see if it functions well Before fitting the idling limiter in place attach the stop solenoid guide 6 and the engine stop lever 3 in their respective positions When installi...

Page 143: ...top solenoid guide 5 install the injection pump first into position Replace the hi idling body gasket with a new one Before fitting the boost compensator assembly 2 to the gear case make sure that the solenoid guide 5 is at the initial position When installing the stop solenoid 3 be careful to keep the O ring in place Be sure to insert the push rod of the stop solenoid into the hole at the center ...

Page 144: ...tool 1 undo the large governor spring 2 from the fork lever 3 4 Using the governor spring hooking special tool 1 undo the small governor spring 4 from the fork lever 3 5 Set the speed control lever 5 as shown in the figure 6 Take out the speed control plate 6 with care not to let the large and small governor springs 4 2 come off this plate and fall into the gear case W1148604 1 Governor Spring Hoo...

Page 145: ...he small governor spring too long because otherwise it may get deformed permanently Using the governor spring hooking special tool 1 hook the large governor spring 2 onto the fork lever 3 Make sure both the governor springs 2 4 are tight on the fork lever 3 Apply and tighten up the two bolts and two nuts on the speed control plate 6 Check that the speed control lever 5 positions low idle after ass...

Page 146: ...to see if there are four O rings 1 inside the gear case 2 Apply a thin film of engine oil to the oil seal 3 and install it noting the lip come off Before installing the gear case gasket apply a non drying adhesive W1024531 Crankshaft Oil Slinger 1 Remove the crankshaft collar 3 2 Remove the O ring 2 3 Detach the crankshaft oil slinger 1 When reassembling Insert the crankshaft collar 3 after instal...

Page 147: ...ank gear 5 cam gear 3 and balancer gear 4 2 Marks Cam gear 3 and idle gear 2 3 Marks Idle gear 2 and injection pump gear 1 4 Marks Idle gear 2 and balancer gear 7 W1024941 Camshaft for D1803 M 1 Remove the camshaft set screws 1 and draw out the camshaft 2 When reassembling When installing the idle gear be sure to align the alignment marks on the cam gear and the idle gear W1046059 1 Injection Pump...

Page 148: ...k lever holder mounting screws 2 4 Draw out the fuel camshaft assembly 5 6 and fork lever assembly 3 4 7 at the same time When reassembling After installation check to see that the fork lever 1 3 and fork lever 2 4 are fixed to the fork lever shaft and that they can turn smoothly in the holder 7 W1025309 Oil Pump 1 Remove the nut 2 Draw out the oil pump drive gear 2 with a gear puller 1 3 Remove t...

Page 149: ...1 S49 L3540 L4240 L5040 L5240 L5740 WSM ENGINE Crank Gear 1 Draw out the crank gear 2 with a puller 1 2 Remove the feather key W1025476 1 Crank Puller 2 Crank Gear KiSC issued 04 2010 A ...

Page 150: ... strainer 1 and the O ring 4 When reassembling After cleaning the oil strainer 1 check to see that the filter mesh is clean and install it Visually check the O ring 4 apply engine oil and install it Securely fit the O ring 4 to the oil strainer 1 Replace the oil pan gasket 2 with new one To avoid uneven tightening tighten the oil pan mounting screws in diagonal order from the center W1025687 1 Oil...

Page 151: ... example mark 1 on the No 1 piston Place the piston rings with their gaps at 0 79 rad 45 from the piston pin s direction as shown in the figure Carefully insert the pistons using a piston ring compressor 6 When inserting the piston in place be careful not to get the molybdenum disulfide coating torn off its skirt This coating is useful in minimizing the clearance with the cylinder liner Just after...

Page 152: ... the oil ring gap 11 Apply engine oil to the piston pin 9 When installing the connecting rod 7 to the piston 6 immerse the piston 6 in 80 C 176 F oil for 10 to 15 minutes and insert the piston pin 9 to the piston 6 When installing the connecting rod 7 to the piston 6 align the mark 8 on the connecting rod 7 to the fan shaped concave 5 NOTE Q Mark the same number on the connecting rod 7 and the pis...

Page 153: ...g case cover 6 to remove it IMPORTANT Q The length of inside screws 5 and outside screws 3 are different Do not take a mistake using inside screws and outside screws When reassembling Fit the bearing case gasket 1 and the bearing case cover gasket 2 with correct directions Install the bearing case cover 6 to position the casting mark UP on it upward Apply engine oil to the oil seal lip and take ca...

Page 154: ...e third cylinder 4 Repeat the above steps to draw out all the crankshaft For V2403 M 1 Remove the main bearing case screw 2 1 2 Turn the crankshaft to set the crank pin of the 4th cylinder to the horizontal directions Right or Left Then draw out all the crankshaft holding the crank pins to the horizontal directions Right or Left When reassembling IMPORTANT Q Install the crankshaft sub assembly ali...

Page 155: ...es vary install them in order of markings A B for 3 cylinders and A B C for 4 cylinders from the gear case side Match the alignment numbers 1 and mark 2 on the main bearing case When installing the main bearing case 1 and 2 face the mark FLYWHEEL to the flywheel Install the thrust bearing with its oil groove facing 7 outward Confirm that the main bearing case moves smoothly after tightening the ma...

Page 156: ...ber Be sure to check the valve recessing after correcting W1027737 Cylinder Head Flaw 1 Prepare an air spray red check Code No 07909 31371 2 Clean the surface of the cylinder head with detergent 2 3 Spray the cylinder head surface with the read permeative liquid 1 Leave it five to ten minutes after spraying 4 Wash away the read permeative liquid on the cylinder head surface with the detergent 2 5 ...

Page 157: ...e 1 Remove carbon from the valve guide section 2 Measure the valve stem O D with an outside micrometer 3 Measure the valve guide I D with a small hole gauge and calculate the clearance 4 If the clearance exceeds the allowable limit replace the valves If it still exceeds the allowable limit replace the valve guide W1077495 Valve recessing Factory spec 0 050 protrusion to 0 15 recessing mm 0 0020 pr...

Page 158: ...ve guide with a hammer during replacement W1027889 Valve Seating 1 Coat the valve face lightly with prussian blue and put the valve on its seat to check the contact 2 If the valve does not seat all the way around the valve seat or the valve contact is less than 70 correct the valve seating as follows 3 If the valve contact does not comply with the reference value replace the valve or correct the c...

Page 159: ... seat and fit them with valve lapping tool 4 Check the valve seating with prussian blue The valve seating surface should show good contact all the way around W10283500 Valve Lapping 1 Apply compound evenly to the valve lapping surface 2 Insert the valve into the valve guide Lap the valve onto its seat with a valve flapper or screwdriver 3 After lapping the valve wash the compound away and apply oi...

Page 160: ...place it W1078436 Oil Clearance between Rocker Arm and Rocker Arm Shaft 1 Measure the rocker arm shaft O D with an outside micrometer 2 Measure the rocker arm I D with an inside micrometer and then calculate the oil clearance 3 If the oil clearance exceeds the allowable limit replace the rocker arm and measure the oil clearance again If it still exceeds the allowable limit replace also the rocker ...

Page 161: ...f the tappet guide bore with a cylinder gauge and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit or the tappet is damaged replace the tappet W1028249 Push rod alignment Allowable limit 0 25 mm 0 0098 in Oil Clearance between tappet and tappet guide bore Factory spec 0 020 to 0 062 mm 0 00079 to 0 0024 in Allowable limit 0 07 mm 0 003 in Tappet O D Factory spec 23 95...

Page 162: ...Factory spec 0 04150 to 0 1122 mm 0 00164 to 0 004417 in Allowable limit 0 15 mm 0 0059 in Backlash between idle gear and cam gear Factory spec 0 04150 to 0 1154 mm 0 001634 to 0 004543 in Allowable limit 0 15 mm 0 0059 in Backlash between idle gear and injection pump gear Factory spec 0 04150 to 0 1154 mm 0 001634 to 0 004543 in Allowable limit 0 15 mm 0 0059 in Backlash between crank gear and oi...

Page 163: ... Side Clearance for V2203 M and V2403 M 1 Set a dial indicator with tip on the balancer shaft 2 Measure the side clearance by moving the balancer shaft to the front and rear 3 If the measurement exceeds the allowable limit replace the balancer shaft W1030111 Camshaft side clearance Factory spec 0 07 to 0 22 mm 0 0028 to 0 0086 in Allowable limit 0 30 mm 0 012 in Side clearance of balancer shaft Fa...

Page 164: ... in Balancer shaft bearing 1 I D Factory spec 43 980 to 44 045 mm 1 7315 to 1 7340 in Oil clearance of balancer shaft journal 2 Factory spec 0 030 to 0 111 mm 0 00119 to 0 00437 in Allowable limit 0 20 mm 0 0079 in Balancer shaft journal 2 O D Factory spec 41 934 to 41 950 mm 1 6510 to 1 6515 in Balancer shaft bearing 2 I D Factory spec 41 980 to 42 045 mm 1 6528 to 1 6553 in Oil clearance of bala...

Page 165: ...e the camshaft alignment 4 If the measurement exceeds the allowable limit replace the camshaft W1031413 Cam Height 1 Measure the height of the cam at its highest point with an outside micrometer 2 If the measurement is less than the allowable limit replace the camshaft W1031532 A When Removing B When installing Camshaft alignment Allowable limit 0 01 mm 0 0004 in Cam height of intake Factory spec ...

Page 166: ... gauge and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit replace the camshaft W1031662 Oil clearance of camshaft journal Factory spec 0 050 to 0 091 mm 0 0020 to 0 0035 in Allowable limit 0 15 mm 0 0059 in Camshaft journal O D Factory spec 39 934 to 39 950 mm 1 5722 to 1 5728 in Cylinder block bore I D Factory spec 40 000 to 40 025 mm 1 5748 to 1 5757 in KiSC issue...

Page 167: ...ace the piston pin W1031982 Replacing Connecting Rod Small End Bushing When removing 1 Press out the small end bushing with a connecting rod small end bushing replacing tool When installing 1 Clean a new small end bushing and bore and apply engine oil to them 2 Press fit a new bushing taking due care to see that the connecting rod hole matches the bushing hole W1032140 Piston pin bore I D Factory ...

Page 168: ...nd 1 Install the piston pin into the connecting rod 2 Install the connecting rod on the connecting rod alignment tool 3 Put a gauge over the piston pin and move it against the face plate 4 If the gauge does not fit squarely against the face plate measure the space between the pin of the gauge and the face plate 5 If the measurement exceeds the allowable limit replace the connecting rod W1032720 To...

Page 169: ... indicator with its tip on the intermediate journal at right angle 2 Rotate the crankshaft on the V blocks and get the misalignment half of the measurement 3 If the misalignment exceeds the allowable limit replace the crankshaft W1033001 Crankshaft side clearance Factory spec 0 15 to 0 31 mm 0 0059 to 0 012 in Allowable limit 0 50 mm 0 020 in Oversize 0 20 mm 0 0079 in 0 40 mm 0 016 in Dimension A...

Page 170: ...while the connecting rod screws are tightened Reference Undersize dimensions of crankpin W1033106 Oil clearance between crankpin and crankpin bearing Factory spec 0 025 to 0 087 mm 0 00099 to 0 0034 in Allowable limit 0 20 mm 0 0079 in Crankpin O D Factory spec 46 959 to 46 975 mm 1 8488 to 1 8494 in Crankpin bearing I D Factory spec 47 000 to 47 046 mm 1 8504 to 1 8522 in Undersize 0 20 mm 0 0079...

Page 171: ... press in a new bearing 1 2 so that its seam 1 directs toward the exhaust manifold side W1033946 Oil clearance between crankshaft journal and crankshaft bearing 1 Factory spec 0 0400 to 0 118 mm 0 00158 to 0 00464 in Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Factory spec 59 921 to 59 940 mm 2 3591 to 2 3598 in Crankshaft bearing 1 I D Factory spec 59 980 to 60 039 mm 2 3615 to 2 363...

Page 172: ...he wear exceeds the allowable limit or when the engine oil leaks replace the crankshaft sleeve W1033354 Oil clearance between crankshaft and crankshaft bearing 2 Factory spec 0 0400 to 0 104 mm 0 00158 to 0 00409 in Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Factory spec 59 921 to 59 940 mm 2 3591 to 2 3598 in Crankshaft bearing 2 I D Factory spec 59 980 to 60 025 mm 2 3615 to 2 3631...

Page 173: ... 1 to the crankshaft as shown in figure 4 Heat a new sleeve to a temperature between 150 to 200 C 302 to 392 F and fix the sleeve to the crankshaft as shown in figure 5 Press fit the sleeve using the auxiliary socket for pushing 4 NOTE Q Mount the sleeve with its largely chamfered surface facing outward W1033503 1 Stopper 2 Sleeve Guide 3 Crankshaft Sleeve 4 Auxiliary Socket for Pushing 5 Cranksha...

Page 174: ...e allowable limit bore and hone it to the specified dimension 2 Replace the piston and piston rings with oversize 0 25 mm 0 0098 in ones NOTE Q When the oversize cylinder is worn beyond the allowable limit replace the cylinder block with a new one W1034448 Cylinder I D Factory spec D1803 M V2203 M V2403 M 87 000 to 87 022 mm 3 4252 to 3 4260 in Maximum wear Allowable limit D1803 M V2203 M V2403 M ...

Page 175: ...ith grease 2 Install the cover and tighten the screws 3 Remove the cover carefully and measure the width of the press gauge with a sheet of gauge 4 If the clearance exceeds the factory specifications replace oil pump rotor assembly W1035444 Clearance between inner rotor and outer rotor Factory spec 0 030 to 0 14 mm 0 0012 to 0 0055 in Allowable limit 0 20 mm 0 0079 in Clearance between outer rotor...

Page 176: ...2 CLUTCH KiSC issued 04 2010 A ...

Page 177: ...CONTENTS MECHANISM 1 FEATURE 2 M1 KiSC issued 04 2010 A ...

Page 178: ... the pedal 5 and release fork 3 have been linked as shown in figure W1012642 1 Clutch Disc 2 Pressure Plate Assembly 3 Release Fork 4 Clutch Pedal Rod 5 Clutch Pedal 6 Release Bearing 7 Release Hub 8 Clutch Lever Shaft 9 Flywheel 10 Pressure Plate 11 Diaphragm Spring 12 Main Shaft 13 Clutch Cover 14 PTO Shaft 15 Spring Hub A Manual Transmission and GST Model B HST Model KiSC issued 04 2010 A ...

Page 179: ...G AND ADJUSTING 2 S4 5 PREPARATION 2 S5 1 COOLANT AND LUBRICANTS 2 S5 2 SEPARATING ENGINE AND CLUTCH HOUSING 2 S5 1 Engine Separating ROPS Model 2 S5 2 Dismounting Cabin from Tractor Cabin Model 2 S5 3 Engine Separating Cabin Model 2 S6 6 DISASSEMBLING AND ASSEMBLING 2 S7 7 SERVICING 2 S8 KiSC issued 04 2010 A ...

Page 180: ...sure plate worn or broken Replace Pressure Plate assembly 2 S7 Chattering Grease or oil on clutch disc facing Replace 2 S7 Clutch disc or pressure plate warped Replace 2 S7 Clutch disc boss spline worn or rusted Replace or remove rust 2 S7 Gear shaft bent Replace 3 S54 S73 S100 Pressure plate or flywheel face cracked or scored Replace 2 S7 Clutch disc boss spline and gear shaft spline worn Replace...

Page 181: ...le Limit Clutch Pedal Free play 20 to 30 mm 0 78 to 1 18 in Clutch Disc Boss to Gear Shaft Backlash Displacement Around Disc Edge 2 0 mm 0 079 in Clutch Disc Disc Surface to Rivet Top Depth 0 3 mm 0 012 in Diaphragm Spring Mutual Difference 0 5 mm 0 020 in Pressure Plate Flatness 0 2 mm 0 008 in KiSC issued 04 2010 A ...

Page 182: ...and nuts on the table below are especially specified For general use screws bolts and nuts Refer to 5 TIGHTENING TORQUES at G GENERAL section W1032791 Item N m kgf m lbf ft Clutch mounting screws 24 to 27 2 4 to 2 8 18 to 20 Release fork setting screws 24 to 27 2 4 to 2 8 18 to 20 KiSC issued 04 2010 A ...

Page 183: ...e clutch pedal and measure free travel L at top of clutch pedal 2 If the measurement is not within the factory specifications loosen the lock nut 2 remove the clevis pin 3 adjust the length of rod 1 within acceptable limits 3 Retighten the lock nut 2 and split the cotter pin W1032993 Clutch pedal free travel L Factory spec 20 to 30 mm 0 78 to 1 18 in 1 Clutch pedal Rod 2 Lock Nut 3 Clevis Pin L Fr...

Page 184: ...N at 1 ENGINE section 2 SEPARATING ENGINE AND CLUTCH HOUSING 1 Engine Separating ROPS Model Separating Engine and Clutch Housing 1 Refer to the 5 2 SEPARATING ENGINE AND CLUTCH HOUSING at 1 ENGINE section W1038316 2 Dismounting Cabin from Tractor Cabin Model Separating Cabin 1 Refer to 6 2 1 Separating Cabin from Tractor at 10 CABIN section W1027030 KiSC issued 04 2010 A ...

Page 185: ...40 L4240 L5040 L5240 L5740 WSM CLUTCH 3 Engine Separating Cabin Model Separating Engine and Clutch Housing 1 Refer to 5 2 SEPARATING ENGINE AND CLUTCH HOUSING at 1 ENGINE section W1020571 KiSC issued 04 2010 A ...

Page 186: ...w grease and oil on the clutch disc facing W1019957 Release Holder and Clutch Lever 1 Draw out the clutch release hub 7 and the release bearing 5 as a unit 2 Remove the release fork setting screws 4 and fork keys 2 3 Draw out the clutch lever 3 to remove the release fork 1 When reassembling Make sure the direction of the release fork 1 is correct Inject grease to the release hub 7 Be sure to set t...

Page 187: ... In this case inspect transmission gear shaft oil seal engine rear oil seal and other points for oil leakage W1017162 Checking Pressure Plate Assembly and Flywheel 1 Wash the disassembling parts except clutch disc with a suitable cleaning solvent to remove dirt and grease before making inspection and adjustment 2 Check friction surface of pressure plate and flywheel for scoring or roughness Slight...

Page 188: ...ints 2 If the clearance exceeds the allowable limit replace it 3 When the pressure plate is worn around its outside and its inside surface only is in contact with the straight edge replace even if the clearance is within the allowable limit W1017439 Clearance between pressure plate and straight edge Allowable limit 0 2 mm 0 008 in A Inside B Outside KiSC issued 04 2010 A ...

Page 189: ...3 TRANSMISSION KiSC issued 04 2010 A ...

Page 190: ...NE 3 M9 2 POWER TRAIN 3 M10 3 ELECTRICAL CONTROL SYSTEM 3 M11 1 Electrical Control 3 M11 2 Construction and Function of Components 3 M11 4 HYDRAULIC CONTROL SYSTEM 3 M12 1 Hydraulic Circuit and System Outline 3 M12 2 Construction and Function of Components 3 M14 5 FRONT WHEEL DRIVE SECTION 3 M21 6 CREEP GEAR SECTION 3 M21 7 SHIFT LINKAGE MECHANISM 3 M21 4 HYDROSTATIC TRANSMISSION HST MODEL 3 M22 1...

Page 191: ...5240 L5740 WSM TRANSMISSION 1 STRUCTURE 1 Main Gear Shift Section 2 PTO Clutch Section 3 Shuttle Shift Section 4 Range Gear Creep Gear Shift Section 5 Front Wheel Drive Shift Section 6 PTO Gear Shift Section 2 3 4 1 5 3TLAAAK3P001A 6 KiSC issued 04 2010 A ...

Page 192: ...0 L5240 L5740 WSM TRANSMISSION 1 Main Gear Shift Section 2 Clutch Pack for GST 3 PTO Clutch Section 4 Hi Lo Shift Shuttle Shift Section 5 Range Gear Shift Creep Gear Shift Section 6 Front Wheel Drive Shift Section 3 4 5 6 1 2 3TLAAAK3P002A KiSC issued 04 2010 A ...

Page 193: ...SION HST MODEL 3 M3 L3540 L4240 L5040 L5240 L5740 WSM TRANSMISSION 1 Hydrostatic Transmission Section 2 PTO Clutch Section 3 Range Gear Shift Section 4 Front Wheel Drive Shift Section 2 3 3TLAAAK3P003A 1 KiSC issued 04 2010 A ...

Page 194: ...shift the shifters and transmits to the counter shaft 3 W1012742 2 Shuttle Shift Section The shuttle shift section is located in the mid case and it uses a single cone type synchromesh It allows the operator to change forward and reverse for each speed from the first to eight with single shift lever W1012964 1 Gear Shaft Input 2 Main Shaft 3 Counter Shaft 4 Shuttle Shaft 5 Gear for 4th 6 Synchrome...

Page 195: ... reduce a travelling speed It is shifted by the creep shift lever to shift the shifter 3 The power train of creep speed is as shown in figure W1021456 1 Shuttle Gear Shaft 2 Gear for Low 3 Shifter 4 Gear for High 5 Range Gear Shaft 6 Counter Gear 7 Spiral Bevel Pinion L Low Speed H High Speed N Neutral 1 Creep Output Gear 2 Range Gear Shaft 3 Shifter 4 Low Speed Counter Gear 5 Spiral Bevel Pinion ...

Page 196: ... the differential gear case Two wheel drive or four wheel drive is selected by operating the front wheel drive lever to shift the shifter gear 4 W1013518 1 Spiral Bevel Pinion 2 Gear 3 Front Wheel Drive Gear 4 Shifter Gear 5 Front Wheel Drive Shaft Connected to Propeller Shaft a Four Wheel Drive Position KiSC issued 04 2010 A ...

Page 197: ...e Lever The links are connected from the shift lever 1 to the shift fork 7 as shown in the figure When the shift lever 1 is moved to the F side the shift fork 7 is moved toward the F side allowing the operator to shift to forward by means of the shuttle universal joint 2 shuttle shift shaft 3 shift arm 6 and shuttle fork rod 5 When the shift lever 1 is moved to the R side the shift fork 7 is shift...

Page 198: ...so moved to the A side then the front wheel drive is Engaged When the shift lever 1 is moved to the B side the front wheel drive is Disengaged W1014303 5 Creep Gear Shift Lever The links are connected from the shift lever 3 to the shift fork 1 as shown in the left figure When the shift lever 3 is moved to the A side the shift fork 1 is moved to the A side by means of the rod 4 sub arm 5 and shift ...

Page 199: ...on the movement and gear shifting according to the oil temperature and the traveling speed can be achieved by having electronically controlled the GST system and a smoother operation can be done Moreover because the selected speed and the traveling speed can be confirmed by the liquid crystal display LCD 1 of electronic instrument panel IntelliPanel 2 it can do a comfortable tractor operation And ...

Page 200: ...e shift pattern input to the electric control unit ECU The shift pattern is shown in the table below Front wheel drive section is basically similar to manual transmission model Forward shift pattern Reverse shift pattern 1 Main Shift Section 2 GST Clutch Pack 3 Sub range Shift Section 4 Shuttle Shift Section 5 Main Range Shift Section Lever Location at Lever Guide 1 2 3 4 5 6 7 8 9 10 11 12 Displa...

Page 201: ...g speed engine speed and oil temperature from various sensors and pressure in the hydraulic clutch is raised according to the respective condition NOTE Q By means of speed increasing speed decreasing traveling speed engine speed and oil temperature the indicated pressure period from c to d is controlled at appropriate pressure respectively 7 A pressurizing to hydraulic clutch has been done until i...

Page 202: ... 13 3 4 Shift Piston 14 Solenoid Valve 4 15 1 2 Shift Piston 16 Solenoid Valve 2 17 Shift Piston Sub range Shift 18 Shift Check Valve Main Range Shift 19 3 4 Shift Check Valve 20 1 2 Shift Check Valve 21 Shift Check Valve Sub range Shift 22 Shift Check Valve Shuttle 23 Pressure Switch 24 Clutch Valve 25 Low pass Valve 26 Proportional Reducing Valve 27 GST Clutch 28 GST Valve Assembly a To Steering...

Page 203: ...valve 24 is actuated And oil flows through the low pass valve 25 and the proportional reducing valve 26 to the GST clutch 27 This oil flows until becoming the compound pressure which is both of setting pressure for closing of low pass valve and controlled indication pressure of the proportional reducing valve Reference Setting pressure for closing of low pass valve 0 24 MPa 2 5 kgf cm2 34 1 psi 7 ...

Page 204: ...ure in the GST system circuit to 2 45 MPa 25 0 kgf cm2 356 psi The oil from the power steering pump passes through the regulating valve 3 and check valve 4 and then it flows to power steering circuit The regulating valve 3 is provided to maintain 2 94 MPa 30 0 kgf cm2 427 psi at inlet pressure of the pressure reducing valve 5 except when the power steering is operated Thereby getting 2 45 MPa 25 0...

Page 205: ...peration When the solenoid is not excited oil from regulating valve flows to the shift piston through the surrounding of the ball 10 in the valve When the solenoid is excited plunger 9 presses the ball against the valve seat 11 to open the unload passage 12 and drain the oil W1019949 1 GST Valve Assembly 2 Clutch Valve 3 Low pass Valve 4 Connector for Pressure Switch 5 Proportional Reducing Valve ...

Page 206: ...h are connected to each shift rod and shift the gear There are neutral positions in 1 2 shift piston 2 and 3 4 shift piston 1 W1020109 1 3 4 Shift Piston 2 1 2 Shift Piston 3 Main Range Shift Piston 4 Sub range Shift Piston 5 Shifter 6 Valve Body 7 Cover 8 Piston 9 Ball for Check Valve 10 Spring 11 Check Pin 12 Ball for Detent 13 Neutral Piston A Shift Piston for Main Range Shift B 1 2 and 3 4 Shi...

Page 207: ... 2 shift check valve 6 and 3 4 shift check valve 5 compose a serial circuit When either valve is closed the oil in the pilot circuit will not be drained into the tank In case of the shuttle shifting the shift check valve 3 is opened and closed by the groove of the shuttle shift rod Note that the shuttle shift fork rod has a slot into which the shift fork mounting bolt is inserted Therefore when th...

Page 208: ...ary to flow oil to the GST clutch quickly It is the low pass valve that does this operation with the proportional reducing valve 10 simultaneously The oil from the regulating valve flows in from the IN port A passes through the low pass valve poppet 4 flows out from OUT port B and flows to the clutch valve 7 and clutch 9 When the pressure on the side of the OUT port B reaches setting pressure the ...

Page 209: ...microcomputer of ECU calculates and judges the charging of pressure and its time according to the oil temperature sensor and gear shifting period and the traveling speed and speed acceleration according to the traveling speed sensor By these instructions from microcomputer of ECU the proportional reducing valve adjusts pressure in the clutch to become a appropriate acceleration W1021268 1 Proporti...

Page 210: ...ort flows out from the D port and flows to the GST clutch 6 When the pilot circuit pressure is zero that is from the start to the left with the spring 3 to cut the oil flow of B and C port and stopping the oil flow to the GST clutch 6 Furthermore the oil of the GST clutch flows in from D port and is drained from E port and then the GST clutch is disengaged W1021514 1 Plug 2 Spool 3 Spring 4 Stoppe...

Page 211: ...e engine stop the shift levers are neutral position between from start to end of the gear shifting The oil of the GST clutch 1 is pushed out with return spring 9 and piston 6 and flowed to the tank W1021896 5 FRONT WHEEL DRIVE SECTION Refer to the 2 MANUAL TRANSMISSION MODEL in this section for the front wheel drive section of GST model 6 CREEP GEAR SECTION Refer to the 2 MANUAL TRANSMISSION MODEL...

Page 212: ...s a result the HST pedal feels extremely light and smoother pedal operation can be done HST assembly is chiefly composed of HST case clutch housing variable displacement piston pump variable displacement piston motor charge pump Hi Lo solenoid valve and proportional valves Refer to the next page for detailed parts in the HST 1 Input Shaft 2 HST Case Clutch Housing 3 Outlet Port To Oil Cooler 4 Che...

Page 213: ... 10 Output Shaft Motor Shaft 11 Cylinder Block Motor 12 Hi Lo Solenoid Valve 13 Spool Pressure Selector 14 Spool Hi Lo 15 Variable Swashplate Motor 16 Piston Lo 17 Variable Swashplate Pump 18 Regulator Assembly 19 Charge Pump 20 Case Relief Valve 21 Charge Relief Valve 22 Check and High Pressure Relief Valve X Sectional View X X Y Sectional View Y Y Z Sectional View Z Z KiSC issued 04 2010 A ...

Page 214: ...9 Oil from the hydraulic pump is fed to the c port of the regulator valve The regulator valve sets the pressure of the PTO valve and proportional valve Oil from the regulator valve is guided to the servo piston by the motion of the proportional valve The proportional valve is controlled by the operation of the HST pedal Oil from the regulator valve is supplied to the PTO valve and power steering c...

Page 215: ...18201 for the operation of the servomechanism that is the operation of servo piston Q Valves As for the mechanism and function of check and high pressure relief valve charge relief valve and case relief valve refer to Workshop Manual of TRACTOR MECHANISM Code No 9Y021 18201 1 Servo Piston 2 Feedback Rod Connected to Swash Plate Position Sensor 3 Swash Plate Position Sensor 4 Swash Plate 5 Piston A...

Page 216: ...ed by the regulator valve and sent to the PTO valve power steering controller and proportional control valve respectively 1 Pump Swash Plate 2 Pump Piston 3 Pump Cylinder Block 4 HST Filter 5 Charge Pump 6 Check and High Pressure Relief Valve 7 Charge Relief Valve 8 Motor Cylinder Block 9 Motor Piston 10 Motor Swash Plate 11 Out Put Shaft Motor Shaft 12 Piston H 13 Piston L 14 Hi Lo Spool 15 Spool...

Page 217: ...tion of the pedal 1 Pump Swash Plate 2 Pump Piston 3 Pump Cylinder Block 4 HST Filter 5 Charge Pump 6 Check and High Pressure Relief Valve 7 Charge Relief Valve 8 Motor Cylinder Block 9 Motor Piston 10 Motor Swash Plate 11 Out Put Shaft Motor Shaft 12 Piston H 13 Piston L 14 Hi Lo Spool 15 Spool Pressure Selector 16 Hi Lo Solenoid Valve 17 Oil Cooler 18 Power Steering Controller 19 Proportional Va...

Page 218: ...motion of the pedal 1 Pump Swash Plate 2 Pump Piston 3 Pump Cylinder Block 4 HST Filter 5 Charge Pump 6 Check and High Pressure Relief Valve 7 Charge Relief Valve 8 Motor Cylinder Block 9 Motor Piston 10 Motor Swash Plate 11 Out Put Shaft Motor Shaft 12 Piston H 13 Piston L 14 Hi Lo Spool 15 Spool Pressure Selector 16 Hi Lo Solenoid Valve 17 Oil Cooler 18 Power Steering Controller 19 Proportional ...

Page 219: ...Motor Piston 10 Motor Swash Plate 11 Out Put Shaft Motor Shaft 12 Piston H 13 Piston L 14 Hi Lo Spool 15 Spool Pressure Selector 16 Hi Lo Solenoid Valve 17 Oil Cooler 18 Power Steering Controller 19 Proportional Valve Reverse 20 Proportional Valve Forward 21 Regulator Valve 22 Hydraulic Pump 23 Engine 24 PTO Valve 25 Filter 26 Transmission Case 27 Servo Piston 28 Servo Position 29 ECU 30 Hi Lo Sel...

Page 220: ... the two speed change spool to the pistons on the Hi side and the angle of the swash plate on the motor side is changed as shown in the drawing the inclination angle becomes smaller As a result the revolving speed of the motor shaft is increased When the angle of the swash plate on the motor side is changed the swash plate on the pump side goes back slightly toward the neutral position to achieve ...

Page 221: ...der Block 9 Motor Piston 10 Motor Swash Plate 11 Out Put Shaft Motor Shaft 12 Piston H 13 Piston L 14 Hi Lo Spool 15 Spool Pressure Selector 16 Hi Lo Solenoid Valve 17 Oil Cooler 18 Power Steering Controller 19 Proportional Valve Reverse 20 Proportional Valve Forward 21 Regulator Valve 22 Hydraulic Pump 23 Engine 24 PTO Valve 25 Filter 26 Transmission Case 27 Servo Piston 28 Servo Position 29 ECU ...

Page 222: ...peed change spool to the piston on the Lo side and the angle of the swash plate on the motor side is changed as shown in the drawing The inclination angle becomes larger As a result the revolving speed of the motor shaft is decreased When the angle of the swash plate on the motor side is changed the swash plate on the pump side is tilted toward the forward side to achieve smooth shift transmission...

Page 223: ...tor Cylinder Block 9 Motor Piston 10 Motor Swash Plate 11 Out Put Shaft Motor Shaft 12 Piston H 13 Piston L 14 Hi Lo Spool 15 Spool Pressure Selector 16 Hi Lo Solenoid Valve 17 Oil Cooler 18 Power Steering Controller 19 Proportional Valve Reverse 20 Proportional Valve Forward 21 Regulator Valve 22 Hydraulic Pump 23 Engine 24 PTO Valve 25 Filter 26 Transmission Case 27 Servo Piston 28 Servo Positio...

Page 224: ...y from the regulator by the proportional control valve the servo piston is moved toward the neutral direction As a result the swash plate on the pump side moves toward the neutral direction This decreases loads applied to the pump resulting in the decrease in loads applied to the motor In this way engine stall can be prevented When the pedal is maintained at the same position the load is decreased...

Page 225: ... High Pressure Relief Valve 7 Charge Relief Valve 8 Motor Cylinder Block 9 Motor Piston 10 Motor Swash Plate 11 Out Put Shaft Motor Shaft 12 Piston H 13 Piston L 14 Hi Lo Spool 15 Spool Pressure Selector 16 Hi Lo Solenoid Valve 17 Oil Cooler 18 Power Steering Controller 19 Proportional Valve Reverse 20 Proportional Valve Forward 21 Regulator Valve 22 Hydraulic Pump 23 Engine 24 PTO Valve 25 Filter...

Page 226: ...ads applied on the engine are controlled by returning the swash plate on the pump side toward the neutral side When the loads cannot be controlled just by returning the swash plate on the pump side toward the neutral side and the engine speed is decreased more the Hi Lo solenoid valve is closed by signals from the ECU Lo position Then the position of the two speed change spool is changed by the fo...

Page 227: ... Pressure Relief Valve 7 Charge Relief Valve 8 Motor Cylinder Block 9 Motor Piston 10 Motor Swash Plate 11 Out Put Shaft Motor Shaft 12 Piston H 13 Piston L 14 Hi Lo Spool 15 Spool Pressure Selector 16 Hi Lo Solenoid Valve 17 Oil Cooler 18 Power Steering Controller 19 Proportional Valve Reverse 20 Proportional Valve Forward 21 Regulator Valve 22 Hydraulic Pump 23 Engine 24 PTO Valve 25 Filter 26 T...

Page 228: ...ied on the pump are decreased more and reduces the load on the engine This increases the engine speed and prevents an engine stall When the pedal is maintained at the same position the load is decreased and engine speed is increased again In this state signals are being continuously transmitted from the engine speed sensor to the ECU Then the signals are sent from the ECU to the proportional contr...

Page 229: ... in the differential gear case 2 wheel drive or 4 wheel drive is selected by operating the front wheel drive lever to shift the shifter gear 6 W1024918 1 Counter Shaft 2 Gear for L 3 Shifter Gear for M 4 Range Gear Shaft 5 Spline Boss 6 Gear for H 7 Spiral Bevel Pinion Shaft L Low Speed Position N Neutral Position M Middle Speed Position H High Speed Position 1 Spiral Bevel Pinion Shaft 2 Front Wh...

Page 230: ...is section for the Front Wheel Drive Lever mechanism 1 Range Gear Shift Lever The links are connected from the shift lever 3 to the shift fork 1 as shown in figure W1025045 1 Shift Fork 2 Shift Arm 3 Range Gear Shift Lever 4 Rod 5 Sub arm L Low Speed Position M Middle Speed Position H High Speed Position KiSC issued 04 2010 A ...

Page 231: ... the PTO clutch valve The power train from the clutch to the PTO shaft is composed as shown in figure above Reference PTO speed of each model is as shown in the table below 1 PTO Gear Shaft 1 2 PTO Gear Shaft 2 3 PTO Clutch Pack 4 PTO Counter Shaft 5 PTO Drive Shaft 6 PTO Shaft 7 Output Shaft Motor Shaft 8 PTO Gear Shaft 1 9 PTO Gear Shaft 2 A Manual Transmission Model B GST Model C HST Model KiSC...

Page 232: ...L3540 L4240 L5040 L 540 min 1 rpm at 2550 min 1 rpm engine speed H 750 min 1 rpm at 2550 min 1 rpm engine speed Rear PTO L5040 540 min 1 rpm at 2550 min 1 rpm engine speed Rear PTO L4240 540 min 1 rpm at 2640 min 1 rpm engine speed L5240 L5740 540 min 1 rpm at 2590 min 1 rpm engine speed KiSC issued 04 2010 A ...

Page 233: ...is set at the DISENGAGED position W1025261 2 Oil Flow Oil flows into the clutch valve 2 after it is regulated to the system pressure As for the system pressure of the PTO clutch valve it is controlled When the PTO lever is at the DISENGAGED position the oil does not flow through the PTO clutch valve 2 to the clutch pack When the PTO lever is at the ENGAGED position the oil flows through the PTO cl...

Page 234: ...ol 2 is turned to b position then the oil is stopped by the spool 2 and the oil in the PTO clutch pack and accumulator is drained into the transmission case Thus the piston 4 is pushed back the brake plate 7 is also moved to contact the brake disc 6 so as to stop the rotation and the drag of the PTO shaft W1025465 1 Check Valve Except HST Model 2 Spool 3 Plate 4 Piston 5 Brake Spring 6 Brake Disc ...

Page 235: ...gure When the PTO speed change lever 1 is moved to L side the shift fork 4 is moved to the L side by means of the rod 2 to the Lo speed side When the PTO speed change lever 1 is moved to the H side the shift fork 4 is moved to the Hi speed side W1022707 1 Gear for High 2 Gear for Low 3 PTO Drive Shaft 4 Shifter 5 PTO Counter Shaft L Lo speed Shift N Neutral Position H Hi speed Shift 1 PTO Speed CH...

Page 236: ...t Panel intellipanel 3 S33 2 Hydraulic Checking and Adjusting 3 S37 5 PREPARATION 3 S41 1 COOLANT AND LUBRICANTS 3 S41 2 ROPS MODEL 3 S41 1 Dismounting the Step and Floor Seat 3 S41 3 CABIN MODEL 3 S50 1 Dismounting Cabin from Tractor 3 S50 6 DISASSEMBLING AND ASSEMBLING 3 S51 1 MANUAL TRANSMISSION MODEL 3 S51 1 Clutch Housing 3 S51 2 Mid Case 3 S56 3 Transmission Case 3 S61 2 GLIDE SHIFT TRANSMIS...

Page 237: ...ring Gear and Shaft 3 S121 2 Synchronizer Gear 3 S121 3 PTO Clutch 3 S121 4 Differential Gears 3 S121 5 GST Clutch 3 S121 3 HYDROSTATIC TRANSMISSION HST MODEL 3 S123 1 Bearing Gear and Shaft 3 S123 2 PTO Clutch 3 S123 3 Differential Gears 3 S123 4 HST 3 S123 KiSC issued 04 2010 A ...

Page 238: ... or shift fork worn or damaged Replace Shift fork interlock ball spring weaken or damaged Replace 3 S54 S73 Interlock ball fallen Reassemble 3 S54 S73 Synchronizer unit damaged Replace 3 S116 Gears worn or broken Replace Hard Shifting Shifter or shift fork worn or damaged Replace 3 S115 Shift fork bent Replace 3 S115 Shift linkage rusted Repair Shaft part of shift arms rusted Repair Synchronizer u...

Page 239: ...S66 S86 S112 Excessive or Unusual at All Time Improper backlash between spiral bevel pinion and spiral bevel gear Adjust 3 S119 Improper backlash between differential pinion and differential side gear Adjust 3 S120 Bearings worn Replace Insufficient or improper type of transmission fluid used Replenish or replace G 9 Noise While Turning Differential pinion or differential side gears worn or damage...

Page 240: ...3 S3 L3540 L4240 L5040 L5240 L5740 WSM TRANSMISSION 2 MANUAL TRANSMISSION MODEL Q Electrical Diagnosis by Electrical Instrument Panel InteliPanel KiSC issued 04 2010 A ...

Page 241: ...tronic instrument panel memory device has failed Electronic instrument panel memory device failure Replace the electronic instrument panel 9 S18 Wrong setting of electric instrument panel GST or HST specified electronic instrument panel installed wrong on Manual transmission model Input appropriate transmission model by Transmission model Input Mode Mode I 9 S28 KiSC issued 04 2010 A ...

Page 242: ...3 S5 L3540 L4240 L5040 L5240 L5740 WSM TRANSMISSION 3 GST SYSTEM Q Electrical Diagnosis by Electronic Instrument Panel IntelliPanel KiSC issued 04 2010 A ...

Page 243: ...ctronic instrument panel at ECU connector Replace ECU G45 9 S39 9 S42 9 S17 ECU memory device has failed ECU memory device failure Replace ECU 9 S17 Input voltage to lever sensor from ECU is failed Lever sensor input voltage drop below 2 6 V for 0 1 second or more Ground wire of lever sensor short circuited Check the ground cable Check input voltage at ECU connector Check the sensor connector 9 S3...

Page 244: ...noid broken or short circuited Wiring harness broken or short circuited Grounding plate of solenoid is poor contact with chassis Able to travel at speeds other than 1 7 and 8 Forward or 1 and 5 Reverse Check the wiring connector of solenoid Check the resistance between solenoid and GND Replace GST valve 9 S40 9 S40 3 S71 Solenoid 1 failure At reverse Solenoid 2 failure At forward or neutral Able t...

Page 245: ...9 S40 3 S71 Solenoid 4 failure At reverse Solenoid 6 Main range gear shift failure At forward or neutral Able to travel at speeds other than 1 to 6 Forward or 1 to 4 Reverse Check the wiring connector of solenoid Check the resistance between solenoid and GND Replace GST valve 9 S40 3 S71 Solenoid 6 Main range gear shift failure At reverse Solenoid 5 Sub range gear shift failure Able to travel at s...

Page 246: ...ressure 3 S30 GST pilot pressure is too low Solution order 1 Check the orifice of the pilot circuit 3 S31 2 Check the shift check valves 3 S90 3 Check the shift pistons 3 S91 4 Check the movement of the shift forks 5 Check the oil leaking from PTO clutch valve or its clutch pack 3 S117 GST clutch pressure is too low Solution order 1 Check the pressure switch 9 S43 2 Check the filter of proportiona...

Page 247: ...valve 3 S27 Shift shock improperly adjusted Adjust shift shock 3 S29 Temperature sensor defected Replace temperature sensor 9 S43 Quick Engagement While Starting or Large shock While Shifting Oil level is too low Check oil level or fill oil to proper level G 9 Transmission oil quality is too low Replenish correct fluid G 9 GST valve improperly adjusted Adjust GST valve 3 S27 Shift shock improperly...

Page 248: ...3 S11 L3540 L4240 L5040 L5240 L5740 WSM TRANSMISSION 4 HST SYSTEM Q Electrical Diagnosis by Electronic Instrument Panel IntelliPanel KiSC issued 04 2010 A ...

Page 249: ...heck the communication line between ECU and electronic instrument panel at ECU connector Replace ECU G 45 9 S37 9 S42 9 S17 ECU memory device has failed ECU memory device failure Replace ECU 9 S17 Input voltage to sensor from ECU is failed Sensor input voltage drop below 2 6 V for 0 1 second or more Ground wire of lever sensor short circuited Check the ground cable Check the input voltage at ECU c...

Page 250: ...nsor failed Sensor output terminal is out of adjustment Sensor output wire terminal broken or short circuited Input line broken Sensor defective Travel motion is possible Check the sensor connector Check the sensor voltage by Test mode Mode A Check the sensor wire connector voltage or check sensor resistance Replace the sensor 9 S22 9 S46 Cruise control lever failed Lever sensor output terminal is...

Page 251: ...tment HST response control dial output wire terminal broken or short circuited Input line broken HST response control dial defective Travel motion is possible The HST response control is fixed in the center Check HST response control dial connector Check HST response control dial voltage by Test mode Mode A Check HST response control dial wire connector voltage or check sensor resistance Replace H...

Page 252: ...verse failed Output voltage of proportional valve terminal or return current is out of specification Valve wire broken or short circuited Proportional valve defective Travel motion is possible on the forward only Check the proportional valve by Test mode Mode A Automatic shift function is not reformed Replace the proportional valve 9 S22 9 S49 Hi Lo solenoid failed Hi Lo solenoid output terminals ...

Page 253: ...thly Inspect or replace check and high pressure relief valve 3 S125 Component parts defective Replace hydrostatic transmission assembly Electronic control parts defective Inspect or replace electronic control parts Vibration and Noise Oil level is too low Check oil level or fill oil to proper level G 9 Charge pressure is too low Solution order 1 Replace oil filter cartridge G 22 2 Check charge pre...

Page 254: ...ol 3 S125 Component parts defective Replace hydrostatic transmission assembly Speed control pedal linkage defective Repair linkage Electronic control parts defective Inspect or replace electronic control parts Transmission Oil Over Heats Low transmission oil level Fill transmission oil level up to proper level G 9 Radiator net clogged Clean radiator net G 19 Excessive machine load Reduce machine l...

Page 255: ...Solution Reference Page Machine Will not Stop in Neutral Position Potentiometer defective Inspect or replace potentiometer System Operates in One Direction Only Check and high pressure relief valve defective Replace check and high pressure relief valve 3 S125 Potentiometer defective Inspect or replace potentiometer KiSC issued 04 2010 A ...

Page 256: ...te Replace 3 S59 PTO Shaft Does Not Rotate PTO clutch malfunctioning Repair or replace 3 S59 PTO propeller shaft coupling disengaged Engage PTO Clutch Operating Pressure is Low Transmission oil improper or insufficient Replenish or change G 9 Relief valve malfunctioning Adjust or replace 3 S26 S113 PTO Clutch Drags Brake plate excessively worn Replace 3 S60 Return spring weaken or broken Replace 3...

Page 257: ...g to Gear In Contact Side Clearance 0 35 mm 0 014 in Spiral Bevel Gear Turning Torque 4 0 to 6 3 N m 0 40 to 0 65 kgf m 2 9 to 4 7 lbf ft Spiral Bevel Gear to Spiral Bevel Pinion Shaft Backlash 0 15 to 0 30 mm 0 0059 to 0 012 in 0 4 mm 0 02 in Differential Case Bore Differential Case Cover Bore to Differential Side Gear Boss Differential Case Bore and Cover Bore Differential Side Gear Boss Clearan...

Page 258: ... Lever Forward or Reverse Operating Pressure 2 30 to 2 50 MPa 23 5 to 25 5 kgf cm2 334 to 363 psi GST Clutch Pressure Condition Engine Speed Idling Oil Temperature 40 to 60 C 104 to 140 F GST Lever Neutral to 12th or 8th Shuttle Lever Neutral to Forward and Reverse Operating Pressure 2 30 to 2 50 MPa 23 5 to 25 5 kgf cm2 334 to 363 psi GST Clutch Disc Thickness 2 55 to 2 65 mm 0 101 to 0 104 in 2 ...

Page 259: ... to 27 0 kgf cm2 319 to 384 psi Cruise Control Lever Operating Force Forward Direction 14 7 to 29 4 N 1 50 to 2 99 kgf 3 31 to 6 60 lbf PTO Clutch Valve Condition Engine Speed Idling Oil Temperature 40 to 60 C 104 to 140 F Operating Pressure 2 30 to 2 50 MPa 23 5 to 25 5 kgf cm2 334 to 363 psi PTO Clutch Disc Thickness 1 70 to 1 90 mm 0 067 to 0 075 in 1 55 mm 0 061 in PTO Steel Plate Thickness 1 ...

Page 260: ...PS type 260 to 304 26 5 to 31 0 192 to 224 ROPS lower connector mounting screw 103 to 118 10 5 to 12 0 75 9 to 86 8 ROPS plate mounting screw M14 40 138 to 147 14 0 to 15 0 102 to 108 ROPS plate mounting screw M14 30 167 to 196 17 0 to 20 0 123 to 145 ROPS fulcrum bolt and nut 118 to 137 12 0 to 14 0 86 8 to 102 Step mounting bolt and nut 124 to 147 12 6 to 15 0 91 1 to 108 Floor seat mounting bol...

Page 261: ...g screw and nut 220 22 160 Lift arm pin mounting nut 78 to 90 7 9 to 9 2 58 to 66 Lift arm pin lock nut 63 to 72 6 4 to 7 4 47 to 53 Drawbar frame mounting screw M12 78 to 90 7 9 to 9 2 58 to 66 Drawbar frame mounting screw M14 167 to 196 17 0 to 20 0 123 to 144 Hydraulic cylinder hose retaining nut 35 to 48 3 5 to 4 9 26 to 35 ROPS lower frame mounting screw 167 to 196 17 0 to 20 0 123 to 144 Rea...

Page 262: ...eering delivery pipe 39 to 49 4 0 to 4 9 29 to 36 Joint bolt for main delivery pipe 2 39 to 49 4 0 to 4 9 29 to 36 Joint bolt for oil cooler 88 to 98 9 0 to 9 9 65 to 72 Retaining nut for front loader control valve 48 8 to 55 2 4 98 to 5 62 36 0 to 40 7 Hi Lo valve assembly mounting hex socket head screw 29 to 34 3 0 to 3 4 22 to 25 Regulating valve assembly mounting hex socket head screw 29 to 34...

Page 263: ...4 IMPORTANT Q Do not connect the universal joint of the implement to the tractor PTO shaft while testing Condition Engine speed Max speed Oil temperature 40 to 60 C 104 to 140 F Reference Turn to clockwise direction Pressure is increased Turn to counterclockwise direction Pressure is decreased W1012774 PTO operating pressure When PTO shift lever is ENGAGED position 2 30 to 2 50 MPa 23 5 to 25 4 kg...

Page 264: ...N position 3 The Mode Selection Display a is indicated on the LCD 1 And release the switches 4 Press the display mode switch 2 to move the flashing part and flash the E 5 Hold down the display mode switch 2 for more then 2 seconds at this condition and the buzzer rings and Mode E is selected 6 LEVER is displayed b and PUSH SW is displayed c for five seconds 7 Hold down the display mode switch for ...

Page 265: ... f Operate the speed selection lever GST lever as follows disengaged the clutch select forward with the shuttle lever and shift the GST lever from 1 to 12 several times Set the GST lever at the positions other than neutral 8 STEP 05 g Set the GST lever to Neutral position 9 STEP 06 h Set shuttle lever to forward and engage clutch 10 PUSH SW i Push the display mode switch for more than three second...

Page 266: ...ction 9 3 SHOCK is displayed b first and then the numerical code setting is displayed c The number 9 through 9 can be displayed This has been factory adjusted to 0 4 Setting For lighter shifting shock Press the travel speed switch to reduce the number For higher shifting shock Press the display mode switch to increase the number 5 Move the tractor to confirm the shifting shock 6 Turn off the key T...

Page 267: ...dling speed Set the shift levers to Neutral 5 Measure the pressure 6 If the measurement is not within factory specifications adjust the pressure reducing valve adjustor 4 on the regulating valve assembly 5 Condition Engine speed Idling speed Oil temperature 40 to 60 C 104 to 140 F Reference Turn to clockwise direction Pressure is increased Turn to counterclockwise direction Pressure is decreased W...

Page 268: ... the pilot pressure checking port plug PT 1 8 on the GST valve 2 3 Install the adaptor D or GST valve adaptor 3 to the checking port 1 and then install the threaded joint cable and pressure gauge 4 Start the engine and set the maximum speed 5 Disengage the main clutch and shift the GST lever to 1st position shuttle shift lever to Forward or Reverse position 6 Measure the pressure 7 When the pilot ...

Page 269: ... and clutch pack 8 Check the pressure changes while shifting the shuttle shift lever Reverse to Forward and shifting the GST lever from Neutral to 12th or 8th 9 If the pressure does not change correctly check the low pass valve and proportional reducing valve IMPORTANT Q Do not engage the main clutch while checking Condition Engine speed Maximum Oil temperature 40 to 60 C 104 to 140 F Shifting GST...

Page 270: ... to move the flashing part and flash the I 5 Hold down the display mode switch 2 for more than 2 seconds at this condition and the buzzer rings and Mode I is selected 6 MHG is displayed b and the existing symbol setting is flashing 7 Press the display mode switch 2 to move the flashing part and flash the H of the HST model 8 Hold down the display mode switch 2 for more than 2 seconds at this condi...

Page 271: ...g speed 2 Select mode K 3 Hold down the display mode switch for more than 2 seconds 4 HST ADJ b is displayed and release the switch NOTE Q When indication HST ADJ does not change the engine is not idling or the parking brake is not used When ERROR xx is displayed k refer to the below chart 5 PUSH SW is displayed c Hold down the displayed mode switch for more than 2 seconds Reference W1255358 Error...

Page 272: ...Maximum slow position HST pedal Keep the Maximum reverse position 10 STEP 04 is displayed h After completing the above 9 STEP 04 is displayed Then proceed to the next step NOTE Q When ERROR xx m refers to the below chart 11 PUSH SW i is displayed i Hold down the displayed mode switch for more than 2 seconds 12 OK is displayed j The setting has been preserved correctly to the ECU 13 Turn off the ke...

Page 273: ...ing ERROR 75 is displayed h indicated errors as follows The accelerator lever is not in the position of idling The accelerator lever is out of position 5 PUSH SW is displayed c Hold down the displayed mode switch for more than 2 seconds 6 STEP 02 is displayed d and release the switch Set the maximum speed for accelerator lever 7 PUSH SW is displayed e Hold down the displayed mode switch for more t...

Page 274: ...oint in order 5 Check to see that parking brake is applied 6 Run the engine at maximum speed 7 Place the range gear shift lever in H position 8 Depress the HST pedal and measure the check and high pressure relief valve pressure 9 If the measurement is not within the factory specification check the check and high relief valve assembly IMPORTANT Q Measure quickly so that the relief valve may not be ...

Page 275: ...he engine at maximum speed 7 Release the HST pedal to set in neutral and measure the charge pressure 8 If the measurement is not within the factory specifications check charge relief valve or adjust with adjusting shim NOTE Q Adjusting shim is located on between spring guide and plug 7 Reference Thickness of adjusting shim 0 2 mm 0 0082 in Pressure charge per 0 2 mm 0 008 in of shim Approx 50 kPa ...

Page 276: ...to 6 Lift the entire steps as shown below so that the piston can be adjusted 7 If any of the servo piston parts has been replaced readjust the HST neutral position referring to the dimension A of the servo piston adjusting screw 2 8 Start the engine and measure the F and R charge pressures Now adjust the piston neutral position so that the F port side pressure and the R port side one be the same T...

Page 277: ... securely W1063742 HST Pedal NOTE Q When removing the HST pedal carry out the following adjustment 1 Adjust the rod length L so that the face of the HST pedal A becomes horizontal 2 After adjusting the HST pedal perform Mode K Refer to 4 CHECKING AND ADJUSTING at 9 ELECTRICAL SYSTEM section Reference Rod length L 105 mm 4 13 in W1205837 Cruise control lever operating force Factory spec 14 7 to 29 ...

Page 278: ... NOTE Q Do not firmly tighten all screws until most components are attached W1049334 Battery Front Grille Skirt and Bonnet 1 Open the bonnet and disconnect the battery negative cable 2 Disconnect the head light connector and remove the front grille 3 3 Remove the left and right side skirts 2 4 Remove the bonnet 1 NOTE Q When disconnecting the battery cords disconnect the negative cord first when c...

Page 279: ... connector mounting screw 3 103 to 118 N m 10 5 to 12 0 kgf m 75 9 to 86 8 lbf ft Plate mounting screw 4 138 to 147 N m 14 0 to 15 0 kgf m 102 to 108 lbf ft Plate mounting screw 9 167 to 196 N m 17 0 to 20 0 kgf m 123 to 145 lbf ft Tightening torque Fulcrum bolt and nut 10 118 to 137 N m 12 0 to 14 0 kgf m 86 8 to 102 lbf ft 1 Upper Frame 2 Lower Connector 3 Screw M12 55 mm 4 Screw M14 40 mm 5 Top...

Page 280: ...ter sensor 8 and glow plug 6 Disconnect the wiring connector for throttle sensor 10 HST model only When reassembling When the accelerator wire is installed adjust the wiring length as hit both the idling speed adjusting bolt and the maximum speed adjusting bolt by lever within the stroke of the accelerator lever W1138395 1 Shield RH 2 Fuel Tank Frame Support 3 Steering Joint Shaft 2 4 Steering Joi...

Page 281: ...ove the harness bracket with wiring harness W1293536 Panel Cover 1 Remove the floor mat 2 Remove the steering post cover 2 3 and disconnect the shuttle switch connector 4 Manual Transmission and GST Model 3 Remove the steering post cover 1 2 and panel cover 1 W1019247 1 Alternator 2 Fuel Sensor 3 Shield LH 4 Oil Pressure Switch 5 Starter Motor 6 Battery 7 Coolant Temperature Sensor 8 Ground Cable ...

Page 282: ...ct the meter panel connectors 13 and remove the meter panel 12 7 Remove the relays 14 and flasher unit 15 8 Remove the wiring harnesses from the panel frame When reassembling Be sure to check and adjust the clutch and brake pedal free travel Refer to 7 4 CHECK POINTS OF EVERY 100 HOURS at G GENERAL section W1083963 1 Clutch Rod 2 Brake Rod LH 3 Fuse Box 4 Harness Cover 5 Multi Function Switch 6 Be...

Page 283: ...lever 10 position control lever 8 draft control lever 9 if equipped and PTO gear shift lever 11 W1084546 1 Seat 2 Seat Bracket 3 Creep Gear Shift Lever 4 Range Gear Shift Lever 5 Main Gear Shift Lever 6 Front Wheel Drive Lever 7 Cruise Control Lever HST Model 8 Position Control Lever 9 Draft Control Lever If equipped 10 Auxiliary Control Lever 11 PTO Gear Shift Lever A Manual Transmission Model B ...

Page 284: ...ctor 1 3 Remove the proportional valve cover 4 Disconnect the swash plate position sensor connector 2 and proportional valve connectors 3 4 IMPORTANT Q In installing the connector of the proportional valve pay attention to the color of the connector to ensure correct installation W1153706 1 Lowering Speed Adjusting Knob 2 Differential Lock Rod 3 PTO Speed Change Connector 4 Range Gear Shift Rod HS...

Page 285: ...ing the PTO wire 2 to the clutch valve 4 be sure to adjust the length of wire as follows 1 Set the PTO shift lever to OFF Neutral position 2 Loosen the lock nut 3 of wire and connect wire to the clutch valve lever and then place the wire to the hook 3 Tighten the lock nut 3 clockwise pull the wire and lock the nut just before the lever moves W1046922 1 Traveling Speed Sensor Connector 2 PTO wire 3...

Page 286: ...position and then connect the shuttle lever rod securely W1015069 Propeller Shaft 4WD Type Only 1 Slide the propeller shaft cover 4 and 8 after removing the screws 7 2 Tap out the spring pins 2 6 and slide the couplings 1 5 and then remove the propeller shaft with covers 4 8 When reassembling Apply grease to the splines of propeller shaft 1 3 W1069022 Tightening torque Step mounting bolt and nut 1...

Page 287: ...L3540 L4240 L5040 L5240 L5740 WSM TRANSMISSION 3 CABIN MODEL 1 Dismounting Cabin from Tractor Separating Cabin 1 Refer to 6 2 1 Separating Cabin from Tractor at 10 CABIN section W1038316 KiSC issued 04 2010 A ...

Page 288: ...d clutch housing When reassembling Install the O rings 1 3 and collar 2 on the front axle drive shaft 4 as shown in the figure Apply grease to the spline of clutch shaft Apply liquid gasket Three Bond 1211 or equivalent to joint face of the flywheel housing and clutch housing W1069899 Tightening torque Joint screw for PTO delivery pipe 35 to 39 N m 3 5 to 3 9 kgf m 26 to 29 lbf ft 1 Suction Pipe 1...

Page 289: ... When reassembling the shuttle shift arm 5 to the shuttle fork rod 6 be sure to install it to the groove A W1016127 Separating Clutch Housing and Mid Case 1 Remove the clutch housing and mid case mounting screws and nuts 2 Separate the clutch housing and mid case When reassembling Apply liquid gasket Three Bond 1208C or equivalent to joint face of the clutch housing and mid case W10134850 Tighteni...

Page 290: ...ing screws 2 Screw down the two M6 jack bolts 1 into the shaft case 2 and pull it out 3 Take out the shaft case 2 When reassembling Apply liquid gasket Three Bond 1208C or equivalent to joint face of the shaft case and clutch housing When replacing oil seal in shaft case Install the oil seal 3 as shown in the figure noting its direction Apply grease to the oil seal 3 W10128390 Tightening torque Ma...

Page 291: ...sing bearing holder 5 with using two jack bolts 6 NOTE Q Take care not to fly out the detent balls 3 and springs 4 when pull out the bearing holder 5 When reassembling Tap in the clutch housing bearing holder 5 with plastic hummer until contact to clutch housing case and then tighten the screws to specified torque Install the three interlock balls 2 with a small amount of grease to the clutch hous...

Page 292: ...stall the synchronizer keys 9 in the key grooves of the synchronizer rings 6 firmly 1 External Snap Ring 2 Collar 3 Counter Shaft Assembly 4 Shift Rods 5 18T Gear Shaft Assembly 6 Idle Shaft Assembly 7 PTO Counter Shaft Assembly 8 Main Gear Shaft Assembly 1 Internal Snap Ring 2 Bearing 3 Needle Bearing 4 24T Gear 4th 5 External Snap Ring 6 Synchronizer Ring 7 Synchronizer Spring 8 Hub 9 Synchroniz...

Page 293: ...ssion Case 1 Separate the mid case and transmission case after removing their mounting screws When reassembling Confirm to insert the PTO shaft to PTO clutch firmly turning the PTO shaft Apply liquid gasket Three Bond 1208C or equivalent to joint face of the mid case and transmission case W1074779 Tightening torque Joint screw for PTO delivery pipe 35 to 39 N m 3 5 to 4 0 kgf m 26 to 28 lbf ft 1 S...

Page 294: ... case bearing holder mounting screws and then take out the bearing holder 2 with PTO clutch 1 as a unit NOTE Q Take care not to fly out the ball 5 and spring 4 when pull out the bearing holder 2 When reassembling Tap in the mid case bearing holder 2 with plastic hummer until contact to mid case and then tighten the screws to specified torque W1019191 Tightening torque Clutch housing and mid case m...

Page 295: ...ransmission fluid to the needle bearings 3 and thrust collar 13 Direct the grooved side of the thrust collar 13 to the needle bearing 3 side Install the external snap ring 7 to the groove of the shuttle shaft 2 firmly Install the synchronizer keys 6 in the key grooves of the synchronizer rings 5 12 firmly W1019932 1 Reverse Gear Shaft 2 Shuttle Gear Shaft 3 Shuttle Shaft Assembly 4 Shuttle Fork Ro...

Page 296: ... steel plates Assemble the plug rubbers portion of the three steel plates 6 are same positions while assembling them Refer to figure below Apply enough transmission fluid to the discs 5 Confirm the moving of the piston 11 smoothly when pressure air at 0 29 to 0 39 MPa 3 to 4 kgf cm2 42 to 57 psi is sent to clutch pack Refer to the figure left W10159250 Accumulator of PTO Clutch 1 Remove the intern...

Page 297: ... and be sure to install the three O rings 5 W10167880 Piston 1 Press the washer 7 lightly by the hand press using the hand made jig Refer to the figure left 2 Remove the external snap ring 3 washer 7 and spring 6 3 Draw out the piston 5 When reassembling Apply enough transmission fluid to seal rings 4 and 8 W10169240 1 External Snap Ring 2 Collar 3 Bearing Holder 4 Collar 5 Brake Disc 6 Brake Plat...

Page 298: ...wheel drive lever 10 5 Disconnect the brake rods 11 6 Remove the ROPS lower frames 3 When reassembling W1142329 1 Main Delivery Pipe 1 2 PTO Speed Change Rod Tightening torque Rear wheel mounting screw and nut 220 N m 22 kgf m 160 lbf ft Tightening torque Lift arm pin mounting nut 78 to 90 N m 7 9 to 9 2 kgf m 58 to 66 lbf ft Lift arm pin lock nut 63 to 72 N m 6 4 to 7 4 kgf m 47 to 53 lbf ft Draw...

Page 299: ...tly When reassembling Apply grease to the steel ball seats Do not grease excessively Apply liquid gasket Three Bond 1208C or equivalent to joint face of the brake cae and transmission case Be sure to apply liquid gasket to A position Be sure to fix the brake cam and cam plate Before installing the brake case to the transmission case install the cam plate to the transmission case W10194530 Tighteni...

Page 300: ...emove the lock nut 5 3 Remove the pinion bearing case mounting screws 4 Take out the pinion bearing cover 4 and shims 1 When reassembling Make sure of the number of shims in the pinion bearing case Replace the lock nut 5 with a new one and stake the lock nut firmly after installing the parts on the shaft W1022792 Tightening torque Mid case and transmission case mounting screw 78 to 90 N m 7 9 to 9...

Page 301: ...earing holder 1 When reassembling Tap in the transmission bearing holder with soft hummer until contact to transmission case and then tighten the screws to specified torque Tap in the spring pin 8 so that its split portion may face forward Refer to figure W1023062 Tightening torque Transmission bearing holder mounting screw 48 to 55 N m 4 9 to 5 7 kgf m 36 to 41 lbf ft 1 Transmission Bearing Holde...

Page 302: ...mbling Shaft Assemblies 1 Disassembling the each shaft referring to the figure W1079930 1 Traveling Speed Sensor 2 Creep Gear 3 External Snap Ring 4 Creep Gear Shaft 5 Front Wheel Drive Shaft 6 PTO Drive Shaft 7 Spiral Bevel Pinion Shaft 8 Range Gear Shaft 9 Shift Fork Rod 10 Shift Fork 11 Shift Fork Rod 1 49T 19T 20T Gear 2 Range Gear Shaft 3 17T Gear 4 35T Gear 5 50T Gear 6 18T Gear L3540 19T Ge...

Page 303: ...ne After replacing be sure to stake it firmly Install the slinger 5 firmly Apply grease to the oil seal 4 and install it noting its direction W10242030 Differential Gear Assembly 1 Remove the differential support noting the number of left shims 2 Take out the differential gear assembly noting the number of right shims When reassembling Check the spiral bevel gear for wear or damage If it is no lon...

Page 304: ...he inner circumferential surface of the differential side gear boss W10247220 Spiral Bevel Gear 1 Remove the spiral bevel gear When reassembling Check the spiral bevel gear for wear or damage If it is no longer serviceable replace it Then also replace the spiral bevel pinion shaft Apply liquid lock Three Bond 1372 or equivalent to the spiral bevel gear UBS screws W10249330 Tightening torque Differ...

Page 305: ... Three Bond 1901 or equivalent to the inner circumferential surface of the differential pinions Install the parts to their original position Install the differential pinion washer 4 noting its groove position W10250420 Differential Side Gear 1 Take out the differential side gear 2 and differential side gear washer 1 When reassembling Check the thrust and bearing surface of both differential side g...

Page 306: ...tch housing When reassembling Install the O rings 1 3 and collar 2 on the front axle drive shaft 4 as shown in the figure Apply grease to the spline of clutch shaft Apply liquid gasket Three Bond 1211 or equivalent to joint face of the flywheel housing and clutch housing W1081825 Tightening torque Joint screw for PTO delivery pipe 35 to 39 N m 3 5 to 3 9 kgf m 26 to 28 lbf ft 1 Suction Pipe 1 2 PT...

Page 307: ...Draw out the clutch lever 3 to remove the release fork 1 When reassembling Make sure the direction of the release fork 1 is correct Inject grease to the release hub 7 Be sure to set the snap pins 6 W1307531 Tightening torque Release fork setting screws 24 to 27 N m 2 4 to 2 8 kgf m 18 to 20 lbf ft 1 Release Fork 2 Fork Key 3 Clutch Lever 4 Setting Screw 5 Release Bearing 6 Snap Pin 7 Release Hub K...

Page 308: ...sition main range shift pin 10 at L position forward and sub range shift pin 11 at Hi position rearward and then assemble the GST valve Be sure to match the each shift pin and shift piston Apply liquid gasket Three Bond 1208C or equivalent to joint face of the GST valve assembly Install the GST valve 4 by hand and then tighten the screws Do not use the hummer Replace the pipe 9 with a new one if d...

Page 309: ...ws 2 Screw down the two M6 jack bolt 1 into the shaft case 2 and pull it out 3 Take out the shaft case 2 When reassembling Apply liquid gasket Three Bond 1208C or equivalent to joint face of the shaft case and clutch housing When replacing oil seal in shaft case Install the oil seal 3 as shown in the figure noting its direction Apply grease to the oil seal 3 W10838340 Tightening torque Clutch hous...

Page 310: ...er 4 with using two jack bolts 3 When reassembling Tap in the clutch housing bearing holder 4 with plastic hummer until contact to clutch housing case and then tighten the screws to specified torque Install the three interlock balls 2 with a small amount of grease to the clutch housing bearing holder 4 after setting the shift forks and shift rods to the neutral position W1049879 1 24T Gear Shaft L...

Page 311: ...t side after assembling the clutch housing and mid case Then install the bearing 13 sleeve 14 collar 15 oil seal 12 internal snap ring 11 O ring 16 and spacer 17 in order W1050076 1 External Snap Ring 2 Collar 3 Shuttle Shift Arm 4 18T Gear Shaft Assembly 5 Idle Shaft Assembly 6 PTO Counter Shaft Assembly 7 Main Gear Shaft Assembly 8 Front Axle Drive Shaft 9 Counter Shaft Assembly 10 Shift Fork 11...

Page 312: ...ngs 5 When reassembling Reinstall the synchronizer keys 9 in the key grooves of the synchronizer rings 6 firmly W1050447 1 Internal Snap Ring 2 Bearing 3 Needle Bearing 4 24T Gear 4th 5 External Snap Ring 6 Synchronizer Ring 7 Synchronizer Spring 8 Hub 9 Synchronizer Key 10 Shifter 11 29T Gear 3rd 12 Counter Shaft 13 34T Gear 2nd 14 Needle Bearing 15 37T Gear 1st 16 Bearing 17 Bearing Holder KiSC ...

Page 313: ...nge shift pin 6 at L position forward and then assemble the GST valve Be sure to match the each shift pin and shift piston Install the GST valve 1 by hand and then tighten the screws Do not use the hummer Apply liquid gasket Three Bond 1208C or equivalent to joint face of the GST valve assembly Replace the pipe 5 with a new one if damaged W1050592 Tightening torque Joint screw for PTO delivery pip...

Page 314: ...install it to the groove A W1051037 PTO Clutch Valve 1 Remove the PTO clutch valve 2 as a unit 2 Pull out the pipe 1 When reassembling Apply small amount of grease for the O ring 3 Install the pipe 1 to the hole 4 of the PTO clutch valve 2 firmly Replace the pipe 1 with a new one W1180630 Tightening torque Mid case and transmission case mounting screw 78 to 90 N m 7 9 to 9 2 kgf m 58 to 66 lbf ft ...

Page 315: ...othly when pressure air at 0 29 to 0 39 MPa 3 to 4 kgf cm2 42 to 57 psi is sent to clutch pack Air must be sent from hole A W1180845 Shaft Assemblies 1 Pull out the sub range shift rod 4 and remove the shift fork 3 2 Remove the external snap ring 2 which is located at rear side of the mid case 3 Draw out the shaft assemblies 1 5 6 and shuttle fork rod 7 W1183161 Disassembling PTO Clutch Refer to 2...

Page 316: ...he figure W1051729 Clutch Case and GST Clutch Piston 1 Remove the external snap ring 1 while pushing the spring retainer 2 by hand press 2 Take out the spring retainer 2 springs 3 and piston 4 When reassembling Apply small amount of the grease to the seal rings 8 when assemble the clutch case 7 Apply enough transmission fluid to the O ring 6 and D ring 5 W1052192 1 Clutch Case 2 Clutch Hub 3 Clutc...

Page 317: ...ap ring 18 and remove the hub 17 with shifter and synchronizer rings When reassembling Direct the groove side of the thrust collars 4 21 to the gear side Reinstall the synchronizer keys in the key grooves of the synchronizer rings Direct the groove side of the hub 8 and shuttle forward shaft 14 as shown in figure Apply enough transmission fluid to the needle bearings 9 12 15 20 W1052955 1 External...

Page 318: ...g stand under the transmission case and support it with a jack 2 Remove the rear wheels 3 After removing the rear wheels support it at both sides of rear axle by stands When reassembling W1187806 Tightening torque Joint screw for PTO delivery pipe 35 to 39 N m 3 5 to 4 0 kgf m 26 to 29 lbf ft 1 Main Delivery Pipe 2 2 GST Pipe 3 Brake Rod 4 Orifice 5 Joint Screw Tightening torque Rear wheel mountin...

Page 319: ...en reassembling Apply liquid gasket Three Bond 1208C or equivalent to joint face of the rear axle and brake case W1054206 Tightening torque Lift arm pin mounting nut 77 5 to 90 2 N m 7 9 to 9 2 kgf m 57 1 to 66 5 lbf ft Lift arm pin lock nut 62 8 to 72 6 N m 6 4 to 7 4 kgf m 46 3 to 53 5 lbf ft Drawbar frame mounting screw M12 77 5 to 90 2 N m 7 9 to 9 2 kgf m 57 1 to 66 5 lbf ft Drawbar frame mou...

Page 320: ... shift piston Install the GST valve by hand and then tighten the screws Do not use the hummer Apply liquid gasket Three Bond 1208C or equivalent to joint face of the GST valve assembly Replace the pipe 3 with a new one if damaged W1139844 Separating Mid Case and Transmission Case 1 Separate the mid case and transmission case after removing their mounting screws and nut When reassembling Confirm to...

Page 321: ...by copper hummer or soft hummer 4 Jack up more and remove the transmission bearing holder 1 When reassembling Tap in the transmission bearing holder with soft hummer until contact to transmission case and then tighten the screws to specified torque Tap in the spring pin 8 so that its split portion may face forward Refer to figure W1089880 Tightening torque Lock nut 150 to 190 N m 15 to 20 kgf m 11...

Page 322: ... front wheel drive shaft assembly 5 W1121735 Disassembling Shaft Assemblies 1 Disassemble the each shaft referring to the figure W1055343 1 Traveling Speed Sensor 2 Creep Gear 3 External Snap Ring 4 Creep Gear Shaft 5 Front Wheel Drive Shaft 6 PTO Drive Shaft 7 Spiral Bevel Pinion Shaft 8 Range Gear Shaft 9 Shift Fork Rod 10 Shift Fork 11 Shift Fork Rod 1 49T 19T 20T Gear 2 Range Gear Shaft 3 17T ...

Page 323: ...ne After replacing be sure to stake it firmly Install the slinger 5 firmly Apply grease to the oil seal 4 and install it noting its direction W12044640 Differential Gear Assembly 1 Remove the differential support noting the number of left shims 2 Take out the differential gear assembly noting the number of right shims When reassembling Check the spiral bevel gear for wear or damage If it is no lon...

Page 324: ...3 S87 L3540 L4240 L5040 L5240 L5740 WSM TRANSMISSION Disassembling Differential Gears Refer to 3 Transmission of 1 MANUAL TRANSMISSION MODEL in this section W1056552 KiSC issued 04 2010 A ...

Page 325: ...e power steering hydraulic pump 7 When reassembling Install the copper washers firmly Apply grease to the O ring 6 and take care not to damage it W1056783 1 Bonnet 2 Skirt RH 3 Front Grille Tightening torque Joint bolt for PTO GST delivery pipe 5 and regulating valve 35 to 39 N m 3 5 to 4 0 kgf m 26 to 28 lbf ft Joint bolt for power steering delivery pipe 4 and regulating valve 40 to 49 N m 4 0 to...

Page 326: ...en take out the spring 13 and the poppet 9 5 Take out the spring retainer 5 and spring 10 When reassembling Take care not to damage the O rings IMPORTANT Q After reassembling the adjustment of regulating pressure should be performed W1057149 Tightening torque Joint bolt 14 35 to 39 N m 3 5 to 4 0 kgf m 26 to 28 lbf ft Plate 8 9 8 N m 1 0 kgf m 7 2 lbf ft Regulating valve case and support mounting ...

Page 327: ...ing valve connector 2 solenoid valve connector 5 and oil temperature sensor connector 4 3 Disconnect the GST delivery pipe 3 4 Remove the GST valve assembly 6 with using two jack bolts NOTE Q Do not fall down the shuttle check pin while assembling When reassembling Place the 1 2 shift pin 7 and the 3 4 shift pin 8 at neutral position main range shift pin 10 at L position forward and sub range pin ...

Page 328: ...positions as shown in the photo and table below W1058270 No Solenoid Name Color of wiring 6 Shift Solenoid 1 1st shift Black 1 Shift Solenoid 2 2nd shift White 3 Shift Solenoid 3 3rd shift Red 2 Shift Solenoid 4 4th shift Green 5 Shift Solenoid 5 Sub range shift Blue 4 Shift Solenoid 6 Main range shift Yellow 1 Solenoid 2 2 Solenoid 4 3 Solenoid 3 4 Solenoid 6 5 Solenoid 5 6 Solenoid 1 7 Cover 8 C...

Page 329: ...t the springs 13 balls 12 and filter 14 from upper body 2 When reassembling Take care so that only the main range shift check pin 6 is short length W1058592 Tightening torque Lower body mounting hex socket head cap screw 9 8 to 10 N m 1 0 to 1 1 kgf m 7 3 to 7 9 lbf ft 1 Hex Socket Head Cap Screw 2 Upper Body 3 Plate 4 Lower Body 5 Ball 6 Main Range Shift Check Pin 7 Sub range Shift Check Pin 8 Sh...

Page 330: ...iston 4 Remove the internal snap ring 12 and cover 8 and then take out the shift piston 7 11 For main range and sub range shift piston When reassembling Take care not to damage the O ring 13 and piston seal 14 W1059069 1 Internal Snap Ring 2 Cover 3 Neutral Piston 4 3 4 Shift Piston 5 Shifter 6 Spring Pin 7 Sub range Shift Piston 8 Cover 9 1 2 Shift Piston 10 Lower Body 11 Main Range Shift Piston ...

Page 331: ...ody 2 Remove the plug 5 3 Remove the stopper plate 6 and remove the low pass poppet 4 and spring 3 W1059505 Clutch Valve 1 Separate the upper body and lower body 2 Remove the stopper plate 4 while pushing the plug 1 3 Take out the spool 2 and spring 3 When reassembling Be careful about the direction of the spool 2 and the plugs 1 referring to the figure W1059735 1 Lock Nut 2 Adjustor 3 Spring 4 Lo...

Page 332: ...ng W1059897 Check Valve Oil Temperature Sensor Orifice and Filter 1 Remove the oil temperature sensor 3 and take out the spring 2 and ball 1 2 Remove the plug 6 and take out the spring 5 and orifice plug 4 with filter 7 When reassembling Be careful about the direction of the orifice support 4 and filter 7 W1060139 1 Hex Socket Head Cap Screw 2 Proportional Reducing Valve 3 Plug 4 Orifice Support 5...

Page 333: ...peller shaft 2 4 as shown in the figure Apply grease to the spline of clutch shaft Apply liquid gasket Three Bond 1211 or equivalent to joint face of the flywheel housing and clutch housing W1298437 Tightening torque Joint screw for power steering delivery pipe 39 to 49 N m 4 0 to 4 9 kgf m 29 to 36 lbf ft Joint screw for main delivery pipe 2 39 to 49 N m 4 0 to 4 9 kgf m 29 to 36 lbf ft Joint scr...

Page 334: ...ly grease to the oil seal 11 W11671250 Filter Bracket Suction Pipes and Brake Rod 1 Remove the suction pipes 5 2 Remove the hydraulic filter with bracket 2 3 Remove the brake rods 4 4 Remove the PTO delivery pipe 1 5 Remove the HST suction pipe 3 When reassembling Apply oil to the O rings Replace the gasket 6 with a new one W11679360 Tightening torque Release fork mounting screw 24 to 27 N m 2 4 t...

Page 335: ...g screws and nuts 2 Separate the clutch housing and mid case When reassembling Be sure to install the gasket W10679060 Tightening torque Clutch housing and mid case mounting nut 103 to 117 N m 10 5 to 12 0 kgf m 76 0 to 86 7 lbf ft Clutch housing and mid case mounting screw 78 to 90 N m 7 9 to 9 2 kgf m 58 to 66 lbf ft KiSC issued 04 2010 A ...

Page 336: ...ay stick to the port block but they are not fixed Take care not to drop them And these valve plates are not interchangeable W1018180 Tightening torque Hi Lo valve assembly mounting hex socket head screw 29 to 34 N m 3 0 to 3 4 kgf m 22 to 25 lbf ft 1 Hi Lo valve Assembly Tightening torque Regulating valve assembly mounting hex socket head screw 29 to 34 N m 3 0 to 3 4 kgf m 22 to 25 lbf ft 1 Regul...

Page 337: ...ear shaft 2 5 Take out the 24T gear 4 When reassembling Be sure to install the gasket When replacing oil seal in shaft case Install the oil seal 5 as shown in the figure noting its direction Apply grease to the oil seal 5 Replace the gasket with a new one W1019266 Tightening torque Shaft case mounting bolt 24 to 28 N m 2 5 to 2 8 kgf m 18 to 20 lbf ft 1 Shaft Case 2 26T Gear Shaft 3 M6 Jack Bolt 4...

Page 338: ...ounting hex socket head screws 6 3 Tap the pump shaft 3 with a plastic hammer slightly to slide out it with cradle bearing bracket 5 to the rear side 4 Pull out the pump shaft 3 When reassembling Place the swashplate 1 into the housing align the slot guide 4 of swashplate and groove 2 of servo piston Apply clean transmission oil to the surface of swashplate and cradle bearing W1018971 1 Motor Cyli...

Page 339: ...sition in this section W1019685 Hi Lo Valve 1 Remove the hex socket head screw 6 and remove the spring 5 and Hi Lo spool 4 2 Remove the hex socket head screw 1 and remove the pressure selector 2 3 Remove the cover 9 4 Remove the external snap ring 7 5 Remove the Hi Lo solenoid 8 with connector When reassembling Be sure to install the belleville spring 10 Replace the gasket 11 with a new one W11015...

Page 340: ...gh Pressure Relief Valve 1 Remove the hex socket head plug 1 and remove the spring 3 and relief valve assembly 4 5 When reassembling Take care not to damage the O ring on the plug W1018316 Tightening torque Hex socket head plug of change relief valve 30 to 37 N m 3 1 to 3 7 kgf m 23 to 27 lbf ft 1 Valve Poppet 2 Spring 3 Spring Guide 4 Shim 5 Hex Socket Head Plug Tightening torque Hex Socket head ...

Page 341: ...e The PTO delivery pipe joint screw 8 with orifice 7 assemble to PTO valve Check the orifice hole is not clogged W12151920 Hydraulic Pipes 1 Remove the delivery pipe 1 for 3 point hitch When reassembling W12155150 Tightening torque Joint screw for PTO delivery pipe 34 to 39 N m 3 5 to 3 9 kgf m 25 to 28 lbf ft 1 PTO Delivery Pipe 2 Bracket 3 HST Suction Pipe 4 Brake Rod 5 Suction Pipe 6 Gasket 7 O...

Page 342: ...PTO clutch valve 2 as a unit 2 Pull out the pipe 1 When reassembling Apply small amount of grease for the O ring 3 Install the pipe 1 to the hole 4 of the PTO clutch valve 2 firmly Replace the pipe 1 with a new one W1260974 Tightening torque Mid case and transmission case mounting screw 78 to 90 N m 7 9 to 9 2 kgf m 58 to 66 lbf ft Mid case and transmission case mounting nut 103 to 117 N m 10 5 to...

Page 343: ...ith plastic hummer until contact to mid case and then tighten the screws to specified torque W1072101 Disassembling PTO Clutch 1 Refer to 2 Mid Case of 1 MANUAL TRANSMISSION MODEL in this section W1294451 Tightening torque Mid case bearing holder mounting screw 48 to 55 N m 4 9 to 5 7 kgf m 36 to 41 lbf ft 1 PTO Drive Shaft 2 Mid Case Bearing Holder 2 3 Mid Case 4 21T Gear Shaft 5 Mid Case Bearing...

Page 344: ...reassembling Apply oil to the O rings Replace the gasket 6 with a new one The PTO delivery pipe joint screw 8 with orifice 7 assemble to PTO valve Check the orifice hole is not clogged W11273620 Hydraulic Pipes 1 Remove the delivery pipe 1 for 3 point hitch When reassembling W12164570 Tightening torque Rear wheel mounting screw and nut 220 N m 22 kgf m 160 lbf ft Tightening torque Joint screw for ...

Page 345: ...le and brake case W1266378 Tightening torque Lift arm pin mounting nut 78 to 90 N m 7 9 to 9 2 kgf m 58 to 66 lbf ft Lift arm pin lock nut 63 to 72 N m 6 4 to 7 4 kgf m 47 to 53 lbf ft Drawbar frame mounting screw M12 78 to 90 N m 7 9 to 9 2 kgf m 58 to 66 lbf ft Drawbar frame mounting screw M14 167 to 196 N m 17 0 to 20 0 kgf m 123 to 144 lbf ft Hydraulic cylinder hose retaining nut 35 to 48 N m ...

Page 346: ...ly Apply liquid gasket Three Bond 1208C or equivalent to joint face of the mid case and transmission case W1073847 Pinion Bearing Cover 1 Remove the stake of lock nut 5 2 Lock the turning of spiral bevel pinion and remove the lock nut 5 3 Remove the pinion bearing case mounting screws 4 Take out the pinion bearing cover 4 and shims 1 When reassembling Make sure of the number of shims in the pinion...

Page 347: ...smission bearing holder 1 When reassembling Tap in the transmission bearing holder with soft hummer until contact to transmission case and then tighten the screws to specified torque Tap in the spring pin 8 so that its split portion may face forward Refer to figure W1267434 Tightening torque Transmission bearing holder mounting screw 48 to 55 N m 4 9 to 5 7 kgf m 36 to 41 lbf ft 1 Transmission Bea...

Page 348: ...ront wheel drive shaft 2 When reassembling Apply transmission fluid to needle bearings 12 W1268230 1 Traveling Speed Sensor 2 Front Wheel Drive Shaft 3 PTO Drive Shaft 4 Spiral Bevel Pinion Shaft 5 Range Gear Shaft 6 Shift Fork 7 52T Gear 8 35T Shifter Gear 9 Spline Boss 10 19T Gear 11 19T Gear L4240 16T Gear L5240 L5740 12 Needle Bearing 13 29T Gear 4240 31T Gear L5240 L5740 14 24T Shifter Gear L...

Page 349: ...move the bearing case mounting screws and draw out the PTO shaft 1 with bearing case 2 3 Remove the internal snap ring 3 4 Top out the PTO shaft 1 to the front When reassembling If the lock nut 6 was removed replace it with a new one After replacing be sure to stake it firmly Install the slinger 7 firmly Apply grease to the oil seal 4 and install it noting its direction W12700450 1 Differential Lo...

Page 350: ...m regulating valve 8 5 Remove the PTO delivery pipe 7 6 Remove the regulating valve assembly 8 When reassembling IMPORTANT Q When installing the connector of the proportional valve pay attention to the color of the connector to ensure correct installation W11996110 Tightening torque Differential support mounting screw 48 to 55 N m 4 9 to 5 7 kgf m 36 to 41 lbf ft Tightening torque Joint bolt for m...

Page 351: ...e plugs 12 15 4 Remove the spring retainers 8 21 with balls 7 22 5 Remove the springs 9 20 6 Remove the collar 11 and retainer 19 with ball 18 7 Remove the spools 10 17 When reassembling Take care not to damage the O rings W12002100 1 Cap Nut 2 O ring 3 Lock Nut 4 O ring 5 Plug 6 O ring 7 Ball 8 Retainer 9 Spring 10 Spool 11 Collar 12 Plug 13 O ring 14 O ring 15 Plug 16 Valve Body 17 Spool 18 Ball...

Page 352: ...rk and Shift Gear Groove 1 Place for in the groove to check clearance with feeler gauge 2 If the clearance exceeds allowable limit replace W10269970 Clearance between Gear and Shaft 1 Measure the shaft O D rubbing surface 2 Measure the gear I D rubbing surface 3 Measure the O D of the two needles installed diagonally in the needle bearing 4 Calculate the clearance Clearance Gear I D 2 needle O D s...

Page 353: ...e spring for fatigue or wear on the area where the spring contacts with the keys 3 If there is any defect replace them W1021026 Side Clearance between Synchronizer Ring and Gear In Contact 1 Press the synchronizer ring against the tapered portion of the gear and measure the side clearance 2 Apply thin film of red lead to the tapered portion press the ring against it by hand rub them together a few...

Page 354: ...3 If the gauge can be inserted replace it W1021557 Piston Return Spring Free Length 1 Measure the free length of spring with vernier calipers 2 If the measurement is less than the allowable limit replace it W1021677 Thickness of PTO clutch disc Factory spec 1 70 to 1 90 mm 0 0670 to 0 0748 in Allowable limit 1 55 mm 0 0610 in Thickness of PTO steel plate Factory spec 1 15 to 1 25 mm 0 0453 to 0 04...

Page 355: ...ck the turning torque by using turning torque tool 1 Turning Torque Tool Weld socket on the brake shaft Brake shaft Part No TA040 26710 3 Add or reduce the thickness of shims 3 to make the specified turning torque 4 After getting the specified turning torque divide the thickness of shims to left and right side 5 Assemble the transmission case and adjust the backlash and tooth contact with spiral b...

Page 356: ... in 1 0 mm 0 039 in 0 5 mm 0 020 in 0 8 mm 0 031 in 1 2 mm 0 047 in 0 6 mm 0 024 in 0 9 mm 0 035 in 1 4 mm 0 055 in Thickness of shims 6 0 4 mm 0 016 in 0 8 mm 0 031 in 1 2 mm 0 047 in 0 6 mm 0 024 in 1 0 mm 0 039 in 1 6 mm 0 063 in W10279260 More than 35 contact area on the gear tooth surface The center of tooth contact at 1 3 of the entire width from the small end W10187470 Replace the adjusting...

Page 357: ...r washer 1 5 mm 0 059 in 1 7 mm 0 067 in 1 6 mm 0 063 in W10289200 Clearance between differential case bore and differential side gear boss Factory spec 0 050 to 0 151 mm 0 0020 to 0 00594 in Allowable limit 0 35 mm 0 014 in Differential case bore I D Factory spec 40 500 to 40 550 mm 1 5945 to 1 5964 in Differential side gear boss O D Factory spec 40 388 to 40 450 mm 1 5901 to 1 5925 in Clearance ...

Page 358: ...s less than the allowable limit replace it W1061099 Flatness of Piston and Steel Plate 1 Place the part on a surface plate 2 Check it unable to insert a feeler gauge allowable limit size underneath it at least four points 3 If the gauge can be inserted replace it W1061290 Piston Return Spring Free Length 1 Measure the free length of spring with vernier calipers 2 If the measurement is less than th...

Page 359: ...1 Measure the thickness of seal rings 1 with an outside micrometer 2 If the measurement is less than the allowable limit replace it W1061536 Thickness of seal ring Factory spec 2 45 to 2 50 mm 0 0965 to 0 0984 in Allowable limit 2 0 mm 0 079 in 1 Seal Ring KiSC issued 04 2010 A ...

Page 360: ...aft and Motor Shaft 1 Check the seal surface 4 and the bearing surface 3 2 If the shaft is rough or groove replace it W1026037 Cylinder Block Bore and Pistons 1 Lift the pistons gently with the retainer plate 1 2 Check the pistons for their free movement in the cylinder block bores 3 If the piston or the cylinder block bore is scored replace cylinder block assembly W1026142 Piston Slipper 1 Check ...

Page 361: ...ecking coat them with transmission oil Valve plates are not interchangeable W1026799 Swashplate and Cradle Bearing 1 Check the piston contact face of swashplate 1 for scratched and excessive wear and check the holes 2 of swashplate 1 for clogged 2 If worn or scored replace and if holes are clogged clean them 3 Check the surface of cradle bearings 3 for scratches and excessive wear 4 If worn or sco...

Page 362: ...ure Refer to 3 HYDRAULIC TRANSMISSION HST MODEL of 4 CHECKING AND ADJUSTING in this section W1027404 Servo Piston 1 Check the surface of servo piston for scratches and excessive wear 2 If worn or scored replace the servo piston assembly W1027526 Hi Lo Valve 1 Check the surface of Hi Lo spool 4 and pressure selector 2 for scratches and damage 2 If anything unusual replace the Hi Lo valve assembly W...

Page 363: ...4 REAR AXLE KiSC issued 04 2010 A ...

Page 364: ...CONTENTS MECHANISM 1 STRUCTURE 4 M1 KiSC issued 04 2010 A ...

Page 365: ...ear wheels The rotation speed is reduced by the final gears 9 The rear axles are the semi floating type with the ball bearing 1 between the rear axle 2 and rear axle case 3 which support the rear wheel load besides transmitting power to the rear wheel The rear axles also support the weight of the tractor 1 Ball Bearing 2 Rear Axle 3 Rear Axle Case 4 Differential Gear Shaft 5 Brake Case 6 Brake Dis...

Page 366: ...1 Rear Axle Cover 2 Ball Bearing 3 Rear Axle 4 Rear Axle Case 5 Spacer 6 Differential Gear Shaft 7 Brake Case 8 Brake Disc 9 Differential Pinion 10 Ring Gear 11 Differential Side Gear 12 Differential Case 13 Differential Lock Shifter 14 Final Gear KiSC issued 04 2010 A ...

Page 367: ...CONTENTS SERVICING 1 TROUBLESHOOTING 4 S1 2 TIGHTENING TORQUES 4 S2 3 PREPARATION 4 S3 4 DISASSEMBLING AND ASSEMBLING 4 S6 KiSC issued 04 2010 A ...

Page 368: ...bable Cause Solution Reference Page Excessive or Unusual Noise at All Time Bearing worn Replace Insufficient or improper type of transmission fluid used Replenish or change G 9 Noise while Turning Differential gear shaft and final gear worn or damaged Replace 4 S5 S6 KiSC issued 04 2010 A ...

Page 369: ... 197 to 225 20 0 to 23 0 145 to 166 ROPS lower frame mounting screw 167 to 196 17 0 to 20 0 123 to 144 Cabin mounting bolt and nut 123 to 147 13 0 to 15 0 94 1 to 108 Cabin mount bracket mounting screw 167 to 196 17 0 to 20 0 123 to 144 Rear axle case mounting screw M10 48 to 55 4 9 to 5 7 36 to 41 Rear axle case mounting nut M10 9T 61 to 70 6 2 to 7 2 45 to 52 Rear axle case mounting screw M12 79...

Page 370: ...ands of fluid together W1012304 Rear Wheel and ROPS ROPS Model 1 Place the disassembling stand under the transmission case 2 Remove the rear wheel mounting screws and nuts 3 Remove the rear wheels 4 Remove the top link 2 and lift rod 4 5 Disconnect the check chain 6 and remove the lower link 5 6 Remove the ROPS lower frame mounting screws 7 Dismount the ROPS assembly 1 3 When reassembling W1011043...

Page 371: ... the washers plate and mount rubbers etc in their original positions W1011906 Cabin Mount Bracket Cabin Model 1 Remove the cabin mount bracket 1 When reassembling W1013640 Tightening torque Rear wheel mounting screw and nut 197 to 225 N m 20 0 to 23 0 kgf m 145 to 166 lbf ft Cabin mounting bolt and nut 128 to 147 N m 13 0 to 15 0 kgf m 94 1 to 108 lbf ft 1 Lift Rod 2 Lower Link 3 Check Chain 4 Blo...

Page 372: ...case from brake case When reassembling Apply liquid gasket Three Bond 1208C or equivalent to joint face of the rear axle case and brake case W10113490 Tightening torque Rear axle case mounting screw and nut M10 screw 48 to 55 N m 4 9 to 5 7 kgf m 36 to 41 lbf ft M10 nut 9T Except L3540 61 to 70 N m 6 2 to 7 2 kgf m 45 to 52 lbf ft M12 screw Except L3540 78 to 90 N m 7 9 to 9 2 kgf m 58 to 66 lbf f...

Page 373: ...PECIAL TOOLS at G GENERAL section L5040 L5240 L5740 When reassembling Apply grease to the oil seal 2 and install it Replace the lock nut with new one and after tightening it to specified torque stake it firmly Assemble the oil seal 2 with correct direction See figure W10116810 1 Rear Axle 2 Oil Seal 3 Internal Snap Ring 4 Ball Bearing 5 Spacer 6 Rear Axle Case 7 Gear 8 Lock Nut 9 Ball Bearing 10 B...

Page 374: ...5 BRAKES KiSC issued 04 2010 A ...

Page 375: ...CONTENTS MECHANISM 1 STRUCTURE 5 M1 2 OPERATION 5 M2 KiSC issued 04 2010 A ...

Page 376: ...rake pedals through the mechanical linkages The parking brake is a mechanical type which is designed to actuate the travelling brakes Pulling the parking brake lever 10 results in the same state as that obtained when the brake cam lever 4 are operated 1 Brake Pedal Turnbuckle Rod 2 Brake Pedal 3 Brake Rod 4 Brake Cam Lever 5 Parking Brake Rod 6 Brake Disc 7 Brake Plate 8 Cam Plate 9 Parking Brake ...

Page 377: ...wo brake discs are provided respectively and the plate 6 fixed to the brake case are arranged between the brake discs Q During Braking When the brake pedal is pressed the force causes the brake cam lever 5 to move in the direction of allow through the brake rod At the same time the brake cam 7 spline couples with the brake cam lever also moves Due to this force cam plate 3 moves in the direction o...

Page 378: ...OOTING 5 S1 2 SERVICING SPECIFICATIONS 5 S2 3 TIGHTENING TORQUES 5 S3 4 CHECKING AND ADJUSTING 5 S4 1 BRAKE PEDAL 5 S4 5 DISASSEMBLING AND ASSEMBLING 5 S5 1 BRAKE PEDAL 5 S5 2 BRAKE CASE 5 S7 6 SERVICING 5 S11 KiSC issued 04 2010 A ...

Page 379: ...ped Replace 5 S10 S11 Brake Drags Brake pedal play too small Adjust 5 S4 Ball holes of cam plate for uneven wear Replace 5 S10 S11 Brake pedal return spring weaken or broken Replace 5 S6 Brake cam rusted Repair 5 S10 Poor Braking Force Brake pedal play excessive Adjust 5 S4 Brake disc worn Replace 5 S10 Cam plate warped Replace 5 S10 Brake cam or lever damaged Replace 5 S10 Transmission fluid impr...

Page 380: ...t Brake Pedal Free Travel 15 to 20 mm 0 59 to 0 78 in Cam Plate Flatness 0 30 mm 0 012 in Cam Plate and Ball Height 20 9 to 21 1 mm 0 823 to 0 830 in 20 5 mm 0 807 in Brake Disc Thickness 4 60 to 4 80 mm 0 181 to 0 188 in 4 20 mm 0 165 in Plate Thickness 2 54 to 2 66 mm 0 100 to 0 104 in 2 1 mm 0 083 in KiSC issued 04 2010 A ...

Page 381: ...PS lower frame mounting screw 167 to 196 17 0 to 20 0 123 to 144 Cabin mounting bolt and nut 123 to 147 13 0 to 15 0 94 1 to 108 Cabin mount bracket mounting screw 167 to 196 17 0 to 20 0 123 to 144 Rear axle case mounting screw M10 48 to 55 4 9 to 5 7 36 to 41 Rear axle case mounting nut M10 9T 61 to 70 6 2 to 7 2 45 to 52 Rear axle case mounting screw M12 79 to 90 7 9 to 9 2 58 to 66 Brake case ...

Page 382: ...lay CAUTION Stop the engine and chock the wheels before checking parking lever 1 Release the parking brake lever 1 2 Measure the length of L 3 Confirm there is free play in a right and left parking brake rod 3 4 Adjust the parking brake rod 3 length to become the same when right and left free play is different at that time 5 Pull the parking lever 1 by one notch At that time confirm there is no fr...

Page 383: ...ard switch connector 4 main switch connector 7 mode switch connector 5 position switch connector 8 and brake switch connector 6 2 Remove the meter panel 1 with panel frame 3 as a unit W1017912 1 Panel Cover 1 Meter Panel 2 Panel Connector 3 Panel Frame 4 Hazard Switch Connector 5 Mode Switch Connector 6 Brake Switch Connector 7 Main Switch Connector 8 Position Switch Connector KiSC issued 04 2010 ...

Page 384: ...utch pedal 9 6 Remove the brake pedals 5 8 and springs 6 Parking Brake Rod 1 Remove the parking brake rod 2 from the brake cam lever 1 When reassembling Adjust the parking brake free play W1014262 1 Brake Switch 2 External Snap Ring 3 Oil Seal 4 Needle Bearing 5 Brake Pedal RH 6 Spring 7 Spring Pin 8 Brake Pedal LH 9 Clutch Pedal 10 Brake Pedal Shaft 11 Brake Pedal Rod RH 12 Brake Rod RH 13 Brake ...

Page 385: ...ds of fluid together W1015074 Rear Wheel and ROPS ROPS Model 1 Place the disassembling stand under the transmission case 2 Remove the rear wheel mounting screws and nuts 3 Remove the rear wheels 4 Remove the top link 2 and lift rod 4 5 Disconnect the check chain 6 and remove the lower link 5 6 Remove the ROPS lower frame mounting screws 7 Dismount the ROPS assembly 1 3 When reassembling W10162430 ...

Page 386: ...the washers plate and mount rubbers etc in their original positions W1015630 Cabin Mount Bracket Cabin Model 1 Remove the cabin mount bracket 1 When reassembling W1016764 Tightening torque Rear wheel mounting screw and nut 197 to 225 N m 20 0 to 23 0 kgf m 145 to 166 lbf ft Cabin mounting bolt and nut 128 to 147 N m 13 0 to 15 0 kgf m 94 1 to 108 lbf ft 1 Lift Rod 2 Lower Link 3 Check Chain 4 Bloc...

Page 387: ...se from brake case When reassembling Apply liquid gasket Three Bond 1208C or equivalent to joint face of the rear axle case and brake case W10230590 Tightening torque Rear axle case mounting screw and nut M10 screw 48 to 55 N m 4 9 to 5 7 kgf m 36 to 41 lbf ft M10 nut 9T Except L3540 61 to 70 N m 6 2 to 7 2 kgf m 45 to 52 lbf ft M12 screw Except L3540 78 to 90 N m 7 9 to 9 2 kgf m 58 to 66 lbf ft ...

Page 388: ... of the brake case and differential gear case Be sure to apply the liquid gasket to a position Apply grease to the steel ball seats Do not grease excessively Be sure to fix the brake cam 13 and cam plate 9 Before installing the brake case to the transmission case install the cam plate 9 to the transmission case W1015647 Brake Cam and Brake Cam Lever 1 Remove the brake cam mounting nut and remove t...

Page 389: ...wable limit replace the cam plate and balls 3 Inspect the ball holes of cam plate for uneven wear If the uneven wear is found replace it W10147220 Brake Disc Wear 1 Measure the brake disc thickness with vernier calipers 2 If the measurement is less than the allowable limit replace it W10148530 Plate Wear 1 Measure the plate thickness with vernier calipers 2 If the measurement is less than the allo...

Page 390: ...6 FRONT AXLE KiSC issued 04 2010 A ...

Page 391: ...CONTENTS MECHANISM 1 STRUCTURE 6 M1 KiSC issued 04 2010 A ...

Page 392: ... case 6 The revolution is greatly reduced by the bevel gears 15 4 then the power is transmitted to the axle 1 The differential system allows each wheel to rotate at a different speed to make turning easier 1 Axle 2 Collar 3 Axle Flange 4 Bevel Gear 5 Bevel Gear 6 Bevel Gear Case 7 Bevel Gear 8 Differential Side Gear 9 Differential Pinion 10 Pinion Shaft 11 Collar 12 Front Axle Bracket Front 13 Spi...

Page 393: ...evel Gear Case 9 Differential Side Gear 10 Differential Pinion 11 Pinion Shaft 12 Collar 13 Front Axle Bracket Front 14 Spiral Bevel Gear 15 Spiral Bevel Pinion Shaft 16 Bevel Gear 17 Front Gear Case 18 Bevel Gear Shaft 19 Front Axle Case 20 Differential Yoke Shaft 21 Differential Case 22 Front Axle Bracket Rear 23 Coupling 24 Propeller Shaft KiSC issued 04 2010 A ...

Page 394: ...6 S1 2 SERVICING SPECIFICATIONS 6 S2 3 TIGHTENING TORQUES 6 S5 4 CHECKING AND ADJUSTING 6 S6 5 DISASSEMBLING AND ASSEMBLING 6 S8 1 SEPARATING FRONT AXLE ASSEMBLY 6 S8 2 DISASSEMBLING FRONT AXLE 6 S10 6 SERVICING 6 S17 KiSC issued 04 2010 A ...

Page 395: ... S7 Front wheel sway excessive Replace 6 S6 Tie rod end loose Tighten 6 S11 Air sucked in power steering circuit Bleed 7 S5 Front Wheels Can Not Be Driven Propeller shaft broken Replace 6 S8 Front wheel drive gears in transmission broken Replace 3 S54 S74 S97 Front differential gear broken Replace 6 S16 Shift fork broken Replace Coupling displaced Reassemble 6 S8 Noise Gear backlash excessive Adju...

Page 396: ...8 in 0 20 mm 0 0079 in for L5040 L5240 and L5740 Differential Case Differential Case Cover to Differential Side Gear Differential Case Differential Case Cover Differential Side Gear Clearance I D I D O D 0 050 to 0 114 mm 0 0020 to 0 00448 in 32 000 to 32 025 mm 1 2599 to 1 2608 in 32 000 to 32 025 mm 1 2599 to 1 2608 in 31 911 to 31 950 mm 1 2564 to 1 2578 in 0 20 mm 0 0079 in Pinion Shaft to Dif...

Page 397: ... 0 30 mm 0 0079 to 0 011 in Front Axle Case Boss Front to Bracket Bushing Front Axle Case Boss Front Bushing Clearance O D I D 0 120 to 0 275 mm 0 00473 to 0 0108 in 49 950 to 49 975 mm 1 9666 to 1 9675 in 50 095 to 50 225 mm 1 9723 to 1 9773 in 0 50 mm 0 20 in for L3540 and L4240 Front Axle Case Boss Rear to Bracket Bushing Front Axle Case Boss Rear Bushing Clearance O D I D 0 100 to 0 292 mm 0 0...

Page 398: ...e Limit for L5040 L5240 and L5740 Bevel Gear Case Boss to Front Axle Support Bushing Bevel Gear Case Boss Front Axle Support Bushing Clearance O D I D 0 080 to 0 248 mm 0 0032 to 0 00976 in 54 970 to 55 000 mm 2 1642 to 2 1653 in 55 080 to 55 218 mm 2 1685 to 2 1739 in 1 0 mm 0 039 in KiSC issued 04 2010 A ...

Page 399: ...to 86 7 Tie rod end nut L3540 and L4240 40 to 45 4 0 to 4 6 29 to 33 Tie rod end nut L5040 L5240 and L5740 157 to 176 16 0 to 18 0 116 to 130 Bevel gear case mounting screw L3540 and L4240 124 to 147 12 6 to 15 0 91 2 to 108 Bevel gear case mounting screw L5040 L5240 and L5740 167 to 196 17 0 to 20 0 123 to 144 Axle flange mounting screw and nut L3540 and L4240 24 to 27 2 4 to 2 8 18 to 20 Axle fl...

Page 400: ...k nut 1 3 Turn the tie rod joint 2 to adjust the rod length until the proper toe in measurement is obtained 4 Retighten the tie rod lock nut 1 5 Attach the snap ring 3 IMPORTANT Q A right and left tie rod joint is adjusted to the same length W10213280 Axial Sway of Front Wheel 1 Jack up the front side of tractor 2 Set a dial gauge on the outside of rim 3 Turn the wheel slowly and read the runout o...

Page 401: ...ht until the front gear case 1 contacts with the bevel gear case 2 at right hand side of the front axle 3 If the front gear case 1 can not be contacted with the bevel gear case 2 shorten the length of stopper 3 4 Keeping the front gear case 1 contact with the bevel gear case 2 make a specified clearance A as shown in the lower table 5 After adjustment secure the stopper with the lock nut 4 6 For a...

Page 402: ...ft 1 3 W1035934 Power Steering Hoses 1 Disconnect the power steering hoses 1 2 from steering cylinder 2 Remove the cylinder cover When reassembling W10225690 1 Coupling 2 Spring Pin 3 Propeller Shaft 1 4 Propeller Shaft Cover 5 Coupling 6 Spring Pin 7 Screws 8 Propeller Shaft Cover Tightening torque Power steering hose retaining nut 25 to 29 N m 2 5 to 3 0 kgf m 18 to 21 lbf ft Cylinder cover moun...

Page 403: ...ket rear mounting screws and nuts 6 Separate the front axle from front axle bracket When reassembling IMPORTANT Q Be sure to adjust the front axle rocking force Refer to 4 CHECKING AND ADJUSTING at this section W10136920 Tightening torque Frontwheel mounting nut L3540 L4240 137 N m 14 0 kgf m 101 lbf ft L5040 L5240 L5740 186 N m 19 0 kgf m 137 lbf ft Bracket mounting screw and nut L3540 L4240 78 t...

Page 404: ...lling plug 2 and check plug 1 IMPORTANT Q Use KUBOTA SUPER UDT fluid or SAE80 90 gear oil Refer to 4 LUBRICANTS FUEL AND COOLANT at G GENERAL section W10128890 Propeller Shaft 1 Slide the propeller shaft cover 4 and 8 after removing the screws 7 2 Tap out the spring pins 2 6 and slide the couplings 1 5 and then remove the propeller shaft with covers 4 8 When reassembling Apply grease to the spline...

Page 405: ...240 and L5740 1 Remove the bevel gear case mounting screws 2 Remove the bevel gear case 3 and front gear case 4 as a unit from the front axle case 1 When reassembling Apply grease to the O ring 2 and take care not to damage it Do not interchange right and left bevel gear case assemblies W10155120 Tightening torque Tie rod end nut L3540 L4240 40 to 45 N m 4 0 to 4 6 kgf m 29 to 33 lbf ft L5040 L524...

Page 406: ...ear case 2 and separate it from the front gear case 3 4 Remove the internal snap ring 4 5 Take out the bevel gears 5 6 with ball bearings and shims 8 When reassembling Install the shims 8 to their original position Install the oil seal 9 of bevel gear case noting its direction W10160540 Tightening torque Axle flange mounting screw and nut L3540 L4240 24 to 27 N m 2 4 to 2 8 kgf m 18 to 20 lbf ft L...

Page 407: ...below W10163910 Power Steering Hoses 1 Disconnect the power steering hoses 1 2 from steering cylinder 2 Remove the cylinder cover When reassembling W10517600 1 Collar 2 Bevel Gear 3 Axle 4 Axle Flange 5 Oil Seal Tightening torque Power steering hose retaining nut 25 to 29 N m 2 5 to 3 0 kgf m 18 to 21 lbf ft Cylinder cover mounting screw 61 to 70 N m 6 2 to 7 2 kgf m 45 to 52 lbf ft 1 Power Steeri...

Page 408: ...ove the cylinder set screw 3 5 Remove the nipples 2 from steering cylinder 6 Remove the internal snap ring 4 7 Draw out the steering cylinder 5 When reassembling Apply liquid lock Three Bond 1324 or equivalent to the tie rod joint W10165600 Tightening torque Tie rod joint to steering cylinder 167 to 196 N m 17 0 to 20 0 kgf m 123 to 144 lbf ft 1 Tie rod Joint 2 Nipple 3 Cylinder Set Screw 4 Intern...

Page 409: ...11 and oil seal 6 with new ones Apply grease to the oil seal 6 Install the shims and collars to their original position Install the taper roller bearings correctly noting their direction and apply gear oil to them Tighten up the lock nut 11 until the turning torque of the spiral bevel pinion shaft reaches the factory specification When press fitting an oil seal 6 observe the dimension A described ...

Page 410: ...al side gears 12 When reassembling Apply molybdenum disulfide Three Bond 1901 or equivalent to the inner circumferential surface of the differential side gears 12 and differential pinions 4 W10174670 Tightening torque Differential case cover mounting screw L3540 L4240 48 to 58 N m 4 9 to 6 0 kgf m 36 to 43 lbf ft L5040 L5240 L5740 61 to 70 N m 6 2 to 7 2 kgf m 45 to 52 lbf ft 1 Shim 2 Differential...

Page 411: ...4 in Allowable limit 0 20 mm 0 0079 in Differential case bore I D Factory spec 32 000 to 32 062 mm 1 2599 to 1 2622 in Differential case cover bore I D Factory spec 32 000 to 32 025 mm 1 2599 to 1 2608 in Differential side gear O D Factory spec 31 911 to 31 950 mm 1 2564 to 1 2578 in Clearance between differential case differential case cover and differential side gear Factory spec 0 050 to 0 114 ...

Page 412: ...ure the turning torque of spiral bevel pinion shaft 3 Calculate the backlash from the ratio of the shaft diameter to the gear diameter Backlash play x 2 0 4 If the turning torque is not within the factory specifications adjust with the lock nut If the turning torque is not able to adjust by lock nut 2 change the thickness of collar 1 and adjust with lock nut 2 again Reference Standard size of coll...

Page 413: ...ating the above procedures W10186900 Backlash between Bevel Gear and Bevel Gear 1 Stick a strip of fuse to three spots on the bevel gear 1 with grease 2 Fix the front axle case bevel gear case and front gear case 3 Turn the axle 4 Remove the bevel gear case from front axle case and measure the thickness of the fuses with an outside micrometer 5 If the backlash is not within the factory specificati...

Page 414: ...asure the thickness of the fuse with an outside micrometer 5 If the backlash is not within the factory specifications adjust with shim 3 Reference Thickness of adjusting shims 0 4 mm 0 016 in 2 0 mm 0 079 in 0 5 mm 0 020 in Tooth contact More than 35 W10196490 Backlash between bevel gear 2 and bevel gear 1 Factory spec L3540 L4240 0 15 to 0 30 mm 0 0059 to 0 011 in L5040 L5240 L5740 0 20 to 0 3 0 ...

Page 415: ... 0 50 mm 0 020 in Front axle case boss front O D Factory spec 49 950 to 49 975 mm 1 9666 to 1 9675 in Bracket bushing front I D Factory spec 50 095 to 50 225 mm 1 9723 to 1 9773 in Clearance between front axle case boss rear and bracket bushing rear Factory spec 0 100 to 0 292 mm 0 00394 to 0 0114 in Allowable limit 1 0 mm 0 039 in Front axle case boss rear O D Factory spec 69 970 to 70 000 mm 2 7...

Page 416: ...ing I D and calculate the clearance 3 If the clearance exceeds the allowable limit replace it W10198060 Clearance between bevel gear case boss and front axle support bushing Factory spec 0 080 to 0 248 mm 0 0032 to 0 00976 in Allowable limit 1 0 mm 0 039 in Bevel gear case boss O D Factory spec 54 970 to 55 000 mm 2 1642 to 2 1653 in Front axle support bushing I D Factory spec 55 080 to 55 218 mm ...

Page 417: ...7 STEERING KiSC issued 04 2010 A ...

Page 418: ...CONTENTS MECHANISM 1 STRUCTURE 7 M1 2 HYDRAULIC CIRCUIT 7 M2 3 HYDRAULIC PUMP 7 M3 4 STEERING CONTROLLER 7 M4 5 STEERING CYLINDER 7 M6 KiSC issued 04 2010 A ...

Page 419: ...teering system is composed of steering wheel steering joint shafts steering controller steering cylinder and other components shown in the figure 1 Steering Wheel 2 Steering Joint Shaft 1 3 Hydraulic Pump 4 Steering Cylinder 5 Steering Controller 6 Steering Joint Shaft 3 7 Steering Joint Shaft 2 8 Steering Shaft KiSC issued 04 2010 A ...

Page 420: ...inder rod then moves to control the directional movement of the front wheels Return oil from steering cylinder 2 passes through control valve 10 is sent to the PTO clutch valve HST GST valve etc When the engine is not operating and the steering wheel is turned gerotor 1 rotates to supply oil to steering cylinder 2 Thus the machine can be steered manually W1012726 1 Gerotor 2 Steering Cylinder 3 St...

Page 421: ...nts as shown in the figure The hydraulic pump pressure fed the oil drawn from the transmission case through oil filter to power steering circuit and main hydraulic circuit W1014335 1 Drive Gear 1 2 Coupling 3 Drive Gear 2 4 Driven Gear 1 5 Bushing 6 Bushing 7 Driven Gear 2 8 Side Plate A From Power Steering Controller B From Transmission Case C To Power Steering Controller D To Main Hydraulic Circ...

Page 422: ...t corresponding to the turn of the steering wheel 1 and the gerotor performs the metering function and lets oil through it the amount of which corresponds to the turn of the steering wheel 1 The oil which has passed through gerotor 3 flows back to the control valve in which it is directed to cylinder port R to operate steering cylinder 4 Consequently the front wheels are moved to the right through...

Page 423: ...eft turn as well except that oil flows into and out of steering cylinder in the directions opposite to those at a right turn W1013826 1 Steering Wheel 2 Valve Plate 3 Gerotor 4 Steering Cylinder 5 Steering Controller 6 Relief Valve P Pump Port T Tank Port R Cylinder Port R L Cylinder Port L KiSC issued 04 2010 A ...

Page 424: ...ed to both knuckle arm guarantees equal steering movement to both front wheels The steering cylinder provides force in both directions Depending upon direction the steering wheel is turned pressure oil enters at one end of the cylinder to extend or the other end to retract it thereby turning front wheel of the tractor 1 Tie rod 2 Piston Rod 3 Head Cover 4 Cylinder Tube 5 Head Cover 6 Front Axle Ca...

Page 425: ... SPECIFICATIONS 7 S2 3 TIGHTENING TORQUES 7 S3 4 CHECKING AND ADJUSTING 7 S4 1 STEERING CONTROLLER 7 S4 5 DISASSEMBLING AND ASSEMBLING 7 S5 1 STEERING CONTROLLER 7 S5 2 STEERING CYLINDER 7 S6 1 Servicing 7 S7 3 STEERING LINKAGE 7 S8 KiSC issued 04 2010 A ...

Page 426: ...te G 67 Steering controller malfunctioning Replace 7 S5 Relief valve malfunctioning Replace 7 S4 Steering Force Fluctuates Air sucked in pump due to leaking or missing of oil Replenish Air sucked in pump from suction circuit Repair Excessive Steering Wheel Play Steering linkage worn Replace 7 S8 Front Wheels Wander to Right or Left Air sucked in pump due to leak of oil Replenish Air sucked in pump...

Page 427: ...ngine Speed Maximum Oil Temperature 40 to 60 C 104 to 140 F Setting Pressure L3540 L4240 L5040 L5240 L5740 10 7 to 11 7 MPa 110 to 119 kgf cm2 1560 to 1690 psi 12 7 to 13 7 MPa 130 to 139 kgf cm2 1850 to 1980 psi Steering Cylinder I D 55 000 to 55 074 mm 2 1654 to 2 1682 in 55 100 mm 2 1693 in Rod to Bushing Clearance 0 009 to 0 127 mm 0 000355 to 0 00500 in 0 135 mm 0 00531 in KiSC issued 04 2010...

Page 428: ...and LH retaining nut 25 to 29 2 5 to 3 0 18 to 21 Front wheel mounting nut 137 14 0 101 Tie rod end slotted nut 40 to 49 4 0 to 5 0 29 to 36 Tie rod joint 167 to 196 17 0 to 20 0 123 to 144 Tie rod end lock nut 167 to 196 17 0 to 20 0 123 to 144 Guide assembly 182 to 289 18 5 to 29 5 134 to 213 Front wheel mounting nut L3540 L4240 137 14 0 101 Front wheel mounting nut L5040 L5240 L5740 186 19 0 13...

Page 429: ...peed 5 Fully turn the steering wheel to the left and read the pressure when the relief valve functions 6 Stop the engine 7 If the pressure is not within the factory specifications check the pump delivery line or replace the steering controller assembly Condition Engine speed Maximum Oil temperature 40 to 60 C 104 to 140 F W1016736 Power steering relief valve setting pressure Factory spec L3540 L42...

Page 430: ... 2 Remove the steering joint shaft 2 3 When reassembling Tighten the steering joint shaft support mounting screw after adjusting the position of steering joint shaft support 4 for smooth rotation of the steering wheel W1020832 Steering Controller Assembly 1 Disconnect the power steering delivery pipe 4 steering hoses 3 5 and return hose 2 2 Remove the steering controller mounting screw 6 and take ...

Page 431: ...raw out the cylinder rod 6 When reassembling Apply transmission fluid to the oil seal and O ring Apply liquid lock Three Bond 1324B or equivalent to the thread of tie rod joint 4 W1018590 Tightening torque Front wheel mounting nut L3540 L4240 137 N m 14 0 kgf m 101 lbf ft L5040 L5240 L5740 186 N m 19 0 kgf m 137 lbf ft Tie rod end slotted nut L3540 40 to 45 N m 4 0 to 4 6 kgf m 29 to 33 lbf ft L42...

Page 432: ... 1 Measure the bushing I D with a cylinder gauge 2 Measure the rod O D with a outside micrometer and calculate the clearance 3 If the clearance exceeds the allowable limit replace as a unit W10182660 Steering cylinder I D Factory spec 55 000 to 55 074 mm 2 1654 to 2 1682 in Allowable limit 55 100 mm 2 1693 in Clearance between rod and bushing Factory spec 0 00900 to 0 127 mm 0 000355 to 0 00500 in...

Page 433: ...e steering joint shaft 2 1 When reassembling Tighten the steering joint shaft support mounting screw after adjusting the position of steering joint shaft support 2 for smooth rotation of the steering wheel W1019696 Steering Joint Shaft 1 and Steering Post 1 Remove the steering joint shaft 1 2 2 Remove the steering post 1 W1019851 Tightening torque Steering wheel mounting nut 48 1 to 55 9 N m 4 9 t...

Page 434: ...8 HYDRAULIC SYSTEM KiSC issued 04 2010 A ...

Page 435: ...HITCH HYDRAULIC CIRCUIT 8 M7 2 REAR HYDRAULIC BLOCK 8 M8 3 POSITION CONTROL VALVE 8 M9 4 POSITION CONTROL LINKAGE 8 M11 5 LOWERING SPEED ADJUSTING VALVE 8 M12 6 HYDRAULIC CYLINDER 8 M13 5 POSITION CONTROL WITH DRAFT CONTROL LINKAGE IF EQUIPPED 8 M14 1 POSITION CONTROL OPERATION 8 M15 2 DRAFT CONTROL OPERATION 8 M16 3 MIXED CONTROL 8 M17 6 FRONT HYDRAULIC BLOCK 8 M18 7 AUXILIARY CONTROL VALVE 8 M19...

Page 436: ...d of two hydraulic pumps relief valve position control valve hydraulic cylinder oil filter and other components as shown in the figure 1 Cylinder Safety Valve 2 Check Valve 3 Rear Hydraulic Outlet 4 Lowering Speed Adjusting Valve 5 Oil Filter 6 Front Hydraulic Block 7 Regulator Valve 8 Power Steering Controller 9 Hydraulic Pump 1 10 Hydraulic Pump 2 11 Relief Valve 12 Hydraulic Cylinder KiSC issue...

Page 437: ...ion control valve hydraulic cylinder oil filters oil cooler and other components as shown in the figure 1 Oil Filter HST 2 Cylinder Safety Valve 3 Check Valve 4 Rear Hydraulic Outlet 5 Lowering Speed Adjusting Valve 6 Oil Filter 7 Front Hydraulic Block 8 Hydraulic Pump 2 9 Hydraulic Pump 1 10 Oil Cooler 11 Power Steering Controller 12 Relief Valve 13 Hydraulic Cylinder KiSC issued 04 2010 A ...

Page 438: ...Hydraulic Cylinder 4 Cylinder Safety Valve 5 Auxiliary Control Valve 6 Power Steering Controller Refer to STEERING Section 7 PTO Clutch Valve Refer to TRANSMISSION section 8 Regulating Valve Refer to TRANSMISSION Section 9 Hydraulic Pump 2 10 Rear Hydraulic Block 11 Oil Filter 12 Hydraulic Pump 1 13 Relief Valve 14 Front Hydraulic Block KiSC issued 04 2010 A ...

Page 439: ...ing Speed Adjusting Valve 5 Auxiliary Control Valve 6 Power Steering Controller Refer to STEERING Section 7 PTO Clutch Valve Refer to TRANSMISSION Section 8 GST Valve Assembly Refer to TRANSMISSION Section 9 Regulating Valve 10 Hydraulic Pump 2 11 Oil Filter 12 Hydraulic Pump 1 13 Relief Valve 14 Front Hydraulic Block 15 Rear Hydraulic Block KiSC issued 04 2010 A ...

Page 440: ... Valve 5 Auxiliary Control Valve 6 Power Steering Controller Refer to STEERING Section 7 Oil Filter 8 Oil Cooler 9 Hydrostatic Transmission HST Refer to TRANSMISSION Section 10 Hydraulic Pump 2 11 Regulating Valve 12 PTO Clutch Valve Refer to TRANSMISSION Section 13 Oil Filter 14 Hydraulic Pump 1 15 Relief Valve 16 Front Hydraulic Block 17 Rear Hydraulic Block KiSC issued 04 2010 A ...

Page 441: ...ponents as shown in the figure The hydraulic pump pressure fed the oil drawn from the transmission case through oil filter to power steering circuit and main hydraulic circuit W1013488 1 Drive Gear 1 2 Coupling 3 Drive Gear 2 4 Driven Gear 1 5 Bushing 6 Bushing 7 Driven Gear 2 8 Side Plate A From Power Steering Controller B From Transmission Case C To Power Steering Controller D To Main Hydraulic ...

Page 442: ... in neutral position oil is channeled from N port to the control valve 1 4 The hydraulic system has a relief valve 10 which restricts the maximum pressure in the circuit The hydraulic cylinders 2 have a cylinder safety valve 3 to relieve shock pressure due to heavy implement bounce 5 The control valve 1 is actuated by the mechanical linkage for Position control function 1 Position Control Valve 2 ...

Page 443: ...lic outlet port The hydraulic outlet port is located top of the rear hydraulic block to take power out from the tractor to operate the hydraulic cylinders on the implement 1 Cylinder Safety Valve 2 Lowering Speed Adjusting Valve 3 Position Control Valve 4 Cover Rear Hydraulic Outlet Port 5 Check Valve A From Hydraulic Pump B To or From Hydraulic Cylinder C To or From Hydraulic Cylinder KiSC issued...

Page 444: ...e kept at a steady height W1013891 Q Lifting When the control lever is moved to LIFT position spool 1 is pushed by the spool operating lever forming a circuit with the P port and chamber A The pressurized oil thus flows into the chamber A and closes unload poppet 1 2 The oil from C1 port flows into hydraulic cylinder through check valve in the rear hydraulic block to lift the implement W1014132 1 ...

Page 445: ... Lowering When the control lever is moved to DOWN position spool 2 moves to arrow mark direction and pushes the poppet 2 1 It forms a circuit with the C2 port and T2 port The oil in the hydraulic cylinder is forced out by the weight of the implement and returns to the tank through the C2 port and T2 port lowering the implement The pressurized oil at the P port pushes open unload poppet 1 3 and ret...

Page 446: ... rotated to the arrow since the feedback rod is actuated Therefore the spool drive lever 3 moves around the fulcrum Q and pull the spool 1 3 The lift arm stops when the spool returns to the neutral position Q Down 1 When the position control lever is moved to the DOWN position the control arm shaft 2 rotates to the arrow Therefore the spool drive lever 3 moves around the fulcrum P and pull the spo...

Page 447: ...ases lowering speed of the three points linkage When the rotor shaft 2 is completely closed the three point linkage is held at its position since oil in the hydraulic cylinder is sealed between the hydraulic cylinder and rotor 4 W1015173 1 Holder 2 Rotor Shaft 3 Pin 4 Rotor 5 Position Control Valve A Closed Position B Open Position C Cylinder Port T Tank Port KiSC issued 04 2010 A ...

Page 448: ... is single acting type and it is installed directly between hydraulic lift arm and lower link The main components of the hydraulic cylinder are shown in the figure W1015282 1 Cylinder Tube 2 Rod 3 Wiper 4 Snap Ring 5 O ring 6 Head 7 Bushing 8 Snap Ring 9 Bearing Ring 10 Backup Ring 11 Seal 12 Piston A To Transmission Case B To or From Position Control Valve KiSC issued 04 2010 A ...

Page 449: ...d excessively The setting traction load can be adjusted by changing the position of the draft control lever The draft control system uses the same control valve as the position control system Therefore it is possible to use the mixed control The traction load applied to the tractor is sensed and is fed back to the control valve by means of the other linkage mechanism 1 Position Control Lever 2 Dra...

Page 450: ...e lift circuit and the lift arm goes up 2 Down b 1 When the position control lever 3 is moved to the DOWN side the position control link 2 is also rotated 2 By this action the arm 2 5 and the arm 1 1 are returned by the return spring 4 3 The position control valve becomes the down circuit and the lift arm is lowered Reference For the feedback mechanism of the position control refer to Position Con...

Page 451: ...to push the arm 1 5 3 At the same time the arm 2 11 is moved the connected position control valve becomes the lift circuit and the lift arm goes up 2 Movement of the Link Under Decreased Load b 1 When the lift arm goes up the traction load is decreased and the draft control rod 1 is returned 2 At the same time the arm 2 11 arm 1 5 and draft control link 1 4 are returned by the return spring 8 3 Th...

Page 452: ... the lift arms implement lower to the height set by the position control only when traction load increases slippage or engine stop may occur unless the implement is raised With the draft control only plowing depth cannot be kept constant if soil hardness changes greatly The mixed control serves to eliminate such disadvantages W1017580 A Position Controlled B Draft Controlled C Not Deep Even in Sof...

Page 453: ...the tractor to operate the hydraulic cylinders on the implement such as front end loader front blade and so on 1 Cap 2 Front Hydraulic Block 3 Relief Valve A To Implement Control Valve B From Implement Control Valve C To Position Control Valve P From Hydraulic Pump T1 To Transmission Case T2 From Implement Control Valve KiSC issued 04 2010 A ...

Page 454: ...smission case through T port W1021629 Q Down When the spool 2 is moved in the direction of the arrow the pressure fed oil in the P port opens the check valve 1 and flows to the implement cylinder via A port Return oil from the implement cylinder flows from the B port to the transmission case through T port W1021856 1 Check Valve 2 Spool A A Port Implement Cylinder B B Port Implement Cylinder P Pum...

Page 455: ... the arrow the pressure fed oil in the P port opens the check valve 2 and flows to the implement cylinder via B port Return oil from the implement cylinder flows from the A port to the transmission case through T port 1 Spool 2 Check Valve 3 Detent Ball 4 Detent Sleeve A A Port Implement Cylinder B B Port Implement Cylinder P Pump Port N Neutral Port T Tank Port 1 Spool 2 Check Valve A A Port Impl...

Page 456: ... detent sleeve 4 hold the spool 1 at the floating position as shown in the figure The pressure fed oil from the hydraulic pump flows to position control valve via N port And the A port and B port lead to the T port along the notched sections of the spool 1 This result in the attached implement to follow the contour of the terrain 1 Spool 2 Check Valve A A Port Implement Cylinder B B Port Implement...

Page 457: ...rol valve via N port Q Lift W1022197 When the spool 2 is moved in the direction of the arrow the pressure fed oil in the P port opens the check valve 1 and flows to the implement cylinder via A port 1 Check Valve 2 Spool A A Port Implement Cylinder P Pump Port N Neutral Port T Tank Port 1 Check Valve 2 Spool A A Port Implement Cylinder P Pump Port N Neutral Port T Tank Port KiSC issued 04 2010 A ...

Page 458: ... SYSTEM Q Down W1022307 When the spool 2 is moved in the direction of the arrow return oil from the implement cylinder flows from the A port 1 Check Valve 2 Spool A A Port Implement Cylinder P Pump Port N Neutral Port T Tank Port KiSC issued 04 2010 A ...

Page 459: ...C PUMP 8 S16 1 Removing Hydraulic Pump Assembly 8 S16 2 Disassembling Hydraulic Pump 8 S18 2 THREE POINT HITCH HYDRAULIC BLOCK ASSEMBLY 8 S19 1 Separating Hydraulic Block Assembly 8 S19 2 Disassembling Hydraulic Assembly 8 S20 3 POSITION CONTROL VALVE 8 S21 1 Separating Control Valve 8 S21 4 LIFT ARM SUPPORT AND HYDRAULIC CYLINDER 8 S22 1 Separating Hydraulic Cylinder 8 S22 2 Disassembling Hydraul...

Page 460: ...adjusted Adjust Hydraulic arm shaft lift arm improperly assembled Adjust 8 S24 3 point link improperly set Adjust Implement Does Not Lower Position control valve malfunctioning Spool damaged Replace 8 S21 Poppet 2 push rod improperly adjusted Adjust 8 S21 Implement Drops by Weight Hydraulic cylinder worn or damaged Replace 8 S23 Safety valve damaged Replace 8 S25 Hydraulic piston and O ring worn o...

Page 461: ... min 4 28 U S gals min 3 56 Imp gals min 15 6 L min 4 12 U S gals min 3 43 Imp gals min Hydraulic Pump for Three Point Hitch Condition Engine Speed Approx 2700 min 1 rpm Except L5040 L5240 Approx 2600 min 1 rpm L5040 L5240 Rated pressure L3540 17 1 to 18 1 MPa 175 to 184 kgf cm2 2480 to 2620 psi L4240 L5040 L5240 L5740 18 1 to 19 1 MPa 185 to 194 kgf cm2 2630 to 2770 psi Oil Temperature 40 to 60 C...

Page 462: ... 0 5898 in 15 000 to 15 051 mm 0 5906 to 0 5926 in 0 15 mm 0 0059 in Side Plate Thickness 2 48 to 2 50 mm 0 0976 to 0 0984 in 2 40 mm 0 0945 in Relief Valve Condition Engine Speed Maximum Oil Temperature 40 to 60 C 104 to 140 F Setting Pressure L3540 L4240 L5040 L5240 L5740 17 1 to 18 1 MPa 175 to 184 kgf cm2 2480 to 2620 psi 18 1 to 19 1 MPa 185 to 194 kgf cm2 2630 to 2770 psi Lift Arm Free Play ...

Page 463: ... joint screw 35 to 39 3 5 to 4 0 26 to 28 Regulating valve mounting screw 18 to 20 1 8 to 2 1 13 to 15 Hydraulic pump assembly mounting screw and nut 24 to 27 2 4 to 2 8 18 to 20 Pump cover mounting screw 40 to 44 4 0 to 4 5 29 to 32 Hydraulic cylinder hose retaining nut 35 to 48 3 5 to 4 9 26 to 35 Delivery pipe joint screw 49 to 68 5 0 to 7 0 37 to 50 Unload plug 40 to 58 4 0 to 6 0 29 to 43 Plu...

Page 464: ...ipe 5 When reassembling Install the copper washers firmly Tighten the steering joint shaft support mounting screw after adjusting the position of steering joint shaft support 3 for smooth rotation of the steering wheel W1012306 Tightening torque Regulator delivery pipe joint screw 40 to 49 N m 4 0 to 5 0 kgf m 29 to 36 lbf ft 1 Fuel Tank Frame Support 2 Steering Joint Shaft 3 Steering Joint Shaft ...

Page 465: ... to generate pressure approx 9 8 MPa 100 kgf cm2 1422 psi Hold in this condition until oil temperature reaches approx 40 C 104 F 7 Open the loading valve completely 8 Set the engine speed Refer to Condition 9 Read and note the pump delivery at no pressure 10 Slowly close the loading valve to increase pressure Rated pressure As the load is increased engine speed drops therefore reset the engine spe...

Page 466: ... pump delivery at rated pressure Factory spec Above 18 2 L min 4 81 U S gals min 4 00 lmp gals min Allowable limit 16 2 L min 4 28 U S gals min 3 56 lmp gals min Hydraulic pump delivery at no pressure Factory spec Above 17 9 L min 4 73 U S gals min 3 94 lmp gals min Hydraulic pump delivery at rated pressure Factory spec Above 17 5 L min 4 62 U S gals min 3 85 lmp gals min Allowable limit 15 6 L mi...

Page 467: ... Using Flow meter Preparation 1 Open the bonnet 2 Remove the side skirt RH 3 Remove the main delivery pipe 1 When reassembling Install the copper washers firmly W1012121 Tightening torque Main delivery pipe joint screw 49 to 54 N m 5 0 to 5 6 kgf m 37 to 40 lbf ft 1 Main Delivery Pipe KiSC issued 04 2010 A ...

Page 468: ...ure approx 14 7 MPa 150 kgf cm2 2133 psi Hold in this condition until oil temperature reached approx 40 C 104 F 7 Open the loading valve completely 8 Set the engine speed Refer to Condition 9 Read and note the pump delivery at no pressure 10 Slowly close the loading valve to increase Rated pressure As the load is increased engine speed drops therefore reset the engine speed 11 Read and note the pu...

Page 469: ...7 Imp gals min Hydraulic pump delivery at no pressure Factory spec Above 35 6 L min 9 40 U S gals min 7 83 Imp gals min Hydraulic pump delivery at rated pressure Factory spec Above 34 9 L min 9 22 U S gals min 7 68 Imp gals min Allowable limit 31 2 L min 8 24 U S gals min 6 86 Imp gals min Hydraulic pump delivery at no pressure Factory spec Above 37 0 L min 9 77 U S gals min 8 14 Imp gals min Hydr...

Page 470: ...re test reset the position control lever stopper firmly When reassembling Take care not to damage the O ring Condition Engine speed Maximum Oil temperature 40 to 60 C 104 to 140 F Reference Thickness of shims 4 0 1 mm 0 0039 in 0 2 mm 0 0079 in 0 4 mm 0 0157 in Pressure change per 0 1 mm 0 0039 in shim Approx 264 8 kPa 2 7 kgf cm2 38 4 psi W1014806 Relief valve setting pressure Factory spec L3540 ...

Page 471: ...the lock nut 3 firmly When reassembling Install the safety valve to the rear hydraulic block taking care not to damage the O ring and apply transmission fluid NOTE Q 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 W1012986 Tightening torque Safety valve assembly 40 to 49 N m 4 0 to 5 0 kgf m 29...

Page 472: ...nut 5 7 Set the engine speed at the maximum 8 Move the position control lever 1 to the lowest position and uppermost position to check the relief valve does not operate 9 Set the position control lever 1 to the uppermost position then move the lift arm to the upper end by hand and measure the free play 10 If the measurement is not within the factory specifications adjust the position control feedb...

Page 473: ...ntrol lever 2 between 4 and 5 4 Set the draft control lever 1 between lever guide 1 and 2 5 Lift the test bar 5 upward until the top link bracket 4 comes in contact with the stopper 6 Confirm that the lower link begin to rise 7 If the specified play is not obtained adjust the feedback rod 3 to A or B position W1017519 1 Draft Control Lever 2 Position Control Lever 3 Feedback Rod 4 Top Link Bracket...

Page 474: ...t bar 2 upward until the top link bracket 1 comes in contact with the stopper 6 Confirm the lower link does not rise 7 Set the draft control lever 4 to 7 position of the lever guide 8 Lift the test bar 2 9 Confirm the lower links 3 must rise before the top link bracket 1 contact the stopper 10 If the specified play is not obtained readjust the feedback rod Refer Adjusting Draft Control Position Se...

Page 475: ... Bonnet and Side Skirt RH 1 Open the bonnet 1 2 Remove the side skirt RH 2 W1014408 Regulating Valve Manual Transmission and GST Models 1 Disconnect the power steering delivery pipe 4 and return hose 3 2 Disconnect the GST PTO delivery pipe 5 and regulator delivery pipe 1 3 Remove the regulating valve 2 When reassembling Apply grease to the O ring and take care not to damage it Install the copper ...

Page 476: ...nnect the suction hose 1 and main delivery pipe 3 2 Remove the hydraulic pump assembly 2 When reassembling Apply grease to the O ring and take care not to damage it W1014977 Tightening torque Power steering delivery pipe joint screw 40 to 49 N m 4 0 to 5 0 kgf m 29 to 36 lbf ft 1 Oil Cooler Return Pipe 2 Power Steering Delivery Pipe Tightening torque Hydraulic pump assembly mounting screw and nut ...

Page 477: ...y during running in recheck should be performed 1 Install the hydraulic pump to the tractor and mount the suction pipe and delivery pipe securely 2 Set the engine speed at 1300 to 1500 min 1 rpm and operate the hydraulic pump at no load for about 10 minutes 3 Set the engine speed at 2000 to 2200 min 1 rpm and with the hydraulic pump applied with 2 94 MPa 30 0 kgf cm2 426 psi to 4 90 MPa 50 0 kgf c...

Page 478: ...raft feedback rod 9 If equipped When reassembling Install the copper washers firmly Visually inspect the gasket if damaged replace with new one Be sure to assemble the stopper to the original position After reassembling be sure to adjust the position control feedback rod length Refer to 4 CHECKING AND ADJUSTING in this section W1016371 1 Seat 2 Cover Tightening torque Hydraulic cylinder hose retai...

Page 479: ... the spring 4 seat 5 and ball 6 When reassembling Take care not to damage the O rings IMPORTANT Q After disassembling and assembling the cylinder safety valve assembly be sure to check the operating pressure W1017017 Position Control Valve 1 Remove the position control valve 1 from rear hydraulic block 2 When reassembling Take care not to damage the O rings W1017276 1 Rear Hydraulic Block 2 Rotor ...

Page 480: ...he adjusting screw 27 unless necessary If disassembled due to unavoidable reasons be sure to set the dimension A to 0 2 mm 0 008 in When reassembling Take care not to damage the backup ring and O rings W1017707 1 Nut 2 External Snap Ring 3 Unload Plug 4 Spring 5 Unload Poppet 6 Valve Body 7 Unload Poppet 2 8 Spring 9 Plug 2 10 Spool 11 Spring 12 Plain Washer 13 External Snap Ring 14 Spool Joint 15...

Page 481: ...2 When reassembling Apply grease to the hydraulic cylinder pins Install the cylinder pin lower from right hand side W1018343 Tightening torque Lift arm pin mounting nut 78 to 90 N m 7 9 to 9 2 kgf m 58 to 66 lbf ft Lift arm pin lock nut 63 to 72 N m 6 4 to 7 4 kgf m 47 to 53 lbf ft 1 Lift Rod LH 2 PTO Cover 3 Lift Rod RH Tightening torque Drawbar frame mounting screw M14 167 to 196 N m 17 0 to 20 ...

Page 482: ...ng Apply transmission fluid to the piston 2 head 5 and cylinder tube 3 Take care not to damage the O ring backup ring and seal Apply liquid gasket Three Bond 1208C or equivalent to the top of head 5 while pressing the head 5 against internal snap ring 4 After reassembling the cylinder be sure to close the drilled hole by liquid gasket W1018811 3 Separating Lift Arm Support Top Link Holder and Lift...

Page 483: ...1 and lift arm LH 7 as a unit 4 Remove the collar 4 and O ring 3 When reassembling Align the alignment marks 8 of the lift arm shaft and lift arms Apply grease to the right and left bushings of lift arm support and O rings Take care not to damage the O rings W1019375 1 Lift Arm Shaft 2 Lift Arm Support 3 O ring 4 Collar 5 External Snap Ring 6 Lift Arm RH 7 Lift Arm LH 8 Alignment Mark KiSC issued ...

Page 484: ...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 W1054901 Tightening torque Safety valve assembly 40 to 49 N m 4 0 to 5 0 kgf m 29 to 36 lbf ft Safety valve lock nut 59 to 78 N m 6 0 to 8 0 kgf m 44 to 57 lbf ft 1 Safety Valve Assembly 2 Adjust Screw 3 Lock Nut 4 Spring 5 Seat 6 Ball 7 ...

Page 485: ...e DX bushing is worn beyond the alloy portion A replace it Reference W1020043 Lift Arm Bushing 1 Visually inspect the DX bushings for signs of wear or damage The DX bushing tends to show concentrated wear 2 If the DX bushing is worn beyond the alloy portion A replace it Reference W1020165 Lift arm support bushing Alloy thickness A 0 57 mm 0 022 in Lift arm bushing Alloy thickness A 0 57 mm 0 022 i...

Page 486: ...hing is worn beyond the alloy portion A replace it Reference W1019611 Hydraulic Cylinder I D 1 Measure the hydraulic cylinder I D with a cylinder gauge 2 If the cylinder I D exceed the allowable limit replace the cylinder tube W1019902 Hydraulic cylinder rod bushing Alloy thickness A 0 57 mm 0 022 in Hydraulic cylinder I D Factory spec 55 000 to 55 074 mm 2 1654 to 2 1683 in Allowable limit 55 100...

Page 487: ...a unit W1015746 Side Plate Thickness 1 Measure the side plate thickness with an outside micrometer 2 If the thickness is less than the allowable limit replace it W10134960 Clearance between bushing and gear shaft Factory spec 0 020 to 0 081 mm 0 00079 to 0 0031 in Allowable limit 0 15 mm 0 0059 in Gear shaft O D Factory spec 14 970 to 14 980 mm 0 58937 to 0 58976 in Bushing I D Factory spec 15 000...

Page 488: ...9 ELECTRICAL SYSTEM KiSC issued 04 2010 A ...

Page 489: ...tems 9 M9 2 CONSTRUCTION AND FUNCTION OF COMPONENTS 9 M10 3 BASIC CONTROL SYSTEM 9 M21 1 Normal Display 9 M21 2 Attention Display At Engine Starting 9 M22 3 Service Interval Alert 9 M25 4 Warning Display or Warning Information 9 M25 5 Lamp Control 9 M27 4 ASSISTANT CONTROL SYSTEM 9 M28 1 Fail safe Function 9 M28 2 Self diagnosis Function 9 M28 3 testing Setting and adjusting Function 9 M30 4 Glow ...

Page 490: ...5 G R 0 5 Y 0 85 B 0 5 G L 1 25 B 1 25 L 1 25 L 1 25 Y 0 5 L B 0 5 B 3 R 1 25 B 1 25 L 3 B R 0 5 B R 0 5 R W 2 B R 1 25 R W 2 B R 0 5 B 3 B R 0 5 B L 60A 30A 50A 40A 45A 1 25 Y 0 5 R B 0 5 Y 0 85 R L 0 5 L B 2 W R 1 25 W R 1 25 W G 1 25 R W 1 25 Y R 0 5 R 0 5 B W 3 B W 3 R W 3 R W 3 B R 3 R 3 R W 3 B W 7 5 A 10 A 5 A 7 5 A 25 A 20 A 30 A 5 A 20 A 5 A 5 A B S 1 5 A 3A 10 9 8 7 6 5 4 3 8 7 6 5 4 3 2...

Page 491: ...L 1 25 L 1 25 B 0 5 G R 0 5 B 0 5 G R 0 5 G R 0 5 G L 0 5 B 1 25 G 0 5 B W 1 25 G 1 25 W G 0 5 L 0 5 L 0 5 Lg B 0 5 W R 0 5 Br Y 0 5 B R 0 5 B W 0 5 O B 0 5 B W 0 5 G L 0 5 B R 0 5 R 0 5 R L 0 5 B 0 5 B Y 0 5 B 0 5 Br W 0 5 G R 0 5 Br 0 5 O 0 5 W 0 5 Lg 0 5 Y L 0 5 G R 0 5 V 0 5 G R 0 5 R B 0 5 Lg B 0 5 L 0 5 R B 1 25 L 1 25 L 1 25 Y 1 25 B 0 5 G R 0 5 G L 0 5 B 0 5 G R 0 5 B W 0 5 B B S 10 9 8 7 ...

Page 492: ... B W 0 5 G L 0 5 B R 0 5 R 0 5 R L 0 5 B 0 5 B Y 0 5 B 0 5 Br W 0 5 G R 0 5 Br 0 5 O 0 5 W 0 5 Lg 0 5 Y L 0 5 G R 0 5 R B 0 5 L W 0 5 Lg B 0 5 L 0 5 R B 0 5 G R 0 5 R B 1 25 W G 1 25 G 3 B R 3 R L 5 R 3 R W 3 B R 3 B R 5 R 3 R W 3 R W 3 B W 0 85 R B 0 5 L Y 0 5 P 2 R 1 25 Y 1 25 R W 2 L 2 W G 1 25 Y R 0 5 R 2 L 0 5 L B 1 25 R W 0 85 R L 0 5 B W 3 B W 1 25 Y 1 25 W R 1 25 W G 2 P L 10A 7 5A 5A 5A 2...

Page 493: ...R W 3 R W 3 B R 3 R L 3 B R 3 B W 5 R 3 B R 3 R W 0 5 R 1 25 Y R 0 5 R 0 5 R Y 0 85 R L 0 5 R W 2 L 2 L 1 25 R W 1 25 Y 0 5 L B 2 W G 1 25 W G 1 25 W R 0 5 P 2 R 0 5 L Y 2 P L 3 B W 0 5 B W 0 85 R B 1 25 Y 5A 10A 5A 10A 10A 7 5A 7 5A 20A 20A 20A 25A 5A 20A 10A 15A 5A 30A 30A 30A 0 5 W L 0 5 W L 0 5 Br W 0 5 Y 0 5 Br W 0 5 0 B 0 5 Br W 0 5 Br 0 5 Lg 0 5 O 0 5 G R 0 5 B R 0 5 V 0 5 P 0 5 R 0 5 R B 0...

Page 494: ... B 1 25 L 1 25 B 1 25 Y 1 25 L 0 5 L 0 5 Lg B 0 5 L 0 5 W R 0 5 Br Y 0 5 V 0 5 B R 0 5 B W 0 5 B Y 0 5 B W 0 5 G L 0 5 B R 0 5 R 0 5 R L 0 5 B 0 5 B Y 0 5 B 0 5 Br W 0 5 G R 0 5 Br 0 5 O 0 5 W 0 5 Lg 0 5 Y L 0 5 G R 3 B R 3 R L 5 R 3 R W 3 B R 3 B R 5 R 3 R W 3 R W 3 B W 0 5 L B 0 5 L Y 0 5 P 2 R 1 25 Y 1 25 R W 2 L 2 P L 2 W G 1 25 Y R 0 5 R 0 5 R 2 L 0 85 R B 1 25 W G 1 25 W R 0 5 R W 0 85 R L 1...

Page 495: ...W 0 85 Lg 0 85 Lg B 0 5 Lg R 0 5 Lg L 1 25 Y G 0 5 L 0 85 R B 2 P L 1 25 L 1 25 R W 0 5 L Y 0 5 G L 0 5 P 2 B 0 5 G R 2 B 1 25 L 0 5 G B 0 5 B 2 R 2 Y B 2 B 2 Y B 2 B 0 5 B 0 5 G W 0 5 Y 0 5 W B 0 5 W 0 5 W 0 5 B 0 5 G L 0 5 G R 2 Y B 0 5 G W 0 5 G W 2 B 0 5 B 0 5 B 2 B 2 B 1 25 B 0 5 Y B 0 5 B Working Light LH Working Light RH Front Rear Front Rear Diode 1 Blower Mower Beacon Light Defogger Relay...

Page 496: ...w G W Green White R Y Red Yellow Br Brown G Y Green Yellow V W Violet White GY Gray L B Blue Black W B White Black Lg Light Green L G Blue Green W G White Green Or Orange L Or Blue Orange W L White Blue Sb Sky Blue L R Blue Red W R White Red B G Black Green L W Blue White W Y White Yellow B L Black Blue L Y Blue Yellow Y B Yellow Black B P Black Pink Lg B Light Green Blue Y G Yellow Green B Pu Bla...

Page 497: ... digital transmission In data communication the transmission capacity of the line and the capacity of signal transmission reception are represented by the number of bits that can be transmitted or received for one second When the capacity of the transmission line is extremely larger than the ability of the transmission reception performed by a terminal device signals from plural terminals can be t...

Page 498: ...rature etc on the LCD which are basic information necessary for the tractor operation Attention Display at engine starting Display the operator s guidance of levers and pedals at the engine starting on the LCD Service Interval Display Display and alert the service interval periodically on the LCD and panel Warning Display Display the fuel level warning and overheat warning on the LCD and panel Err...

Page 499: ...osition Sensor 13 Range Gear Shift Sensor 14 Hi Lo Solenoid Valve 15 Proportional Valve Reverse 16 Proportional Valve Forward 17 Electronic Instrument Panel InteliPanel 18 Electronic Control Unit ECU 19 GST Lever Sensor 20 Oil Temperature Sensor 21 Oil Pressure Switch 22 GST Valve 23 Battery 24 Glow Relay 25 Engine Tachometer sensor 26 Alternator 27 Traveling Speed Sensor 28 Coolant Temperature Se...

Page 500: ...tronic instrument panel detects the signals and determines whether the engine can be started safety W1014104 Q Multi Function Combination Lever Turn Signal and Head Light Switch The multi function combination lever 1 is located on the right of the steering handle The head light low beam is turned on by turning the lever clockwise from the OFF position The headlight high beam is turned on by turnin...

Page 501: ...at the right of the IntelliPanel and both are of tact type Usually the display mode switch 1 is used at the switching of display indication and the traveling speed switch 2 is used to switching to the traveling speed display as well as at data input and fine adjustment W1029741 Q Brake Lamp Switch This switch is mounted on the brake pedal When the brake pedal is depressed this switch is turned on ...

Page 502: ...s turned on by the PTO speed change lever operation and sends a signal to the IntelliPanel W1014252 Q Fuel Sensor This sensor 1 is designed to detect the fuel level in the fuel tank It detects the position of the float that moves according to the quantity of fuel through the variation in resistance of the variable resistor in order to indicate the fuel level on the LCD Refueling alarm Suppose that...

Page 503: ...the battery charge The alternator sends a signal for making the alarm lamp at the electronic instrument panel to light up if the electricity charge system becomes abnormal W1014934 Q Engine Tachometer Sensor This sensor 1 is mounted at the right side of the engine gear case and generates pulses proportional to the rotation of the fuel camshaft and the number of the cam gear teeth The engine speed ...

Page 504: ...perature sensor W1015142 Q Electric Control Unit ECU for GST and HST Model The ECU 1 functions to operate GST and HST in accordance with information coming from various sensors It has the role of controlling all the components while sharing sensor information necessary for control and control information with the electronic instrument panel and consists of 16 bit CPU and interface that corresponds...

Page 505: ... sends a signal to the electronic instrument panel and ECU W1015572 Q Oil Pressure Switch for GST Model This switch 1 is designed to detect that the gear shift completion of GST and pressurizing of GST clutch pressure and is mounted at the side of GST valve It is turned on when the pilot pressure has become higher than 0 49 MPa 5 kgf cm2 71 psi and is turned off when the pressure has become lower ...

Page 506: ... the HST pedal When the HST pedal is operated signals are sent to the ECU W1015847 Q Cruise Control Lever Position Sensor for HST Model The cruise control lever position sensor is located under the cruise control lever When the cruise control lever is operated signals are sent to the ECU When the cruise control lever is operated a lamp lights up on the panel W1015910 Q Clutch Pedal Switch for HST ...

Page 507: ...t of the tractor is operated by shuttle lever Be sure to connect the ECU connector when using the emergency connector W1031207 Q Flusher Unit Flusher unit controls the blinking frequency as a only one side of lamp blinking of turn signal and both right and left side lamps blinking of hazard signal The blinking frequency is 60 to 80 times per minutes W1039173 Q HST Response Control Dial The HST res...

Page 508: ...sent to the ECU When the H DS lever is pulled up the HST motor is changed to the Hi side When the H DS lever is pushed down the HST motor is changed to the Lo side When the HST motor is set to the Lo side by means of the H DS lever it is not automatically changed to the Hi side even if the HST mode is set to the automatic transmission mode W1040152 Q Throttle Sensor The throttle sensor is located ...

Page 509: ... by switching the valve W1040825 Q Proportional Valve The proportional valves are located on the right of the HST There are two proportional valves one for forward motion and the other for the reverse motion The proportional valve is controlled by signals from the ECU and feeds oil sent from the regulating valve to the servo piston W1040965 1 Hi Lo Solenoid Valve 1 Proportional Valve Reverse 2 Pro...

Page 510: ...17233 NOTE Q Trip meter can be reset to 0 0 h by pushing and holding the display mode switch for about two seconds with trip meter displayed W1015278 1 IntelliPanel Electronic Instrument Panel 2 Liquid Crystal Display LCD 3 Display Mode Switch 4 Travel Speed Switch 5 Periodic Service Required Readout 6 Fuel Gauge 7 Selected Speed Indication HST and GST Model Only 8 Message Display 9 Unit Indicatio...

Page 511: ... Model The safety switch for engine starting is adapted for the shuttle lever and the PTO shift lever in these models Reference As for the manual transmission model selected speed displayed on left edge is not indicated Q When the shuttle lever is not set at a Neutral position Shift the shuttle lever to Neutral position W1017623 Q When the PTO shift lever is not set at a Neutral Position Shift the...

Page 512: ...n Release the HST pedal to set the Neutral Position W1017819 Q When the PTO shift lever is not set at a Neutral position Shift the PTO shift lever to Neutral position W1017869 Q When the clutch pedal is not depressed Depress the clutch pedal W1017913 Q When the HST pedal and PTO shift lever are not set a Neutral position Release the HST pedal and shift the PTO shift lever to set the Neutral positi...

Page 513: ...018012 Q When the PTO shift lever is not set a Neutral position and the clutch pedal is not depressed Shift the PTO shift lever to Neutral position and depress the clutch pedal W1018064 Q When the HST pedal and PTO shift lever are not set a Neutral position and clutch pedal is not depressed Release the HST pedal and shift the PTO shift lever to set a Neutral position and depress the clutch pedal W...

Page 514: ...change to other standard display by pushing the display mode switch Clearing Operation Keep pushing both switches 2 3 for two seconds or more while displaying the hour meter Normal Display 1 W1018218 4 Warning Display or Warning Information Q Fuel Level Warning If the fuel in the tank goes below the prescribed level less than approximate 5 L 1 3 U S gals FUEL is displayed on the LCD 1 in the panel...

Page 515: ...p 6 comes on when the overheat display 1 1 is displayed and it keeps being on until water temperature is becoming 100 C 212 F or less W1018762 Q Engine Oil Pressure and Electric Charging Warning If the engine oil pressure goes below the 49 kPa 0 5 kgf cm2 7 1 psi the warning lamp 1 will come on If this should happen during operation and it does not go off when the engine is accelerated to more tha...

Page 516: ... guard lamp and Auto H DS lamp will come 7 H DS Low Range Speed Lamp If the H DS lever is pushed down the H DS low speed lamp will come on 8 H DS High Range Speed Lamp If the H DS lever is pushed up the H DS high speed range lamp will come on 9 Glow Indicator Lamp If the main switch is turned to ON position the glow indicator lamp comes on and goes off automatically when preheating is completed 10...

Page 517: ...o matter which position the shift lever stays in 2 Self diagnosis Function If any of the following troubles occurs its related error code gets displayed flashing in the panel s LCD screen as shown in figure With the repair finished the error code disappears The error information will be however put in the memory device of the electronic instrument panel and can be reviewed in the Error Information...

Page 518: ...olenoid 3 in trouble ERROR 64 Shift solenoid 4 in trouble ERROR 65 Shift solenoid 6 in trouble ERROR 66 Shift solenoid 5 in trouble Q For HST Model ERROR 80 Range gear shift sensor in trouble ERROR 81 HST pedal sensor in trouble ERROR 82 Swash plate position sensor in trouble ERROR 83 Cruise control lever position sensor in trouble ERROR 84 Throttle sensor in trouble ERROR 85 HST response dial in ...

Page 519: ...mation E GST Lever Sensor Fine adjustment Mode For setting the Neutral position of GST lever sensor Input the sensor information to ECU F GST Valve Fine adjustment Mode For setting the function of proportional reducing valve Input the valve information to ECU G GST Shift Shock Fine adjustment Mode For adjusting the clutch engaging interval H Error Information Display Mode For reviewing error infor...

Page 520: ...the temperature of the coolant is detected with the coolant temperature sensor and the time to supply current to the glow plug and the glow indicator lamp is controlled by CPU according to the detected temperature And the supply current to the glow plug is stopped automatically when the preheating time is completed and monitor lamp on the electronic meter panel is turned off Refer to STARTING SYST...

Page 521: ...NG SYSTEM AND STOPPING SYSTEM 1 MANUAL TRANSMISSION MODEL 1 Battery 2 Main Switch 3 Key Stop Solenoid Relay 4 Key Stop Solenoid 5 Starter Relay 6 Starter 7 Shuttle Switch 8 PTO Switch 9 Glow Relay 10 Glow Plug 11 Electronic Instrument Panel IntelliPanel KiSC issued 04 2010 A ...

Page 522: ...40 L5240 L5740 WSM ELECTRICAL SYSTEM 2 GST MODEL 1 Main Switch 2 Shuttle Switch 3 PTO Switch 4 ECU 5 Engine Stop Solenoid Relay 6 Engine Stop Solenoid 7 Starter Relay 8 Starter 9 Meter Panel 10 Battery KiSC issued 04 2010 A ...

Page 523: ...0 WSM ELECTRICAL SYSTEM 3 HST MODEL 1 Main Switch 2 HST Pedal Sensor 3 PTO Switch 4 Clutch Pedal Switch 5 ECU 6 Meter panel 7 Starter Relay 8 Starter 9 Engine Stop Solenoid Relay 10 Engine Stop Solenoid 11 Battery KiSC issued 04 2010 A ...

Page 524: ... in Neutral position the electrical circuit is closed W1048427 Q Clutch Pedal Switch for HST Model This switch detects the clutch pedal whether being depressed When the clutch pedal is depressed and the clutch disengaged this switch is pushed in and electric circuit is closed W1048539 Q HST Pedal Sensor for HST Model The HST pedal sensor is located on the right of the HST pedal When the HST pedal ...

Page 525: ...9 M36 L3540 L4240 L5040 L5240 L5740 WSM ELECTRICAL SYSTEM Q ECU Electrical Control Unit for GST and HST Model The ECU is located under the floor sheet W1048721 1 ECU KiSC issued 04 2010 A ...

Page 526: ... switch ST terminal and the engine can be started W1048996 W1049162 1 Shuttle Shift Lever 2 PTO Clutch Lever 3 Clutch Pedal 4 HST Pedal A Manual Transmission and GST Model B HST Model Clutch Pedal Switch Pedal depressed ON Pedal free OFF PTO Switch Neutral ON Engaged OFF Shuttle Switch Neutral ON Engaged OFF HST Pedal Sensor Neutral ON Engaged OFF Manual Transmission and GST Model ON ON HST Model ...

Page 527: ...nction of Proportional Reducing Valve 9 S26 8 Mode G GST Shift Shock Fine adjustment Mode Adjusting the Clutch Engaging Interval 9 S27 9 Mode H Error Information Display Mode Confirming or Reviewing the Error Information 9 S27 10 Mode I Transmission Model Input Mode Input the transmission model into electronic instrument panel 9 S28 11 Mode J Speed Unit Selection Mode Input the traveling speed uni...

Page 528: ...9 S59 1 Multi Function Combination Lever Combination Switch 9 S59 9 WARNING LAMPS 9 S62 1 Checking 9 S62 10 MONITOR LAMP 9 S64 11 GAUGES 9 S65 1 Checking 9 S65 2 Coolant Temperature Sensor 9 S65 12 OTHERS 9 S66 5 DISASSEMBLING AND ASSEMBLING 9 S68 1 STARTER 9 S68 2 ALTERNATOR 9 S69 6 SERVICING 9 S71 1 STARTER 9 S71 2 ALTERNATOR 9 S74 KiSC issued 04 2010 A ...

Page 529: ... Starter Motor Does Not Operate Battery discharged or defective Recharge or replace G 31 Slow blow fuse blown Replace G 45 Safety switch improperly adjusted or defective Repair or replace 9 S54 Wiring harness disconnected or improperly connected between main switch terminal and safety switches between safety switches and starter motor between battery positive terminal and starter motor Repair or r...

Page 530: ...tion lever B1 terminal between combination switch 1 terminal and head light between multi function combination lever 2 terminal and head light Repair or replace Hazard Light Does Not Light Fuse blown Replace G 45 Bulb blown Replace G 46 Wiring harness disconnected or improperly connected Repair or replace Flasher unit defective Replace 9 S61 Hazard switch defective Replace 9 S60 Engine Oil Pressur...

Page 531: ...ce 9 S16 Slow blow fuse blown Replace G 45 Electronic instrument panel connector disconnect Connect 9 S37 Electronic instrument panel defective Replace 9 S18 Indication on LCD Does Not Change When Pushing the Display Mode Switch Display mode switch defective Replace 9 S38 Wiring harness disconnected Repair Traveling Speed is Not Indicating Wiring harness disconnected Repair Traveling speed sensor ...

Page 532: ...lectronic instrument panel memory device has failed Electronic instrument panel memory device failure Replace the electronic instrument panel 9 S18 Wrong setting of electric instrument panel GST or HST specified electronic instrument panel installed wrong on Manual transmission model Input appropriate transmission model by Transmission model Input Mode Mode I 9 S28 KiSC issued 04 2010 A ...

Page 533: ...lectronic instrument panel at ECU connector Replace ECU G45 9 S42 9 S42 9 S17 ECU memory device has failed ECU memory device failure Replace ECU 9 S17 Input voltage to lever sensor from ECU is failed Lever sensor input voltage drop below 2 6 V for 0 1 second or more Ground wire of lever sensor short circuited Check the ground cable Check input voltage at ECU connector Check the sensor connector 9 ...

Page 534: ...enoid broken or short circuited Wiring harness broken or short circuited Grounding plate of solenoid is poor contact with chassis Able to travel at speeds other than 1 7 and 8 Forward or 1 and 5 Reverse Check the wiring connector of solenoid Check the resistance between solenoid and GND Replace GST valve 9 S40 9 S44 3 S71 Solenoid 1 failure At reverse Solenoid 2 failure At forward or neutral Able ...

Page 535: ... Reverse Check the wiring connector of solenoid Check the resistance between solenoid and GND Replace GST valve 9 S44 3 S71 Solenoid 6 Main range gear shift failure At reverse Solenoid 5 Sub range gear shift failure Able to travel at speeds other than 3 5 7 and 9 Forward Check the wiring connector of solenoid Check the resistance between solenoid and GND Replace GST valve 9 S44 3 S71 Starter relay...

Page 536: ...eck the communication line between ECU and electronic instrument panel at ECU connector Replace ECU G 45 9 S39 9 S42 9 S17 ECU memory device has failed ECU memory device failure Replace ECU 9 S17 Input voltage to sensor from ECU is failed Sensor input voltage drop below 2 6 V for 0 1 second or more Ground wire of lever sensor short circuited Check the ground cable Check the input voltage at ECU co...

Page 537: ...sensor failed Sensor output terminal is out of adjustment Sensor output wire terminal broken or short circuited Input line broken Sensor defective Travel motion is possible Check the sensor connector Check the sensor voltage by Test mode Mode A Check the sensor wire connector voltage or check sensor resistance Replace the sensor 9 S21 9 S46 Cruise control lever failed Lever sensor output terminal ...

Page 538: ...justment HST response control dial output wire terminal broken or short circuited Input line broken HST response control dial defective Travel motion is possible The HST response control is fixed in the center Check HST response control dial connector Check HST response control dial voltage by Test mode Mode A Check HST response control dial wire connector voltage or check sensor resistance Replac...

Page 539: ...otion is possible on the forward only Check the proportional valve by Test mode Mode A Automatic shift function is not reformed Replace the proportional valve 9 S21 9 S49 Hi Lo solenoid failed Hi Lo solenoid output terminals voltage is out of specification Hi Lo solenoid broken or short circuited Wiring harness broken or short circuited Engine does not start Check the Hi Lo solenoid resistance Rep...

Page 540: ... 106 5 to 113 5 Ω Coolant Temperature Sensor at 20 C 4 F at 40 C 104 F at 100 C 212 F Resistance Resistance Resistance Approx 18 80 kΩ 1 136 kΩ 0 1553 kΩ Starter Commutator Mica Brush Brush Holder and Holder Support O D Under Cut Length Resistance 30 0 mm 1 181 in 0 50 to 0 80 mm 0 0197 to 0 0315 in 15 0 mm 0 591 in Infinity 29 0 mm 1 142 in 0 20 mm 0 0079 in 11 0 mm 0 433 in Alternator Stator Rot...

Page 541: ...s and nuts on the table below are especially specified For general use screws bolts and nuts Refer to 5 TIGHTENING TORQUES at G GENERAL section W10557950 Item N m kgf m lbf ft Starter terminal nut 5 9 to 11 0 60 to 1 2 4 4 to 8 6 Alternator pulley nut 58 4 to 78 9 5 95 to 8 05 43 10 to 58 2 KiSC issued 04 2010 A ...

Page 542: ... this advice is disregarded damage to alternator and regulator may result 1 BATTERY 1 Checking Battery Voltage 1 Stop the engine and turn the main switch off 2 Connect the COM lead of the voltmeter to the battery s negative terminal post and the lead to the positive terminal post and measure the battery voltage 3 If the battery voltage is less than the factory specification check the battery speci...

Page 543: ...ctory installed battery is of non refillable type If the indicator turns white do not charge the battery but replace it with new one W1016405 State of indicator display Green Specific gravity of electrolyte and quality of electrolyte are both in good condition Black Needs charging battery White Needs changing battery 1 Battery 2 Indicator KiSC issued 04 2010 A ...

Page 544: ...the battery as early as possible Failure to do this will shorten the battery s service life 3 The battery is charge if the indicator display turns green from black 4 When exchanging an old battery for a new one use battery of equal specification shown in table Table W1016725 Directions for Storage 1 When shutting down the tractor for long periods of time remove the battery from the tractor store t...

Page 545: ...mover the seat 1 with cover 2 2 Disconnect the ECU connector 3 NOTE Q HST Model When replacing the ECU be sure to adjust the mode N first Then adjust the mode K and mode L GST Model When replacing the ECU be sure to adjust the mode N first Then adjust the mode E and mode F W1331706 1 Seat 2 Cover 3 ECU Connector KiSC issued 04 2010 A ...

Page 546: ...r 1 2 Disconnect the panel connectors 4 5 3 Remove the electronic instrument panel 3 from panel frame 2 NOTE Q When replacing the electronic instrument panel be sure to adjust the mode I first Then adjust to mode B C and mode J W1335923 1 Panel Cover 2 Panel Frame 3 Electronic Instrument Panel IntelliPanel 4 Connector A 20P 5 Connector B 16P KiSC issued 04 2010 A ...

Page 547: ...and the confirmation respectively 1 While holding down both the display mode switch and the travel speed switch at once turn the main switch to ON or START position 2 Mode selection display is indicated on the LCD 3 Press the display mode switch 2 and the flashing part moves 4 Hold down the display mode switch 2 for more than 2 seconds and the buzzer rings and flashing symbol is selected NOTE Q To...

Page 548: ...e shifting shock is not comfortable H Error Information Display Mode When checking the error history I Transmission Model Input Mode When the IntelliPanel is replaced or changed J Speed Unit Input Mode When the IntelliPanel is replaced or changed N Tractor Model Select Mode When the ECU is replaced or changed Mode Details of Mode Necessary Situation A Test Mode When the checking of sensor voltage ...

Page 549: ...at once turn the main switch to ON or START position 2 Select the mode A 3 T1 is displayed b 4 Each time the display mode switch is pressed the symbol changes from T1 to T16 with the buzzer sound 5 Turn off the main switch to end the test mode W1150666 a Mode Selection Display b Testing Display KiSC issued 04 2010 A ...

Page 550: ...77 to 3 37 3 91 to 4 51 V T8 Oil temperature sensor voltage 20 60 100 C 4 140 212 F 4 46 to 4 57 1 71 to 1 91 0 34 to 0 38 V T9 Throttle sensor voltage Idling Max 0 63 to 1 95 3 19 to 4 51 V T10 HST Pedal sensor voltage main Reverse N Forward 0 55 to 1 67 1 94 to 3 06 3 33 to 4 45 V T11 HST Pedal sensor voltage sub Reverse N Forward 3 34 to 4 44 1 95 to 3 05 0 56 to 1 66 V T12 Swash plate position...

Page 551: ... Numeric modification Each time the display mode switch is pressed the flashing number shifts Press the travel speed switch to change the number 5 Hold down the display mode switch for more than 2 seconds to preserve the code in the panel s memory 6 OK is displayed c The code has been input correctly 7 NG is displayed d Incorrect input Repeat the procedure W1155754 Tractor Model Rear wheel tire si...

Page 552: ...t correctly 7 NG is displayed d The code number has not been input correctly Repeat the procedure W1159042 5 Mode D Error Information Reset Mode Delete the Error Information from the Electronic Instrument Panel 1 While holding down the both switches at once turn on the main switch 2 Select the mode D 3 CLEAR is displayed b and PUSH SW is displayed c for two seconds 4 Hold down the display mode swi...

Page 553: ...more than 2 seconds This preserve the adjusted value to the ECU 6 OK is displayed d on LCD screen to tell that preserving to ECU has been made correctly Turn off the main switch to end the mode 7 If NG is displayed f it means the preserving has not been made correctly Turn off the main switch and repeat the procedure 8 If LEVER is displayed b first and then ERROR 70 shows up e it means the lever s...

Page 554: ...engaged the clutch select forward with the shuttle lever and shift the GST lever from 1 through 12 several times Set the GST lever at the positions other than neutral 8 STEP 05 is displayed g Set the GST lever to Neutral position 9 STEP 06 is displayed h Set shuttle lever to forward and engage clutch 10 PUSH SW is displayed i Push the display mode switch for more than three seconds 11 STEP 07 is d...

Page 555: ...etting will be put in memory NOTE Q If the shift shock has been adjusted but no remarkable effect can be felt keep the setting at 0 W1167904 9 Mode H Error Information Display Mode Confirming or Reviewing the Error Information 1 While holding down the both switches at once turn on the main switch 2 Select mode H 3 If there is not error information in memory NO ERROR is displayed b 4 If there is er...

Page 556: ...tly 6 If NG is displayed d The tractor model has not been input correctly Repeat the procedure W1169635 11 Mode J Speed Unit Selection Mode Input the traveling speed unit to the electronic instrument panel 1 While holding down the both switches at once turn on the main switch 2 Select mode J 3 12 is displayed b and existing number is flashing Reference 1 Traveling speed unit is mph 2 Traveling spe...

Page 557: ...d 2 Select mode K 3 Hold down the display mode switch for more than 2 seconds 4 HST ADJ b is displayed and release the switch NOTE Q When indication HST ADJ does not change the engine is not idling or the parking brake is not used When ERROR xx is displayed k refer to the below chart 5 PUSH SW is displayed c Hold down the displayed mode switch for more than 2 seconds Reference W1173479 Error Displ...

Page 558: ...m reverse position 10 STEP 04 is displayed h After completing the above 9 STEP 04 is displayed Then proceed to the next step NOTE Q When ERROR xx m refers to the below chart 11 PUSH SW i is displayed i Hold down the displayed mode switch for more than 2 seconds 12 OK is displayed j The setting has been preserved correctly to the ECU 13 Turn off the key Reference W1175235 Error Display Fine adjustm...

Page 559: ...ndicated errors as follows The accelerator lever is not in the position of idling The accelerator lever is out of position 5 PUSH SW is displayed c Hold down the displayed mode switch for more than 2 seconds 6 STEP 02 is displayed d and release the switch Set the maximum speed for accelerator lever 7 PUSH SW is displayed e Hold down the displayed mode switch for more than 2 seconds NOTE Q ERROR 75...

Page 560: ...the coefficient number and hold down the display mode switch for more than 2 seconds Reference 8 OK is displayed e The code number has been input correctly IMPORTANT Q After setting mode N set mode K and mode L The tractor does not move normally without setting mode K and mode L HST Model Only W1179179 Operation Coefficient No GST Model HST Model 00 L3240 L3540 01 L3940 L3240 L3540 02 L4240 L3940 ...

Page 561: ...s of panel or electronic control unit If any defect is found there check individual sensors switches or solenoids to see whether the defect exists at the sensor switch and solenoid side or at the wire harness side When the normal function is restored as the result of replacement of the part which is suspected to see that the trouble is regenerated IMPORTANT Q When connecting or disconnecting the c...

Page 562: ...lectrical system Refer to troubleshooting section of this manual If any of them should blow replace with a new one of the same capacity Q Protected Circuit W1049036 Fuse No Capacity A Protected circuit ROPS CABIN 1 25 Head light 2 20 Flasher 3 20 Hazard 4 5 Panel 5 5 T M controller 1 GST HST type 6 7 5 Alternator 7 5 Lamp relay 8 10 Patrol lamp 9 7 5 Work light 10 5 Brake lamp switch 11 10 T M con...

Page 563: ...nector 1 Disconnect the connectors 1 2 and check their terminals for contamination and deformation 2 Check to see that cable does not broken or terminals are not shelled off 3 If any defective parts are found repair or replace them IMPORTANT Q Connect connectors surely after checked W1035253 1 Ground Cable A Located at Left Side of Front Axle Frame B Located at Left Side of Transmission Case 1 Con...

Page 564: ...e switch 10 11 Black Red Glow relay 12 Green Blue Turn signal switch LH 13 Black White Turn signal switch RH 14 Black White Main switch ST 15 Blue White PTO Speed Change Switch 16 17 Violet Trailer Indicator 18 White Red Charge 19 20 Blue Oil switch No Color of wiring Terminal Name 1 Yellow Blue Fuel unit 2 White Coolant temperature 3 4 Brown Communication line 5 Brown White Communication line 6 B...

Page 565: ...6395 Connector Voltage Q Main Voltage 1 Measure the voltage between the terminal 8 and terminal 14 2 If the voltage differs from the battery voltage 11 to 14 V the wiring harness or battery is faulty W1036564 1 Panel Cover 2 Panel Frame 3 Electronic Instrument Panel IntelliPanel 4 Connector A 20P 5 Connector B 16P Voltage Terminal 8 to 14 Approx battery voltage 1 Connector B 16P A Connector B 16P ...

Page 566: ...erminal a 3 and c 5 while pushing the display made switch 1 2 It is OK if 0 ohm is indicated 3 Check the resistance between terminal b 4 and c 5 while pushing the travel speed switch 2 NOTE Q It is not necessary to adjust any kind of mode W1048960 1 Display Mode Switch 2 Travel Speed Switch 3 Terminal a 4 Terminal b 5 Terminal c KiSC issued 04 2010 A ...

Page 567: ...connected securely to the tractor chassis 2 If the grand cable is broken or disconnected replace it W1058245 Checking ECU Connector 1 Disconnect the connector 1 and check their terminals for contamination and deformation 2 Check to see that cable does not broken or terminals are not shelled off 3 If any defective parts are found repair or replace them IMPORTANT Q Connect connectors surely after ch...

Page 568: ...alve 5 27 6 Red 12 V power source from battery 28 Black Red Starter relay 7 Pink TXD for check connector 29 Black GND ground for circuit line 8 Violet RXD for check connector 30 Red White 5 V power source for sensor 9 Black Red PTO switch 31 Black White GND ground for sensor 10 32 Blue Red Return line terminal for proportional reducing valve 11 Red Green Shuttle switch Forward 33 12 Orange Traveli...

Page 569: ...or 10 32 Green White Return line terminal for proportional valve Forward 11 Green Red Brake switch 33 12 Orange Traveling speed sensor 34 Green Red HST mode select switch 13 Light Green Engine tachometer sensor 35 Green White Green Blue Return line terminal for proportional valve Reverse 14 Brown Communication line to Panel 36 15 Brown White Communication line to Panel 37 Blue Hi Lo switch Lo 16 O...

Page 570: ...nuity 1 Disconnect the connector B 16P from electronic instrument panel 2 Measure the resistance between terminal 4 of panel connector and terminal 14 of ECU connector and between terminal 5 of panel connector and terminal 15 3 If 0 ohm is not indicated the wiring harness is faulty W1041490 Voltage Terminal 23 to 29 Approx battery voltage Terminal 30 to 31 Approx 5 V 1 ECU 2 ECU Connector A Connec...

Page 571: ...sistance comes to have shown in the table below NOTE Q It is not necessary to adjust any kind of mode CAUTION Be sure to depress the clutch pedal so that the tractor should not move while shifting each lever W1042028 Oil Temperature Sensor Resistance 1 Measure the resistance between the sensor terminals 2 It is OK if the resistance value approximates to the value shown in the table below 3 If the ...

Page 572: ... and Switch for HST Model H DS Lever Continuity Shuttle Switch 1 Remove the steering post cover 1 2 Disconnect the connector 2 3 Measure the resistance between connector terminals referring to the table below 4 If the measurement does not between as table switch is faulty NOTE Q It is not necessary to adjust any kind of mode W1218744 Resistance Reference value 8 to 9 Ω Measuring point Resistance S...

Page 573: ...nd b 3 while shifting the range gear shift lever 2 It is OK if the resistance is smoothly changing NOTE Q When replacing the sensor be sure to adjust the mode K Reference The maximum resistance value between to terminal a 2 and c 4 is 4 32 to 6 48 kΩ W1080989 1 Range Gear Shift Lever Sensor 2 Terminal a 3 Terminal b 4 Terminal c KiSC issued 04 2010 A ...

Page 574: ...ates to the value shown in the table below NOTE Q When replacing the each sensor be sure to adjust the mode K Reference The change of resistance can be checking easily when an analog tester is employed W1237169 Reference Terminal B Terminal GND Approx 1 kΩ Terminal GND Terminal a Resistance is normal if smoothly changing Approx 1 kΩ to 0 Ω Terminal GND Terminal b Resistance is normal if smoothly c...

Page 575: ... b 3 while slowly turning the sensor shaft 3 It is OK if the resistance value approximates to the value shown in the table below NOTE Q When replacing the sensor be sure to adjust the mode L Reference The change of resistance can be checking easily when an analog tester is employed W1238529 Reference between connector terminal When switch spring is pushed 0 Ω When switch spring is released Infinit...

Page 576: ...tween as the table dial is faulty Q HST Mode Switch 1 Measure the resistance between terminal 4 and terminal 5 while pushing the HST mode select switch 3 2 It is OK if O ohm is indicated NOTE Q When replacing the HST response control dial be sure to adjust the mode K W1238856 Resistance Terminal 1 Terminal 3 Approx 1 kΩ HST response control dial position Measuring terminal Resistance FAST Terminal...

Page 577: ...t the mode K W1340231 Hi Lo Solenoid 1 Remove the cover 2 Disconnect the connector 1 3 Remove the Hi Lo solenoid valve assembly 4 Disassembling the Hi Lo solenoid valve assembly 5 Measure the resistance with an ohmmeter across the terminal on the connector and valve body 6 It is OK if the resistance comes to have shown in the table below NOTE Q It is not necessary to adjust any kind of mode W13409...

Page 578: ...U Connector NOTE Q It is not necessary to adjust any kind of mode W1341273 Resistance Terminal 11 of panel connector Terminal 2 of sensor connector 0 Ω Resistance Terminal 23 of ECU connector Terminal 1 of sensor connector 0 Ω Terminal 12 of ECU connector Terminal 2 of sensor connector Terminal 31 of ECU connector Terminal 3 of sensor connector 1 Traveling Speed Sensor 2 Terminal 1 3 Terminal 2 4 ...

Page 579: ...ector NOTE Q It is not necessary to adjust any kind of mode W1342257 Resistance Terminal 6 of panel connector Terminal 3 of sensor connector 0 Ω Resistance Terminal 10 of panel connector Terminal 2 of sensor connector Resistance Terminal 13 of ECU connector Terminal 2 of sensor connector 0 Ω Terminal 23 of ECU connector Terminal 1 of sensor connector 1 Engine Tachometer Sensor 2 Terminal 1 3 Termi...

Page 580: ...e resistance across the B terminal and the AC terminal 3 If 0 ohm is not indicated renew the main switch W1014494 Main Switch at START Position 1 Turn and hold the main switch at the START position 2 Measure the resistances across the B terminal and the AC terminal and across the B terminal and the ST terminal 3 If 0 ohm is not indicated renew the main switch W1014907 1 Main Switch 2 Main Switch C...

Page 581: ...erminal across B terminal and IG1 terminal and B terminal and IG2 terminal 3 If 0 ohm is not indicated renew the main switch W1014641 Main Switch at START Position 1 Turn and hold the main switch at the START position 2 Measure the resistances across the B terminal and the IG1 terminal and across the B terminal and the ST terminal 3 If 0 ohm is not indicated renew the main switch W1015222 Voltage ...

Page 582: ...huttle switch is faulty W1044817 Clutch Pedal Switch For HST Model 1 Remove the panel cover 2 Disconnect the clutch pedal switch connector 2 3 Measure the resistance between connector terminals while pushing the clutch pedal switch 4 If 0 ohm is not indicated switch is faulty W1045306 Resistance between connector terminal When switch spring is pushed Neutral 0 Ω When switch spring is Released Infi...

Page 583: ... check the motor W10142670 Magnet Switch Test Pull in Holding Coils 1 Remove the motor from the starter housing 2 Prepare a 6 V battery for the test 3 Connect jumper leads from the battery negative terminal to the housing and the starter C terminal 4 The plunger should be attached and the pinion gear should pop out when a jumper lead is connected from the battery positive terminal to the S termina...

Page 584: ...tion is not indicated the glow plug is faulty W10151150 Glow Relay 1 Connector Voltage 1 Turn the main switch off 2 Disconnect the 4P connector from glow relay 3 Measure the voltage across the terminal 3 Positive and chassis Negative 4 If the voltage differs from the battery voltage the wiring harness is faulty 5 Turn the main switch on 6 Measure the voltage across the terminal 1 Positive and chas...

Page 585: ...d relay 3 Measure the voltage across the terminal 3 Positive and chassis Negative 4 If the voltage differs from the battery voltage the wiring harness is faulty 5 Turn the main switch on 6 Measure the voltage across the terminal 1 Positive and chassis Negative 7 If the voltage differs from the battery voltage the wiring harness is faulty 2 Engine Stop Solenoid Relay 1 Remove the engine stop soleno...

Page 586: ...t the negative cable from the battery 5 Measure the voltage between the B terminal 2 and the chassis 6 If the measurement is less than the factory specification disassemble the alternator and check the IC regulator Reference Once the engine has started the alternator temperature rises quickly up to an ambient temperature of 70 to 90 C 158 to 194 F As the temperature goes higher than 50 C 122 F the...

Page 587: ...rs from the battery voltage the wiring harness is faulty W12517870 2 Light Switch and Turn Signal Light Switch Continuity 1 Measure the resistance across seven terminal referring to the table below Light Switch Turn Signal Switch W12524280 Voltage Factory spec More than 14 V 1 Multi Function Combination Lever 2 Multi Function Combination Lever Connector Voltage Main switch at OFF position B termin...

Page 588: ...nal a and terminal c and across the terminal d and terminal e 2 If the measurement is not following below the hazard switch or the bulb are faulty W1047271 Flasher Unit 1 Disconnect the connector from the flasher unit 2 Measure the voltage across the terminal h and chassis 3 If the voltage differ from the battery voltage the wiring harness is faulty W1047788 1 Beacon Switch 2 Hazard Switch Voltage...

Page 589: ...ge differ from the battery voltage the wiring harness is faulty Reference Q Flasher Unit Actuation Test 1 Set the hazard switch to the ON position and make sure the hazard light gives 60 to 120 flashers for a minute 2 Set the main switch to the ON position and move the turn signal switch to the left Make sure the left hand light gives flashes Then move the turn signal switch to the right and make ...

Page 590: ...arness 1 Disconnect the lead 2 from the engine oil pressure switch after turning the main switch OFF 2 Turn the main switch ON and connect a jumper lead from the lead to the chassis 3 If the engine oil pressure indicator lamp does not light the panel circuit or the wiring harness is faulty W10259540 Resistance between connector terminals When brake pedal is released Infinity When brake pedal is de...

Page 591: ...g Circuit Panel Board and Wiring Harness 1 Disconnect the 2P connector from the alternator after turning the main switch OFF 2 Turn the main switch ON and connect a jumper lead from the wiring harness connector terminal WR to the chassis 3 If the charge lamp does not light the panel board circuit alternator wiring harness or fuse is fault W10262530 Resistance Switch terminal Chassis In normal stat...

Page 592: ...Panel and Wiring Harness 1 Disconnect the connector from the parking brake switch after turning the main switch OFF 2 Turn the main switch ON and connect a jumper lead between the connector terminals of wiring harness 3 If the parking brake indicator lamp does not light the panel circuit or wiring harness is faulty W1026754 Resistance Across switch terminals In normal state Infinity 1 Parking Brak...

Page 593: ...istance across the sensor terminal and the chassis 2 If the measurement is not indicated the sensor is faulty When galvarnometer shows 0 zero When galvarnometer shows 0 zero W1022725 Resistance Sensor terminal its body Reference value Float at upper most position 1 8 to 4 2 Ω Float at lower most position 106 5 to 113 5 Ω Characteristics of Thermistor Temperature Resistance of VR Condition 20 C 4 F...

Page 594: ...PTO speed change switch connector 2 Measure the resistance between connector terminal as shown in table below 3 If the switch is defective replace it W1042180 Resistance between connector terminal When switch spring is pushed Neutral 0 Ω When switch spring is Released Infinity 1 PTO Speed Change Switch 2 Connector of Switch Side KiSC issued 04 2010 A ...

Page 595: ... or contact condition is not properly between the slip ring 2 and contact terminal 3 as shown photo W1043216 2 Horn Switch Continuity 1 Measure the resistance with ohmmeter between the 1P terminal flat shape and 1P terminal round shape 2 If the measurement is not following below the horn switch 1 is faulty W1046628 Voltage 1P terminal 1P terminal Approx battery voltage 1 Horn Switch 2 Slip Ring 3 ...

Page 596: ...agnet Switch 1 Remove the drive end frame 1 mounting screws 2 Take out the overrunning clutch 2 ball 3 spring 4 gears 5 rollers 6 and retainer 7 When reassembling Apply grease to the gear teeth of the gears 5 and overrunning clutch 2 and ball 3 W10167280 Plunger 1 Remove the end cover 1 2 Take out the plunger 2 W10168830 Tightening torque Nut 7 5 9 to 11 N m 0 60 to 1 2 kgf m 4 4 to 8 6 lbf ft 1 A...

Page 597: ...he B terminal nut and remove the rear end cover W10189820 Brush Holder 1 Unscrew the two screws holding the brush holder and remove the brush holder 1 W10190540 IC Regulator 1 Unscrew the three screws holding the IC regulator and remove the IC regulator 1 W10191230 Rectifier 1 Remove the four screws holding the rectifier and the stator lead wires 2 Remove the rectifier 1 W10191920 Tightening torqu...

Page 598: ... ring or fan etc W10194380 Retainer Plate 1 Unscrew the four screws holding the retainer plate and remove the retainer plate 1 W10195420 Bearing on Drive End Side 1 Press out the bearing from drive end frame 3 with a press and jig 1 W10196110 Bearing at Slip Ring Side 1 Lightly secure the rotor 1 with a vise to prevent damage and remove the bearing 2 with a puller 3 W10197010 1 Rear End Frame 1 Ro...

Page 599: ...ightly worn 2 Measure the commutator O D with an outside micrometer at several points 3 If the minimum O D is less than the allowable limit replace the armature 4 If the difference of the O D s exceeds the allowable limit correct the commutator on a lathe to the factory specification 5 Measure the mica undercut 6 If the undercut is less than the allowable limit correct it with a saw blade and cham...

Page 600: ...y across the brush holder and the holder support with an ohmmeter 2 If it conducts replace the brush holder W10176720 Armature Coil 1 Check the continuity across the commutator and armature coil core with an ohmmeter 2 If it conducts replace the armature 3 Check the continuity across the segments of the commutator with an ohmmeter 4 If it does not conduct replace the armature W10177670 Brush lengt...

Page 601: ...the continuity across the lead 1 and brush 2 with an ohmmeter 2 If it does not conduct replace the yoke assembly 3 Check the continuity across the brush 2 and yoke 3 with an ohmmeter 4 If it conducts replace the yoke assembly W10180150 1 Lead 2 Brush 3 Yoke KiSC issued 04 2010 A ...

Page 602: ...eck the continuity across the slip ring and core with an ohmmeter 4 If infinity is not indicated replace it W10200940 Slip Ring 1 Check the slip ring for score 2 If scored correct with an emery paper or on a lathe 3 Measure the O D of slip ring with vernier calipers 4 If the measurement is less than the allowable limit replace it W10202080 Brush Wear 1 Measure the brush length with vernier caliper...

Page 603: ...uto digital multimeter Because it s very hard to check the continuity of rectifier by using it W10204520 IC Regulator 1 Check the continuity across the B terminal and the F terminal of IC regulator with an analog ohmmeter Conduct the test in the R 1 setting 2 The IC regulator is normal if the IC regulator conducts in one direction and does not conduct in the reverse direction IMPORTANT Q Do not us...

Page 604: ...10 CABIN KiSC issued 04 2010 A ...

Page 605: ...NDITIONER SYSTEM 10 M1 1 OUTLINE OF AIR CONDITIONING SYSTEM 10 M1 2 SYSTEM CONTROL 10 M3 3 ELECTRICAL SYSTEM 10 M4 1 Electrical Circuit 10 M4 2 Air Conditioner Relay Blower Relays and Compressor Relay 10 M5 KiSC issued 04 2010 A ...

Page 606: ... Heater Hose Out Side 2 Heater Hose In Side 3 Water Valve 4 Control Panel 5 Outside Air Filter 6 Inner Roof 7 Inside Air Filter 8 Side Air Outlet 9 Front Air Outlet 10 High Pressure Pipe 11 Low Pressure Pipe 12 Compressor 13 Condenser 14 Pressure Switch 15 Receiver 16 Air Conditioner Unit KiSC issued 04 2010 A ...

Page 607: ...il The compressor oil dissolves in the refrigerant circulates through the air conditioning cycle and functions to lubricate the compressor But the conventional compressor oil for R12 doesn t dissolve in R134a so it doesn t circulate through the cycle and the lifespan of the compressor is considerably shortened It is still essential to ensure that the correct refrigerant oil is used R12 systems wer...

Page 608: ...valve The air flows to door D3 12 side passing through the heater core 3 Outlet air flow is controlled by door D3 Moving the mode switch 2 opens and shuts door D3 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 is moved to establish the air passages to outlets O1 and O2 Air comes out from both outlets Q DEF Moving...

Page 609: ...M 1 Electrical Circuit 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 04 2010 A ...

Page 610: ...to turn off the blower motor 6 could result in a discharged battery 3 To protect against such trouble relays have been provided These relays have been made so that when current flows through its coil 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 r...

Page 611: ...igerant 10 S19 4 Checking Charge Refrigerant Amount 10 S21 6 CHECKING DISASSEMBLING AND SERVICING 10 S22 1 CHECKING AND ADJUSTING 10 S22 1 Compressor 10 S22 2 Control Panel Blower Switch A C Switch Mode Control Dial and Temperature Control Dial 10 S23 3 Blower Resistor 10 S25 4 Blower Motor 10 S26 5 Temperature Motor 10 S26 6 Mode Motor 10 S27 7 Air Conditioner Relay and Blower Relay 10 S27 8 Pres...

Page 612: ... Cool Compressor Does Not Rotate Fuse blown Replace G 45 Magnetic clutch defective Repair or replace 10 S22 Blower switch defective Replace 10 S23 Pressure switch defective Replace 10 S28 Belt slipping Adjust or replace G 35 Does Not Cool Others Insufficient refrigerant Check with manifold gauge 10 S13 Expansion valve defective Replace Compressor defective Replace 10 S42 Insufficient Cooling Insuf...

Page 613: ...epair Too Low Air Flow Rate Flow Rate Does Not Change in 4 Steps Blower resistor defective Replace 10 S25 Blower relay defective Replace Blower switch defective Replace 10 S23 Too Low Air Flow Rate Others Blower is not tightened enough Check and repair 10 S26 Blower deformed Replace 10 S26 Blower in contact with casing Check and repair 10 S26 Obstacle at or near suction port Check and repair Evapo...

Page 614: ...ion valve clogged Replace Insufficient Cooling Both Hi pressure and Low pressure Level is Too High Refrigerant overcharged Check with manifold gauge 10 S13 Insufficient Cooling Both Hi pressure and Low pressure Level is Too Low Refrigerant too short Check with manifold gauge 10 S13 Temperature Cannot be Controlled Temperature Motor and or Temperature control dial Malfunction Temperature motor defe...

Page 615: ...rrupts movement of link mechanism Repair 10 S54 Wiper arm seized or rusted Lubricate or replace 10 S54 Windshield Wiper Operating Speed Is Too Low Wiper motor defective Short circuit of motor armature worn motor brush or seized motor shaft Replace 10 S30 Low battery voltage Recharge or replace G 31 Humming occurs on motor in arm operating cycle due to seized arm shaft Lubricate or replace 10 S54 W...

Page 616: ...psi 1 27 to 1 66 MPa 13 to 17 kgf cm2 185 to 242 psi Pressure Switch Dual Type When pressure switch is turned OFF Setting Pressure LO Pressure Side Setting Pressure HI Pressure Side Less than approx 0 196 MPa 2 0 kgf cm2 28 4 psi More than approx 3 14 MPa 32 kgf cm2 455 psi Air gap of A C Compressor Magnet Clutch Air gap 0 20 to 0 45 mm 0 008 to 0 018 in Air Conditioner Drive Belt Tension 10 to 12...

Page 617: ...ng 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 pipe 1 mounting screw Compressor side 7 95 to 11 7 0 80 to 1 20 5 86 to 8 67 High pressure side 1 retaining nu...

Page 618: ...e service can unless necessary When it has to be heated use warm water of 40 C 104 F or lower Do not heat using boiling water IMPORTANT Q If the refrigerant O rings etc for R12 are used in the R134a air conditioner system problems such as refrigerant leakage or cloudiness in the sight glass may occur Therefore in order to prevent charging of refrigerant or erroneous connections the shapes of the p...

Page 619: ... 70 to 1 91 lbs Factory spec L4240 L5240 L5740 R134a 800 to 900 g 1 77 to 1 98 lbs Quantity Total Brand Name 50 to 70 cc 0 053 to 0 073 U S qts 0 044 to 0 061 Imp qts ND OIL 8 PAG oil Replacing Parts Replenish Quantity Brand Name Condenser 20 cc 0 021 U S qts 0 018 Imp qts ND OIL 8 PAG oil Evaporator 10 cc 0 011 U S qts 0 0088 Imp qts Receiver 10 cc 0 011 U S qts 0 0088 Imp qts Hose 10 cc 0 011 U ...

Page 620: ...t be opened W1013376 Q When LO Valve is Opened and HI Valve is Closed Two circuits are established Port C LO pressure gauge 1 Port B Port D Port A HI pressure gauge 2 NOTE Q Schrader valve D must be opened W1013454 Q When LO Valve is Closed and HI Valve is Opened Two circuits are established Port C LO pressure gauge 1 Port B Port D Schrader valve must be opened Port A HI pressure gauge 2 NOTE Q Sc...

Page 621: ...disconnect connector should the sleeve 7 move before the quick link connector can be connected to the charging valve move the quick sleeve to its original position and try again When some refrigerant remains in the charging hose at the time of connections it may be difficult to connect the quick link connector In this case perform the operation after removing any residual pressure in the hose Remo...

Page 622: ...for R134a and cannot be used Therefore a new electric gas leak tester with greater sensitivity has been designed and can be used with both R134a and R12 Reference Leak tester with halide torch Since the reaction with chlorine within the refrigerant is used to detect gas leaks R134a which contains no chlorine cannot be detected W1014905 5 Can Tap Valve The can tap valve that is used to charge the r...

Page 623: ...ant Recovery and Recycling Machine When there is necessity of discharging the refrigerant on repairing the tractor it should use recovery and recycling machine Don t release the refrigerant into the atmosphere IMPORTANT Q Use only R134a refrigerant recovery and recycling machine eliminate mixing R134a equipment refrigerant and refrigerant oils with R12 systems to prevent compressor damage W1015488...

Page 624: ...ve out the air in the charging hoses at the manifold gauge connection end by utilizing the refrigerant pressure in the refrigerating cycle 3 Start the engine and set at approx 1500 min 1 rpm 4 Turn on the A C switch and set the temperature control lever to maximum cooling position 5 Set the blower switch to HI position W1015662 Normal Operating If the refrigerating cycle is operating normally the ...

Page 625: ...Insufficient Condenser Cooling 1 Symptoms seen in refrigerating cycle Both LO and HI pressure side 1 2 pressures too high LO pressure side 1 0 20 to 0 35 MPa 2 0 to 3 5 kgf cm2 28 4 to 49 8 psi HI pressure side 2 1 96 to 2 45 MPa 20 to 25 kgf cm2 284 5 to 355 6 psi 2 Probable cause Overcharging refrigerant into cycle Condenser cooling faulty 3 Solution Clean condenser Refer to 7 5 CHECK POINTS OF ...

Page 626: ...ation W1016771 Moisture Entered in the Cycle 1 Symptoms seen in refrigerating cycle The air conditioner operates normally at the beginning but over time LO pressure side 1 pressure is vacuum and HI pressure side 2 is low pressure LO pressure side 1 Vacuum HI pressure side 2 0 69 to 0 98 MPa 7 to 10 kgf cm2 99 6 to 142 2 psi 2 Probable cause The moisture in the refrigerating cycle freezes in the ex...

Page 627: ...xpansion valve Replace the receiver Evacuate and charge in proper amount of new refrigerant Refer to 3 Charging the Refrigerant in this section If caused by gas leakage in heat sensitizing tube replace the expansion valve W1017346 Expansion Valve Opens Too Far or Improper Installation of Heat Sensitizing Tube 1 Symptoms seen in refrigerating cycle Both LO and HI pressure side 1 2 pressures too hig...

Page 628: ...ischarging the Refrigerant Prepare for the R134a refrigerant recovery and recycling machine 9 1 Connect low pressure side hose blue 4 from the recovery and recycling machine 9 to LO pressure side charging valve 1 Connect high pressure side hose red 5 to HI pressure side charging valve 2 2 Follow the manufacturers instructions and discharge the system IMPORTANT Q Use only R134a refrigerant recovery...

Page 629: ...acuum pump 8 to evacuate the refrigerant cycle For approx 15 minutes 5 When LO pressure gauge 3 reading is more than 750 mmHg 299 in Hg stop the vacuum pump 8 and close both valves 5 6 of manifold gauge fully 6 Wait for over 5 minutes with the HI and LO pressure side valves 5 and 6 of gauge manifold closed and then check that gauge indicator does not return to 0 7 If the gauge indicator is going t...

Page 630: ...acuated completely 2 Connect the center charging hose green 5 to the can tap valve 3 fitting and then loosen the center charging hose green 5 at the center fitting of manifold gauge until hiss can be heard Allow the air to escape for few seconds and tighten the nut 3 Open the HI pressure side valve 2 fully and keep the container upside down to charge the refrigerant in the liquid state from the HI...

Page 631: ...Set the temperature control lever to maximum cooling position and the blower switch to HI position 4 Open the LO pressure side valve 5 of manifold gauge and the can tap valve 3 on refrigerant container and charge the refrigerant until air bubbles in the sight glass of the receiver vanish 5 After charging the specified amount of refrigerant into the system close the LO pressure side valve 5 of mani...

Page 632: ...ough the sight glass becomes as stated below depending on refrigerant charged amount A Insufficient refrigerant charge Air bubbles pass continuously the sight glass when pressure on the LO pressure side is over 99 0 kPa 1 01 kgf cm2 14 4 psi In this case charge the refrigerant from the LO pressure side B Properly refrigerant charge Air bubbles pass through the sight glass continuously when pressur...

Page 633: ... specifications replace the stator coil W1014331 Air Gap 1 Check the air gap with feeler gauge 2 If the measurement is not within the factory specifications adjust it Refer to 3 SERVICING in this section W1018230 Adjusting Air Conditioner Belt Tension Cabin Model CAUTION Be sure to stop the engine before checking air conditioner belt tension 1 Stop the engine and remove the key 2 Apply 98 N 10 kgf...

Page 634: ...4 If the voltage differs from the battery voltage the wiring harness A C relay fuse or main switch is faulty W1019240 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 W1019735 Voltage Terminal a Terminal b Approx battery voltage 1 Control Panel 2 6P Connector A 6P Connector Wire Harness Side Ter...

Page 635: ...oner 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 W1020998 Mode Control Dial Checking 1 Disconnect the 16P connector from control panel switch 2 Check the continuity through the switch with an ohmmeter 3 If the continuity sp...

Page 636: ... 8 Turn the main switch to ON position 9 Check that an output voltage is approximately 10 V when turning the temperature control dial counterclockwise till it stops COOL position 10 If an output voltage differs from approximately 10 V the control panel wiring harness of fuse is faulty W1021942 3 Blower Resistor A C Blower Resistor 1 Remove the outer roof 2 Disconnect the 4P connector 1 for A C blo...

Page 637: ...eck the motor W1020120 5 Temperature Motor Temperature Motor Checking 1 Confirm whether the temperature control dial 2 is defective Refer to 4 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 opera...

Page 638: ...W1044370 7 Air Conditioner Relay and Blower Relay Checking Air Conditioner Relay and Blower Relay 1 Remove the air conditioner relay and blower relay 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 W1072514 1 Mode Motor 2 Mode Switch 3 Blower Switch a Air is blown from only the defroster air outle...

Page 639: ...etic clutch is turned off At this time read the HI pressure gauge of the manifold gauge If this pressure reading differs largely with the setting pressure replace the pressure switch with a new one 2 LO Pressure 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 ref...

Page 640: ...faulty 2 Front Wiper Switch 1 Check the continuity through the switch with an ohmmeter 2 If continuity specified below is not indicated the switch is faulty Reference WASH Ι OFF side of the wiper switch remains pushed in WASH ΙΙ ON side remains pushed in after the wiper switch is switched ON and remains switched ON W1021874 1 Front Wiper Switch Voltage W terminal Chassis Approx battery voltage Ter...

Page 641: ...nal W and chassis 3 If the voltage differs from the battery voltage the wiring harness fuse or main switch is faulty 2 Rear Wiper Switch 1 Check the continuity through the switch with an ohmmeter 2 If continuity specified below is not indicated the switch is faulty Reference WASH Ι OFF side of the wiper switch remains pushed in WASH ΙΙ ON side remains pushed in after the wiper switch is switched O...

Page 642: ...ain switch ON 3 Push the rear wiper switch to ON position 4 Count the number of wiper arm rocking per minutes 5 If the number differs from the factory specifications replace the wiper motor assembly W1031594 No load rotating speed Factory spec 49 to 61 min 1 rpm 1 Wiper Arm 2 Wiper Blade KiSC issued 04 2010 A ...

Page 643: ...ines fresh water circulates through the heater This means that one more liter or so of fresh water is required In changing fresh water pour fresh water up to the filter port of the recovery tank Turn ON the heater shift the temperature control lever toward WARM and run the engine for a while in order to warm fresh water Then stop the engine When fresh water has cooled down some of the fresh water ...

Page 644: ...heater hoses 3 and then reconnect their hoses to make loop NOTE Q Put a mark to the each heater hose before disconnecting 6 Disconnect the wiring connector for window washer tank 4 and compressor 1P connector 5 7 Disconnect the brake pedal rod 12 When reassembling Tighten the steering joint shaft mounting screw after adjusting the position of steering joint shaft support 6 for smooth rotation of t...

Page 645: ...rn and battery 3 Remove the clamps and ground cable of wiring harness and collect wiring harness to the step or cabin 4 Remove the clamps 8 of A C hoses 5 When reassembling Be sure to check and adjust the clutch and brake pedal free travel Refer to 7 4 CHECK POINTS OF EVERY 100 HOURS at G GENERAL section W1039585 1 Alternator 2 Oil Pressure Switch 3 Fuel Unit 4 Clutch Rod 5 A C Hoses 6 Brake Pedal...

Page 646: ...r 6 main shift lever 4 GST Model 3 Remove the lever grip for creep shift lever 6 and disconnect the range gear sensor connector 9 HST Model 3 Remove the lever grip for range gear shift lever 5 W1061567 1 Seat 2 Seat Bracket 3 Front Wheel Drive Lever 4 Main Gear Shift Lever 5 Range Gear Shift Lever 6 Creep Shift Lever 7 GST Lever 8 Cruise Control Lever 9 Range Gear Sensor Connector A Manual Transmi...

Page 647: ...rod 2 it is at right side for manual transmission and GST model and left side for HST model The PTO speed change lever equip for manual transmission model 2 Remove the lowering speed adjusting knob 3 3 Remove the PTO speed change lever 1 if equipped 4 Disconnect the PTO speed sensor 4 if equipped W1063358 1 PTO Speed Change Lever 2 Differential Lock Rod 3 Lowering Speed Adjusting Knob 4 PTO Speed ...

Page 648: ...nector to ensure correct installation W1079091 Electric Connector for GST 1 Remove the GST valve cover 2 Disconnect the pressure switch connector 1 proportional reducing valve connector 2 solenoid valve connector 3 oil temperature sensor connector 5 and ground cables 4 W1055035 1 Solenoid Cover 2 Step LH 3 Ground Cable 4 Solenoid Valve Connector 5 Proportional Valve Cover 6 Step RH 7 Servo Piston ...

Page 649: ...GENERAL section W1064487 Auxiliary Hydraulic Out Let and Control Lever 1 Remove the auxiliary hydraulic out let 2 with stay 1 from the cabin 2 Disconnect the auxiliary control lever 4 from the auxiliary control valve 5 3 Remove the lever grip for position control lever 3 W1055606 1 Parking Brake Cable 1 Stay 2 Auxiliary Hydraulic Out Let 3 Position Control Lever 4 Auxiliary Control Lever 5 Auxilia...

Page 650: ... valve lever be sure to adjust the length of wire as follows 1 Set the PTO shift lever to OFF Neutral position 2 Loosen the lock nut of wire and connect wire to the clutch valve lever and then place the wire to the hook 3 Tighten the lock nut clockwise pull the wire and lock the nut just before the lever moves Lock each cable at the center of the screw W1080099 1 PTO wire 2 Speed Sensor Connector ...

Page 651: ... 3 2 Remove the panel cover 1 3 Remove the mats 4 4 Remove the brake rods 7 and clutch rod 5 5 Remove the universal joint bolt 6 and disconnect the steering joint shaft 1 8 W1128466 1 Panel Cover 2 Steering Post Cover 1 3 Steering Post Cover 2 4 Mat 5 Clutch Rod 6 Universal Joint Bolt 7 Brake Rod 8 Steering Joint Shaft 1 KiSC issued 04 2010 A ...

Page 652: ... from tractor body NOTE Q Lift the cabin while making sure it does not catch on anything When reassembling Be sure to install the washers and mount rubbers etc in their original positions as shown in figure W1031590 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 124 to 147 N m 12 6 to 15 0 kgf m 91 2 to 108 lbf ft 1 Radia...

Page 653: ...e O rings and take care not to damage them S letter is marked on the compressor for connecting the low pressure pipe suction side D letter is marked on the compressor for connecting the high pressure pipe discharge side When replacing the compressor with a new one meet the oil amount with old one Push on the belt between the pulleys with a finger Deflection L of 10 to 12 mm 0 40 to 0 48 in under a...

Page 654: ...by hand after assembling and not contact with stator and hub plate Check and adjust the air gap before tight the magnet clutch mounting screw or nut to the specified torque Refer to 3 SERVICING in this section W1059166 Rotor 1 Remove the circlip 1 2 Remove the rotor 3 When reassembling Do not use the circlip again Assemble the circlip for the tapered side to become outside of rotor The width of ex...

Page 655: ...anding of circlip is set is boss of shaft as a minimum Match and assemble the concave part 3 of the front housing 5 and the pin 4 of stator W1059953 3 Removing Air Conditioner Unit Draining Coolant Refer to 2 DISASSEMBLING AND ASSEMBLING in this section W1045207 Discharging Refrigerant Gas Refer to 2 DISCHARGING EVACUATING AND CHARGING of 5 CHECKING AND CHARGING REFRIGERANT CYCLE in this section W...

Page 656: ... 3 W1045533 Wiring Harness 1 Disconnect the temperature motor connector 1 and thermostat connectors 2 2 Disconnect the mode motor connector 3 and blower resister connector 4 W1045808 1 Outer Roof 2 Ground cable 3 Stay 1 Temperature Motor Connector 2 Thermostat Connector 3 Mode Motor Connector 4 Blower Resister Connector KiSC issued 04 2010 A ...

Page 657: ... hand 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 W1025169 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 00 to 1 ...

Page 658: ...02 Hose Clamp 1 Remove the hose clamp 4 2 Disconnect the pressure switch 6 connector 3 Disconnect the high pressure pipe 1 5 from the receiver 1 and low pressure pipe 3 from the compressor then cap the open fittings immediately to keep moisture out of the system When reassembling Apply compressor oil DENSO ND OIL 8 or equivalent to the O rings and take care not to damage them W1026689 1 Bonnet 2 W...

Page 659: ...fittings immediately to keep moisture out of the system 4 Remove the inner covers 3 When reassembling Replace the rubber with a new one Apply compressor oil DENSO ND OIL 8 or equivalent to the O rings and take care not to damage them W1026890 Tightening torque High pressure pipe 2 retaining nut 12 to 14 N m 1 2 to 1 5 kgf m 8 7 to 10 lbf ft Low pressure pipe retaining nut 30 to 34 N m 3 0 to 3 5 k...

Page 660: ...d right side skirts 3 4 Disconnect window washer hoses 2 5 Remove the bonnet 1 NOTE Q When disconnecting the battery cords disconnect the negative cord first when connecting positive cord first W1057798 Hose Clamp 1 Remove the hose bands 1 2 Remove the hose clamp 2 NOTE Q Before disconnecting the heater hoses 3 put the parting marks on the hoses for marking proper reconnecting 3 Disconnect the hea...

Page 661: ... 4 Pull out 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 ...

Page 662: ...ke See the left figure 2 Pull the piano wire inward outward alternately to cut the adhered part NOTE Q Do not let the piano wire make sliding contact with the edge of glass plate forcibly In case of using cutter knife When glass is totally crushed finely 1 Insert the knife 3 into the adhered part 2 Keep the edge of knife blade square to the glass edge at the part a Slide the knife blade along the ...

Page 663: ... shown in figure 4 Install the rear windshield 1 to the cabin and fix tit with a gummed tape 5 Leave it for one hour NOTE Q Apply the Sika Tack Ultrafast or equivalent with the jig having the specified tip shape as shown in the figure left Apply it with a uniform speed to minimize unevenness Follow the instruction manual of Sika Tack Ultrafast When the gummed tape is removed the rear windshield ma...

Page 664: ...rance E approx 5 mm 0 2 in between the lower and upper windshield The level unevenness between the upper and lower windshields should be 1 to 1 mm 0 04 to 0 04 in or less at the windshield surface 6 Leave it for one hour 7 Remove the jig 8 8 Install the H rubber 7 between the lower and upper windshield 2 3 9 Apply the Shin Etsu silicon KE420 in H rubber 7 10 Apply the Shin Etsu silicon KE420 on th...

Page 665: ... bilateral symmetry W1025464 3 SERVICING Adjustment of Air Gap 1 Measure the air gap with a feeler gauge 2 When the measurement value comes off from factory specification adjustment shim 1 is added or deleted Reference W1060178 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 spec 90 to 110 mm 3 5 to 4 3 in 1 Meter Panel 2 Steering...

Page 666: ...ode No 9Y111 01023 2007 11 S E I E I e KUBOTA Corporation EDITOR KUBOTA FARM INDUSTRIAL MACHINERY SERVICE LTD 64 ISHIZU KITAMACHI SAKAI KU SAKAI CITY OSAKA 590 0823 JAPAN PHONE 81 72 241 1129 FAX 81 72 245 2484 E mail ksos pub kubota co jp ...

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Kubota L3540, Workshop Manual

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