Kubota WSM F2880 Workshop Manual Download

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WORKSHOP MANUAL

F2880,F3680,RCK72-F36,

RCK72R-F36,RCK60-F36,

RCK60R-F36

KiSC issued 04, 2006 A

Summary of Contents for WSM F2880

Page 1: ...WORKSHOP MANUAL F2880 F3680 RCK72 F36 RCK72R F36 RCK60 F36 RCK60R F36 KiSC issued 04 2006 A ...

Page 2: ...ore proceeding with troubleshooting disassembling and servicing Refer to Diesel Engine Tractor Mechanism Workshop Manual Code No 97897 01873 97897 18200 for the one which has not been described to this workshop manual Servicing Information on the troubleshooting servicing specification lists tightening torque checking and adjusting disassembling and assembling and servicing which cover procedures ...

Page 3: ...s used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury Read these instructions carefully It is essential that you read the instructions 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 potenti...

Page 4: ...supported solely 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 be...

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

Page 6: ...K60R F36 WSM 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 2006 A ...

Page 7: ...5 F2880 F3680 RCK72 F36 RCK72R F36 RCK60 F36 RCK60R F36 WSM SAFETY INSTRUCTIONS KiSC issued 04 2006 A ...

Page 8: ...6 F2880 F3680 RCK72 F36 RCK72R F36 RCK60 F36 RCK60R F36 WSM SAFETY INSTRUCTIONS KiSC issued 04 2006 A ...

Page 9: ...l fuel No 2 D Capacities Fuel tank 61 L 16 1 U S gals 13 4 Imp gals Engine crankcase 3 8 L 4 0 U S qts 3 3 Imp qts Engine coolant 4 6 L 4 9 U S qts 4 0 Imp qts Recovery tank 0 6 L 0 6 U S qts 0 5 Imp qts Transmission case 14 0 L 14 8 U S qts 12 3 Imp qts Rear axle differential case 1 5 L 1 59 U S qts 1 32 Imp qts Rear axle gear case 0 5 L 0 53 U S qts 0 44 Imp qts Tire Front 24 12 12 4PR Turf Rear...

Page 10: ...m at 3000 engine rpm Drive system Shaft drive KUBOTA 10 tooth involute spline 2545 rpm Clutch type Wet multi plates PTO brake Wet single plate Steering Hydraulic power steering Transmission Hydrostatic transmission High Low gear shift 2 forward 2 reverse Brake Wet disk type Minimum turning radius Less than 750 mm 29 5 in inside of front tire Differential Front Bevel gear Rear Bevel gear 4WD system...

Page 11: ...9 F2880 F3680 RCK72 F36 RCK72R F36 RCK60 F36 RCK60R F36 WSM DIMENSIONS DIMENSIONS KiSC issued 04 2006 A ...

Page 12: ...G GENERAL KiSC issued 04 2006 A ...

Page 13: ...GS G 9 6 MAINTENANCE CHECK LIST G 10 7 CHECK AND MAINTENANCE G 12 1 DAILY CHECK G 12 2 CHECK POINTS OF INITIAL 50 HOURS G 17 3 CHECK POINTS OF EVERY 50 HOURS G 19 4 CHECK POINTS OF EVERY 100 HOURS G 25 5 CHECK POINTS OF EVERY 200 HOURS G 26 6 CHECK POINTS OF EVERY 400 HOURS G 29 7 CHECK POINTS OF EVERY 1500 HOURS G 30 8 CHECK POINTS OF EVERY 3000 HOURS G 30 9 CHECK POINTS OF EVERY 1 YEAR G 30 10 C...

Page 14: ...e engine was manufactured in January 2005 W1010714 Alphabet or Number Year Alphabet or Number Year 1 2001 F 2015 2 2002 G 2016 3 2003 H 2017 4 2004 J 2018 5 2005 K 2019 6 2006 L 2020 7 2007 M 2021 8 2008 N 2022 9 2009 P 2023 A 2010 R 2024 B 2011 S 2025 C 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 E999...

Page 15: ... before measuring 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 w...

Page 16: ... time recommend the dealer to perform periodic check Do not attempt to modify 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 17: ... for movable part where sag may be required W10115870 When installing a part take care not to trap or damage the wiring W10116700 After installing wiring check protection of terminals and clamped condition of wiring before connecting battery W10117350 1 Clamp Wind Clamp Spirally 2 Wire Harness 3 Clamp 1 Wiring 2 Clamp A Correct B Incorrect 1 Wiring A Incorrect 1 Cover Securely Install Cover KiSC i...

Page 18: ...h water immediately Before recharging the battery remove it from the machine Before recharging remove cell caps Recharging should take place in a well ventilated place where there is no open flame nearby as hydrogen gas and oxygen are produced which is highly flammable W10118160 3 FUSE Use fuses with specified capacity Neither too large or small capacity fuse is acceptable Never use steel or coppe...

Page 19: ...0 Make certain that there is no uninsulated femal connectors W10124300 Make certain the plastic cover is large enough to cover whole connector W10125190 5 HANDLING OF CIRCUIT TESTER Use the tester according to its own operating instructions 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 issue...

Page 20: ...F SAE10W 10W 30 or 10W 40 0 to 25 C 32 to 77 F SAE20 10W 30 or 10W 40 Above 25 C 77 F SAE30 10W 30 or 10W 40 4 Transmission case 14 0 L 14 8 U S qts 12 3 Imp qts KUBOTA UDT or SUPER UDT fluid 5 Rear axle differential case 1 5 L 1 59 U S qts 1 32 Imp qts KUBOTA UDT SUPER UDT fluid or SAE85W SAE90 gear oil API Service Classification more than GL 3 6 Rear axle gear case 0 5 L 0 53 U S qts 0 44 Imp qt...

Page 21: ...4 9 to 5 7 35 5 to 41 2 39 3 to 44 1 4 0 to 4 5 29 0 to 32 5 60 9 to 70 6 6 2 to 7 2 44 9 to 52 0 M12 12 mm 0 47 in 62 8 to 72 5 6 4 to 7 4 46 3 to 53 5 77 5 to 90 2 7 9 to 9 2 57 2 to 66 5 62 8 to 72 5 6 4 to 7 4 46 3 to 53 5 103 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 ...

Page 22: ...9 80 0 to 96 0 149 2 to 179 0 15 22 to 18 27 110 0 to 132 0 9 16 149 2 to 179 0 15 22 to 18 27 110 0 to 132 0 217 0 to 260 4 22 14 to 26 57 160 0 to 192 0 5 8 203 4 to 244 1 20 75 to 24 91 150 0 to 180 0 298 3 to 358 0 30 44 to 36 53 220 0 to 264 0 Shape Size Material of opponent part Ordinariness Aluminum N m kgf m ft lbs N m kgf m ft lbs Tapered screw R1 8 13 to 22 1 3 to 2 2 9 6 to 16 2 10 to 1...

Page 23: ...50 400 450 500 550 600 1 Safety device Check every 50Hr G 19 2 Greasing every 50Hr G 20 3 Oiling every 50Hr G 21 4 Battery condition Check every 50Hr G 22 5 Air cleaner element Clean every 50Hr 1 G 24 Replace every 1 year G 30 6 Engine oil Change every 100Hr G 17 7 Fan belt Adjust every 100Hr G 25 8 Brake pedal free travel Adjust every 100Hr G 25 9 Fuel filter Check every 100Hr G 25 Replace every ...

Page 24: ...ce every 2 years G 33 19 Intake air line Check every 200Hr G 29 Replace every 2 years 20 Rear axle pivot Adjust every 400Hr G 29 21 Fuel injection nozzle injection pressure Check every 1500Hr G 30 22 Injection pump Check every 3000Hr G 30 23 Radiator Clean every 1 year G 31 24 Coolant Change every 1 year G 31 25 Fuel system Bleed Service as Required G 34 26 Fuse Replace G 34 27 Light bulb Replace ...

Page 25: ...e oil level 4 Transmission fluid level 5 Battery electrolyte 6 Coolant level in the recovery tank 7 Damage of machine body tightness of all screws bolts and nuts 8 Radiator screen 9 Bonnet screen 10 Brake pedal free travel 11 Fuel level 12 Air cleaner While sitting in the operator s seat 1 Speed control pedal 2 Brake pedal 3 Parking brake Turning the key switch ON 1 Performance of the easy checker...

Page 26: ...ck 2 wipe it clean reinsert it and draw it out again Check to see that the oil level is between the two notches 4 Add new oil to the prescribed level at the oil inlet 1 if necessary 5 When using a different brand or viscosity oil from the previous one remove all of the old oil and oil filter Never mix two different types of oil 6 Use the proper Engine Oil SAE according to the ambient temperatures ...

Page 27: ...he temperature is below 10 C 14 F 3 Always use a strainer when refueling to prevent fuel injection pump contamination NOTE No 2 D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service SAE J313 JUN87 Grade of Diesel Fuel Oil according to ASTM D975 W1048002 Fuel tank capacity 61 L 16 1 U S gals 13 4 Imp gals Flash point C Water and sediment volume Carbon residue...

Page 28: ...s covered with grass during operation remove the grass from bonnet screen by hand Check the radiator screen 1 from time to time if grass accumulates W1050141 Checking Tire Pressure WARNING Do not attempt to mount a tire on a rim This should be done by a qualified person with the proper equipment Always maintain the correct tire pressure Do not inflate tires above the recommended pressure CAUTION N...

Page 29: ...removing cap completely Check the coolant level daily both the radiator and the recovery tank 2 before starting engine 1 Remove the radiator cap 1 and check to see that the coolant level is just below the fill port 2 Check to see that the coolant level is between the FULL and LOW marks of recovery tank 2 3 When the coolant level drops due to evaporation add water only up to just below the fill por...

Page 30: ... 7 W1030749 Replacing Engine Oil Filter Cartridge CAUTION Be sure to stop the engine and remove the key before changing the oil and the oil filter cartridge Allow engine to cool down sufficiently oil can be hot and may cause burns 1 Remove the oil filter cartridge 1 with the filter wrench 2 Put a film of engine oil on the rubber seal of the new filter cartridge 3 Tighten the filter cartridge quick...

Page 31: ...lter wrench 2 Apply a slight coat of oil onto the cartridge gasket 3 To install the new cartridge screw it in by hand Over tightening may cause deformation of the rubber gasket 4 After the new cartridge is replaced the transmission fluid level normally decreases a little Add fluid if necessary 5 Check for oil leaks around the filter gasket IMPORTANT To prevent serious damage to the hydraulic syste...

Page 32: ...Test 2 Switch for the brake pedal 1 Sit on the operator s seat 2 Do not depress the brake pedal 2 3 Shift the PTO lever 3 to the DISENGAGE position 4 Turn the main switch 1 to the START position 5 The engine must not crank Test 3 Switch for the PTO lever 1 Sit on the operator s seat 2 Depress the brake pedal 2 fully 3 Shift the PTO lever 3 to the ENGAGE position 4 Turn the main switch 1 to the STA...

Page 33: ... All Grease Nipple 1 Apply grease to the following locations as shown in the figures CAUTION Be sure to stop the engine and remove the key before greasing W1033255 1 Speed Control Pedal Shaft 2 Link Pivot LH and RH 3 Differential Lock Pedal Boss 4 Universal Joint KiSC issued 04 2006 A ...

Page 34: ...own in the figures CAUTION Be sure to stop the engine and remove the key before greasing W1033769 Oiling 1 Apply oil to the following locations as shown in the figures CAUTION Be sure to stop the engine and remove the key before oiling W1034719 1 Rear Wheel Drive Shaft 2 Knuckle Arm LH 3 Knuckle Arm RH 1 Seat Adjuster 2 Accelerator Cable KiSC issued 04 2006 A ...

Page 35: ...gularly and add distilled water as required so that the fluid level is between the UPPER and LOWER levels CAUTION Never remove the vent plugs while the engine is running Keep electrolyte away from eyes hands and clothes If you are spattered with it immediately wash it away completely with water and get medical attention Wear eye protection and rubber gloves when working around the battery 1 Mishan...

Page 36: ...dy 3 To slow charge the battery connect the battery positive terminal to the charge positive terminal and the negative to the negative then recharge in the standard fashion 4 A boost charge is only for emergencies It partially charges 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 wil...

Page 37: ... if it is damaged or not 3 Replace the air cleaner element 3 Once a year or after every six times of cleaning whichever comes first IMPORTANT Be sure to clean the inside of air cleaner and cover The air cleaner uses a dry element never apply oil Do not run the engine with filter element removed Be sure to refit the air cleaner cover 1 with the arrow on the rear of cover upright If the air cleaner ...

Page 38: ...If turn assist brake device and speed set device are attached see the instruction manuals 1 Release the parking brake 2 Slightly depress the main brake pedal and measure free travel S1 at top of pedal stroke 3 If adjustment is needed loosen the lock nut 2 and turn the turnbuckle 3 to adjust the rod length within acceptable limits 4 Retighten the lock nut W1045829 Checking Fuel Filter 1 Checking th...

Page 39: ...TA SUPER UDT fluid Use of other oils may damage the transmission or hydraulic system Refer to LUBRICANTS FUEL AND COOLANT See page G 7 Never work the machine immediately after changing the transmission fluid Keeping the engine at medium speed for a few minutes to prevents damage to the transmission Do not mix different brands fluid together W1046657 Replacing Transmission Oil Filter Cartridge 1 Se...

Page 40: ...ICANTS FUEL AND COOLANT See page G 7 W1047609 Checking Radiator Hose and Hose Clamp NOTE Check to see if the radiator hoses are properly connected every 200 hours of operation or six months whichever comes first 1 If the hose clamps 2 are loose or water leaks tighten the hose clamps 2 securely 2 Replace the radiator hoses 1 and tighten the hose clamps 2 securely if the radiator hoses 1 are swollen...

Page 41: ...maged replace or repair them at once 3 The fuel line is made of rubber and deteriorates regardless of period of service Replace the fuel hose together with the clamp every two years and tighten securely 4 However if the fuel hose and clamp are found damaged or deteriorated earlier than two years repair before running machine 5 After the fuel line and clamp have been changed bleed the fuel system I...

Page 42: ...are found worn or damaged replace or repair them at once W1038340 6 CHECK POINTS OF EVERY 400 HOURS Adjusting Rear Axle Pivot 1 Loosen the lock nut 2 tighten the adjusting screw 1 all the way and then loosen the adjusting screw 1 by 1 6 turn 2 Retighten the lock nut 2 Replacing Fuel Filter 1 Replace the fuel filter 1 1 Hose Clamp 2 Hose 1 Adjusting Screw 2 Lock Nut 1 Fuel Filter KiSC issued 04 200...

Page 43: ...1 YEAR Replacing Air Cleaner Element 1 Replace the air cleaner element 3 IMPORTANT The air cleaner uses a dry element never apply oil Do not run the engine with filter element removed Be sure to refit the air cleaner cover 1 with the arrow on the rear of cover upright If the air cleaner cover is improperly fitted evacuator valve 2 will not function and dust will adhere to the element W1049835 1 Ai...

Page 44: ... 6 After flushing fill with clean water and anti freeze until the coolant level is just below the fill port 7 Fill with clean water and anti freeze up to the FULL mark on the recovery tank 2 8 Start and operate the engine for few minutes 9 Stop the engine Check coolant level of recovery tank 2 and add coolant if necessary 10 Install the radiator cap 1 securely IMPORTANT Do not start engine without...

Page 45: ...SAE J814c 4 Mix the anti freeze with water and then fill the radiator At 101kPa 760 mmHg Pressure atmospheric A higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system NOTE The above data represent industry standards that necessitate a minimum glycol content in the concentrated anti freeze When the coolant level drops du...

Page 46: ...and Hose Clamp See page G 27 W1050581 Replacing Hydraulic Hose 1 Replacing the hydraulic hoses every 2 years or earlier if checked and found that the hydraulic hoses are swollen hardened or crocked W1039376 Replacing Fuel Line 1 replace the fuel hoses 1 and hose clamps 2 Refer to Checking Fuel Line See page G 28 W1050661 1 Radiator Hose 2 Hose Clamp 1 Radiator Hose 2 Hose Clamp 1 Fuel Hose 2 Hose ...

Page 47: ...use indicates that there is an overload or short somewhere in the electrical system 2 If any of the fuses should blow replace with a new one of the same capacity IMPORTANT Before replacing a blown fuse determine why the fuse blew and make any necessary repairs Failure to follow this procedure may result in serious damage to the electrical system Protected circuit W1051895 Replacing Light Bulb 1 He...

Page 48: ...cylinder W1024100 Piston Ring Tool Code No 07909 32121 Application Use exclusively for removing or installing the piston ring with ease W1024150 Diesel Engine Compression Tester for Injection Nozzle 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 ...

Page 49: ...15 Diameter 28 6 mm 1 126 in 38 0 mm 1 496 in 31 6 mm 1 244 in 41 3 mm 1 626 in 35 0 mm 1 378 in 50 8 mm 2 000 in W1024458 Radiator Tester Code No 07909 31551 Application Use to check of radiator cap pressure and leaks from cooling system Remarks Adaptor 1 BANZAI Code No RCT 2A 30S W1024532 Connecting Rod Alignment Tool Code No 07909 31661 Application Use to check the connecting rod alignment Appl...

Page 50: ... 500 kgf cm2 0 to 7000 psi W1024653 Plastigage Code No 07909 30241 Application Use to check the oil clearance between crankshaft and bearing etc Measuring Green 0 025 to 0 076 mm 0 001 to 0 003 in range Red 0 051 to 0 152 mm 0 002 to 0 006 in Blue 0 102 to 0 229 mm 0 004 to 0 009 in W1024719 Red Check Code No 07909 31371 Application Use to check cracks on cylinder head cylinder block etc W1024909 ...

Page 51: ...I 17 mm dia 0 67 in dia J 8 mm dia 0 31 in dia K 1 0 mm 0 039 in L 17 mm dia 0 67 in dia M 6 10 to 6 20 mm dia 0 2402 to 0 2441 in dia N 8 mm 0 31 in O 4 mm 0 16 in P 11 97 to 11 99 mm dia 0 4713 to 0 4720 in dia Q PF 1 2 R 23 mm 0 91 in S 17 mm 0 67 in T 4 mm 0 16 in U 12 00 to 12 02 mm dia 0 4724 to 0 4732 in dia V 100 mm 3 94 in W M12 P1 5 X 5 mm 0 20 in A 225 mm 8 86 in B 70 mm 2 76 in C 45 mm...

Page 52: ... mm 0 9449 in C 120 mm 4 7244 in D 21 8 to 21 9 mm dia 0 8583 to 0 8622 in dia E 24 8 to 24 9 mm dia 0 9764 to 0 9803 in dia F 20 mm dia 0 7874 in dia a 6 3 µm 250 µin b 6 3 µm 250 µin A 196 mm 7 7165 in B 26 mm 1 0236 in C 150 mm 5 9055 in D 25 8 to 25 9 mm dia 1 0157 to 1 0197 in dia E 28 8 to 28 9 mm dia 1 1339 to 1 1378 in dia F 20 mm dia 0 7874 in dia a 6 3 µm 250 µin b 6 3 µm 250 µin A 20 mm...

Page 53: ... 51 4 mm dia 2 0157 to 2 0236 in dia H 47 3 to 47 5 mm dia 1 862 to 1 870 in dia 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 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 24 mm 0 95 in F 20 mm dia 0 79 in dia G 68 mm dia 2 68 in dia H 47 3 to 47 5 mm dia 1 862 to 1 870 in dia C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 07...

Page 54: ... 0 20 in dia K 52 mm dia 2 05 in dia L 40 mm dia 1 57 in dia M 10 mm 0 39 in N 33 mm 1 30 in O 20 mm dia 0 79 in dia P 40 mm dia 1 57 in dia Q 72 10 to 72 15 mm dia 2 840 to 2 841 in dia R 73 mm dia 2 87 in dia S 83 mm dia 3 27 in dia C0 3 Chamfer 0 3 mm 0 01 in C1 Chamfer 1 mm 0 04 in C5 Chamfer 5 mm 0 2 in A 42 mm 1 65 in B 12 mm 0 47 in C 30 mm 1 18 in D M10 Pitch 1 25 E 2 mm 0 08 in F 10 mm 0 ...

Page 55: ...aptor B M18 P1 5 07916 50361 6 Adaptor C PS3 8 07916 50371 7 Adaptor D PT1 8 07916 50381 8 Adaptor E PS3 8 07916 50392 9 Adaptor F PF1 2 07916 62601 10 Adaptor 58 PT1 4 07916 52391 1 Hydrostatic Transmission Tester 07916 52040 2 Gasket 04714 00200 3 Connector 3 07916 51331 4 Vacuum Gauge 07916 51331 5 Pressure Gauge Low Pressure 07916 51301 6 Pressure Gauge High Pressure in Relief Valve Set Pressu...

Page 56: ...essure Do not inflate tires above the recommended pressure as shown below IMPORTANT Do not use tires larger than specified W1044037 Though the tire pressure is factory set to the prescribed level it naturally drops slowly in the course of time Thus check it everyday and inflate as necessary Tire sizes Recommended Inflation Max Pressure Front 24 12 12 4PR 140 kPa 1 4 kgf cm2 20 psi Rear 18 9 5 8 4P...

Page 57: ...sted below or which are otherwise unfit for use with the KUBOTA Machine may result in malfunctions or failures of the machine damage to other property and injury to the operator or others Any malfunctions or failures of the machine resulting from use with improper implements are not covered by the warranty Maximum loading weight Lift link end maximum loading weight W0 Maximum total weight Front ax...

Page 58: ...1 ENGINE KiSC issued 04 2006 A ...

Page 59: ...CONTENTS MECHANISM 1 ENGINE BODY 1 M1 2 LUBRICATING SYSTEM 1 M2 3 COOLING SYSTEM 1 M3 4 FUEL SYSTEM 1 M4 1 GOVERNOR 1 M5 KiSC issued 04 2006 A ...

Page 60: ...dopted to prevent the release of blow by gas into the atmosphere After its oil content is filtered by oil shield 4 the blow by gas is fed back to the intake manifold through breather valve 3 to be used for re combustion W1012956 1 Breather Tube 2 Cylinder Head Cover 3 Breather Valve 4 Oil Shield 5 Rubber Packing KiSC issued 04 2006 A ...

Page 61: ...ed to crankshaft 7 connecting rods 15 idle gear 6 governor shaft 5 camshaft 13 and rocker arm shaft 3 to lubricate each part Some part of oil splashed by the crankshaft or leaking and dropping from gaps of each part lubricates these parts pistons 14 cylinders small ends of connecting rods tappets 12 push rods 11 inlet and exhaust valves 4 and timing gears 1 Rocker Arm 2 Oil Pressure Switch 3 Rocke...

Page 62: ...mprove cooling The water pump 2 sucks the cooled coolant forces it into the cylinder block and draws out the hot coolant Then the cooling is repeated Furthermore to control temperature of coolant a thermostat is provided in the system When the thermostat opens the coolant moves directly to radiator but when it closes the coolant moves toward the water pump 2 through the bypass between thermostat a...

Page 63: ...he opening pressure 13 73 to 14 71 MPa 140 to 150 kgf cm2 1991 to 2133 psi of the injection nozzle 4 is injected into the combustion chamber Part of the fuel fed to the injection nozzle 4 lubricates the moving parts of the plunger inside the nozzle then returns to the fuel tank through the fuel overflow pipe 1 from the upper part of the nozzle holder 1 Fuel Overflow Pipe 2 Fuel Filter 3 Fuel Pump ...

Page 64: ...rload The start spring 2 is hooked to a slide plate and holds the control rack in the direction of the full fuel position Fork lever 2 9 and the floating lever are installed in fork lever 1 6 with the fork lever shaft 4 The max torque limitation 1 device limits the amount of the fuel exhalation at overload with the torque pin At Rated Operation When the engine is running the fork lever 2 5 and the...

Page 65: ...he floating lever pushes the fork lever 1 3 in the way to increase the fuel supply with the help of the torque spring tension The fuel supply increases b in relation to the degree of the torque pin motion thus preventing the engine speed from dropping At this time the maximum torque limiter 1 prevents superfluous fuel supply and suppresses the generation of black smoke 1 Max Torque Limiter 2 Fuel ...

Page 66: ... S15 2 PREPARATION 1 S19 1 Separating Engine 1 S19 3 DISASSEMBLING AND ASSEMBLING 1 S24 1 External Components 1 S24 2 Cylinder Head and Valve 1 S24 3 Oil Pan Timing Gears Camshaft and Fuel Camshaft 1 S28 4 Piston and Connecting Rod 1 S32 5 Crankshaft 1 S35 4 SERVICING 1 S37 1 Cylinder Head and Valves 1 S37 2 Timing Gears Camshaft and Governor Gear 1 S43 3 Piston and Connecting Rod 1 S46 4 Cranksha...

Page 67: ...ton cylinder or bearing Repair or replace Compression leak from cylinder Replace head gasket tighten cylinder head screw glow plug and nozzle holder 1 S27 Improper valve timing Correct or replace timing gear 1 S31 Piston ring and cylinder worn Repair or replace 1 S34 Excessive valve clearance Adjust 1 S12 Starter Does Not Run Battery discharged Charge G 22 Starter malfunctioning Repair or replace ...

Page 68: ...5 Engine s moving parts seem to be seizing Repair or replace Uneven fuel injection Replace injection pump 1 S30 Deficient nozzle injection Repair or replace nozzle 1 S18 S25 Compression leak Replace head gasket tighten cylinder head screw glow plug and nozzle holder 1 S25 S27 Excessive Lubricant Oil Consumption Piston ring s gap facing the same direction Shift ring gap direction 1 S33 Oil ring wor...

Page 69: ...ype of oil G 7 Oil pump defective Repair or replace 1 S53 High Oil Pressure Different type of oil Use specified type of oil G 7 Relief valve defective Replace Engine Overheated Engine oil insufficient Replenish G 7 Fan belt broken or elongated Replace or adjust G 25 1 S13 to S14 Cooling water insufficient Replenish G 7 Radiator net and radiator fin clogged with dust Clean Inside of radiator corrod...

Page 70: ... Recessing Intake and Exhaust 0 05 to 0 25 mm 0 0020 to 0 0098 in 0 40 mm 0 0157 in Valve Stem to Valve Guide Valve Stem Valve Guide Clearance O D I D 0 035 to 0 065 mm 0 0014 to 0 0025 in 6 960 to 6 975 mm 0 2741 to 0 2746 in 7 010 to 7 025 mm 0 2760 to 0 2765 in 0 10 mm 0 0039 in Valve Face Angle Intake Angle Exhaust 1 047 rad 60 0 785 rad 45 Valve Seat Angle Intake Angle Exhaust Width 1 047 rad...

Page 71: ...et Guide Tappet Tappet Guide Clearance O D I D 0 020 to 0 062 mm 0 0008 to 0 0024 in 19 959 to 19 980 mm 0 7858 to 0 7866 in 20 000 to 20 021 mm 0 7874 to 0 7882 in 0 07 mm 0 0028 in Timing Gear Crank Gear to Idle Gear 1 Idle Gear 1 to Cam Gear Idle Gear 1 to Injection Pump Gear Backlash Backlash Backlash 0 032 to 0 115 mm 0 0013 to 0 0045 in 0 036 to 0 114 mm 0 0014 to 0 0045 in 0 034 to 0 116 mm...

Page 72: ... Oil Clearance O D I D 0 050 to 0 091 mm 0 00197 to 0 00358 in 35 934 to 35 950 mm 1 4147 to 1 4153 in 36 000 to 36 025 mm 1 4173 to 1 4183 in 0 15 mm 0 0059 in Idle Gear Shaft to Gear Bushing Idle Gear 1 Idle Gear Shaft 1 Idle Gear Bushing Oil Clearance O D I D 0 020 to 0 054 mm 0 0008 to 0 0021 in 25 967 to 25 980 mm 1 0223 to 1 0228 in 26 000 to 26 021 mm 1 0236 to 1 0244 in 0 10 mm 0 0039 in P...

Page 73: ...Bearing Crankpin Crankpin Bearing Oil Clearance O D I D 0 029 to 0 091 mm 0 0011 to 0 0036 in 39 959 to 39 975 mm 1 5732 to 1 5738 in 40 004 to 40 050 mm 1 5750 to 1 5768 in 0 20 mm 0 0079 in Crankshaft to Crankshaft Bearing 1 Crankshaft journal Crankshaft Bearing 1 Oil Clearance O D I D 0 034 to 0 114 mm 0 0013 to 0 0045 in 47 934 to 47 950 mm 1 8872 to 1 8878 in 47 984 to 48 048 mm 1 8891 to 1 8...

Page 74: ...1 kPa 2 0 to 4 5 kgf cm2 28 to 64 psi 147 kPa 1 5 kgf cm2 21 psi Inner Rotor to Outer Rotor Clearance 0 06 to 0 18 mm 0 0024 to 0 0071 in Outer Rotor to Pump Body Clearance 0 100 to 0 180 mm 0 0039 to 0 0071 in Inner Rotor to Cover Clearance 0 025 to 0 075 mm 0 0010 to 0 0030 in Fan Belt Tension 7 0 to 9 0 mm 98 N 0 28 to 0 35 in 98 N 10 kgf 22 lbs Radiator Cap Pressure Falling Time 10 seconds or ...

Page 75: ...el Tightness 13 73 MPa 140 kgf cm2 1991 psi Delivery Valve Fuel Tightness 10 seconds 13 73 12 75 MPa 140 130 kgf cm2 1991 1849 psi 5 seconds 13 73 12 75 MPa 140 130 kgf cm2 1991 1849 psi Injection Nozzle Injection Pressure 13 73 to 14 71 MPa 140 to 150 kgf cm2 1991 to 2134 psi Injection Nozzle Valve Seat Valve Seat Tightness When the pressure is 12 75 MPa 130 kgf cm2 1849 psi the valve seat must b...

Page 76: ...to 3 0 14 5 to 21 7 Cylinder head cover cap nut 6 9 to 8 8 0 7 to 0 9 5 1 to 6 5 Injection pipe retaining nut 24 5 to 34 3 2 5 to 3 5 18 1 to 25 3 Nozzle holder assembly 49 0 to 68 6 5 0 to 7 0 36 2 to 50 6 Nozzle holder 34 3 to 39 2 3 5 to 4 0 25 3 to 28 9 Overflow pipe assembly retaining nut 19 6 to 24 5 2 0 to 2 5 14 5 to 18 1 Glow plug 7 8 to 14 7 0 8 to 1 5 5 8 to 10 8 Rocker arm bracket nut ...

Page 77: ...Repeat steps 4 and 5 for each cylinder 7 If the measurement is below the allowable limit apply a small amount of oil to the cylinder wall through the glow plug hole or nozzle hole and measure the compression pressure again 8 If the compression pressure is still less than the allowable limit check the top clearance valve clearance and cylinder head 9 If the compression pressure increases after appl...

Page 78: ...eel and alignment mark 2 on the rear end plate so that the No 1 piston comes to the overlap position 6 Check the following valve clearance marked with using a feeler gauge 7 If the clearance is not with in the factory specifications adjust with the adjusting screw NOTE The sequence of cylinder numbers is given as No 1 No 2 No 3 and No 4 starting from the gear case side After adjusting the valve cl...

Page 79: ... tighten the engine oil pressure switch to the specified torque W10349520 3 Cooling System Fan Belt Tension 1 Measure the deflection A depressing the belt halfway between the fan drive pulley and alternator pulley at specified force 98 N 10 kgf 22 lbs 2 If the measurement is not within the factory specifications loosen the alternator mounting screws and relocate the alternator to adjust W10356670 ...

Page 80: ...ure 88 kPa 0 9 kgf cm2 13 psi and measure the time for the pressure to fall to 59 kPa 0 6 kgf cm2 9 psi 3 If the measurement is less than the factory specification replace the radiator cap W1054156 Radiator Water Leakage 1 Pour a specified amount of water into the radiator 2 Install a radiator tester 1 and an adapter 2 and raise the water pressure to the specified pressure 3 Check the radiator for...

Page 81: ...erclockwise and stop turning when the fuel begins to come up to get the present injection timing 7 Check to see the degree on flywheel The flywheel is marked 1TC 10 and 20 for the crank angle before the top dead center of No 1 cylinder 8 If injection timing is out of adjustment readjust the timing with shims NOTE The liquid gasket is not required for assembling Shims are available in thickness of ...

Page 82: ...proper injection pressure to the injection pump pressure tester 1 5 Run the starter to increase 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 73 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 t...

Page 83: ... handle 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 01 mm 0 0004 in difference of adjusting washer thickness Approx 235 kPa 2 4 kgf cm2 34 psi W10182100 Valve Seat Tightness 1 Set the injection nozzle to a no...

Page 84: ...direction After assembling the nozzle be sure to adjust the fuel injection pressure W1018491 Tightening torque Nozzle holder 34 3 to 39 2 N m 3 5 to 4 0 kgf m 25 3 to 28 9 ft lbs Overflow pipe retaining nut 19 6 to 24 5 N m 2 0 to 2 5 kgf m 14 5 to 18 1 ft lbs Nozzle holder assembly 49 0 to 68 6 N m 5 0 to 7 0 kgf m 36 2 to 50 6 ft lbs 1 Nozzle Holder 2 Adjusting Washer 3 Nozzle Spring 4 Push Rod ...

Page 85: ...ain plug W1019510 Draining Engine Oil 1 Park the machine on level ground 2 Place an oil pan underneath the engine 3 Remove the drain plug 1 to drain oil 4 After draining screw in the drain plugs and tighten When refilling Fill the engine oil up to the upper line on the dipstick 3 IMPORTANT Never mix two different type of oil Use the proper SAE Engine Oil according to ambient temperatures Refer to ...

Page 86: ...Front Suction Pipe 1 Place oil pans underneath the rubber hose 4 and oil strainer 2 2 Remove the rubber hose 4 from the front suction pipe 3 3 Unscrew the front suction pipe mounting screw 1 4 Unscrew the oil strainer 2 and remove the oil strainer and front suction pipe 3 When reassembling W1041888 Battery CAUTION When disassembling the battery cables disconnect the negative cable from the battery...

Page 87: ...he radiator upper hose 2 from the thermostat cover 8 Disconnect the fuel hose 5 and fuel return hose 7 W1033679 Wiring and Hose 1 Disconnect the wiring 2 and 2P connector 3 from the alternator 2 Disconnect the wiring 4 and 1P connectors 5 from the starter 3 Disconnect the 1P connector 7 from the oil pressure switch 4 Disconnect the ground cable 9 5 Disconnect the radiator lower hose 1 6 Remove the...

Page 88: ... differential lock pedal 1 and brake lock lever 3 2 Remove the main brake pedal 2 speed control pedal 4 3 Remove the lever grips from hydraulic lift lever 5 and PTO lever 7 4 Remove the lever grip from high low gear shift lever 6 5 Remove the lever grip from 4WD lock lever 9 6 Remove the fender 8 W1047430 Tightening torque Seat base mounting screw 17 7 to 20 5 N m 1 8 to 2 1 kgf m 13 1 to 15 1 ft ...

Page 89: ...ews 3 2 Remove the radiator assembly 1 with the dust plate 4 W1049330 Drive Shaft 1 Unscrew the drive shaft mounting screws 2 and disconnect the drive shaft 3 from the fan drive pulley 1 When reassembling Apply grease to the all splines on the drive shaft W1059348 1 Fuel Tank 2 Dust Under Plate 3 Fuel Tank Rear Support 1 Pipe Holder 1 Radiator Assembly 2 Dust Plate Stay 3 Dust Plate Mounting Screw...

Page 90: ...w priority valve 9 7 Remove the hydraulic pump 12 with the rear suction pipe 11 8 Remove the engine support LH 5 and RH 10 W1052233 2 Cylinder Head and Valve Cylinder Head Cover 1 Disconnect the breather hose 2 Remove the head cover nut 3 Remove the cylinder head cover 1 When reassembling Check to see if the cylinder head cover gasket is not defective W1028468 1 Cooling Fan 2 Alternator 3 Muffler ...

Page 91: ...rox 6 mm 1 4 in 1 Drive screw driver 1 lightly into the heat seal hole 2 Turn screw driver three or four times each way 3 While turning the screw driver slowly pull the heat seal 4 out together with the injection nozzle gasket 3 4 If the heat seal drops repeat the above procedure When reassembling Heat seal and injection nozzle gasket must be changed when the injection nozzle is removed for cleani...

Page 92: ... rods 2 When reassembling When refitting the push rods 2 into the tappets 3 make sure the push rod locates correctly into the tappet seat IMPORTANT After installing the rocker arm be sure to adjust the valve clearance W1021437 Tightening torque Rocker arm bracket nut 21 6 to 26 5 N m 2 2 to 2 7 kgf m 15 9 to 19 5 ft lbs 1 Rocker Arm Assembly 2 Push Rod 3 Tappet KiSC issued 04 2006 A ...

Page 93: ... using a torque wrench correctly tighten the cylinder head screws to correct torque figure The different type of screw 4 is used for the positions j and n in illust A and n and r in the illust B If mounted W10205250 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 in...

Page 94: ... the thermostat assembly 4 When reassembling Apply a liquid gasket Three Bond 1215 or equivalent only at the thermostat cover side of the gasket 3 W1472583 3 Oil Pan Timing Gears Camshaft and Fuel Camshaft Fan Drive Pulley 1 Secure the flywheel to keep it from turning 2 Remove the fan drive pulley screw 3 Draw out the fan drive pulley with a puller When reassembling Install the pulley to crankshaf...

Page 95: ...nstallation position of the mounting bolt A L 18 mm 0 71 in Pipe Pin Position B L 13 mm 0 51 in Water Pipe Mounting C L 10 mm 0 39 in D Nut W1030917 Speed Control Plate 1 Remove the engine stop solenoid 2 Remove the speed control plate 1 3 Remove the governor spring 2 Be careful not to drop spring into crankcase When reassembling Apply a liquid gasket Three Bond 1215 or equivalent to both sides of...

Page 96: ...ld not be disassembled When reassembling When installing the injection pump insert the control rack pin 2 firmly into the groove 7 of the thrust lever of fork lever NOTE 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 or new gasket shims with the same thickness W1033441 1 ...

Page 97: ...bling Apply engine oil thinly to the fuel camshaft 7 before installation Make sure to assemble the external snap ring 8 of the governor shaft 9 Check the governor shaft 9 for smooth rotation IMPORTANT When replacing the ball bearing of governor shaft securely fit the ball bearing 10 to the crankcase apply an adhesive Three Bond 1324B or equivalent to the set screw 11 and tighten the screw until it...

Page 98: ...the oil pan gasket 1 To avoid uneven tightening tighten oil pan mounting screws in diagonal order from the center W1074670 4 Piston and Connecting Rod Connecting Rod 1 Remove the connecting rod cap When reassembling Align the marks a with each other Face the marks toward the injection pump Apply engine oil to the connecting rod screws and lightly screw it in by hand then tighten it to the specifie...

Page 99: ...cylinder face the mark on the connecting rod to the injection pump IMPORTANT Do not change the combination of cylinder and piston Make sure of the position of each piston by marking For example mark 1 on the No 1 piston When installing the piston into the cylinder place the gaps of all the piston rings as shown in the figure Carefully insert the pistons using a piston ring compressor 1 Otherwise t...

Page 100: ... opposite side of the oil ring gap 11 Apply engine oil to the piston pin When installing the connecting rod to the piston immerse the piston in 80 C 176 F oil for 10 to 15 minutes and insert the piston pin to the piston When installing the connecting rod to the piston align the mark 8 on the connecting rod to the fan shaped concave 9 NOTE Mark the same number on the connecting rod and the piston s...

Page 101: ...e cover 6 When reassembling Fit the bearing case gasket 3 and the bearing case cover gasket 4 in the correct location Install the bearing case cover 6 to position the casting mark UP on it upward Apply engine oil to the oil seal 5 lip and take care that it is not rolled when installing Tighten the bearing case cover mounting screws with even force on the diagonal line W10292140 Tightening torque F...

Page 102: ...il passage in the main bearing cases Apply clean engine oil on the bearings Install the main bearing case assemblies in the original positions Since diameters of main bearing cases vary install them in order of makings b from the gear case side Match the alignment numbers a on the main bearing case assembly 1 When installing the main bearing case 1 and 2 face the mark FLYWHEEL to the flywheel Inst...

Page 103: ...ory specifications check the oil clearance between the crankpin and crankpin bearing and between the piston pin and small end bushing NOTE After checking the top clearance be sure to assemble the cylinder head with a new cylinder head gasket W1020190 Cylinder Head Surface Flatness 1 Clean the cylinder head surface 2 Place a straightedge on the cylinder head s four sides and two diagonal as shown i...

Page 104: ...after replacing the valve replace the cylinder head W10768800 Clearance between Valve Stem and Valve Guide 1 Remove carbon from the valve stem 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 v...

Page 105: ...uide with a hammer during replacement W10278890 Valve Seat 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 contact...

Page 106: ...face and valve seat and fit them with valve lapping tool 4 Check the valve seat 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 a...

Page 107: ...t replace it W10784360 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 ro...

Page 108: ...sure the I D of the tappet guide bore with a cylinder gauge and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit or the tappet is damaged replace the tappet W10293660 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 0008 to 0 0024 in Allowable limit 0 07 mm 0 0028 in Tappet O D Fac...

Page 109: ...tip on the camshaft 2 measure the side clearance by moving the cam gear from the front to rear 3 If the measurement exceeds the allowable limit replace the camshaft stopper W10295630 Backlash between idle gear 1 and crank gear Factory spec 0 032 to 0 115 mm 0 0013 to 0 0045 in Allowable limit 0 15 mm 0 0059 in Backlash between idle gear 1 and cam gear Factory spec 0 036 to 0 114 mm 0 0014 to 0 004...

Page 110: ...haft journal O D with an outside micrometer 2 Measure the cylinder block bore I D for camshaft with a cylinder gauge and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit replace the camshaft W10299330 Camshaft alignment Allowable limit 0 01 mm 0 0004 in Cam lobe height of intake Factory spec 28 80 mm 1 1339 in Allowable limit 28 75 mm 1 1319 in Cam lobe height of exha...

Page 111: ...ving 1 Press out the used idle gear bushing using an idle gear bushing replacing tool See page SPECIAL TOOLS When installing 1 Clean a new idle gear bushing and idle gear bore and apply engine oil to them 2 Press in a new bushing using an idle gear bushing replacing tool until it is flush with the end of the idle gear W10302410 Oil clearance between idle gear shaft 1 and idle gear bushing Factory ...

Page 112: ... page SPECIAL TOOLS When installing 1 Clean a new small end bushing and bore and apply engine oil to them 2 Using a small end bushing replacing tool press in a new bushing service parts taking care to see that the connecting rod oil hole matches the bushing hole W10307120 Piston pin bore I D Factory spec 22 000 to 22 013 mm 0 8661 to 0 8667 in Allowable limit 22 03 mm 0 8673 in Oil clearance betwe...

Page 113: ...ston ring and Piston Ring Groove 1 Clean the rings and the ring grooves and install each ring in its groove 2 Measure the clearance between the ring and the groove with a feeler gauge or depth gauge 3 If the clearance exceeds the allowable limit replace the piston ring 4 If the clearance still exceeds the allowable limit with new ring replace the piston W10312390 Connecting rod alignment Allowable...

Page 114: ...locks on the surface plate at both end journals 2 Set a dial indicator with its tip on the intermediate journal 3 Measure the crankshaft alignment 4 If the measurement exceeds the allowable limit replace the crankshaft W10330010 Crankshaft side clearance Factory spec 0 15 to 0 31 mm 0 0059 to 0 0122 in Allowable limit 0 50 mm 0 0197 in Oversize 0 2 mm 0 008 in 0 4 mm 0 016 in Dimension A 51 5 to 5...

Page 115: ... the crankshaft while the connecting rod screws are tightened Reference Undersize dimensions of crankpin W10331060 Oil clearance between crankpin and crankpin bearing Factory spec 0 029 to 0 091 mm 0 0011 to 0 0036 in Allowable limit 0 20 mm 0 0079 in Crankpin O D Factory spec 39 959 to 39 975 mm 1 5732 to 1 5738 in Crankpin bearing I D Factory spec 40 004 to 40 050 mm 1 5750 to 1 5768 in Undersiz...

Page 116: ...crankshaft bearing 1 replacing tool press in a new bearing 1 2 so that its seam 1 is toward the exhaust manifold side See figure W10339460 Oil clearance between crankshaft journal and crankshaft bearing 1 Factory spec 0 034 to 0 114 mm 0 0013 to 0 0045 in Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Factory spec 47 934 to 47 950 mm 1 8872 to 1 8878 in Crankshaft bearing 1 I D Factory s...

Page 117: ...t 0 20 mm 0 0079 in Crankshaft journal O D Intermediate Factory spec 47 934 to 47 950 mm 1 8872 to 1 8878 in Crankshaft bearing 2 I D Factory spec 47 984 to 48 029 mm 1 8891 to 1 8909 in Oil clearance between crankshaft journal and crankshaft bearing 3 Factory spec 0 034 to 0 098 mm 0 0013 to 0 0039 in Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Flywheel side Factory spec 51 921 to 51...

Page 118: ... 1 Measure the I D of the cylinder at the six positions see figure with a cylinder gauge to find the maximum and minimum I D s 2 Get the difference Maximum wear between the maximum and the minimum I D s 3 If the wear exceeds the allowable limit bore and hone to the oversize dimension Refer to Correcting Cylinder 4 Visually check the cylinder wall for scratches If deep scratches are found the cylin...

Page 119: ...f the clearance exceeds the factory specifications replace the oil pump rotor assembly W10356560 Clearance between Rotor and Cover 1 Put a strip of plastigage onto the rotor face with grease 2 Install the cover and tighten the screws 3 Remove the cover carefully and measure the amount of the flattening with the scale and get the clearance 4 If the clearance exceeds the factory specifications repla...

Page 120: ...2 TRANSMISSION KiSC issued 04 2006 A ...

Page 121: ...re Relief Valve 2 M8 6 Control Linkage 2 M9 3 RANGE GEAR SHIFT SECTION 2 M10 4 REAR WHEEL DRIVE SECTION 2 M11 1 DUAL ACTING OVERRUNNING FOUR WHEEL DRIVE 2 M11 1 Basic Actions in Dual Acting Overrunning 4WD Mode 2 M13 2 Basic Actions in Full Time 4WD Mode 2 M15 5 PTO SECTION 2 M16 6 DIFFERENTIAL GEAR SECTION 2 M18 1 DIFFERENTIAL FUNCTION 2 M18 2 DIFFERENTIAL LOCK 2 M19 KiSC issued 04 2006 A ...

Page 122: ... RCK60 F36 RCK60R F36 WSM TRANSMISSION 1 STRUCTURE 1 Hydrostatic Transmission HST Section 2 Range Gear Shift Section 3 PTO Section 4 Differential Gear Section 5 Rear Wheel Drive Section Dual Acting Overrunning Clutch KiSC issued 04 2006 A ...

Page 123: ...9 cm3 rev 1 15 cu in rev The speed control pedal permits simple operation of the machine starting stopping increasing or decreasing speed 1 Motor Shaft 2 Needle Bearing 3 Thrust Plate 4 Charge Relief Valve 5 Cylinder Block Motor 6 Valve Plate 7 Needle Bearing 8 Oil Seal 9 Needle Bearing 10 Valve Plate 11 Center Section 12 Cylinder Block Pump 13 Piston 14 Retainer Plate 15 Thrust Plate 16 Variable ...

Page 124: ...Neutral position the oil is delivered to the oil cooler 5 The oil from the oil cooler 5 is delivered to the PTO charge relief valve 4 oil filter cartridge 3 and charge relief valve 2 The oil is drained into the transmission case through the hydrostatic transmission housing 1 Pump 2 Charge Relief Valve 3 Oil Filter Cartridge 4 PTO Charge Relief Valve 5 Oil Cooler 6 Check and High Pressure Relief Va...

Page 125: ...der block 7 in the motor is stationary and the motor shaft 8 does not rotate 1 Oil Cooler 2 PTO Charge Relief Valve 3 Oil Filter Cartridge 4 Check and High Pressure Relief Valve Forward 5 Check and High Pressure Relief Valve Reverse 6 Charge Relief Valve 7 Cylinder Block Motor 8 Motor Shaft 9 Piston 10 Hydraulic Pump 11 Power Steering Controller 12 Flow Priority Valve 13 Pump Shaft 14 Swashplate 1...

Page 126: ...the motor shaft 8 rotates with the motor cylinder block 7 This drives the machine forward and the angle of swashplate 14 determines the motor shaft speed 1 Oil Cooler 2 PTO Charge Relief Valve 3 Oil Filter Cartridge 4 Check and High Pressure Relief Valve Forward 5 Check and High Pressure Relief Valve Reverse 6 Charge Relief Valve 7 Cylinder Block Motor 8 Motor Shaft 9 Piston 10 Hydraulic Pump 11 P...

Page 127: ...n the motor shaft 8 rotates with the motor cylinder block 7 This drives the machine backward and the angle of swashplate 14 determines the motor shaft speed 1 Oil Cooler 2 PTO Charge Relief Valve 3 Oil Filter Cartridge 4 Check and High Pressure Relief Valve Forward 5 Check and High Pressure Relief Valve Reverse 6 Charge Relief Valve 7 Cylinder Block Motor 8 Motor Shaft 9 Piston 10 Hydraulic Pump 1...

Page 128: ...d the setting pressure by the charge relief valve 0 40 to 0 58 MPa 4 0 to 6 0 kgf cm2 57 to 85 psi The regulated oil is fed as charge oil to HST main circuit The oil that is relieved by charge relief valve passes to HST housing 1 through the poppet 4 W1014549 1 HST Housing 2 Plug 3 Spring 4 Poppet a From Oil Filter Cartridge KiSC issued 04 2006 A ...

Page 129: ...ure line serves as a high pressure relief valve If the pressure exceeds a high pressure limit level the pressure poppet 2 opens itself against the relief valve spring 3 force and opens the valve that is located between the check valve seat 1 and the pressure poppet 2 Now the flow goes to P2 If the P3 pressure drops the relief valve spring forces the valve seat closed against the pressure The high ...

Page 130: ...utral with the speed change arm 13 when the pedal is released The damper 8 is connected to the speed control pedal 5 linked with the speed control bracket 6 and damper stay 7 restrict the movement of the linkage to prevent abrupt operation or reversing The ball bearing 12 on the neutral arm 11 seats the detent of the speed change arm 13 so that the speed change arm 13 returns to neutral 1 Neutral ...

Page 131: ...he bevel pinion shaft 6 Low Range Motor Shaft 1 28T Gear 2 15T Gear 5 18T 17T Gear Shaft 3 15T 26T Gear 7 Bevel Pinion Shaft 6 Differential Gear 4 High Range Motor Shaft 1 28T Gear 2 15T Gear 5 18T 17T Gear Shaft 3 15T 26T Gear 7 Bevel Pinion Shaft 6 Differential Gear 4 W1015959 1 Motor Shaft 2 28T Gear 3 18T 17T Gear Shaft 4 Differential Gear 5 15T Gear 6 Bevel Pinion Shaft 7 15T 26T Gear KiSC is...

Page 132: ...stem The dual acting overrunning clutch 2 is mounted between the RWD shaft 2 1 and RWD shaft 1 2 Driving power is transmitted to the dual acting overrunning clutch 2 as follows Bevel Pinion Shaft 4 11T Gear 4 16T 33T Gear 6 34T Gear 7 RWD Shaft 1 3 Dual acting Overrunning Clutch 2 1 RWD Shaft 2 2 Dual acting Overrunning Clutch 3 RWD Shaft 1 4 11T Gear 5 Bevel Pinion Shaft 6 16T 33T Gear 7 34T Gear...

Page 133: ...backward runs this also allows small radius turns and in other running styles On slopes the full time 4WD mode may be selected to ensure the best possible traction stability and safety IMPORTANT Do not steer the rear wheels sharply when the Dual acting overrunning 4WD clutch lock lever is in the Full time 4WD position 2WD mode RWD Shaft 1 11 Drive Cam 9 Center Cam 16 Mode 4RM RWD Shaft 1 11 Drive ...

Page 134: ...e slipping When the RWD shaft 1 starts turning the drive cam 4 is activated When the drive cam 4 is about to produce more turns than the driven cam 1 the center cam 5 is moved to the left by the drive cam 4 due to the friction between the brake ring 2 and the brake shoe 3 In this way the center cam 5 and the driven cam 1 are activated by the driven cam 1 which drives all the four wheels W1017156 1...

Page 135: ...cam 5 is disengaged from the drive cam 4 W1017253 While the machine is turning While the machine is turning the center cam 3 is pressed against the drive cam 4 by force of the return spring 2 In this state the driven cam 1 is not activated W1017376 1 Driven Cam 2 Brake Ring 3 Brake Shoe 4 Drive Cam 5 Center Cam 6 Return Spring F Front Side R Rear Side a More Turns b Fewer Turns 1 Driven Cam 2 Brak...

Page 136: ... overrunning 4WD is set at the full time 4WD position the shift fork starts turning to push the clutch bracket 5 to the left By this the center cam 6 comes into contact with the driven cam 4 Now the four wheels are driven W1017500 1 Driven Cam 2 Brake Ring 3 Brake Shoe 4 Drive Cam 5 Center Cam 6 Return Spring F Front Side R Rear Side KiSC issued 04 2006 A ...

Page 137: ... the steel plates 11 clutch discs 12 and pressure plate 13 by this movement The steel plates 11 and pressure plate 13 are held between the clutch discs 12 and piston 10 and the friction between them cause the clutch discs 12 to rotate thus transmitting the power from the engine to the implement as follows Pump Shaft 2 28T Gear 1 33T Gear 13 Piston 10 Clutch Case 9 Clutch Shaft 7 Coupling 6 PTO Sha...

Page 138: ...steel plates 10 and clutch discs 11 causing no friction At the same time the PTO brake disc 4 is held between the PTO brake plates 8 causing friction Therefore the power to the implement is shut off and brake engages to prevent the PTO shaft 5 from the free spinning 1 28T Gear 2 Pump Shaft 3 Return Spring 4 PTO Brake Disc 5 PTO Shaft 6 Coupling 7 Clutch Shaft 8 PTO Brake Plate 9 Piston 10 Steel Pl...

Page 139: ...the differential side gears 3 7 When rotation of one differential side gear becomes lower than the other differential pinions 4 8 begin rotating around differential pinion shaft 5 The other differential side gear is increased in speed by the speed increment of differential pinion shaft 5 This means that rotation of one front axle is slowed down and that of the other front axle is increased Thus th...

Page 140: ...tate which will move the differential lock shift fork 2 and the differential lock clutch 5 toward the spiral gear 8 The differential lock clutch 5 engaged with the teeth of the differential case 6 to cause the differential case 6 and the differential lock clutch 5 to rotate as a unit Therefore differential pinions 1 are unable to rotate around differential pinion shaft 7 and identical revolutions ...

Page 141: ...drostatic Transmission HST 2 S19 3 Separating Transmission Case 2 S20 4 Separating Differential Gear Case 2 S20 3 DISASSEMBLING AND ASSEMBLING 2 S22 1 Hydrostatic Transmission 2 S22 2 Hydraulic PTO Clutch Assembly 2 S24 3 RWD Case 2 S25 4 Transmission Case 2 S26 5 Differential Gear Case 2 S27 4 SERVICING 2 S29 1 Hydrostatic Transmission 2 S29 2 Hydraulic PTO Clutch 2 S31 3 Transmission Case 2 S32 ...

Page 142: ...ective Speed control pedal to speed change arm Repair control linkage 2 S12 S14 S16 Charge pressure is too low Charge relief valve defective Replace charge relief valve 2 S8 S23 Oil filter cartridge clogged Replace oil filter cartridge G 18 PTO charge relief valve defective Replace PTO charge relief valve 2 S9 S19 Check and high pressure relief valve defective Replace check and high pressure relie...

Page 143: ...speed change arm Repair control linkage 2 S12 S14 S16 Improper adjustment of neutral arm holder shaft Adjust 2 S7 System Operate in One Direction Only Control linkage defective Speed control pedal to speed change arm Repair control linkage 2 S12 S14 S16 Check and high pressure relief valve defective Replace check and high pressure relief valve 2 S9 S22 Symptom Probable Cause Solution Reference Pag...

Page 144: ...n shaft and spiral bevel gear Adjust 2 S34 Improper backlash between differential case and differential side gear Adjust 2 S33 Bearing worn Replace Insufficient or improper type of transmission fluid used Replenish or Replace G 7 2 S10 Gear Slip Out of Mesh Differential pinions or differential side gears worn or damaged Replace 2 S28 Differential lock binding does not disengage Replace 3 S4 Bearin...

Page 145: ...5 to 2 05 mm 0 0768 to 0 0807 in 1 80 mm 0 0709 in Clutch Disc Thickness 1 90 to 2 10 mm 0 0748 to 0 0827 in 1 60 mm 0 0630 in Steel Plate Thickness 0 95 to 1 05 mm 0 0374 to 0 0413 in 0 80 mm 0 0315 in Clutch Shaft to 16T 33T Gear 16T 33T Gear Clutch Shaft Needle Clearance I D O D O D 0 007 to 0 047 mm 0 0003 to 0 0018 in 26 007 to 26 028 mm 1 0239 to 1 0247 in 21 987 to 22 000 mm 0 8657 to 0 866...

Page 146: ...Clearance I D O D 0 016 to 0 045 mm 0 0007 to 0 0018 in 16 000 to 16 018 mm 0 6300 to 0 6306 in 15 973 to 15 984 mm 0 6289 to 0 6292 in 0 30 mm 0 0118 in Differential Pinion to Differential Side Gear Backlash 0 1 to 0 3 mm 0 004 to 0 011 in 0 4 mm 0 016 in Bevel Pinion Shaft Side Clearance Less than 0 15 mm Less than 0 006 in Bevel Pinion Shaft to Spiral Bevel Gear Backlash 0 10 to 0 30 mm 0 0040 ...

Page 147: ... screw 27 5 to 29 4 2 8 to 3 0 20 3 to 21 6 Transmission mounting screw M12 62 8 to 72 5 6 4 to 7 4 46 3 to 53 5 Side frame mounting screw and nut 62 8 to 72 5 6 4 to 7 4 46 3 to 53 5 Front wheel mounting nut 39 3 to 44 1 4 0 to 4 5 29 0 to 32 5 PTO pipe mounting nut 54 0 to 63 7 5 5 to 6 5 39 8 to 47 0 HST mounting screw M8 23 6 to 27 4 2 4 to 2 8 17 4 to 20 2 HST mounting screw M10 39 3 to 44 1 ...

Page 148: ...in the center between position A and B and tighten the holder shaft mounting screw 6 firmly This means the hydrostatic transmission is fully in neutral Position N W1011821 Adjusting Speed Control Rod NOTE Before adjusting the neutral of HST adjust the brake system 1 After adjusting the neutral of HST pull the parking lock lever 3 2 Check that the groove of brake lock 5 engages with the pin of spee...

Page 149: ...hen connect the cable Code No 07916 50331 threaded joint Code No 07916 51301 to threaded joint in order 6 Reinstall the seat assembly 7 Run the engine at maximum speed 8 Place the high low gear shift lever in neutral 9 Release the speed control pedal to set in neutral and measure the charge pressure 10 If the charge pressure is not within the factory specifications change the charge relief valve a...

Page 150: ... assembly IMPORTANT Measure quickly otherwise the relief valve may not be in operation more than 10 seconds When reassembling Install the plug R 1 4 to P1 1 or P3 3 port with seal tape W1033699 PTO Charge Pressure CAUTION When checking park the machine on flat ground apply the parking brake NOTE Use a new transmission oil filter 1 Remove the seat assembly and plate 2 2 Unscrew the plug 1 from the ...

Page 151: ...uid 1 Place oil pans underneath the transmission case 2 Remove the drain plugs 1 3 Drain the transmission fluid 4 After draining reinstall the three drain plug and tighten When reassembling Fill the transmission fluid from oil inlet 3 up to the upper line on the dipstick 2 After running the engine for few minutes stop it and check the fluid level again add the fluid to prescribed level if it is no...

Page 152: ...l 1 Separate the front panel 1 from the rear panel 4 2 Disconnect the connectors from the easy checker fuel gauge coolant temperature gauge and hour meter in front panel 1 3 Disconnect the connectors 2 3 from the main switch and head light switch 4 Remove the horn 5 5 Remove the rear panel 4 W1040859 Tightening torque Oil strainer 98 1 to 137 2 N m 10 0 to 14 0 kgf m 72 4 to 101 2 ft lbs 1 Front S...

Page 153: ...ver grip from 4WD lock lever 9 6 Remove the fender 8 W1041101 Fuel Tank 1 Disconnect the fuel hose and return hose from the fuel tank 1 2 Disconnect the 1P connector from the fuel sensor 3 Remove the fuel tank 1 4 Remove the dust under plate 2 5 Remove the fuel tank rear support 3 W1041351 1 Differential Lock Pedal 2 Main Brake Pedal 3 Brake Lock Lever 4 Speed Control Pedal 5 Hydraulic Lift Lever ...

Page 154: ...ing hoses and pipes 3 7 8 9 to their original position and tighten them to the specified torque W1041728 Tightening torque Power steering hose mounting screw 24 6 to 29 4 N m 2 5 to 3 0 kgf m 18 1 to 21 6 ft lbs Power steering pipe mounting screw 54 0 to 63 7 N m 5 5 to 6 5 kgf m 39 8 to 47 0 ft lbs 1 Accelerator Wire 2 Wire Harness 3 Return Pipe 1 4 10P Connector 5 2P Connector 6 4P Connector 7 C...

Page 155: ...the delivery pipe mounting nuts to specified torque Apply liquid lock Three Band 1324 or its equivalent to the plate mounting screws W1042155 Fuel Filter and Fuel Pump 1 Disconnect 2P connector 2 from the PTO switch 2 Disconnect 2P connector 4 from the fuel pump 1 3 Remove the fuel filter 3 and fuel pump 1 4 Remove the negative cable 5 W1042801 Tightening torque Delivery pipe mounting nut 39 3 to ...

Page 156: ...aft mounting screws 2 to the specified torque W1016116 Separating Transmission Case and Engine Frame 1 Support the rear end of the transmission and frame 2 Unscrew the transmission mounting screws 1 2 and separate the transmission case and engine frame When reassembling NOTE Apply liquid lock Three Bond 1324 or its equivalent to the transmission mounting screws 1 2 Screw in the reamer screws 2 fir...

Page 157: ...liquid lock Three Bond 1324 or its equivalent to the side frame mounting screws and speed change arm mounting screw Adjust the length A of adjusting screw 10 with adjusting nuts 9 Adjust the length B of lift spring rod 7 with adjusting nuts 11 Reference Length A 15 to 20 mm 0 59 to 0 78 in Length B LH 70 mm 2 8 in Length B RH 50 mm 2 0 in W1043994 1 Fender Support LH 2 Connecting Plate 3 Fender Su...

Page 158: ...ove the cotter pin and clevis pin and disconnect the lift link 1 and lift arm 2 2 Remove the front wheel 3 3 Unscrew the pin mounting screw and pull out the mower lift arm pin 4 and remove the mower lift arm 5 When reassembling Apply grease to the mower lift arm pin 4 and pivot of mower lift arm IMPORTANT Be sure to tighten the front wheel mounting nuts to the specification torque W1045417 1 Suppo...

Page 159: ...vis pins 3 and slide the brake arm 2 4 2 Remove the brake rod 2 1 3 Remove the brake switch 2 4 Remove the front frame 6 When reassembling NOTE Apply liquid lock Three Bond 1324 or its equivalent to the front frame mounting screws W1045685 1 Brake Rod 2 2 Brake Switch 3 Clevis Pin 4 Brake Arm 2 5 Snap Pin 6 Front Frame KiSC issued 04 2006 A ...

Page 160: ...RTANT Be sure to tighten PTO pipe mounting nut 1 to the specified torque Separating Hydrostatic Transmission HST 1 Remove the external snap ring 3 from RWD shaft 1 2 Only 4WD Model 2 Separate HST 1 from transmission case When reassembling Apply liquid gasket Three Bond 1208D or its equivalent to the joint surface of transmission case NOTE Securely fit the external snap ring 3 to RWD shaft 1 2 IMPO...

Page 161: ...ansmission case mounting screws and nut W1047514 4 Separating Differential Gear Case Hydraulic Cylinder Assembly 1 Remove the hydraulic cylinder assembly 1 from the differential gear case When reassembling Apply liquid gasket Three Bond 1208D or its equivalent to joint surface of the differential gear case and hydraulic cylinder assembly 1 Check the face of stopper plate 2 as shown in the figure W...

Page 162: ...ential gear case 2 When reassembling Apply liquid gasket Three Bond 1208D or its equivalent to joint surface of the differential gear case 2 and front axle cases 1 W1048133 Tightening torque Front axle case mounting screw 39 3 to 44 1 N m 4 0 to 4 5 kgf m 29 0 to 32 5 ft lbs 1 Front Axle Case 2 Differential Gear Case KiSC issued 04 2006 A ...

Page 163: ...ket head screws to the specified torque W1034463 Check and High Pressure Relief Valve 1 Remove the valve plug 1 and remove the check valve spring 2 and relief valve assembly 3 When reassembling Take care not to damage the O ring on the plug W1034707 Motor Cylinder Block and Pump Cylinder Block 1 Pull out the output shaft 4 and motor cylinder block 3 with pistons as a unit 2 Slide out the pump cyli...

Page 164: ...er B 4 Then pry the cover B 4 open with a screw driver Pry the cover A 2 in the same way 3 Take out the trunnion shaft 3 When reassembling NOTE Take care not to damage the O rings W1035205 Charge Relief Valve 1 Remove the internal snap ring 1 and remove the plug 2 2 Remove the spring 3 and push out the charge relief poppet 4 When reassembling NOTE Take care not to damage the O ring W1035400 1 Inpu...

Page 165: ... CAUTION Return spring 9 is under pressure and retained by external snap ring 11 Carefully compress return spring 9 before trying to remove external snap ring 11 then carefully release pressure after external snap ring 11 is removed When reassembling Apply transmission fluid to O ring 23 D ring 7 seal ring 27 and take care not to damage it Replace O ring D ring and seal ring if it is defective 1 B...

Page 166: ...ng clutch When reassembling Take care not to damage the O rings 7 on the shift rod 8 NOTE When inserting the shift rod 8 take care not to damage the surface of shift rod Apply transmission oil to the thrust collar 10 When assembling the dual acting overrunning clutch 11 into RWD shaft 2 9 aligning the positions A B as shown in the figure W1024639 1 PTO Control Valve 2 O ring 3 RWD Case 4 Ball Bear...

Page 167: ... align the gear of center cam 4 and drive cam 2 W1024976 4 Transmission Case Bevel Pinion Shaft and 18T 17T Gear Shaft 1 Remove the bevel pinion shaft 3 from the transmission case 1 2 Remove the external snap ring 4 and 11T gear 5 3 Remove the ball bearing 6 and 15T 26T gear 7 4 Remove the external snap ring 9 and two ball bearings 8 5 Remove the 18T 17T gear shaft 2 from the transmission case 1 W...

Page 168: ... and left bearings from the differential case NOTE Be careful to note location of all shims when disassembling Shims will need to be reinstalled in the location they came from W1027669 Spiral Bevel Gear 1 Remove the spiral bevel gear UBS screws 1 2 Remove the spiral bevel gear 2 from differential case 3 When reassembling Apply liquid lock Three Bond 1324 or its equivalent to the spiral bevel gear ...

Page 169: ...differential side gear 1 2 Tap out the dowel pin 3 3 Remove the differential pinion shaft 4 Remove the differential pinion 4 differential side gear 1 and shim 5 When reassembling Install the differential pinion and differential side gear aligning the parting marks W1027910 1 Differential Side Gear 2 Differential Pinion 3 Dowel Pin 4 Differential Pinion 5 Shim KiSC issued 04 2006 A ...

Page 170: ... 2 If rounded replace it 3 Measure the thickness of piston slipper 4 If the measurement is less than the allowable limit replace 5 Check the lubricant hole 2 for clogging IMPORTANT Do not interchange pistons between pump and motor cylinder block Pistons and cylinder blocks are matched W1035895 Cylinder Block Face 1 Check the polished face 1 of cylinder block for scoring 2 If scored replace cylinde...

Page 171: ...30 Trunnion Shaft Cover 1 Check the bearing 2 for scratches and excessive wear 2 If worn or scored replace it 3 Check the oil seal 3 and the O rings 1 for damage NOTE After checking coat the bearings with hydrostatic transmission oil and the oil seal lip and the O rings 1 with grease W1036765 Oil Seals and Bearings for Shaft 1 Check the oil seals 1 for damage 2 Check the bearings 2 for wear 3 If t...

Page 172: ...d steel plate with the outside micrometer 2 If the thickness is less than the allowable limit replace it W1017366 1 Valve Plug 2 Spring 3 Valve Poppet PTO brake plate thickness Factory spec 4 35 to 4 65 mm 0 1713 to 0 1830 in Allowable limit 4 25 mm 0 1673 in PTO brake disc thickness Factory spec 3 65 to 3 95 mm 0 1437 to 0 1555 in Allowable limit 3 30 mm 0 1299 in Thickness of pressure plate Fact...

Page 173: ... outer race to check rotation 3 For needle bearing invert the needle rollers to check for any damage and wear 4 If defects are found replace it W1024506 Clearance between Shift Fork and 15T 26T Gear Groove 1 Insert the shift fork into the 15T 26T gear groove and measure the clearance with a feeler gauge 2 If the clearance exceeds the allowable limit replace it W1026751 Clearance between clutch sha...

Page 174: ...nion and side gear against the differential case 4 Hold the differential pinion and move the differential side gear to measure the backlash 5 If the backlash exceeds the allowable limit adjust with differential side gear shims Reference Thickness of shims 0 8 mm 0 0315 in 1 0 mm 0 0394 in 1 2 mm 0 0472 in W1028708 Clearance between differential case spiral bevel gear and differential side gear Fac...

Page 175: ... 6 5 Measure the backlash by fixing the bevel pinion shaft 3 and moving spiral bevel gear 6 by hand 6 If the backlash is not within the factory specifications adjust with the shims 1 4 at bearing holder 5 and differential case 7 Adjust the backlash properly by repeating the above procedures When adjusting W1029368 Reference Thickness of shims 1 4 0 2 mm 0 008 in 0 5 mm 0 020 in Thickness of shims ...

Page 176: ...3 FRONT AXLE KiSC issued 04 2006 A ...

Page 177: ...CONTENTS MECHANISM 1 STRUCTURE 3 M1 KiSC issued 04 2006 A ...

Page 178: ...ports the front wheel load as well as transmitting power to the front wheels The differential gear assembly 8 automatically controls the revolution of right and left wheels when the front wheels encounter unequal road resistance during turning 1 Differential Gear Shaft 2 Ball Bearing 3 Front Axle Case 4 Front Axle 5 57T Gear 6 Ball Bearing 7 Spiral Bevel Gear 8 Differential Gear Assembly KiSC issu...

Page 179: ...CONTENTS SERVICING 1 TROUBLESHOOTING 3 S1 2 TIGHTENING TORQUES 3 S2 3 CEHCKING DISASSEMBLING AND SERVICING 3 S3 1 PREPARATION 3 S3 2 DISASSEMBLING AND ASSEMBLING 3 S4 KiSC issued 04 2006 A ...

Page 180: ...ution Reference Page Differential Lock can not be Set Differential lock shift fork damaged Replace 3 S4 Differential lock clutch damaged Replace 3 S4 Differential Lock Pedal does not Return Differential lock pedal return spring weaken or damaged Replace Differential lock fork shaft rusted Repair 3 S4 4 S8 KiSC issued 04 2006 A ...

Page 181: ...TENING TORQUES Tightening torques of screws bolts and nuts on the table below are especially specified For general use screws bolts and nuts See page G 8 W1012736 Item N m kgf m ft lbs Front axle case mounting screw and nut 39 3 to 44 1 4 0 to 4 5 29 0 to 32 5 KiSC issued 04 2006 A ...

Page 182: ...ion fluid from oil inlet 3 up to the upper line on the dipstick 2 After running the engine for few minutes stop it and check the fluid level again add the fluid to prescribed level if it is not correct level IMPORTANT Use only KUBOTA SUPER UDT fluid Use of other oils may damage the transmission or hydraulic system Refer to LUBRICANTS FUEL AND COOLANT See page G 7 Do not mix different brands fluid ...

Page 183: ...and differential gear case W1010993 2 DISASSEMBLING AND ASSEMBLING Front Axle 1 Remove the spring 1 2 Draw out the differential lock clutch 3 and differential lock shift fork 2 3 Remove the external snap ring 5 and remove the bearing 4 4 Draw out the 57T gear 7 from the front axle 6 5 Tap out the front axle to the outside of front axle case When reassembling Apply grease to the lip of oil seal W10...

Page 184: ...4 BRAKES KiSC issued 04 2006 A ...

Page 185: ...CONTENTS MECHANISM 1 FEATURES 4 M1 2 OPERATION 4 M2 KiSC issued 04 2006 A ...

Page 186: ...aking and require little adjustment The parking brake is a mechanical type which is designed to actuate the travelling brakes through the linkage Pulling the parking lock lever 5 results in the same state as the obtained when the main brake pedal is pressed 1 Return Spring 2 Brake Cam Lever 3 Brake Rod 1 4 Brake Rod 2 5 Parking Lock Lever 6 Main Brake Pedal 7 Speed Control Bracket 8 Brake Arm 1 9 ...

Page 187: ...front axle case is arranged between the brake discs 7 During Braking When the main brake pedal is pressed the linkage causes the brake cam lever 2 and brake cam 3 to turn into the direction of arrow shown in the above figure Therefore the actuator 6 also moves the direction of arrow At this time since the actuator 6 rides on the steel balls 5 set in the grooves of the front axle case to press the ...

Page 188: ...SERVICING SPECIFICATIONS 4 S2 3 TIGHTENING TORQUES 4 S3 4 CHECKING DISASSEMBLING AND SERVICING 4 S4 1 CHECKING AND ADJUSTING 4 S4 2 DISASSEMBLING AND ASSEMBLING 4 S5 1 Brake Pedal 4 S5 2 Brake Assembly 4 S6 3 SERVICING 4 S9 KiSC issued 04 2006 A ...

Page 189: ...uator warped Replace 4 S9 Brake Drags Brake pedal free travel too small Adjust 4 S4 Ball hoses of actuator for uneven wear Replace 4 S9 Brake pedal return spring weaken or broken Replace 4 S5 Brake cam lever rusted Repair 4 S9 Poor Braking Force Brake pedal free travel excessive Adjust 4 S4 Brake disc worn Replace 4 S9 Actuator warped Replace 4 S9 Brake cam lever damaged Replace 4 S9 Transmission ...

Page 190: ...o 30 mm 0 79 to 1 18 in Main Brake Pedal Force 373 to 411 N 38 to 42 kgf 84 to 92 lbs Actuator and Bearing Holder Flatness 0 30 mm 0 0118 in Actuator and Ball Height 22 89 to 22 99 mm 0 9012 to 0 9051 in 22 40 mm 0 8819 in Brake Disc Thickness 3 3 to 3 5 mm 0 130 to 0 137 in 3 0 mm 0 118 in Friction Plate Thickness 1 92 to 2 08 mm 0 0756 to 0 0818 in 1 52 mm 0 0598 in KiSC issued 04 2006 A ...

Page 191: ...NING TORQUES Tightening torques of screws bolts and nuts on the table below are especially specified For general use screws bolts and nuts See page G 8 W1012736 Item N m kgf m ft lbs Front axle case mounting screw and nut 39 3 to 44 1 4 0 to 4 5 29 0 to 32 5 KiSC issued 04 2006 A ...

Page 192: ...rake pedal is securely locked W1011243 Brake Rod 2 1 Measure the spring length L with vernier calipers 2 If the measurement is not within the reference value adjust the brake rod 2 with the adjusting nuts 1 3 Press the main brake pedal to lock the position of third notch and measure the force of main brake pedal 4 If the measurement is not within the factory specifications adjust the spring length...

Page 193: ... 2 Remove the return springs 2 and brake rod 1 3 3 Remove the differential lock rod 4 Remove the brake rod 2 1 5 Remove the clevis pins brake arm 1 4 and brake arm 2 5 and pull out the brake shaft 6 When reassembling Apply grease to the brake rod 2 and moving parts Take care not to damage the brake switch 1 Brake Rod 2 2 Return Spring 3 Brake Rod 1 4 Brake Arm 1 5 Brake Arm 2 6 Brake Shaft 7 Speed...

Page 194: ...nlet 3 up to the upper line on the dipstick 2 After running the engine for few minutes stop it and check the fluid level again add the fluid to prescribed level if it is not correct level IMPORTANT Use only KUBOTA SUPER UDT fluid Use of other oils may damage the transmission or hydraulic system Refer to LUBRICANTS FUEL AND COOLANT See page G 7 Do not mix different brands fluid together W1014130 Tr...

Page 195: ...ont axle case and differential gear case W1014366 Front Axle 1 Remove the spring 1 2 Draw out the differential lock clutch 3 and differential lock shift fork 2 3 Remove the external snap ring 5 and remove the bearing 4 4 Draw out the 57T gear 7 from the front axle 6 5 Tap out the front axle to the outside of front axle case When reassembling Apply grease to the lip of oil seal W1014606 Tightening ...

Page 196: ...o not forget to install the straight pin 8 Refer to the figure W1012864 Brake Discs and Friction Plates 1 Remove the external snap ring 1 2 Remove the brake discs and friction plates 2 3 Remove the bearing holder 3 When reassembling Install the brake discs with their holes 5 offset at least 1 3 of the total hole area W1015294 1 Bearing Holder 2 Differential Gear Shaft 3 Front Axle Case 4 Internal ...

Page 197: ... of Actuator and Ball 1 Measure the dimensions of the actuator with the ball installed 2 If the measurement is less than the allowable limit replace the actuator and balls 3 Inspect the ball holes of cam plate for uneven wear 4 If the uneven wear is found replace it Brake Disc and Friction Plate Wear 1 Measure the brake disc thickness and the friction plate thickness with an outside micrometer 2 I...

Page 198: ...5 REAR AXLE KiSC issued 04 2006 A ...

Page 199: ...CONTENTS MECHANISM 1 STRUCTURE 5 M1 KiSC issued 04 2006 A ...

Page 200: ...he revolution is greatly reduced by the bevel gears 23 3 then the power is transmitted to the rear wheel hub 1 The differential system allows each wheel to rotate at a different speed to make turning easier 1 Rear Wheel Hub 2 Rear Axle Cover 3 Bevel Gear 4 Rear Axle Gear Case 5 Bevel Gear 6 Knuckle Arm 7 Tie Rod 8 Differential Gear Assembly 9 Differential Pinion Gear 10 Rear Axle Bracket Rear 11 T...

Page 201: ...VICING SPECIFICATIONS 5 S2 3 TIGHTENING TORQUES 5 S3 4 CHECKING DISASSEMBLING AND SERVICING 5 S4 1 CHECKING AND ADJUSTING 5 S4 2 PREPARATION 5 S5 1 Separating Rear Axle 5 S5 3 DISASSEMBLING AND ASSEMBLING 5 S8 4 SERVICING 5 S12 KiSC issued 04 2006 A ...

Page 202: ...cessive Replace Tie rod end loose Tighten 5 S7 Air sucked in power steering circuit Bleed Rear Wheels Can Not Be Driven Rear wheel driving gears in rear axle gear case broken Replace 5 S9 Rear wheel drive shaft broken Replace 5 S6 Rear wheel drive gears in transmission broken Replace 2 S20 Rear differential gear broken Replace 5 S10 to S11 Coupling displaced Reassemble 5 S6 Noise Gear backlash exc...

Page 203: ...4 mm 0 00080 to 0 00211 in 20 000 to 20 021 mm 0 78741 to 0 78822 in 19 967 to 19 980 mm 0 78611 to 0 78661 in 0 20 mm 0 0079 in Differential Pinion Gear to Differential Case Differential Pinion Gear Boss Differential Case Clearance O D I D 0 032 to 0 068 mm 0 00127 to 0 00266 in 14 950 to 14 968 mm 0 58859 to 0 58929 in 15 000 to 15 018 mm 0 59056 to 0 59125 in 0 20 mm 0 0079 in Pinion Shaft Turn...

Page 204: ...le bracket mounting screw and nut 124 to 147 12 6 to 15 0 91 1 to 108 4 Rear wheel mounting nut 81 8 9 0 65 1 Slotted nut of tie end end 17 7 to 34 3 1 8 to 3 5 13 0 to 25 3 Bevel gear case mounting screw 48 1 to 55 8 4 9 to 5 7 35 5 to 41 2 Knuckle arm mounting screw M10 screw 39 3 to 64 7 4 0 to 6 6 29 0 to 47 7 Knuckle arm mounting screw M12 screw 80 to 110 8 2 to 11 2 59 1 to 81 1 Knuckle arm ...

Page 205: ... the rear side of frame 2 Set a spring balance to the rear axle flange 3 Measure the rear axle rocking force 4 If the measurement is not within the factory specifications adjust with the adjusting screw 1 5 Tighten the lock nut 2 firmly W1011523 Tie rod B A Factory spec 0 to 10 mm 0 to 0 39 in A Wheel to Wheel Distance at Front B Wheel to Wheel Distance at Rear C Front Rear axle rocking force Fact...

Page 206: ... LUBRICANTS FUEL AND COOLANT See page G 7 W1011744 Draining Rear Axle Differential Case Oil 1 Place oil pans underneath the rear axle differential case 2 Remove the drain plug 2 and oil filler plug 1 to drain oil 3 Screw in the drain plug When reassembling Fill new oil up to the upper level on the oil filler plug IMPORTANT Use the specified oil Refer to LUBRICANTS FUEL AND COOLANT See page G 7 W10...

Page 207: ...12134 Rear Wheel Drive Shaft 1 Slide the external snap rings 2 and couplings 1 2 Remove the rear wheel drive shaft 3 When reassembling Apply grease to the all splines IMPORTANT If the external snap rings are defective replace them Securely fit the external snap rings 2 of the rear wheel drive shaft W1012268 Tightening torque Slotted nut 17 7 to 34 3 N m 1 8 to 3 5 kgf m 13 0 to 25 3 ft lbs 1 Knuck...

Page 208: ...ease to the inside of rear axle brackets 3 4 and bosses of rear axle differential case 5 Apply liquid lock Three Bond 1324 or its equivalent to the rear axle bracket mounting screws IMPORTANT Be sure to tighten the rear wheel mounting nuts to the specified torque Be sure to tighten the slotted nuts to the specified torque W1012615 Tightening torque Rear axle bracket mounting screw and nut 124 to 1...

Page 209: ...ing Apply grease to the bushing Install the knuckle arm 1 to the rear axle case 4 noting the number of shims 2 between them W1019003 Tightening torque Bevel gear case mounting screw 48 1 to 55 8 N m 4 9 to 5 7 kgf m 35 5 to 41 2 ft lbs 1 Rear Axle Differential Case 2 Bevel Gear Case 3 Rear Axle Gear Case Tightening torque Knuckle arm mounting screw M10 39 3 to 64 7 N m 4 0 to 6 6 kgf m 29 0 to 47 ...

Page 210: ... case 4 from the rear axle gear case 3 When reassembling Apply grease to the lip of oil seals 10 Apply liquid gasket Three Bond 1208D or its equivalent to both side of a new gasket Install the bevel gear 5 with the bearing noting the number of shims W1019233 Tightening torque Bevel support cover mounting screw 18 7 to 32 3 N m 1 9 to 3 3 kgf m 13 8 to 23 8 ft lbs 1 Bevel Support Cover 2 Bevel Gear...

Page 211: ...l Pinion and Differential Gear Assembly 1 Remove the internal snap ring 1 and adjusting collar 2 2 Remove the bevel pinion shaft 3 3 Draw out the differential gear assembly 7 with left and right differential yoke shaft 6 8 from the differential gear case 5 W1019873 Tightening torque Axle flange mounting screw 44 2 to 63 7 N m 4 5 to 6 5 kgf m 32 6 to 47 0 ft lbs 1 Rear Axle Gear Case 2 Bearing 3 B...

Page 212: ...ng 10 and remove the bevel gear 11 with the ball bearing 5 Remove the ball bearing 13 from the differential case 12 When reassembling Apply molybdenum disulfide Three Bond 1901 or its equivalent to inner circumferential surface of differential side gears 5 7 and the differential pinion gears 6 9 W1020050 1 Differential Yoke Shaft Right 2 Spring Pin 3 Differential Yoke Shaft Left 4 Thrust Collar 5 ...

Page 213: ... W1020423 Clearance between Differential Case and Differential Yoke Shaft 1 Measure the differential yoke shaft O D 2 Measure the differential case bore I D and calculate the clearance 3 If the clearance exceeds the allowable limit replace faulty parts W1020615 Clearance between knuckle arm support and knuckle arm Factory spec 0 1 to 0 3 mm 0 0040 to 0 0118 in Clearance between knuckle arm support...

Page 214: ... the turning force 4 If the turning force is not within the factory specifications adjust with the lock nut NOTE The turning torque is figured by multiplying the radius distance from the center of the spiral bevel pinion shaft to a point on the circumference from which the string is pulled by the reading on the spring balance After turning force adjustment be sure to stake the lock nut W1020967 Cl...

Page 215: ...usting collars 3 4 3 4 mm 0 134 in 3 6 mm 0 142 in 3 8 mm 0 150 in 4 0 mm 0 157 in 4 1 mm 0 161 in 4 2 mm 0 165 in 4 4 mm 0 173 in 4 6 mm 0 181 in W1021136 Backlash between 12T Bevel Gear and 12T Bevel Gear 1 Place three trips of fuse wire around the 12T bevel gear 1 with grease 2 Fix the rear axle case bevel gear case and front gear case 3 Turn the axle 4 Remove the bevel gear case from rear axle...

Page 216: ...e the rear axle bracket I D with a cylinder gauge Reference W1017939 Rear axle case boss front O D Factory spec 64 910 to 64 940 mm 2 55551 to 2 55669 in Rear axle case bracket front I D Factory spec 65 000 to 65 020 mm 2 55906 to 2 56024 in Rear axle case boss rear O D Factory spec 44 950 to 44 975 mm 1 76970 to 1 77067 in Rear axle case bracket rear I D Factory spec 45 000 to 45 099 mm 1 77166 t...

Page 217: ...6 STEERING KiSC issued 04 2006 A ...

Page 218: ...CONTENTS MECHANISM 1 STRUCTURE 6 M1 2 STEERING CONTROLLER 6 M2 KiSC issued 04 2006 A ...

Page 219: ...ity valve 9 steering controller 2 and steering cylinder 1 etc Flow priority valve divides the oil into two direction One is the control flow to power steering constantly 10 L min 2 64 U S GPM 2 20 Imp GMP and the other is excessive flow to control valve of implement lift control By operating the power steering body the required amount of oil is fed to the steering cylinder 1 1 Steering Cylinder 2 ...

Page 220: ...med between the rotor 12 and the stator 13 while oil is discharged from other two chambers On the other hand rotation of the steering wheel is directly transmitted to the rotor through the spool 7 drive shaft 10 etc Accordingly the metering device serves to supply the steering cylinder with oil amount of which corresponds to the rotation of the steering wheel The wheels are thus turned by the angl...

Page 221: ...ING DISASSEMBLING AND SERVICING 6 S4 1 CHECKING AND ADJUSTING 6 S4 1 Relief Valve 6 S4 2 PREPARATION 6 S5 1 Separating Power Steering Controller 6 S5 2 Separating Steering Support 6 S6 3 DISASSEMBLING AND ASSEMBLING 6 S7 1 Steering Support 6 S7 4 SERVICING 6 S8 1 Steering Cylinder 6 S8 KiSC issued 04 2006 A ...

Page 222: ...el Turns SpontaneouslyWhen Released Steering controller malfunctioning Repair or replace 6 S6 Rear Wheels Wander to Right and Left Steering controller malfunctioning Replace 6 S6 Air sucked in pump due to lack of oil Replenish G 7 Air sucked in pump from suction circuit Repair Insufficient bleeding Bleed Steering cylinder malfunctioning Replace 6 S8 Improper toe in adjustment Adjust 5 S5 Tire pres...

Page 223: ...1013973 Item Factory Specification Allowable Limit Relief Valve Setting Pressure 10 8 to 11 3 MPa 110 2 to 115 2 kgf cm2 1567 to 1638 psi Cylinder Length Rod End to Rod End 439 to 441 mm 17 29 to 17 36 in Rod End Length 15 mm 0 59 in Set Angle C Angle 0 175 rad 10 Set Angle D Angle 0 314 rad 18 Set Angle E Angle 0 349 rad 20 KiSC issued 04 2006 A ...

Page 224: ... of screws bolts and nuts on the table below are especially specified For general use screws bolts and nuts See page G 8 W1012736 Item N m kgf m ft lbs Power steering hose mounting nut 24 6 to 29 4 2 5 to 3 0 18 1 to 21 6 Power steering pipe mounting nut 54 0 to 63 7 5 5 to 6 5 39 8 to 47 0 KiSC issued 04 2006 A ...

Page 225: ... Code No 07916 50321 between them using power steering adaptor 1 Code No 07916 54021 and cable Code No 07916 50331 2 Start the engine 3 Fully turn the steering wheel to the left or right and read the pressure gauge when the relief valve operates NOTE After set a pressure gauge be sure to bleed air from the system W1011368 Relief valve setting pressure Factory spec 10 8 to 11 3 MPa 110 2 to 115 2 k...

Page 226: ...or from the seat switch 2 Remove the seat 1 with the seat base W1040675 Panel 1 Separate the front panel 1 from the rear panel 4 2 Disconnect the connectors from the easy checker fuel gauge coolant temperature gauge and hour meter in front panel 1 3 Disconnect the connectors 2 3 from the main switch and head light switch 4 Remove the horn 5 5 Remove the rear panel 4 W1013706 1 Positive Cable 2 Neg...

Page 227: ...ost covers 4 Disconnect the accelerator wire 5 5 Remove the OPC controller 1 and head lamp 2 6 Unscrew the steering support mounting screw 3 and remove the steering support 4 W1014193 Tightening torque Power steering hose mounting nut 24 6 to 29 4 N m 2 5 to 3 0 kgf m 18 1 to 21 6 ft lbs Power steering pipe mounting nut 54 0 to 63 7 N m 5 5 to 6 5 kgf m 39 8 to 47 0 ft lbs 1 Power Steering Control...

Page 228: ...and remove the universal joint 1 3 Remove the external snap rings 4 10 and washers 5 9 from the steering shaft 7 4 Remove the steering shaft 7 5 Remove the bushes 6 8 When reassembling Apply grease to the inside of bushes 6 8 W1012459 1 Universal Joint 2 Power Steering Controller 3 Universal Joint Mounting Screw 4 External Snap Ring 5 Washer 6 Bush 8 steering Shaft 8 Bush 9 Washer 10 External Snap...

Page 229: ...RTANT When adjusting the cylinder length A be sure to set the direction of the rod ends 1 4 with joint boss of cylinder 1 as shown in figure W1011546 Length A Factory spec 439 to 441 mm 17 29 to 17 36 in Length B Factory spec 15 mm 0 59 in Set angle C Factory spec 0 175 rad 10 Set angle D Factory spec 0 314 rad 18 Set angle E Factory spec 0 349 rad 20 1 Rod End Knuckle Arm 2 Lock Nut 3 Lock Nut 4 ...

Page 230: ...7 HYDRAULIC SYSTEM KiSC issued 04 2006 A ...

Page 231: ...S MECHANISM 1 HYDRAULIC CIRCUIT 7 M1 2 HYDRAULIC PUMP 7 M2 3 FLOW PRIORITY VALVE 7 M3 4 RELIEF VALVE 7 M4 5 IMPLEMENT CONTROL VALVE 7 M5 6 FEEDBACK LINKAGE 7 M6 7 HYDRAULIC CYLINDER 7 M7 KiSC issued 04 2006 A ...

Page 232: ...ne When an engine is started hydraulic pump 9 starts running sucks oil from a transmission case The hydraulic pump 9 forces out the oil to the hydraulic block type outlet 3 implement control valve 6 hydraulic cylinder 5 steering controller 2 PTO control valve 16 hydraulic PTO clutch 17 and hydrostatic transmission 12 1 Steering Cylinder 2 Steering Controller 3 Hydraulic Block Type Outlet 4 Lowerin...

Page 233: ...ase 1 cover 3 side plate 5 and two spur gears drive gear 4 and driven gear 2 Hydraulic pump is driven by the governor shaft W1013860 Displacement Engine speed Condition 24 0 L min 6 3 U S gals min 5 2 Imp gals min At 2700 min 1 rpm 9 8 MPa 100 kgf cm2 1422 psi 1 Case 2 Driven Gear 3 Cover 4 Drive Gear 5 Side Plate KiSC issued 04 2006 A ...

Page 234: ...w from single hydraulic source hydraulic pump to actuates two circuits position control circuit and power steering circuit simultaneously This valve feeds fixedly controlled flow 10 L min 2 6 U S GPM 2 2 Imp GPM to the PF port with priority and excessive flow to the EF port W1013500 1 Spring 2 Spool 3 Valve Body EF EF Port PF PF Port P P Port KiSC issued 04 2006 A ...

Page 235: ...t 6 minimizing valve vibration with the damping effect of the chamber When the oil pressure in the circuit is lower that the setting pressure of the relief valve the relief valve is not operated and the oil fed to the relief valve from the hydraulic pump flows into the implement control valve As the oil pressure in the circuit increases so does the pressure in the damping chamber D C When the pres...

Page 236: ...ement control valve 1 through P port flows to C port The oil pushes and flows into the hydraulic cylinder through the C port to lift the implement W1013558 Down When the hydraulic control lever is moved to DOWN position the spool 2 is moved to the right Oil in the hydraulic cylinder is forced out to the transmission case through the T1 port by the weight of the implement causing the implement to l...

Page 237: ...the uppermost position the spool is pushed in and returned to form a neutral circuit by the motions of the feedback pin 8 feedback rod 3 hydraulic control lever 2 2 control lever arm 5 and control lever shaft 6 W1014224 1 Hydraulic Control Lever 1 2 Hydraulic Control Lever 2 3 Feedback Rod 4 Interlocker 5 Control Lever Arm 6 Control Lever Shaft 7 Implement Control Valve 8 Feedback Pin 9 Lift Arm A...

Page 238: ...s time the lowering speed of the implement can be controlled by the lowering speed adjusting valve 2 attached to the hydraulic cylinder case 4 Turning the lowering speed adjusting knob clockwise decreases the lowering speed and counterclockwise increases lowering speed When the lowering speed adjusting valve 2 is completely closed the lift arm 7 is held at its position since oil in the hydraulic c...

Page 239: ...ERVICING 7 S4 1 CHECKING AND ADJUSTING 7 S4 1 Hydraulic Pump and Flow Priority Valve 7 S4 2 Hydraulic Cylinder Assembly 7 S5 2 DISASSEMBLING AND ASSEMBLING 7 S6 1 Hydraulic Pump and Flow Priority Valve 7 S6 2 Hydraulic Cylinder Assembly 7 S7 3 SERVICING 7 S11 1 Hydraulic Pump 7 S11 2 Hydraulic Cylinder 7 S12 KiSC issued 04 2006 A ...

Page 240: ... Open Noise Oil strainer clogged Clean or replace G 26 Suction pipe loosen or broken Repair or replace 2 S11 Suction pipe connecting hose loosen or broken Repair or replace 2 S11 Suction pipe O ring broken Replace 7 S6 Insufficient transmission oil Refill G 7 Relief valve setting pressure too low Adjust or replace 7 S5 S10 Hydraulic pump broken Replace 7 S6 Implement Does Not Lower Control valve m...

Page 241: ... 145 kgf cm2 1992 to 2062 psi Tip of Gear to Casing Hydraulic Pump Clearance 0 15 mm 0 0059 in Bushing to Gear Shaft Hydraulic Pump Gear Shaft Bush Clearance O D I D 0 025 to 0 111 mm 0 0010 to 0 0044 in 14 970 to 14 980 mm 0 5894 to 0 5898 15 005 to 15 081 0 5908 to 0 5938 0 12 mm 0 0047 in Side Plate Hydraulic Pump Thickness 2 48 to 2 50 mm 0 0976 to 0 0984 in 2 40 mm 0 0945 in Hydraulic Cylinde...

Page 242: ...00 to 1 15 7 24 to 8 32 Flow priority valve mounting screw 17 7 to 20 6 1 8 to 2 1 13 0 to 15 2 Delivery hose mounting nut 24 6 to 29 4 2 5 to 3 0 14 5 to 21 6 Hydraulic pump mounting screw and nut 23 6 to 27 4 2 4 to 2 8 17 4 to 20 2 Cover mounting screw 39 2 to 44 1 4 0 to 4 5 28 9 to 32 5 Hydraulic cylinder assembly mounting screw and nut 39 2 to 44 1 4 0 to 4 5 28 9 to 32 5 Control valve mount...

Page 243: ... NOTE Before pump testing perform the Flowmeter Connecting and Test Preparation See page 7 S4 1 Remove the plug 1 and pull out the spool 3 and spring 2 2 Open the loading valve completely 3 Start the engine and set at approx 2700 min 1 rpm 4 Read and note the pump delivery at no pressure 5 Slowly close the loading valve to increase pressure approx 9 8 MPa 100 kgf cm2 1422 psi 6 Read and note the p...

Page 244: ...ly Relief Valve Setting Pressure 1 Remove the seat assembly and plate 2 Remove the plug 1 from rear of hydraulic cylinder block 3 Install the adaptor 58 Then connect the cable and pressure gauge to adaptor 58 4 Reinstall the seat assembly 5 Start the engine and set a maximum speed 6 Move the mower lift lever all way up to operate the relief valve and read the gauge 7 If the pressure is not within ...

Page 245: ...the cover 7 and casing 3 If the oil seal is defective worn or scratched replace it Install the side plate noting its location and direction Install the gears noting its direction W1011445 Tightening torque Engine stop solenoid mounting screw 9 80 to 11 2 N m 1 00 to 1 15 kgf m 7 24 to 8 32 ft lbs Flow priority valve mounting screw 17 7 to 20 6 N m 1 8 to 2 1 kgf m 13 0 to 15 2 ft lbs Delivery hose...

Page 246: ...eat Refer to TRANSMISSION Section See page 2 S11 W1021463 Panel Refer to TRANSMISSION Section See page 2 S11 W1021499 Fender Refer to TRANSMISSION Section See page 2 S12 W1021535 Speed Control Rod Lowering Speed Adjusting Rod and Hydraulic Pipes Refer to TRANSMISSION Section See page 2 S13 W1021571 Feedback Rod and Mower Lift Lever 1 Remove the feedback rod 2 2 Remove the hydraulic control lever a...

Page 247: ...eassembling Take care not to damage the O rings 1 W1013474 Disassembling Control Valve 1 Remove the spring pin 6 and snap ring 5 2 Draw out the spool 4 with the spring 2 W1013678 Tightening torque Hydraulic cylinder assembly mounting screw and nut 39 2 to 44 1 N m 4 0 to 4 5 kgf m 28 9 to 32 5 ft lbs 1 Hydraulic Cylinder Assembly Tightening torque Control valve mounting screw 23 6 to 27 4 N m 2 4 ...

Page 248: ...aulic piston 1 When reassembling Take care not to damage the O ring 3 and backup ring 2 Apply transmission fluid to the O ring Replace the O ring if it is defective worn or scratched which may cause oil leakage W1013522 Lowering Speed Adjusting Valve 1 Remove the lowering speed adjusting valve body 4 with the lowering speed adjusting shaft 6 2 Remove the poppet 2 and spring 1 When reassembling Tak...

Page 249: ...nd the valve seat 6 When reassembling Take care not to damage the O ring IMPORTANT After disassembling and assembling the relief valve be sure to adjust the relief valve setting pressure W1013647 Tightening torque Relief valve plug 49 0 to 68 6 N m 5 0 to 7 0 kgf m 36 2 to 50 6 ft lbs 1 Plug 2 Shim 3 Shim 4 Spring 5 Poppet 6 Valve Seat KiSC issued 04 2006 A ...

Page 250: ... clearance 3 If the clearance exceeds the allowable limit replace the bush W1011967 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 W1012143 Clearance between tip of gear tooth and casing Allowable limit 0 15 mm 0 0059 in a I D b O D Clearance between bushing and gear shaft Factory spec 0 025 to 0 111...

Page 251: ...e 3 If the clearance exceeds the allowable limit replace the bushing W1013775 Cylinder I D Factory spec 70 05 to 70 10 mm 2 7579 to 2 7598 in Allowable limit 70 15 mm 2 7618 in Clearance between hydraulic arm shaft and bushing Left Factory spec 0 020 to 0 110 mm 0 0008 to 0 0043 in Allowable limit 0 30 mm 0 0118 in Right Factory spec 0 020 to 0 110 mm 0 0008 to 0 0043 in Allowable limit 0 30 mm 0 ...

Page 252: ...8 ELECTRICAL SYSTEM KiSC issued 04 2006 A ...

Page 253: ...CONTENTS MECHANISM 1 WIRING DIAGRAM 8 M1 2 STARTING SYSTEM 8 M3 1 OPERATOR PRESENCE CONTROL OPC SYSTEM 8 M3 1 Related Switches and Controller 8 M4 2 Operation 8 M5 KiSC issued 04 2006 A ...

Page 254: ...tch Grow Plug Starting Switch Starter Solenoid 0 5 WB 2 RG 0 5 RY 0 5 YR 3 B 0 85 RL 0 5 B 0 5 RY 0 5 O 0 85 RL 2 RW 2 RG 0 5 RY 0 5 WR 0 5 RY 3 R 3 B 0 5 WG 0 5 WB 10A 5A 20A B 0 5 RL 0 5 Br 3 R 20 BR 3 R B S 0 5 RY 0 5 RY 0 5 RY 0 5 RY 0 5 RY 0 5 RY 0 5 RY 0 5 RY 0 5 RY 0 5 RY 0 5 RY 0 5 B 0 5 YG PTO Switch G ST AC 0 5 O Controller Horn Horn Relay Head Lamp Brake Switch Work Light Fuel Sensor Se...

Page 255: ...W1012663 W White O Orange RW Red White BY Black Yellow R Red WB White Black RG Red Green YR Yellow Red L Blue WR White Red RY Red Yellow YG Yellow Green Y Yellow WG White Green BW Black White LW Blue White B Black WL White Blue BR Black Red BrW Brown White Br Brown RL Red Blue KiSC issued 04 2006 A ...

Page 256: ...is system is controlled by three safety switch seat switch 8 PTO switch 9 and brake switch 10 and controller 11 1 Battery 2 Starter 3 Slow Blow Fuse 50A 4 Main Switch 5 Fuse 5A 6 Glow Plug 7 Glow Plug Lamp 8 Seat Switch 9 PTO Switch 10 Brake Switch 11 Controller 12 Frame Earth 13 Engine Stop Solenoid 1 to 10 Controller Terminals AC AC Terminal G G Terminal ST ST Terminal S S Terminal B B Terminal ...

Page 257: ... is set at the DISENGAGE position the PTO switch 2 is pushed by the PTO lever and is turned ON When the PTO lever 2 is set at the ENGAGE position the PTO switch 1 is not pushed by the PTO lever 2 and is turned OFF W1013949 Brake Switch The brake switch 1 is located on the front frame This switch is the close type In normal operating condition the switch is close circuit When depressing the brake p...

Page 258: ...flows to the pulling in coil 15 of the engine stop solenoid 13 through the starter 2 Figure B The engine can be started W1014766 1 Battery 2 Starter 3 Slow Blow Fuse 50A 4 Main Switch 5 Fuse 5A 6 Glow Plug 7 Glow Plug Lamp 8 Seat Switch 9 PTO Switch 10 Brake Switch 11 Controller 12 Frame Earth 13 Engine Stop Solenoid 14 Holding Coil 15 Pulling in Coil A When the main switch is turned to the ON pos...

Page 259: ...top in 0 6 to 1 4 seconds W1015064 1 Battery 2 Starter 3 Slow Blow Fuse 50A 4 Main Switch 5 Fuse 5A 6 Glow Plug 7 Glow Plug Lamp 8 Seat Switch 9 PTO Switch 10 Brake Switch 11 Controller 12 Frame Earth 13 Engine Stop Solenoid 14 Holding Coil 15 Pulling in Coil A Condition 1 B Condition 2 C Condition 3 Condition Seat Switch 8 Occupied ON Vacant OFF PTO Switch 9 Disengaged ON Engaged OFF Brake Switch...

Page 260: ... S6 1 Battery 8 S6 2 Main Switch 8 S6 3 Starter 8 S8 4 Glow Plug 8 S9 5 Safety Switch 8 S9 6 Fuel Pump 8 S10 7 Engine Stop Solenoid 8 S11 8 Charging System 8 S11 9 Lighting System 8 S13 10 Cooling System 8 S14 11 Gauges 8 S14 2 DISASSEMBLING AND ASSEMBLING 8 S16 1 Starter 8 S16 2 Alternator 8 S17 3 SERVICING 8 S19 1 Starter 8 S19 2 Alternator 8 S22 KiSC issued 04 2006 A ...

Page 261: ...fective Recharge or replace 8 S4 Slow blow fuse blown Replace G 34 Brake switch defective Replace 8 S10 PTO switch defective Replace 8 S10 Seat switch defective Replace 8 S9 Controller defective Replace G 19 6 S6 Wiring harness disconnected or improperly connected Repair or replace Starter defective Repair or replace 8 S19 to S21 Main switch defective Replace 8 S6 to S7 Glow Plug Does Not Glow Bat...

Page 262: ...Light Fuse blown Replace G 34 Bulb blown Replace G 34 Head light switch defective Replace 8 S13 Wiring harness disconnected or improperly connected Repair or replace Oil Pressure Indicator Lamp Lights Up When Engine Is Running Engine oil pressure too low Check and repair G 7 Engine oil insufficient Replenish G 7 Oil pressure switch defective Replace 8 S13 Short circuit between oil pressure switch ...

Page 263: ...Lever Is at Parking Position Seat switch defective Replace 8 S9 Controller defective Replace G 19 6 S6 Engine Stop When Operator Leaves Seat PTO Lever Is Set at DISENGAGE Position Parking Lock Lever Is at Parking Position Brake switch defective Replace 8 S10 PTO switch defective Replace 8 S10 Controller defective Replace G 19 6 S6 Fuel Gauge Does Not Function Fuel gauge defective Replace 8 S15 Fue...

Page 264: ...ication Allowable Limit Commutator O D Difference of O D s 28 0 mm 1 10 in Less than 0 05 mm 0 0020 in 27 0 mm 1 06 in 0 40 mm 0 0157 in Mica Undercut 0 50 to 0 80 mm 0 020 to 0 031 in 0 20 mm 0 0079 in Brush Length 16 0 mm 0 630 in 10 5 mm 0 413 in Slip Ring O D 14 4 mm 0 567 in 14 0 mm 0 551 in Brush Length 10 5 mm 0 413 in 8 4 mm 0 331 in KiSC issued 04 2006 A ...

Page 265: ...ral use screws bolts and nuts See page G 8 W1012736 Item N m kgf m ft lbs Starter B terminal nut 7 8 to 9 8 0 8 to 1 0 5 8 to 7 2 Starter C terminal nut 7 9 to 11 8 0 8 to 1 2 5 8 to 8 7 Starter Magnetic switch mounting nut 5 9 to 10 8 0 6 to 1 1 4 4 to 7 9 Starter Through bolt 4 42 to 7 35 0 45 to 0 75 3 23 to 5 42 Alternator Pulley nut 58 3 to 78 9 5 95 to 8 05 43 0 to 58 2 KiSC issued 04 2006 A...

Page 266: ...e voltmeter to the battery s negative terminal post 2 and the lead to the positive terminal post 1 and measure the battery voltage 3 If the battery voltage is less than the factory specification check the battery specific gravity and recharge the battery W1012467 Battery Terminal Connection 1 Turn the main switch on and turn on the head light 2 Measure the voltage with a voltmeter across the batte...

Page 267: ...ure the resistance with an ohmmeter across the B terminal and the G terminal and measure the resistance across the B terminal and the AC terminal 3 If 0 ohm is not indicated these contacts of the main switch are faulty 4 Main Switch Key at START Position 1 Set and hold the main switch key at the START position 2 Measure the resistance with an ohmmeter across the B terminal and the G terminal acros...

Page 268: ...e starter NOTE B terminal It is the terminal which connect the cable from the battery to the starter C terminal It is the terminal which connects the cable from the motor to the magnet switch W1014468 Magnetic Switch Test 1 Disconnect the battery negative cable from the battery 2 Disconnect the battery positive cable from the battery 3 Disconnect the leads from the starter B terminal 4 Remove the ...

Page 269: ... from the glow plugs 2 Measure the resistance with an ohmmeter between the glow plug terminal and the chassis 3 If 0 ohm is indicated the screw at the tip of the glow plug and the housing are short circuited 4 If the factory specification is not indicated the glow plug is faulty W1015086 5 Safety Switch Seat Switch Continuity 1 Disconnect the 2P connector for the seat switch 1 2 Remove the seat sw...

Page 270: ...ke pedal 3 If there is no continuity the brake switch 1 is faulty 4 Using an ohmmeter check for continuity between the switch terminals while the brake pedal is released 5 If there is continuity the brake switch 1 is faulty 6 If the brake switch 1 is faulty replace it W1021608 6 Fuel Pump Connector Voltage 1 Disconnect the 2P connector from the fuel pump 2 Turn the main switch key to the ON positi...

Page 271: ...terminal to the connector terminal Red and from the battery negative terminal to the chassis Push the solenoid plunger in by your finger and then release it 6 If the solenoid plunger is not held the engine stop solenoid is faulty 7 If the engine stop solenoid is faulty replace it W1020102 Engine Stop Solenoid Continuity 1 Disconnect the 2P connector from the engine stop solenoid 2 Measure the resi...

Page 272: ...e 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 alternator voltage slowly drops at higher tha...

Page 273: ...W1020683 Oil Pressure Indicator Lamp 1 Disconnect the 1P connector from the oil pressure switch 1 2 Turn the main switch key to the ON position and connect a jumper lead from the 1P connector terminal to the chassis 3 If the oil pressure indicator lamp does not light the bulb or wiring harness is faulty W10259540 Oil Pressure Switch Continuity 1 Disconnect the 1P connector from the oil pressure sw...

Page 274: ...nal and the chassis 3 If infinity is indicated at temperature over factory specifications the switch is faulty W1020328 11 Gauges Fuel Level Sensor 1 Remove the fuel level sensor from the fuel tank 2 Measure the resistance with an ohmmeter across the sensor terminal and its body 3 If the reference value are not indicated the sensor is faulty W1020613 Voltage Connector terminal Chassis Factory spec...

Page 275: ...witch to ON position Measure the voltage with a voltmeter across the B terminal 4 and G terminal 2 of the gauge 3 If approx battery voltage is indicated the ignition and ground lead connections are good 4 Turn the main switch to OFF position Connect a jumper lead between S terminal 3 and G terminal 2 of the gauge 5 Turn the main switch to ON position If the gauge registers a full scale reading und...

Page 276: ...he starter drive housing 2 9 Draw out the armature 10 with the drive lever 3 NOTE Do not damage to the brush and commutator When reassembling Apply grease DENSO CO LTD No 50 or equivalent to the parts indicated in the figure Joint of solenoid switch a Bushing b Drive lever c Collar d Teeth of pinion gear e Armature shaft f W1012736 1 Solenoid Switch Mounting Nut 2 Starter Drive Housing 3 Drive Lev...

Page 277: ...r screws and the B terminal nut and remove the rear end cover W1017367 Brush Holder 1 Unscrew the two screws holding the brush holder and remove the brush holder 1 W1017462 IC Regulator 1 Unscrew the three screws holding the IC regulator and remove the IC regulator W1017539 Rectifier 1 Remove the four screws holding the rectifier and the stator lead wires 2 Remove the rectifier 1 W1017612 Tighteni...

Page 278: ...ge the slip 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...

Page 279: ... replace the clutch assembly 2 Check that the pinion turns freely and smoothly in the overrunning direction and does not slip in the cranking direction 3 If the pinion slips or does not turn in both directions replace the overrunning clutch assembly NOTE Do not wash off the grease in the overrunning clutch with the chemicals or oils W1156799 KiSC issued 04 2006 A ...

Page 280: ...ean it with emery paper 2 Measure the brush length A with vernier caliper 3 If the length is than the allowable limit replace the yoke assembly and brush holder W1156360 Commutator O D Factory spec Electromagnetic drive type 28 0 mm 1 102 in Planetary gear reduction type 30 0 mm 1 181 in Allowable limit Electromagnetic drive type 27 0 mm 1 063 in Planetary gear reduction type 29 0 mm 1 142 in Diff...

Page 281: ...stance range of circuit tester 2 If it conducts replace the armature 3 Check the continuity across the segments of the commutator with resistance range of circuit tester 4 If it does not conduct replace the armature W1156507 Field Coil 1 Check the continuity across the lead 1 and brush 2 with a circuit tester 2 If it does not conduct replace the yoke assembly 3 Check the continuity across the brus...

Page 282: ...eplace it 3 Check the continuity across the slip ring and core with resistance range of circuit tester 4 If infinity is not indicated replace it W1020094 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 W1020208 Brush Wear 1 Measure th...

Page 283: ... if the diode in the rectifier conducts in one direction and does not conduct in the reverse direction W1020452 IC Regulator 1 Check the continuity across the B terminal 2 and the F terminal 1 of IC regulator with resistance range of circuit tester 2 The IC regulator is normal if the conducts in one direction and does not conduct in the reverse direction W1020645 1 F Terminal 2 B Terminal KiSC iss...

Page 284: ...9 MOWER KiSC issued 04 2006 A ...

Page 285: ...6 WSM SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS The following safety decals are installed on the mower If a decal becomes damaged illegible or is not on the mower replace it The decal part number is listed in the parts list SAFETY DECALS KiSC issued 04 2006 A ...

Page 286: ...9 2 F2880 F3680 RCK72 F36 RCK72R F36 RCK60 F36 RCK60R F36 WSM SAFETY INSTRUCTIONS KiSC issued 04 2006 A ...

Page 287: ...Center Frame 5 Front Gauge Wheel 6 Gauge Wheel Arm RH 7 Discharge Deflector 8 Anti Scalp Roller 9 Universal Joint 10 Shield 11 Gauge Wheel Arm LH 12 Blade 1 Mower Deck 2 Front Roller 3 Gear Box 4 Center Frame 5 Front Gauge Wheel 6 Gauge Wheel Arm RH 7 Anti Scalp Roller 8 Universal Joint 9 Shield 10 Gauge Wheel Arm LH 11 Blade KiSC issued 04 2006 A ...

Page 288: ... Frame 5 Front Gauge Wheel 6 Gauge Wheel Arm RH 7 Discharge Deflector 8 Anti Scalp Roller 9 Universal Joint 10 Shield 11 Gauge Wheel Arm LH 12 Blade 1 Mower Deck 2 Front Roller 3 Gear Box 4 Center Frame 5 Front Gauge Wheel 6 Gauge Wheel Arm RH 7 Anti Scalp Roller 8 Universal Joint 9 Shield 10 Gauge Wheel Arm LH 11 Blade KiSC issued 04 2006 A ...

Page 289: ...height 25 to 129 mm 1 0 to 5 0 in Discharge sirection Side Rear Side Rear Weight Approx 214 kg 472 lbs 210 kg 463 lbs 180 kg 397 lbs 170 kg 375 lbs Blade spindle speed 2405 min 1 2405 rpm 2695 min 1 2695 rpm Blade tip velocity 78 7 m s 15490 fpm 73 8 m s 14520 fpm Blade length 625 mm 24 6 in 523 mm 20 6 in Number of blades 3 Dimensions Total length 1160 mm 45 7 in 1090 mm 42 9 in Total width 2250 ...

Page 290: ...CONTENTS MECHANISM 1 POWER TRANSMISSION 9 M1 KiSC issued 04 2006 A ...

Page 291: ...ide Front PTO Shaft Universal Joint Pinion Shaft 6 Bevel Gear 4 Bevel Gear 2 Bevel Gear Shaft 15 Center Pulley 1 Mower Belt Side Pulley 8 Blade Shaft 10 Blade Side 12 1 Center Pulley 2 Bevel Gear 3 Collar 4 Bevel Gear 5 Bevel Gear Case 6 Pinion Shaft 7 Feather Key 8 Side Pulley 9 Side Pulley Holder 10 Blade Shaft 11 Dust Cover 12 Blade Side 13 Blade Boss 14 Feather Key 15 Bevel Gear Shaft 16 Blade...

Page 292: ...T 9 S4 6 CHECK AND MAINTENANCE 9 S5 1 Check Points of Daily of Each Use 9 S5 2 Check Point of Initial 50 Hours 9 S7 3 Check Point of every 50 Hours 9 S7 4 Check Point of Every 150 Hours 9 S8 5 Check Point of Every 2 Years 9 S8 2 TROUBLESHOOTING 9 S9 3 SERVICING SPECIFICATIONS 9 S10 4 TIGHTENING TORQUES 9 S11 5 CHECKING DISASSEMBLING AND ASSEMBLING 9 S12 1 CHECKING AND ADJUSTING 9 S12 2 PREPARATION...

Page 293: ... used should be made according to the drawings provided Use KUBOTA genuine parts or KUBOTA recommended parts and lubricants or their equivalents Gaskets and O rings must be replaced during assembly Apply grease to new O rings or oil seals before assembling See the figure When reassembling external snap rings or internal snap rings they must be positioned so that sharp edge faces against the direct...

Page 294: ... to 11 2 1 00 to 1 15 7 24 to 8 31 7 85 to 8 82 0 80 to 0 90 5 79 to 6 50 12 3 to 14 2 1 25 to 1 45 9 05 to 10 4 M8 8 mm 0 31 in 17 7 to 20 5 1 8 to 2 1 13 1 to 15 1 16 7 to 19 6 1 7 to 2 0 12 3 to 14 4 23 6 to 27 4 2 4 to 2 8 17 4 to 20 2 17 7 to 20 5 1 8 to 2 1 13 1 to 15 1 29 5 to 34 3 3 0 to 3 5 21 7 to 25 3 M10 10 mm 0 39 in 39 3 to 45 1 4 0 to 4 6 29 0 to 33 2 31 4 to 34 3 3 2 to 3 5 23 2 to...

Page 295: ...to 224 0 Grade SAE GR 5 SAE GR 8 Unit Nominal Diameter N m kgf m ft lbs N m kgf m ft lbs 5 16 23 1 to 27 8 2 35 to 2 84 17 0 to 20 5 32 5 to 39 3 3 31 to 4 01 24 0 to 29 0 3 8 47 5 to 57 0 4 84 to 5 82 35 0 to 42 0 61 0 to 73 2 6 22 to 7 47 45 0 to 54 0 1 2 108 5 to 130 2 11 07 to 13 29 80 0 to 96 0 149 2 to 179 0 15 22 to 18 27 110 0 to 132 0 9 16 149 2 to 179 0 15 22 to 18 27 110 0 to 132 0 217 ...

Page 296: ...ades for wear or damage 9 S5 Check oil leaks Check all hardware Make sure all pins are in place Clean mower deck Apply grease to universal joint 9 S5 Apply grease to spindle shafts Bevel gear shaft and blade shafts 9 S6 Apply grease to belt tension pulley 9 S6 Apply grease to belt tension pivot 9 S6 Initial 50 hours Change gear box oil 9 S7 Every 50 hours Apply grease to front gauge wheels 9 S7 Ap...

Page 297: ...mower blades if they are as shown in figure 3 IMPORTANT Never forget to set the two cup washers between mower blade and spline boss when reassembling the mower blades NOTE To sharpen the mower blades by yourself clamp the mower blade securely in a vise and use a large mill file along the original bevel To balance the mower blade place a small rod through the center hole and check to see if the bla...

Page 298: ...t W1015209 Greasing Belt Tension Pulley and Greasing Belt Tension Pivot 1 Grease the grease nipple 1 of the belt tension pulley if the amount of grease is insufficient 2 Grease the grease nipple 1 of the belt tension pivot if the amount of grease is insufficient W1015312 1 Grease Nipple Bevel Gear Shaft 2 Grease Nipple Blade Shaft 1 Grease Nipple 2 Grease Nipple KiSC issued 04 2006 A ...

Page 299: ...ase the grease nipples 1 2 of the front gauge wheels if the amount of grease is insufficient W1015754 Greasing Front Roller 1 Grease the grease nipples 1 of the front roller if the amount of grease is insufficient W1015909 Checking Gear Box Oil 1 Place the mower on level ground 2 Remove the oil filler plug 1 or check plug 2 and check to see that the oil level is just below the check plug 2 port 3 ...

Page 300: ... the mower belt if there is any damage found See page 9 S19 W1018143 4 Check Point of Every 150 Hours Checking Gear Box Oil See page 9 S7 W1018524 5 Check Point of Every 2 Years Replacing Gear Box Oil Seal 1 Replace the gear box oil seals 1 2 with new ones See page 9 S20 W1016076 1 Oil Seal 2 Oil Seal KiSC issued 04 2006 A ...

Page 301: ...g 9 S19 Grass clogged Remove grass Cup washer flattened out or worn Replace cup washer 9 S18 Cutting Is Poor Blade worn or broken Sharpen or replace blade 9 S5 S18 Mower blade mounting screw loosen Retighten mounting screw 9 S5 S18 Improper cutting height Adjusting cutting height 9 S13 to S15 Mower Is Not Lifted Trouble of hydraulic system lift cylinder and control valve Check hydraulic system 7 S...

Page 302: ...it Maximum Front Gauge Wheel Tire Pressure 343 kPa 3 5 kgf cm2 49 7 psi Recommended Front Gauge Wheel Tire Pressure 196 kPa 2 0 kgf cm2 28 4 psi Pinion Shaft Turning Force Turning Torque 490 N Less than 50 kgf 110 lbs 5 9 N m Less than 0 6 kgf m 4 3 ft lbs Bevel Gears in Gear Box Backlash 0 13 to 0 25 mm 0 0052 to 0 0098 in KiSC issued 04 2006 A ...

Page 303: ...GHTENING TORQUES Tightening torques of screws bolts and nuts on the table below are especially specified For general use screws bolts and nuts See page 9 S2 W1012736 Item N m kgf m ft lbs Mower blade mounting screw 98 1 to 117 7 10 0 to 12 0 72 3 to 86 8 KiSC issued 04 2006 A ...

Page 304: ...the assembly reposition the tire on the rim relubricate and reinflate After seating the bead adjust inflation pressure as recommended in the inflation pressure chart 1 The tire pressure naturally drops slowly in the course of time Thus check it every day and inflate as necessary CAUTION Do not attempt to mount a tire unless qualified Use proper equipment W1018550 Maximum front gauge wheel tire pre...

Page 305: ...ng Cutting Height and Assist Spring W1014160 W1019807 1 Front Gauge Wheel 2 Lift Rod 3 Front Roller 4 Anti Scapl Roller 5 Adjusting Nut 6 Lift Spring Rod S Side discharge mower R Rear discharge mower RCK72 F36 RCK72R F36 1 2 3 4 RCK60 F36 RCK60R F36 1 2 3 4 KiSC issued 04 2006 A ...

Page 306: ...ight is approx 51 to 77 mm 2 0 to 3 0 in 3 Check the length L of the lift spring rod 6 without the grass catcher Reference Length L LH 70 mm 2 8 in Length L RH 50 mm 2 0 in W1019983 Cutting Height FrontGauge Wheel Lift Rod Front Roller Anti Scalp Roller 25 mm 1 0 in E X a I 32 mm 1 25 in D XII E XII 38 mm 1 50 in E Y 45 mm 1 75 in D YII E YII 51 mm 2 0 in D X b II 58 mm 2 25 in C XII D XII 64 mm 2...

Page 307: ... set pin as shown in the figure W1020910 Adjusting Lift Rod Spacers 1 Park the machine and mower deck on level ground and set the desired cutting height 2 Check the level of mower deck 3 If not adjust the level by the lift rod spacers 2 1 Lift Rod RH 2 Lift Rod LH A B C D Direction where the set pin is inserted 1 Lift Rod Spacer 2 Lift Arm KiSC issued 04 2006 A ...

Page 308: ...n of the arrow and hook the tilt lever 4 CAUTION Securely insert the tilt lever 4 in the tilt pipe 3 Never release the tilt pipe 3 until the tilt lever 4 is locked to the hook securely 6 Start the engine and raise the mower deck fully 7 Lock the lowering speed adjusting valve 8 Stop the engine and remove the key 9 Pull on the lock pins 6 of the anti scalp roller 5 and push them upward 10 Pull on t...

Page 309: ...the DISENGAGE position 2 Place the High Low gear shift lever in the NEUTRAL position 3 Disconnect the universal joint from the machine 4 Start the engine and raise the mower deck fully 5 RCK72 F36 RCK72R F36 Unlock the tilt lever 1 with the tilt pipe Remove the clevis pin 3 and disconnect the gas spring 2 from the mower lift arm 6 6 Shut off the engine pull the lock pins 4 of the lift rods 4 and l...

Page 310: ...between the mower blade and mower deck that it will hold the mower blade safely while loosing or tightening the mower blade mounting screw 1 When reassembling Be sure to assemble two cup washers between the mower blade 4 and spline boss 2 IMPORTANT Make sure the cup washers 3 are not flattened out or worn causing mower blade to slip easily Replace the cup washer 3 if it is damaged W1021356 1 Screw...

Page 311: ... Remove the gear box 2 and the center pulley holder 12 7 Remove the oil seals 7 10 and internal snap ring 9 from the center pulley holder 12 And remove the shim 11 and ball bearing 8 When reassembling Replace the oil seals 7 10 with new one NOTE Be sure to install the shim 11 W1021831 1 Center Frame 2 Gear Box 3 Gear Box Stay RH 4 Tension Pulley 5 Tension Spring 6 Gear Box Stay LH 7 Oil Seal 8 Bal...

Page 312: ...emove the external snap ring 9 and bevel gear 8 and draw out the bevel gear shaft 19 8 Remove the oil seal 22 ball bearing 7 and shim 12 When reassembling Replace the oil seals 13 22 and gear box caps 1 10 with the new ones Check the backlash and turning torque If not correct adjust with the shims 4 12 15 W1023056 1 Gear Box Cap 2 Pinion Shaft Mounting Screw 3 Internal Snap Ring 4 Shim 5 Ball Bear...

Page 313: ...lder 6 from the mower deck 3 Remove the oil seal 4 9 and internal snap ring 5 8 and tap out the blade shaft 10 with ball bearing 7 12 When reassembling Replace the oil seals 4 and 9 with new ones NOTE Be sure to install the shim 11 W1024102 1 Side Pulley 2 Pulley Mounting Nut 3 Feather Key 4 Oil Seal 5 Internal Snap Ring 6 Side Pulley Holder 7 Ball Bearing 8 Internal Snap Ring 9 Oil Seal 10 Blade ...

Page 314: ...tside micrometer Backlash equal thickness of fuse 5 If the backlash is not within the factory specifications adjust with shims 1 2 3 6 Apply red lead lightly over several teeth at three positions equally spaced on the bevel gear 7 Turn the pinion shaft 8 Check the tooth contact If not correct adjust with shim 1 2 3 NOTE After checking the tooth contact checking the backlash between pinion shaft an...

Page 315: ...M INDUSTRIAL MACHINERY SERVICE LTD 64 ISHIZU KITAMACHI SAKAI KU SAKAI CITY OSAKA 590 0823 JAPAN PHONE 81 72 241 1129 FAX 81 72 245 2484 E mail ksos pub kubota co jp Printed in Japan 2006 04 S EI EI e Code No 9Y011 15521 2006 01 S EI EI e ...

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