wsm ME8200 Workshop Manual Download

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WORKSHOP MANUAL

TRACTOR

ME8200,ME9000

KiSC issued 03, 2007 A

Summary of Contents for ME8200

Page 1: ...WORKSHOP MANUAL TRACTOR ME8200 ME9000 KiSC issued 03 2007 A...

Page 2: ...9Y021 18200 for the one which has not been described to this workshop manual Servicing The heading General section comes general precautions check and maintenance and special tools Other section there...

Page 3: ...anual 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 y...

Page 4: ...ack 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 stoppi...

Page 5: ...s 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...

Page 6: ...CTIONS 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 ROPS TYPE SAF...

Page 7: ...5 ME8200 ME9000 WSM SAFETY INSTRUCTIONS KiSC issued 03 2007 A...

Page 8: ...6 ME8200 ME9000 WSM SAFETY INSTRUCTIONS KiSC issued 03 2007 A...

Page 9: ...7 ME8200 ME9000 WSM SAFETY INSTRUCTIONS KiSC issued 03 2007 A...

Page 10: ...8 ME8200 ME9000 WSM SAFETY INSTRUCTIONS KiSC issued 03 2007 A...

Page 11: ...9 ME8200 ME9000 WSM SAFETY INSTRUCTIONS CABIN TYPE KiSC issued 03 2007 A...

Page 12: ...10 ME8200 ME9000 WSM SAFETY INSTRUCTIONS KiSC issued 03 2007 A...

Page 13: ...11 ME8200 ME9000 WSM SAFETY INSTRUCTIONS KiSC issued 03 2007 A...

Page 14: ...61 6 in Rear 1575 to 1870 mm 62 0 to 73 6 in Minimum ground clearance 445 mm 17 5 in BRACKET DRAWBAR 445 mm 17 5 in COVER TANK Weight 2865 kg 6317 lbs 3115 kg 6869 lbs Traveling system Standard tire...

Page 15: ...9 3 in 63 6 in Rear 1580 to 1870 mm 62 2 to 73 6 in Minimum ground clearance 146 mm 18 3 in BRACKET DRAWBAR Weight 2915 kg 6428 lbs 3180 kg 7012 lbs Traveling system Standard tire size Front 12 4R24 R...

Page 16: ...14 ME8200 ME9000 WSM DIMENSIONS DIMENSIONS ROPS TYPE KiSC issued 03 2007 A...

Page 17: ...15 ME8200 ME9000 WSM DIMENSIONS CABIN TYPE KiSC issued 03 2007 A...

Page 18: ...G GENERAL KiSC issued 03 2007 A...

Page 19: ...OINTS OF EVERY 50 HOURS G 18 4 CHECK POINTS OF EVERY 100 HOURS G 19 5 CHECK POINTS OF EVERY 200 HOURS G 24 6 CHECK POINT OF EVERY 300 HOURS G 27 7 CHECK POINTS OF EVERY 400 HOURS G 27 8 CHECK POINTS O...

Page 20: ...al KUBOTA distributor always specify engine serial number tractor serial number CABIN serial number and hour meter reading W1010593 1 Tractor Identification Plate 2 Tractor Serial Number 3 Engine Seri...

Page 21: ...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 be...

Page 22: ...c check for a fee Do not attempt to modify or remodel any electrical parts and wiring When removing the battery cables disconnect the negative cable first When installing the battery cables connect th...

Page 23: ...no twist unnecessary sag or excessive tension except for movable part where sag be required W1011587 In installing a part take care not to get wiring caught by it W1011670 1 Grommet A Correct B Incor...

Page 24: ...t on battery CAUTION Take care not to let battery liquid spill on your skin and clothes If contaminated wash it off with water immediately Before recharging the battery remove it from the machine Befo...

Page 25: ...odies to separate W1012272 Use sandpaper to remove rust from terminals Repair deformed terminal Make certain there is no terminal being exposed or displaced W1012346 Make certain that there is no fema...

Page 26: ...n plastic cover is large enough to cover whole connector W1012519 5 HANDLING OF CIRCUIT TESTER Use tester correctly following manual provided with tester Check for polarity and range W1012684 1 Cover...

Page 27: ...CE or CF Below 0 C 32 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 55 L 58 1 U S qts 48 4 Imp qts KUBOTA SUPER UDT f...

Page 28: ...lubrication of the transmission it is important that a multi grade transmission fluid be used in this system We recommend the use of KUBOTA SUPER UDT fluid for optimum protection and performance Do no...

Page 29: ...29 0 to 33 2 31 4 to 34 3 3 2 to 3 5 23 2 to 25 3 48 1 to 55 8 4 9 to 5 7 35 5 to 41 2 39 3 to 44 1 4 0 to 4 5 29 0 to 32 5 60 9 to 70 6 6 2 to 7 2 44 9 to 52 0 M12 12 mm 0 47 in 62 8 to 72 5 6 4 to...

Page 30: ...13 Fan belt Adjust G 21 14 Brake Adjust G 21 15 Fuel line Check G 21 Replace G 32 16 Power steering oil line Check G 24 Replace G 32 17 Radiator hose and clamp Check G 24 Replace G 32 18 Toe in Adjust...

Page 31: ...29 13 Fan belt Adjust G 21 14 Brake Adjust G 21 15 Fuel line Check G 21 Replace G 32 16 Power steering oil line Check G 24 Replace G 32 17 Radiator hose and clamp Check G 24 Replace G 32 18 Toe in Ad...

Page 32: ...st G 27 2 Inner air filter Clean G 26 3 Fresh air filter Clean G 26 4 Air conditioner Clean G 26 5 Air conditioner pipes and hoses Check G 29 6 CABIN isolation Check G 29 7 Washer liquid Add Service a...

Page 33: ...ROPS attaching hardware 11 Check and clean the radiator screen and grill 12 Check and clean the air conditioner condenser screen and intercooler screen 13 Check the nuts of tires are tight 14 Check th...

Page 34: ...before changing oil filter cartridge Allow engine to cool down sufficiently oil can be hot and can burn 1 Remove the oil filter 1 2 Put a film of clean engine oil on rubber seal of new filter 3 Tighte...

Page 35: ...e sure that the transmission fluid doesn t leak through the seal IMPORTANT To prevent serious damage to the hydraulic system use only a KUBOTA genuine filter W1037606 Changing Transmission Fluid CAUTI...

Page 36: ...se Oil 1 To drain the used oil remove the right and left drain plugs 2 and filling plugs 1 at the front axle gear case and drain the oil completely into the oil pan 2 After draining reinstall the drai...

Page 37: ...Switch for the shuttle shift lever 1 Sit on operator s seat 2 Shift the shuttle shift lever to the forward or reverse position 3 Depress the clutch pedal fully 4 Disengage the PTO clutch control leve...

Page 38: ...mmediately and get medical attention Keep open sparks and flames away from the battery at all times Hydrogen gas mixed with oxygen becomes very explosive Wear eye protection and rubber gloves when wor...

Page 39: ...kgf cm2 30 psi When carbon or oil adheres to the element soak the element in detergent for 15 minutes then wash it several times in water rinse with clean water and dry it naturally After element is f...

Page 40: ...ator and the engine block pull the alternator out until the deflection of the belt falls within acceptable limits 4 Replace fan belt if it is damaged W1040751 Adjusting Brake Pedal 1 Brake Pedal Free...

Page 41: ...vel 1 Gently step on both the right and left pedals at once with your both feet Step on the right pedal all the way the left pedal rises Measure the level difference between the two pedals 2 Next step...

Page 42: ...dy condition lubricate grease fittings more often W1041759 1 Greasing Fitting Front Axle Support 2 Breather Plug 3 Greasing Fitting Parking Brake Lever Shaft 4 Greasing Fitting Front Wheel Case Suppor...

Page 43: ...the event the coolant temperature be nearly or more than the boiling point what is called Overheating 1 Stop the machine operation in a safe place and keep the engine unloaded idling 2 Don t stop the...

Page 44: ...between tire beads at front of tire hub height 5 Measure distance between tire beads at rear of tire hub height 6 Front distance should be shorter than rear distance 7 If not adjust tie rod length To...

Page 45: ...use damage and malfunction Do not use gasoline thinner or similar chemicals to clean the filter as damage to the filter may occur It may also cause an unpleasant odor in the CABIN when the system is u...

Page 46: ...e G 15 W1044400 Replacing Fuel Filter 1 Remove the fuel filter 1 2 Put a film of clean fuel on rubber seal of new filter 3 Tighten the filter until it contacts the mounting surface Tighten filter by h...

Page 47: ...MAX level 2 After installing the vinyl pipes 4 to the bleeder 2 3 loosen the bleeder a half turn 3 Move the brake pedal up and down Repeat this motion until fresh oil overflows W1044840 Adjusting Fro...

Page 48: ...ir Cleaner Primary Element See page G 20 W1045532 Checking Air Conditioner Pipes and Hoses CABIN Type 1 Check to see that all lines and hose clamps are tight and not damaged 2 If hoses and clamps are...

Page 49: ...e for few minutes 10 Stop the engine Check coolant level and add coolant if necessary IMPORTANT Do not start engine without coolant Use clean fresh water and anti freeze to fill the radiator When the...

Page 50: ...fore a long term storage let out cooling water completely or mix fresh water with long life coolant and fill the radiator and reserve tank with the mixture 1 Long life coolant hereafter LLC comes in s...

Page 51: ...represents industry standards that necessitate a minimum glycol content in the concentrated anti freeze When the coolant level drops due to evaporation add water only to keep the antifreeze mixing rat...

Page 52: ...tem To make sure air is completely purged pinch the fuel overflow hose 4 with fingers if a pulsation is felt when the knob is pumped then no air remains 4 Set the hand throttle lever at the maximum sp...

Page 53: ...at this operation several times Prepare and oil can 3 After bleeding the master cylinder install the front brake pipes 4 After installing the vinyl pipe 4 to the bleeder 2 3 loosen the bleeder two tur...

Page 54: ...PORTANT 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 tractor electrical system Refer to...

Page 55: ...or electrical system Refer to troubleshooting section of this manual for specific information dealing with electrical problems W1047748 Fuse No Capacity A Protected circuit 1 15 Flasher Hazard 2 10 Do...

Page 56: ...the bulb W1049044 Light Capacity Head lights 45 W Tail light 10 W Turn signal hazard light front 21 W Turn signal hazard light rear 21 W Sidemarker light 5 W Brake stop light 21 W Number plate light...

Page 57: ...quid CABIN Type 1 Add a proper amount of automobile washer liquid W1049482 Checking the Amount of Refrigerant CABIN Type 1 See page 10 S23 W1049609 Washer liquid tank Capacity 1 3 L 1 4 U S qts 1 1 Im...

Page 58: ...0241000 Piston Ring Tool Code No 07909 32121 Application Use exclusively for removing or installing the piston ring with ease W10241500 Diesel Engine Compression Tester Code No 07909 30208 Assembly 07...

Page 59: ...0 785 rad 45 0 262 rad 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 W10244580 Connecting Rod Alignment Tool Code No 07909 31661 App...

Page 60: ...o 0 152 mm 0 002 to 0 006 in Blue 0 102 to 0 229 mm 0 004 to 0 009 in W10247190 Red Check Code No 07909 31371 Application Use to check cracks on cylinder head cylinder block etc W10249090 NOTE The fol...

Page 61: ...6 1811 in B 14 5 mm 0 571 in C 120 mm 4 7244 in D 30 0 mm dia 1 1811 in dia E 32 95 mm dia 1 2972 in dia F 20 mm dia 0 7874 in dia a 6 3 m 0 00025 in b 6 3 m 0 00025 in A 157 mm 6 1811 in B 14 5 mm 0...

Page 62: ...12 8 mm dia 0 492 to 0 504 in dia L 8 9 to 9 1 mm 0 350 to 0 358 in C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in C0 3 Chamfer 0 3 mm 0 012 in A 20 mm dia 0 79 in dia B 12 96 to 12 98 mm dia...

Page 63: ...1 mm 0 3110 to 0 3189 in G 20 mm 0 0787 in H 130 mm dia 5 1181 in dia I 99 4 to 99 6 mm dia 3 9134 to 3 9213 in dia J 95 05 to 95 20 mm dia 3 7421 to 3 7480 in dia K 3 mm dia 0 1181 in dia L 15 mm 0...

Page 64: ...a 1 61 in dia P 32 mm dia 1 26 in dia Q 33 961 to 34 0 mm dia 1 3370 to 1 3386 in dia R 18 mm dia 0 71 in dia S 19 967 to 20 0 mm dia 0 7861 to 0 7874 in dia U 3 mm 0 12 in V 149 1 to 149 4 mm 5 8701...

Page 65: ...094 in dia G 50 421 to 50 44 mm dia 1 9851 to 1 9858 in dia H 8 mm 0 31 in I 2 mm 0 08 in J 35 mm 1 38 in K 5 mm 0 20 in L 0 26 rad 15 A 35 mm 1 38 in B 33 mm 1 30 in C Chamfer 0 5 mm 0 02 in D 1 mm 0...

Page 66: ...See page G 47 2 Flange Nut 1 3 Washer 1 4 Shaft 1 See page G 48 5 Piece 1 1 See page G 48 6 Clevis 1 7 Washer 1 8 Cotter Pin 1 9 Joint 1 1 See page G 49 10 Piece 2 1 See page G 49 11 Joint 2 1 See pa...

Page 67: ...mm 2 76 in O 19 5 mm 0 77 in P 12 mm 0 47 in Q 0 8 mm 0 03 in R 6 mm 0 24 in A 26 mm 1 02 in B 18 mm 0 71 in C 16 5 to 17 0 mm 0 6496 to 0 6693 in D 1 5 mm 0 06 in E 54 0 to 54 2 mm dia 2 1260 to 2 13...

Page 68: ...3 35 in K 70 mm 2 76 in L 178 mm 7 01 in A 26 mm 1 02 in B 18 mm 0 71 in C 16 5 to 17 0 mm 0 6496 to 0 6693 in D 1 5 mm 0 06 in E 53 5 to 53 7 mm dia 2 1063 to 2 1142 in dia F 50 05 to 50 25 mm dia 1...

Page 69: ...3 35 in K 70 mm 2 76 in L 394 mm 15 51 in A 26 mm 1 02 in B 18 mm 0 71 in C 16 5 to 17 0 mm 0 6496 to 0 6693 in D 1 5 mm 0 06 in E 53 0 to 53 2 mm dia 2 0866 to 2 0945 in dia F 49 55 to 49 75 mm dia 1...

Page 70: ...D 0 5 mm radius 0 02 in radius E 0 89 rad 50 F 10 mm 0 39 in G 20 mm 0 79 in H 5 mm 0 20 in I 95 mm 3 74 in J 125 mm 4 93 in K 5 mm 0 20 in L M16 Pitch 1 5 M 30 mm 1 18 in N 9 5 mm 0 3740 in O 11 mm...

Page 71: ...97 in C 108 5 mm 4 272 in D 263 mm 10 35 in E 12 5 mm 0 492 in F 237 5 mm 9 350 in G 142 5 mm 5 610 in H 95 mm 3 74 in I 4 14 mm dia 0 55 in dia J 40 mm 1 57 in K 210 mm 8 27 in L 190 mm 7 48 in M 10...

Page 72: ...n D 35 mm dia 1 3780 in dia E Chamfer 1 mm 0 0394 in F Chamfer 0 1 mm 0 0039 in G 1 mm 0 0394 in H Chamfer 0 2 mm 0 0079 in I R8 mm 0 3150 in rad J 1 mm 0 0394 in K 1 mm 0 0394 in L Chamfer 0 2 mm 0 0...

Page 73: ...80 Adaptor Set for Flow Meter Code No 07916 54031 Application Use for testing the hydraulic system W10313960 1 Gauge 07916 50322 2 Cable 07916 50331 3 Threaded Joint 07916 50401 4 Threaded Joint 07916...

Page 74: ...ide solution into and removing it from rear wheel W10265850 Brake Air Bleeder Code No 07916 54001 Application This allows easy air bleed of the hydraulic brake W10516480 Relief Valve Setting Pressure...

Page 75: ...ation This pressure gauge is used to measure the low oil pressure W10518650 A 20 mm dia 0 79 in dia B 11 5 mm dia 0 45 in dia C Chamfer 1 mm 0 04 in D 6 mm 0 24 in E 15 mm 0 59 in F 20 mm 0 79 in G We...

Page 76: ...esting or discharging the air conditioning system W1013507 W1014733 Electric Gas Leak Tester Code No DENSO CO 95146 00060 Application Use for gas leak testing the air conditioning system W1013817 1 Ma...

Page 77: ...W1013888 NOTE The following special tools are not provided so make them referring to the figure Draft Control Test Bar Application Use for checking the lift range and floating range of hydraulic draft...

Page 78: ...5 mm 0 5315 to 0 5709 in C 60 mm 2 3622 in D 32 mm 1 26 in 40 mm 1 5748 in E 59 97 to 59 999 mm 2 3610 to 2 3618 in 64 97 to 64 99 mm 2 5579 to 2 5587 in F 70 mm dia 2 76 in dia G 40 mm dia 1 57 in di...

Page 79: ...ake case W1059490 A 24 mm 0 94 in B 27 7 mm 1 09 in C PS1 4 D 11 mm 0 43 in E 15 mm 0 59 in F 40 mm 1 57 in G 60 mm 2 36 in H 15 mm 0 59 in I PT1 8 J 4 mm dia 0 15 in dia C1 Chamfer 1 mm 0 039 in C2 C...

Page 80: ...in dia C 35 mm 13 8 in P 1 05 rad 60 D 23 to 23 3 mm 0 9055 to 0 9713 in Q 3 mm dia 1 18 in dia E 16 mm 0 63 in R 36 mm 1 18 in F 40 mm dia 1 58 in dia S 60 mm 2 36 in G 32 4 to 32 7 mm dia 1 2756 to...

Page 81: ...nut Use radius M A 125 mm 4 92 in H 4 52 rad 120 B 40 mm dia 1 57 in dia I Radius 27 mm Radius 1 06 in C Radius 33 mm Radius 1 30 in J Radius 50 mm Radius 1 97 in D 16 mm 0 63 in K Weld all around E...

Page 82: ...r measuring the braking pressure of trailer brake valve W1060263 A 12 mm 0 47 in E 5 5 mm dia 0 22 in dia B 35 mm 1 38 in F 6 5 mm dia 0 26 in dia C 7 mm 0 28 in G 0 52 rad 30 D 0 4 mm 0 016 in H M8 P...

Page 83: ...3 2 mm t0 126 in D 6 mm 0 24 in Q 4 mm 0 16 in E 45 mm 1 77 in R 72 4 mm 2 85 in F 140 mm 5 51 in S 130 mm 5 12 in G 74 mm 2 91 in T 50 mm 1 97 in H 12 mm 0 47 in U 62 mm 2 44 in I 20 mm 0 79 in J 158...

Page 84: ...g tires can be mounted on model ME8200 and ME9000 IMPORTANT Do not use tires larger than specified W1019656 Model Type of Tire Front Rear ME8200 Farm Tire 11 2 R24 18 4 R30 ME9000 Farm Tire 11 2 R24 1...

Page 85: ...with the standard equipped tires 1 Front Wheel Disc 2 Front Wheel Rim A Tread W10522820 ME8200 11 2R24 1455 mm 57 28 in 1565 mm 61 61 in ME9000 11 2R24 1505 mm 59 25 in 1580 mm 62 20 in 320 70R24 1505...

Page 86: ...ed as illustrated transmission parts may be damaged Do not use tires larger than specified When re fitting or adjusting a wheel tighten the nuts to the following torques then recheck after driving the...

Page 87: ...in front tires if using a front loader of when equipped with lots of front weights W1030823 5 TIRE LIQUID INJECTION Auxiliary weights can be used to increase traction force for plowing in fields or cl...

Page 88: ...ift the rear tires off the ground 2 Turn the tire so that the air valve is at the top 3 Remove the air valve and attach the injector Code No 07916 52501 W1033331 Freezing temp Weight of CaCl2 to be di...

Page 89: ...g used NOTE Once injection is completed reset the air valve and pump air into the tire to the specified pressure Weight of Calcium Chloride Solution Filling 75 of Full Capacity of a Tire W1033435 Tire...

Page 90: ...3 Remove the air valve and drain liquid liquid can only be drained to the level of the valve and liquid under that level remains inside 4 To drain liquid completely use the injector 1 and direct comp...

Page 91: ...OTE Implement size may vary depending on soil operating conditions Tread max width with farm tires Lower link end max loading weight W0 Front Rear ME8200 1520 mm 59 8 in 1920 mm 75 6 in 2500 kg 5513 l...

Page 92: ...5000 L 1320 U S gals 1100 Imp gals 5 Rotary Tiller Max Tilling Width 2400 mm 96 in Max Weight 1000 kg 2200 lbs 6 Bottom Plow Max Size 16 in x 4 18 in x 3 24 in x 1 14 in x 5 16 in x 4 20 in x 3 24 in...

Page 93: ...0 mm 102 in Max Oil Pressure 19 6 MPa 200 kgf cm2 2844 psi 13 Front Loader Max Lifting Capacity 1250 kg 2750 lbs Max Oil Pressure 20 6 MPa 210 kgf cm2 3000 psi 14 Box Blade Max Cutting Width 2430 mm 9...

Page 94: ...1 ENGINE KiSC issued 03 2007 A...

Page 95: ...TS MECHANISM 1 ENGINE BODY 1 M1 1 CYLINDER BLOCK 1 M1 2 CRANKSHAFT 1 M1 2 FUEL SYSTEM 1 M2 1 FUEL FILTER 1 M3 3 LUBRICATING SYSTEM 1 M4 4 COOLING SYSTEM 1 M5 5 TURBOCHARGER SYSTEM 1 M6 KiSC issued 03...

Page 96: ...t The cylinder is a linerless type which enables good cooling operation less strain and good abrasion resistance W1012660 2 CRANKSHAFT This engine adopts the half counter system and lightweight moving...

Page 97: ...062 psi of the injection nozzle 5 is injected into the combustion chamber Part of the fuel fed to the injection nozzle 5 lubricates the moving parts of the plunger inside the nozzle then returns to th...

Page 98: ...ters the outside of the filter element 2 and passes through the filter element under its own pressure As it passes through the dirt and impurities in the fuel are filtered out allowing only clean fuel...

Page 99: ...en the oil is forced to crankshaft 7 connecting rods 17 idle gear 6 governor shaft 5 camshaft 14 rocker arm shaft 3 and fuel injection pump unit 15 some models to lubricate each part through the oil g...

Page 100: ...coolant in the engine is at a low temperature the thermostat valve is closed so that the coolant is circulated in the engine through the bypass pipe When the temperature of the coolant becomes the va...

Page 101: ...uce exhaust emission When the boost pressure is 9 8 kPa 0 1 kgf cm2 1 42 psi or lower the lever 3 2 controls the fork lever 1 4 not to oversupply fuel When the load increases and the boost pressure be...

Page 102: ...2 Disassembling and Assembling 1 S24 3 Servicing 1 S46 3 LUBRICATING SYSTEM 1 S65 1 Checking 1 S65 2 Disassembling and Assembling 1 S65 3 Servicing 1 S66 4 COOLING SYSTEM 1 S67 1 Checking and Adjustin...

Page 103: ...retaining nut Tighten retaining nut 1 S24 Incorrect injection timing Adjust 1 S70 Injection nozzle clogged Clean 1 S72 Injection pump malfunctioning Repair or replace 1 S70 Seizure of crankshaft camsh...

Page 104: ...t injection timing Adjust 1 S70 Oil Leak into Exhaust Pipe or Suction Pipe Waste oil pipe clogged or deformed Repair or replace Piston ring seal faulty Replace the turbocharger assembly 1 S75 Either B...

Page 105: ...r replace nozzle 1 S72 Injection pump broken Replace 1 S28 Water Mixed into Lubricant Oil Head gasket defective Replace 1 S26 Cylinder block or cylinder head flawed Replace 1 S46 Low Oil Pressure Engi...

Page 106: ...ant flow route corroded Clean or replace G 30 Radiator cap defective Replace 1 S68 Overload running Reduce the load Head gasket defective Replace 1 S26 Incorrect injection timing Adjust 1 S70 Unsuitab...

Page 107: ...t Cylinder Head Surface Flatness 0 05 mm 0 0020 in Top Clearance 0 92 to 1 10 mm 0 0362 to 0 0433 in Compression Pressure 3 92 MPa 250 min 1 rpm 40 kgf cm2 250 min 1 rpm 569 psi 250 min 1 rpm 2 99 MPa...

Page 108: ...ing IN 0 2 to 0 mm 0 079 to 0 in 0 4 mm 0 0157 in EX 0 05 to 0 15 mm 0 0019 to 0 0059 in 0 4 mm 0 0157 in Valve Stem to Valve Guide Clearance IN 0 035 to 0 065 mm 0 0014 to 0 0025 in 0 1 mm 0 0039 in...

Page 109: ...1 5 mm 10 296 lbf 1 2401 in Exhaust 117 6 N 35 mm 12 kgf 35 mm 26 4 lbf 1 3780 in 100 N 35 mm 10 2 kgf 35 mm 22 5 lbf 1 3780 in Tilt 1 0 mm 0 039 in Rocker Arm Shaft to Rocker Arm Clearance 0 016 to 0...

Page 110: ...iming Gear Crank Gear to Idle Gear 1 Backlash 0 049 to 0 193 mm 0 0019 to 0 0076 in 0 22 mm 0 0087 in Idle Gear 1 to Cam Gear Backlash 0 49 to 0 189 mm 0 0019 to 0 0074 in 0 22 mm 0 0087 in Idle Gear...

Page 111: ...1811 to 1 1816 in 30 05 mm 1 1831 in Compression Ring 2 to Ring Groove Clearance 0 093 to 0 120 mm 0 0037 to 0 0047 in 0 20 mm 0 0079 in Oil Ring to Ring Groove Clearance 0 02 to 0 06 mm 0 0008 to 0...

Page 112: ...0 0059 to 0 0122 in 0 50 mm 0 0197 in Cylinder Bore I D 98 000 to 98 022 mm 3 8582 to 3 8591 in 98 15 mm 3 8642 in Oversized Cylinder Bore I D 98 500 to 98 522 mm 3 8780 to 3 8788 in 98 65 mm 3 8839 i...

Page 113: ...er tightness at specified pressure 13 7 kPa 1 4 kgf cm2 20 psi Radiator Cap Air Leakage 10 seconds or more 88 59 kPa 0 9 0 6 kgf cm2 13 9 psi Fan Belt Tension 10 to 12 mm 10 kgf 0 394 to 0 472 in 22 1...

Page 114: ...0 to 11 0 72 3 to 79 6 PTO propeller shaft spline hub screw 23 5 to 27 5 2 4 to 2 8 17 4 to 20 3 Flywheel housing screw 77 5 to 90 2 7 9 to 9 2 57 1 to 66 5 Crankcase 2 mounting screw 49 0 to 55 9 5...

Page 115: ...1 S13 ME8200 ME9000 WSM ENGINE NOTE For marked screws bolts and nuts on the table apply engine oil to their threads and seats before tightening KiSC issued 03 2007 A...

Page 116: ...ined reinstall the radiator hose W1015370 Draining Engine Oil 1 Start and warm up the engine for approx 5 minutes 2 Place an oil pan underneath the engine 3 Remove the drain plugs 1 to drain oil 4 Aft...

Page 117: ...luid Use of other fluids may damage the transmission or hydraulic system Refer to LUBRICANTS FUEL AND COOLANT See page G 8 Do not mix difference brands oil together W1015853 Muffler and Bonnet 1 Remov...

Page 118: ...gine side ME9000 only 6 Remove the delivery pipe clamp 7 Remove the muffler 1 8 Disconnect the wiring from the front buzzer 10 and air cleaner sensor 11 W1016534 Discharging Refrigerant CABIN Type 1 R...

Page 119: ...engine side ME9000 only 7 Disconnect the wiring from the front buzzer 5 air cleaner sensor 16 and stay 15 8 Loosen the clamps 13 and disconnect the low pressure pipe from the receiver 14 9 Disconnect...

Page 120: ...eassembling Be sure to adjust the length A and B W1018003 Front Axle Support as a Unit 1 Check the front axle and clutch housing case are securely mounted on the disassembling stands 2 Separate the fr...

Page 121: ...Remove the delivery pipe 2 and 6 3 Remove the accelerator rod 3 4 Disconnect the fuel pipes 4 5 W1018778 Hydraulic Pipes Fuel Pipes and Accelerator Rod CABIN Type 1 Remove the suction pipe 5 and deli...

Page 122: ...or 3 4 Remove the bonnet support 4 W1019516 Wire Harness L H 1 Disconnect the alternator 2P connector 1 and B terminal 2 2 Disconnect the starter motor C terminal 5 and B terminal 4 3 Disconnect the e...

Page 123: ...1 rpm with the starter 4 Read the maximum pressure Measure the pressure more than twice 5 If the measurement is below the allowable limit apply a small amount of oil to the cylinder wall through the...

Page 124: ...he cylinder head and tighten the cylinder head screw to specification Head gasket must be changed to new one 4 Turn the crank shaft until the piston exceeds its top dead center 5 Remove the cylinder h...

Page 125: ...ntil you feel the screw touch the top of valve stem then tighten the lock nut 6 Loosen the lock nut 4 of adjusting screw 3 push rod side and insert the thickness gauge between the rocker arm and the b...

Page 126: ...an the heat seal hole Approx 6 mm 1 4 in 1 Drive screw driver 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 sea...

Page 127: ...en putting the push rods onto the tappets check to see if their ends are properly engaged with the grooves IMPORTANT After reassembling the rocker arm be sure to adjust the valve clearance W1021546 Ti...

Page 128: ...hes and dust Take care for handling the gasket not to damage it Install the cylinder head Tighten the cylinder head screw gradually in the order of 1 to 18 after applying engine oil Be sure to adjust...

Page 129: ...er 3 When reassembling Install the intake valve spring with its small pitch end downward at the head side Wash the valve stem and valve guide hole and apply engine oil sufficiently After installing th...

Page 130: ...ft does not move any longer 5 Tighten the lower fuel cam shaft lock screw until it comes into contact with the fuel cam shaft NOTE Never overtighten the lock screws when they have come into contact wi...

Page 131: ...ose the injection pump unit mounting flange nuts 4 for aligning the injection timing 8 Moving the injection pump unit clockwise viewed from gear case side align the injection timing marks 6 on the inj...

Page 132: ...e nut with the specified torque with using the jig for keeping the governor connecting rod horizontal See the Replacing Injection Pump Assembly After tightening the nut hook the start spring on the ra...

Page 133: ...er and the stop lever NOTE When assembling the inside parts put the oil on each inside part slightly Be careful not to deform the start spring W1024995 Boost Arms If equipped Boost Compensator 1 If ne...

Page 134: ...m the governor housing 3 Remove the start spring 4 and the stop spring 5 W1025690 Stop Lever 1 Remove the stop lever 1 and the return spring 2 2 Remove the stop lever shaft 3 W1026038 1 Speed Control...

Page 135: ...ht mounting nut Otherwise the lock bolts or injection pump housing might get damage When reassembling Press the bearings into the fuel camshaft Set the cir clip at the gear side s bearing Install the...

Page 136: ...governor sleeve NOTE Be careful not to damage the O ring Be careful the direction of the governor sleeve When reassembling the inside parts put the oil on each inside part slightly W1027074 Tightenin...

Page 137: ...the governor connecting rod 7 from the rock pin of injection pump assembly 7 Remove the injection pump mounting bolts and nuts and take out the injection pump assembly 9 NOTE Be careful not to drop th...

Page 138: ...vernor connecting rod 4 To do this turn the jig a little clockwise and counterclockwise and look into the fuel injection pump unit sight hole to see if the governor connecting rod 4 moves right and le...

Page 139: ...W1028550 Fan Drive Pulley 1 Set the stopper to the flywheel 2 Remove the crankshaft screw 1 3 Draw out the fan drive pulley 2 When reassembling W1028911 Tightening torque Anti rotation nut 2 8 to 4 0...

Page 140: ...sket coating surface is free of water dust and oil in order to maintain sealing effect Carefully apply the adhesive evenly Refer to the figure on the left NOTE When mounting the adhesive applied parts...

Page 141: ...the balancer shaft 2 set screws and draw out the balancer shaft 2 6 When reassembling When install the balancer shaft 1 and 2 be sure to place the 4th cylinder piston at the top dead center in compres...

Page 142: ...Bond 1217D adhesive or equivalent over the shaded zones on both sides of the gasket that will be sandwiched between the crankcase and plate Be sure to fix the O rings 4 W1029983 Tightening torque Pla...

Page 143: ...Confirm that the liquid gasket coating surface is free of water dust and oil in order to maintain sealing effect Carefully apply the adhesive evenly NOTE When mounting the adhesive applied parts take...

Page 144: ...ping it from the bottom of the crankcase with the grip of a hammer When reassembling Before inserting the piston into the cylinder apply enough engine oil to the cylinder When inserting the piston int...

Page 145: ...on pin to the piston Assemble the piston to the connecting rod with the aligning the direction of the fan shaped concave 8 of piston head and the mark 9 of connecting rod The end faces of the oil ring...

Page 146: ...haft are fitting together in just one position Make sure they are tightly fit and drive the bolts W1031898 Flywheel Housing 1 Remove the flywheel housing When reassembling Tighten the flywheel housing...

Page 147: ...d parts take care to fit them to the mating parts Assemble the adhesive applied parts within ten minutes W1032347 Crankcase 1 and Crankcase 2 When reassembling Match the crankcase 1 and 2 referring to...

Page 148: ...W1032812 3 Servicing A Cylinder Head Cylinder Head Surface Flatness 1 Clean the cylinder head surface 2 Place a straightedge on the cylinder head s four sides A B C and D and two diagonal E and F as...

Page 149: ...3200 Valve Recessing 1 Clean the cylinder head the valve face and seat 2 Insert the valve into the valve guide 3 Measure the valve recessing with a depth gauge 4 If the measurement exceeds the allowab...

Page 150: ...2 Measure the valve stem O D with an outside micrometer 3 Measure the valve guide I D of the cylinder head at the most wear part as shown in the figure below with a small hole gauge And calculate the...

Page 151: ...he valve with a valve refacer 2 Correcting Valve Seat 1 Slightly correct the seat surface with a 1 047 rad 60 intake valve or 0 785 rad 45 exhaust valve seat cutter Code No 07909 33102 2 Resurface the...

Page 152: ...compress it to the same length it is actually compressed in the engine 2 Read the compression load on the gauge 3 If the measurement is less than the allowable limit replace it W1035246 Free length A...

Page 153: ...e 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 W1035603 Oil clearance of rocke...

Page 154: ...ance by moving the cam gear to the front and rear 3 If the measurement exceeds the allowable limit replace the camshaft stopper W1036161 Backlash between idle gear and crank gear Factory spec 0 049 to...

Page 155: ...rnal 1 Measure the camshaft journal O D with an outside micrometer 2 Measure the cylinder block bore I D for camshaft with an inside micrometer 3 If the oil clearance exceeds the allowable limit repla...

Page 156: ...a new bushing service parts to the specified dimension See figure W1037019 Balancer shaft Side Clearance 1 Set a dial indicator with tip on the balancer shaft 2 Measure the side clearance by moving th...

Page 157: ...f the clearance exceeds the allowable limit replace the balancer shaft W1037480 C Piston and Connecting Rod Piston Pin Bore I D 1 Measure the piston pin bore I D in both the horizontal and vertical di...

Page 158: ...ss out the used bushing using a small end bushing replacing tool When installing 1 Clean a new small end bushing and bore and apply engine oil to them 2 Insert a new bushing onto the tool and press fi...

Page 159: ...f the liner the least worn out part with the piston 2 Measure the ring gap with a feeler gauge 3 If the gap exceeds the allowable limit replace the piston ring W1038560 Factory spec Compression ring 2...

Page 160: ...nnecting rod 3 Install the connecting rod on the connecting rod alignment tool Code No 07909 31661 4 Put a gauge over the piston pin and move it against the face plate 5 If the gauge does not fit squa...

Page 161: ...get the misalignment half of the measurement 3 If the misalignment exceeds the allowable limit replace the crankshaft W1039252 Crankshaft side clearance Factory spec 0 15 to 0 31 mm 0 0059 to 0 0122...

Page 162: ...arance 5 If the oil clearance exceeds the allowable limit replace the crankpin bearing 6 If the same size bearing is useless because of the crankpin wear replace it with an undersize one referring to...

Page 163: ...out color 56 00 to 56 01 mm 2 2047 to 2 2051 in S 1C020 22331 1 495 to 1 500 mm 0 0559 to 0 0590 in Undersize Bearing Code Number Marking 0 2 mm 0 008 in Crankpin bearing 02 1C020 22960 020 US 0 4 mm...

Page 164: ...journal W1069159 Crankshaft journal O D Factory spec 74 977 to 74 990 mm 2 9518 to 2 9524 in Oil clearance between crankshaft journal and crankshaft bearing Factory spec 0 018 to 0 062 mm 0 0007 to 0...

Page 165: ...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 allowa...

Page 166: ...sembly NOTE When the oversize cylinder is worn beyond the allowable limit replace the cylinder block with a new one W1070179 Cylinder I D 2 Factory spec 98 500 to 98 522 mm 3 8780 to 3 8788 in Maximum...

Page 167: ...gn matter in the relief valve When reassembling After checking the engine oil pressure tighten the engine oil pressure switch to the specified torque W1041543 2 Disassembling and Assembling Relief Val...

Page 168: ...ith grease 2 Install the cover and tighten the screws with the specified torque 3 Remove the cover carefully and measure the amount of the flattening with the scale and get the clearance 4 If the clea...

Page 169: ...ion is not within the factory specifications loosen the alternator mounting screws and relocate the alternator to adjust W1042534 Fan Belt Damage and Wear 1 Check the fan belt for damage 2 If the fan...

Page 170: ...or Water Leakage 1 Pour a specified amount of water into the radiator 2 Set a radiator tester Increase water pressure to the specified pressure of 137 kPa 1 4 kgf cm2 20 psi 3 Check the radiator for w...

Page 171: ...rmostat cover 1 2 Remove the thermostat assembly 3 When reassembling Apply a liquid gasket Three Bond 1215 or equivalent only at the thermostat cover side of the gasket 2 Attach the thermostat with it...

Page 172: ...cating every 0 087 rad 5 of crank angle from 0 175 rad 10 to 0 349 rad 20 before mark 1TC Calculate the angle which the projection of the window points out If the calculation differs from specified in...

Page 173: ...to measure the pressure at which fuel begins jetting out from the nozzle 3 If the measurement is not within the factory specifications change the injection nozzle NOTE Heat seal and injection nozzle g...

Page 174: ...500 6 TURBOCHARGER SYSTEM 1 Checking Turbine Side 1 Check the exhaust port 3 and inlet port 2 side of turbine housing 1 to see if there is no exhaust gas leak 2 If any gas leak is found retighten the...

Page 175: ...with a finger and check for contact 3 If the wheel does not turn smoothly and or found the damage and abnormal sound check the axial and radial clearance 4 If the compressor turbine wheel and housing...

Page 176: ...turbocharger Before starting the engine make sure that air cleaner is position Air Cleaner and Muffler 1 Remove the intake pipe 2 Remove the inlet pipe 1 3 Remove the muffler When reassembling Replace...

Page 177: ...00 WSM ENGINE Turbocharger 1 Remove the screw 1 and bolt 2 2 Take off the turbocharger assembly 3 When reassembling Replace the gasket with new one W1046265 1 Screw 2 Bolt 3 Turbocharger Assembly KiSC...

Page 178: ...2 CLUTCH KiSC issued 03 2007 A...

Page 179: ...CONTENTS MECHANISM 1 TRAVELLING CLUTCH 2 M1 2 PTO CLUTCH 2 M2 1 STRUCTURE 2 M2 2 OIL FLOW 2 M2 KiSC issued 03 2007 A...

Page 180: ...shuttle valve 4 moves via the clutch rod 2 5 for the cabin type via the clutch cable 6 As for the oil it does not flow to both the forward and the reverse side of the clutch pack the clutch pack ente...

Page 181: ...TO clutch is set at Disengaged position W1012853 2 OIL FLOW The oil from the steering controller flows into the PTO clutch valve When the PTO is at the disengaged position the oil flows is stopped by...

Page 182: ...2 S3 4 CHECKING DISASSEMBLING AND SERVICING 2 S4 1 TRAVELLING CLUTCH 2 S4 1 Checking and Adjusting 2 S4 2 Disassembling and Assembling 2 S7 3 Servicing 2 S14 2 HYDRAULIC PTO CLUTCH 2 S14 1 Checking an...

Page 183: ...r steel plate Replace 3 S30 Tractor Does Not Keep in Neutral Shuttle linkage defective or deformed Adjust or replace 8 S10 to 15 PTO Clutch Slip Operating pressure is low Adjust 8 S8 PTO clutch valve...

Page 184: ...2 0 mm 0 079 in PTO Clutch Disc Thickness 1 70 to 1 90 mm 0 067 to 0 075 in 1 55 mm 0 061 in PTO Steel Plate Thickness 1 15 to 1 25 mm 0 045 to 0 075 in 1 10 mm 0 043 in PTO Piston Flatness 0 15 mm 0...

Page 185: ...lder mounting screw 23 5 to 27 5 2 4 to 2 8 17 4 to 20 3 Brake plate mounting screw 9 8 to 11 3 1 00 to 1 15 7 2 to 8 3 Rear wheel mounting nut 260 to 304 26 5 to 31 0 192 to 224 Bonnet support mounti...

Page 186: ...edal or turnbuckle is out of above condition adjust with turnbuckle 3 Measure the clutch pedal free travel A 4 If adjustment is needed change the length of turnbuckle of clutch rod 1 so that the free...

Page 187: ...in figure 3 Measure the clutch pedal stroke A 4 If the measurement is not within the factory specifications adjust with stopper bolt 3 NOTE Be sure to fix the coil spring 4 in original direction when...

Page 188: ...mat 1 1 floor mat 2 2 and cover 3 2 Measure the clutch pedal free travel 3 If adjustment is needed loosen the lock nuts 4 and adjust the cable length within acceptable limits 4 Retighten the lock nut...

Page 189: ...uids may damage the transmission or hydraulic system Refer to LUBRICANTS FUEL AND COOLANT See page G 8 Do not mix difference brands oil together W1012953 Draining Coolant CABIN Type CAUTION Never remo...

Page 190: ...harge the refrigerant to the air conditioner system refer to Charging the System See page 10 S21 W1013713 Radiator Hoses and Air Conditioner Hoses CABIN Type 1 Remove the muffler 2 2 Loosen the clamp...

Page 191: ...he engine side 7 Remove the rear bonnet 4 W1014073 Wire Harness L H ROPS Type 1 Disconnect the alternator 2P connector 1 and B terminal 2 2 Disconnect the starter motor C terminal 5 and B terminal 4 3...

Page 192: ...eassembling Be sure to assemble the power steering hoses and pipes to the original position with specified torque W1015339 Tightening torque Main delivery pipe and return pipe retaining nut 47 1 to 51...

Page 193: ...er Cable and Steering Joint CABIN Type 1 Disconnect the meter cable 1 from the engine 2 Disconnect the steering joint 2 from the cabin side W1016057 Wiring Harness CABIN Type 1 Disconnect the connecto...

Page 194: ...ft 7 and pinion shaft Tap in the spring pins 2 4 as shown in figure W1016317 Differential Lock Spring 1 Loosen the lock nut 1 2 Remove the spring 2 from differential lock lever 3 When reassembling Be...

Page 195: ...and clutch housing W1016943 B Damper Disc Damper Disc 1 Remove the damper disc 1 When reassembling Confirm that the bearing 2 is surely assembled to the flywheel Direct the shorter end of the damper d...

Page 196: ...Lever Movement 1 Stop the engine and remove the key 2 Check the PTO clutch lever 1 on the ON and OFF position of PTO clutch lever guide 3 If the adjustment is needed loosen the lock nuts 3 and adjust...

Page 197: ...out the spool 7 3 Remove the cap nut 16 and lock nut 15 4 Remove the adjuster 14 and relief body 13 5 Draw out the relief poppet 8 and relief bush 9 6 Draw out the spring 11 and spring seat 10 12 W10...

Page 198: ...ring wheel 1 with a steering wheel puller Code No 07916 51090 2 Remove the shuttle lever grip 2 and shuttle lever guide 3 3 Remove the meter panel mounting screws and disconnect the meter cable 5 4 Di...

Page 199: ...own in figure W1019282 Fuel Tank Connection Hose 1 Remove the cover 2 2 Remove the connection hose 1 When reassembling W1019664 Lift Rods and Lower Links 1 Remove the lift rods 1 2 Remove the lower li...

Page 200: ...rod end 1 2 Fix the wire 2 so that the threaded portion A and B become the same 3 Disconnect the wire 2 from the select lever 3 once 4 Shift the main speed change lever 7 to the 1st 2nd side until th...

Page 201: ...e rod end 3 so that the wire end is corresponding to the inner surface of the rod end 3 Shift the control lever 5 forward and check the clearance C between the stopper and lever 4 If the clearance is...

Page 202: ...Remove the fender bracket 3 When reassembling Tighten the fender bracket mounting bolt with the ROPS center frame inserted in the fender bracket and check the center frame moves vertically smoothly I...

Page 203: ...fferential lock wire 5 5 Remove the differential lock pedal 4 7 When reassembling Be sure to adjust the differential lock pedal free travel by adjusting the length A W1022227 Length of main speed chan...

Page 204: ...emove the fuel tanks 7 W1022832 Auxiliary Speed Change Rod 1 Disconnect the speed change rod 2 2 Remove the brake pipe 1 W1023059 Hydraulic Pipes 1 Remove the PTO shuttle pipe 1 2 Remove the PTO pipe...

Page 205: ...TO clutch holder holes assemble the PTO clutch valve 2 to the transmission case W1023635 PTO Clutch and Holder 1 Remove the PTO clutch holder mounting screws 2 Remove the PTO clutch 4 with holder When...

Page 206: ...ide the propeller shaft covers 3 5 after removing the screw 6 2 Tap out the spring pins 2 4 and then slide the couplings 1 8 to the front and rear When reassembling Apply grease to the splines of the...

Page 207: ...erential lock pedal free travel by adjusting the length A W1025141 Tightening torque Cover mounting screw 77 5 to 90 2 N m 7 9 to 9 2 kgf m 57 1 to 66 5 lbf ft 1 Connection Hose 2 Cover 1 Fuel Hose 2...

Page 208: ...ble the PTO clutch valve 2 to the transmission case W1025755 PTO Clutch and Holder 1 Remove the PTO clutch holder mounting screws 2 Remove the PTO clutch 4 with holder When reassembling Apply transmis...

Page 209: ...pile up the plug rubbers portions of the another steel plate 8 with the steel plate 9 Refer to figure below Apply enough transmission fluid to the discs 3 Confirm the moving of the piston 15 smoothly...

Page 210: ...seal rings 8 W1026902 Brake Plate 1 Remove the brake plate mounting screws 3 and then take out the brake plate 4 and the springs 2 When reassembling Apply liquid lock Three Bond 1372 or equivalent to...

Page 211: ...s less than the allowable limit replace it W1027707 PTO Steel Plate Wear 1 Measure the thickness of PTO steel plate with vernier calipers 2 If the thickness is less than the allowable limit replace it...

Page 212: ...ce it W1028091 Thickness of Seal Ring 1 Measure the thickness of seal rings 1 with an outside micrometer 2 If the measurement is less than the allowable limit replace it W1028239 Flatness of PTO pisto...

Page 213: ...3 TRANSMISSION KiSC issued 03 2007 A...

Page 214: ...VELLING GEAR 3 M2 1 SHUTTLE SHIFT SECTION 3 M2 2 MAIN GEAR SHIFT SECTION 3 M3 3 AUXILIARY GEAR SHIFT SECTION 3 M3 4 FOUR WHEEL DRIVE SECTION 3 M4 3 POWER TRAIN FOR PTO SYSTEM 3 M5 1 PTO CLUTCH SECTION...

Page 215: ...ANSMISSION 1 STRUCTURE 1 Shuttle Shift Section 2 Main Gear Shift Section 3 Auxiliary Gear Shift Section 4 PTO Clutch Section 5 Four Wheel Drive Section 6 PTO Gear Shift Section 1 2 3 4 6 5 3TMACAD3P00...

Page 216: ...RANSMISSION 2 POWER TRAIN FOR TRAVELLING GEAR 1 SHUTTLE SHIFT SECTION W1012678 1 Input Shaft 2 Clutch Disc and Plate 3 Clutch Body 4 Clutch Disc and Plate 5 1st Shaft 6 Shuttle Shaft F Forward R Rever...

Page 217: ...ILIARY GEAR SHIFT SECTION W1013217 1 1st Shaft 2 Shifter 3 Hub 4 Shifter 5 Hub 6 Counter Shaft 7 Hub 8 Shifter 1 1st Speed 2 2nd Speed 3 3rd Speed 4 4th Speed 5 5th Speed 6 6th Speed 1 Counter Shaft 2...

Page 218: ...3 M4 ME8200 ME9000 WSM TRANSMISSION 4 FOUR WHEEL DRIVE SECTION W1013396 1 Shifter 2 Coupling 3 Shaft 4 Propeller Shaft KiSC issued 03 2007 A...

Page 219: ...IN FOR PTO SYSTEM 1 PTO CLUTCH SECTION W1013605 2 PTO GEAR SHIFT SECTION W1013757 1 PTO Propeller Shaft 1 2 Hub 3 Clutch Disc and Plate 4 Clutch Body 5 PTO Propeller Shaft 2 1 PTO Gear Shaft 2 PTO Sha...

Page 220: ...IONS 3 S2 3 TIGHTENING TORQUES 3 S4 4 CHECKING DISASSEMBLING AND SERVICING 3 S5 1 CLUTCH HOUSING CASE 3 S5 1 Disassembling and Assembling 3 S5 2 Servicing 3 S29 2 TRANSMISSION CASE 3 S31 1 Disassembli...

Page 221: ...26 27 Interlock ball fallen Reassemble 3 S21 27 Synchronizer unit damaged Repair or replace 3 S31 Hard Shifting Shifter or shift fork worn or damaged Replace 3 S30 Shift fork rod bent Replace 3 S21 27...

Page 222: ...mm 0 00276 to 0 00665 in 0 35 mm 0 014 in Differential Case Bore I D 49 070 to 49 150 mm 1 93189 to 1 93504 in Differential Case Cover Bore I D 49 070 to 49 150 mm 1 93189 to 1 93504 in Differential...

Page 223: ...y Control Lever to Stopper ROPS Clearance 0 to 1 mm 0 to 0 039 in Main Speed Change Rod 2 ROPS Length 340 mm 13 39 in Gears on the 1st shaft Side Clearance Less than 0 3 mm 0 0118 in Internal Snap Rin...

Page 224: ...9 to 9 2 57 1 to 66 5 Rear axle case mounting screw and nut 123 6 to 147 1 12 6 to 15 0 91 1 to 108 5 PTO gear case assembly mounting screw 77 5 to 90 2 7 9 to 9 2 57 1 to 66 5 PTO shaft staking nut...

Page 225: ...e 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 fluids may damage the tran...

Page 226: ...s 6 5 Disconnect the main switch connector and head light switch connector hazard and turn signal switch connector 6 Disconnect the engine stop cable 8 at the engine side 7 Remove the rear bonnet 4 W1...

Page 227: ...wiring lead 2 for solenoid valve 2 Disconnect the wiring lead 1 for glow plug 3 Disconnect the 1P connector 3 for coolant thermo sensor 4 Disconnect the 2P connector 5 for power steering oil sensor W...

Page 228: ...shown in figure W1013865 Fuel Tank Connection Hose 1 Remove the cover 2 2 Remove the connection hose 1 When reassembling W1014218 Lift Rods and Lower Links 1 Remove the lift rods 1 2 Remove the lower...

Page 229: ...the rod end 1 2 Fix the wire 2 so that the threaded portion A and B become the same 3 Disconnect the wire 2 from the select lever 3 once 4 Shift the main speed change lever 7 to the 1st 2nd side until...

Page 230: ...the rod end 3 so that the wire end is corresponding to the inner surface of the rod end 3 Shift the control lever 5 forward and check the clearance C between the stopper and lever 4 If the clearance...

Page 231: ...5 7 Remove the fender bracket 3 When reassembling Tighten the fender bracket mounting bolt with the ROPS center frame inserted in the fender bracket and check the center frame moves vertically smoothl...

Page 232: ...differential lock wire 5 5 Remove the differential lock pedal 4 7 When reassembling Be sure to adjust the differential lock pedal free travel by adjusting the length A W1016824 Length of main speed c...

Page 233: ...emove the step 1 3 Disconnect the speed change rod 5 4 Remove the brake pipe 4 W1018041 Tightening torque Turning delivery hose retaining nut 24 5 to 29 4 N m 2 5 to 3 0 kgf m 18 1 to 21 7 lbf ft Main...

Page 234: ...ove the clutch rod 2 2 2 Remove the shuttle rod 1 When reassembling Check the clutch pedal free travel See page 2 S4 Check the hydraulic shuttle lever neutral position See page 8 S10 W1145580 Pedal Fr...

Page 235: ...e page 3 S9 W1019232 Separating Transmission Case 1 Remove the transmission case mounting screws and nut and separate the transmission case from the clutch housing When reassembling Apply liquid gaske...

Page 236: ...ft 1 Slide the propeller shaft covers 3 5 after removing the screw 6 2 Tap out the spring pins 2 4 and then slide the couplings 1 8 to the front and rear When reassembling Apply grease to the splines...

Page 237: ...emove the PTO shuttle pipe 2 8 Remove the PTO pipe 1 When reassembling Be sure to adjust the differential lock pedal free travel by adjusting the length A W1146492 Tightening torque Cover mounting scr...

Page 238: ...and nut and separate the transmission case from the clutch housing When reassembling Apply liquid gasket Three Bond 1216 or equivalent to joint face of the transmission case and clutch housing transm...

Page 239: ...rily 5 Shift the main speed change lever 1 to the 1st 2nd side until the lever touches stopper then shift the select lever 9 to the 1st 2nd side 6 Check that the hole of the wire end 8 is correspondin...

Page 240: ...housing Apply grease to the guide chip 2 so as not to drop it W1147508 Oil Pipe 1 Screw in the M6 x Pitch 1 0 mm screw 1 to the oil pipe 2 2 Pull out the oil pipe 2 as shown in figure When reassembli...

Page 241: ...e fork rod 6 and shift fork 7 5 Remove the fork rod 3 and shift fork 1 NOTE Pay attention so as not to lose the ball 9 10 12 W1031536 Tightening torque Shuttle case mounting screw M8 grade 9 29 4 to 3...

Page 242: ...ve the oil seal 12 and internal snap ring 11 4 Remove the shaft 3 and cam 7 NOTE Pay attention so as not to lose the detent ball 8 When reassembling Align the alignment mark 13 of the shaft 3 and cam...

Page 243: ...e bearing Replace the sleeve 7 with a new one and be sure to install sleeve as shown figure Apply liquid gaskets Three Bond 1216 or equivalent to joint face of the shuttle case 1 3 and shuttle case 2...

Page 244: ...8 and thrust needle bearing 9 Apply transmission fluid to the thrust collar 12 and face the groove to the front side A Attach the allen plug surely when you replace the new input shaft IMPORTANT Do n...

Page 245: ...ring 10 with new one Apply transmission fluid to the D ring 10 and take care not to damage it Assemble the steel plates 5 with rubber 4 and steel plates without rubber 13 alternately and steel plates...

Page 246: ...ll 5 2 Remove the retaining screws and pull the shift lever 1 1 and 2 2 3 Remove the bearing holder 6 mounting screw 4 Remove the auxiliary shift section assembly When reassembling W1098693 1 PTO Prop...

Page 247: ...crew the bearing holder mounting screw 2 Screw in the M10 x Pitch 1 25 mm screws for threaded hole A W1148849 1 Fork Rod 1 2 DT Shaft 3 Fork Rod 2 4 Shift Fork 1 5 Shift Fork 2 6 Ball Interlock 7 Spri...

Page 248: ...g Reference Thickness of the collar Part No 3A294 28490 5 6 mm 0 220 in Part No 3A294 28420 5 8 mm 0 228 in Part No 3A294 28410 6 0 mm 0 236 in Part No 3A294 28440 6 2 mm 0 244 in W1148988 Side cleara...

Page 249: ...outer race in all directions to check for wear and roughness 2 Apply transmission fluid to the bearing and hold the inner race Then turn the outer race to check rotation 3 If there is any defect repla...

Page 250: ...fferent thickness Therefore use the one of the same thickness when you change clutch disc Reference There are two kinds of thickness of clutch disc W1054495 Clearance between Shift Fork and Shifter Gr...

Page 251: ...er key for wear 2 Check the spring for fatigue or wear on the area where the spring contacts with the keys 3 If there is any defect replace them W1055554 2 TRANSMISSION CASE 1 Disassembling and Assemb...

Page 252: ...ne stop cable 8 at the engine side 7 Remove the rear bonnet 4 W1056197 Propeller Shaft 1 Slide the propeller shaft covers 3 5 after removing the screw 6 2 Tap out the spring pins 2 4 and then slide th...

Page 253: ...ol wire 4 5 for auxiliary control valve 6 Remove the speed change base 8 When reassembling Install the control wire 5 of first valve lower side into the rear side slot Execute the following Adjusting...

Page 254: ...e 2 to the select lever 3 W1058464 Adjusting of Control Wire for Auxiliary Control Valve 1 Valve Side Tighten the lock nut 2 so that the length B of the threaded portion become 0 mm 2 Lever Side Screw...

Page 255: ...5 7 Remove the fender bracket 3 When reassembling Tighten the fender bracket mounting bolt with the ROPS center frame inserted in the fender bracket and check the center frame moves vertically smoothl...

Page 256: ...differential lock wire 5 5 Remove the differential lock pedal 4 7 When reassembling Be sure to adjust the differential lock pedal free travel by adjusting the length A W1060913 Length of main speed c...

Page 257: ...4 Remove the fuel tanks 7 W1061592 Auxiliary Speed Change Rod 1 Disconnect the speed change rod 2 2 Remove the brake pipe 1 W1063827 Hydraulic Pipes 1 Remove the PTO shuttle pipe 1 2 Remove the PTO pi...

Page 258: ...ift Rods and Lower Links 1 Remove the lift rods 1 2 Remove the lower links 2 with stabilizer 3 Remove the drawbar 4 Remove the PTO shaft cover 3 5 Remove the rear wheels When reassembling W1064427 Dis...

Page 259: ...1064747 Fuel Tank Connection Hose 1 Remove the cover 2 2 Remove the connection hose 1 When reassembling W1065060 Fuel Tank 1 Disconnect the wire harness 2 2 Disconnect the fuel hoses 1 3 Remove the fu...

Page 260: ...ce of the transmission case and clutch housing transmission upper cover and transmission case W1065808 Tightening torque Delivery pipe nut 108 to 117 N m 11 0 to 12 0 kgf m 79 6 to 86 8 lbf ft Shuttle...

Page 261: ...trol feedback rod and draft control rod W1066039 Rear Axle L H 1 Remove the rear axle case mounting screws and nuts 2 Support the rear axle assembly with nylon lift strap and hoist and then remove it...

Page 262: ...at correct position to mount the PTO cover case Direct the grooves of thrust collars 9 17 to the inner rings 10 15 sides Replace the PTO shaft staking nut 8 with new one and stake it firmly after tigh...

Page 263: ...p ring 5 noting the number of shims 4 When reassembling Be sure to adjust the turning torque of spiral bevel pinion shaft and differential assembly combined See page 3 S48 Be sure to adjust the backla...

Page 264: ...spiral bevel gear When reassembling Check the spiral bevel gear for wear or damage If it is no longer serviceable replace it Then also replace the spiral bevel pinion shaft Apply liquid lock Three Bon...

Page 265: ...nd 1901 or equivalent to the inner circumferential surface of the differential pinions Install the parts to their original position Install the differential pinion washer 4 noting its groove position...

Page 266: ...ng W1070734 Spiral Bevel Pinion Shaft 1 Remove the stake of staking nut 1 2 Set the staking nut locking wrench 2 3 Set the spiral bevel pinion shaft turning wrench 4 Turn the spiral bevel pinion shaft...

Page 267: ...l Bevel Pinion Shaft Only 1 Reassemble the spiral bevel pinion shaft and tighten the staking nut 2 with locking wrench and turning wrench 2 After striking the bevel pinion shaft to the front and rear...

Page 268: ...the spiral bevel pinion shaft and then remove a shim from the bearing R 4 if the turning torque exceeds the factory specifications or add a shim to there if the turning torque is less than the factor...

Page 269: ...bevel gear 6 Turn the spiral bevel pinion shaft while pressing a wooden piece against the periphery on the spiral bevel gear 7 Check the tooth contact If not proper adjust according to the instructio...

Page 270: ...2842 Clearance between Differential Case Bore Differential Case Cover Bore and Differential Side Gear Boss W1072970 A Proper Contact B Shallow Contact C Heel Contact D Deep Contact E Toe Contact Clear...

Page 271: ...lash 3 If the measurement is not within the factory specifications adjust with the differential side gear washer Reference Thickness of differential side gear washer 1 5 mm 0 059 in 1 7 mm 0 067 in 1...

Page 272: ...n the differential lock pedal OFF position 2 If the measurement is not within the factory specifications adjust with adjusting shim 2 Reference Thickness of adjusting shim 2 0 5 mm 0 020 in 1 0 mm 0 0...

Page 273: ...4 REAR AXLE KiSC issued 03 2007 A...

Page 274: ...CONTENTS MECHANISM 1 STRUCTURE 4 M1 KiSC issued 03 2007 A...

Page 275: ...i floating type with the ball bearing between the rear axle 1 and rear axle case 2 which support the rear wheel load as well as transmitting power to the rear wheel They withstand all the forces cause...

Page 276: ...4 S3 4 CHECKING DISASSEMBLING AND SERVICING 4 S4 1 DISASSEMBLING AND ASSEMBLING 4 S4 1 Separating Rear Axle Case from Transmission Case ROPS Type 4 S4 2 Separating Rear Axle Case from Transmission Cas...

Page 277: ...Probable Cause Solution Reference Page Excessive or Unusual Noise at All Time Improper backlash between planetary gear and internal gear Replace 4 S12 Bearing worn Replace Insufficient or improper ty...

Page 278: ...y Gear Thrust Collar Thickness 1 55 to 1 65 mm 0 0610 to 0 0650 in 1 2 mm 0 047 in Planetary Gear to Planetary Gear Shaft Clearance 0 009 to 0 048 mm 0 00035 to 0 00189 in 0 30 mm 0 0118 in Planetary...

Page 279: ...rew and nut 123 6 to 147 1 12 6 to 15 0 91 1 to 108 5 Rear wheel mounting nut 260 to 304 26 5 to 31 0 192 to 224 Fender bracket mounting bolt 197 to 227 20 0 to 23 0 145 to 167 Pilot pipe nut 16 to 24...

Page 280: ...add the fluid to prescribed level if it is not correct level IMPORTANT Use only KUBOTA SUPER UDT fluid Use of other fluids may damage the transmission or hydraulic system Refer to LUBRICANTS FUEL AND...

Page 281: ...e 2 fully to the rod end 1 2 Fix the wire 2 so that the threaded portion A and B become the same 3 Disconnect the wire 2 from the select lever 3 once 4 Shift the main speed change lever 7 to the 1st 2...

Page 282: ...r frame 1 2 Check the clutch housing case and transmission case are securely mounted on the disassembling stands 3 Remove the rear wheels 4 4 Disconnect the jumper lead for hazard and tail light 5 Rem...

Page 283: ...m oil does not leak from the pilot pipe Bleed the air from brake oil line W1014829 Rear Axle Case 1 Remove the rear axle case mounting screws and nuts 2 Support the rear axle case 1 with nylon lift st...

Page 284: ...Valve When Separating Right Side 1 Disconnect the delivery pipe 5 2 Disconnect the other delivery pipe coming from the hydraulic pump 3 Disconnect the trailer brake pipe 1 4 Remove the pilot pipe 2 an...

Page 285: ...rame until the rear bracket 2 becomes free to move 6 Remove the rear bracket 2 When reassembling Check the free play of the parking brake lever Bleed the air from brake oil line W1020355 1 Cabin Dismo...

Page 286: ...nap ring 9 from the brake shaft 8 4 Remove the brake disc 6 and plate 5 5 Remove the brake piston 4 from the brake case with compressed air Slowly inject an air from brake pipe joint When reassembling...

Page 287: ...t 3 2 Draw out the planetary gear shaft 3 and remove the planetary gear 2 3 Tap out the spring pin 1 from the planetary gear shaft 3 When reassembling Apply transmission fluid to the inner surface of...

Page 288: ...o measure the backlash 3 If the measurement exceeds the allowable limit check the planetary gear and planetary shaft W1022163 Thrust Collar Thickness 1 Measure the thickness of the thrust collar 2 If...

Page 289: ...lanetary gear I D 2 x Needle O D Planetary gear shaft O D 6 If the clearance exceeds the allowable limit replace them W1022512 Clearance between planetary gear and planetary gear shaft Factory spec 0...

Page 290: ...5 BRAKES KiSC issued 03 2007 A...

Page 291: ...CONTENTS MECHANISM 1 TRAVELLING BRAKE 5 M1 2 PARKING BRAKE 5 M2 3 BRAKE CASE 5 M3 KiSC issued 03 2007 A...

Page 292: ...e case 6 is perceived to the trailer brake valve 1 through the pilot pipe 7 Then the trailer brake valve 1 feeds pressurized oil to the trailer through the coupler 2 corresponding to the brake oil pre...

Page 293: ...KING BRAKE The parking brake is mechanical wet disc type 1 Parking Brake Lever 2 Parking Brake Rod 3 Brake Shaft 4 Parking Wire 5 Parking Brake Rod Turnbuckle 6 Brake Cam Lever 7 Brake Cam A ROPS Type...

Page 294: ...through the master cylinder the equalizer and the brake pipe The brake piston 8 moves to the right in the figure and presses the brake plate 5 against the disc 4 Parking Brake Operation When the parki...

Page 295: ...QUES 5 S3 4 CHECKING DISASSEMBLING AND SERVICING 5 S4 1 CHECKING AND ADJUSTING 5 S4 2 DISASSEMBLING AND ASSEMBLING 5 S9 1 Removing Master Cylinder and Equalizer 5 S9 2 Separating Brake Case from Trans...

Page 296: ...nder return spring weaken or broken Replace 8 S35 Master cylinder malfunctioning Repair or replace 8 S35 Brake seal failure Replace 5 S10 Brake lines clogged Clean Brake pedal return spring weaken or...

Page 297: ...20 in Brake Piston Flatness 0 3 mm 0 012 in Cam Plate Flatness 0 3 mm 0 012 in Cam Plate and Ball Height 25 45 to 25 55 mm 1 0020 to 1 0059 in 25 00 mm 0 9843 in Brake Disc Thickness 4 15 to 4 35 mm 0...

Page 298: ...UES Tightening torques of screws bolts and nuts on the table below are especially specified For general use screws bolts and nuts See page G 10 W1012736 Item N m kgf m lbf ft Brake pipe nut 16 to 24 1...

Page 299: ...en Right and Left Pedal Strokes CAUTION When checking park the tractor on flat ground and stop the engine 1 Disengage the brake pedal lock 2 Step on either side brake pedal and measure the level diffe...

Page 300: ...not mix brake oils of different brands If brake oils of different brands are mixed chemical reaction may occur causing the boiling point to drop remarkably The boiling point may also drop even when c...

Page 301: ...lling the vinyl pipe 4 to the bleeder 2 3 loosen the bleeder two turns 5 Move the brake pedal up and down Repeat this motion until air bubble in brake oil disappears After bleeding tighten the bleeder...

Page 302: ...ke case touches the brake piston 3 Confirm that the clevis pins 3 5 on both sides of the turnbuckle lightly contact outside of the hole at this time 4 If not adjust it with the turnbuckles 4 5 Check t...

Page 303: ...reassembling the parking brake wire follow the following procedure then check and adjust the parking lever free play 1 Install the outer wire so that the length of the thread portion A may become the...

Page 304: ...cylinder 10 7 Disconnect the brake pipes and remove the equalizer 9 When reassembling After mounting the master cylinder and equalizer be sure to bleed air W1041270 Refer to 8 HYDRAULIC SYSTEM section...

Page 305: ...8 4 Remove the brake disc 6 and plate 5 5 Remove the brake piston 4 from the brake case with compressed air Slowly inject an air from brake pipe joint When reassembling Install the brake seal so as no...

Page 306: ...n a diagonal line 3 If the measurement exceeds the allowable limit replace it W1034507 Height of Cam Plate and Ball 1 Measure the dimensions of the cam plate with the ball installed 2 If the measureme...

Page 307: ...ound replace it W1037346 Brake Disc Wear 1 Measure the brake disc thickness with vernier calipers 2 If the measurement is less than the allowable limit replace it W1037454 Brake Plate Wear 1 Measure t...

Page 308: ...6 FRONT AXLE KiSC issued 03 2007 A...

Page 309: ...CONTENTS MECHANISM 1 STRUCTURE 6 M1 2 FRONT WHEEL ALIGNMENT 6 M2 KiSC issued 03 2007 A...

Page 310: ...e differential system allows each wheel to rotate at a different speed to make turning easier 1 Front Axle Case Support 2 19T Bevel Gear 3 63T Internal Gear 4 22T Planetary Gear 5 Plenetary Gear Pin 6...

Page 311: ...d also maintains the stability in running W1013036 Kingpin Angle The kingpin is titled from the vertical as viewed from the front This angle is called kingpin angle a As with the camber kingpin angle...

Page 312: ...ls is smaller than that between the heels It is called toe in The front wheels tend to roll outward due to the camber but toe in offsets it and ensures parallel rolling of the wheels Another purpose o...

Page 313: ...PECIFICATIONS 6 S2 3 TIGHTENING TORQUES 6 S3 4 CHECKING DISASSEMBLING AND SERVICING 6 S4 1 CHECKING AND ADJUSTING 6 S4 2 DISASSEMBLING AND ASSEMBLING 6 S6 1 Separating Front Axle 6 S6 2 Disassembling...

Page 314: ...f front axle adjusting screw Adjust 6 S5 Front wheel sway excessive Replace 6 S4 Tie rod end loose Tighten 6 S8 Air sucked in power steering circuit Bleed Front Wheels Can Not Be Driven Propeller shaf...

Page 315: ...to 15 984 mm 0 62858 to 0 62929 in Differential Pinion Gear I D 16 000 to 16 018 mm 0 62992 to 0 63063 in Pinion Shaft Case Cover Boss Pinion Bearing Case O D 65 000 to 65 030 mm 2 55906 to 2 56024 in...

Page 316: ...to 196 1 17 0 to 20 0 123 0 to 144 7 Knuckle arm mounting screw M12 77 5 to 90 2 7 9 to 9 2 57 1 to 66 5 Knuckle arm mounting screw M14 123 6 to 147 1 12 6 to 15 0 91 1 to 108 5 Bevel gear case mounti...

Page 317: ...t 2 to adjust the rod length until the proper toe in measurement is obtained 4 Retighten the tie rod joint lock nut 3 5 Attach the snap ring 1 of the tie rod joint W1010662 Axial Sway of Front Wheel 1...

Page 318: ...th the bevel gear case 2 shorten the length of stopper 3 4 Keeping the knuckle arm 1 contact with the bevel gear case 2 make a specified clearance as shown in the table 5 After adjustment secure the s...

Page 319: ...Front Differential Case Oil 1 Place oil pan underneath the differential case 2 Remove the drain plug 1 and filling plug 2 to drain the oil 3 After draining reinstall the drain plug 1 and filling plug...

Page 320: ...sen the front wheel mounting nuts 3 Lift the front axle and remove the front wheels 4 Remove the cylinder cover 3 5 Disconnect the power steering hoses 1 2 When reassembling W1024925 1 Coupling 2 Spri...

Page 321: ...od end lifter Code No 07909 39051 When reassembling Replace cotter pin with a new one Bend the cotter pin as shown in the figure W1027740 Thread length A and B Factory spec A B Tightening torque Brack...

Page 322: ...front wheel case support DX bushing and front wheel case DX bushing Install the oil seal to the front case support so that its lip faces the outward Apply gear oil to the bearing W1071003 Tightening...

Page 323: ...e bevel gear 8 and bearing 9 as a unit When reassembling Apply grease to the front wheel case DX bushing 2 Apply grease to the oil seal Install the oil seal 1 to the front wheel case so that its lips...

Page 324: ...pin 6 into the planetary gear shaft 5 4 Draw out the planetary gear shaft 5 and remove the planetary gear 3 5 Tap out the spring pin 6 from the planetary gear shaft 5 When reassembling Apply gear oil...

Page 325: ...1 Straight Pin 2 O ring 3 Internal Gear 4 Ball Bearing 5 Spring Pin 6 Thrust Collar 7 Planetary Gear 8 Thrust Collar 9 Needle Bearing 10 Planetary Gear Shaft 11 Bevel Gear 12 Ball Bearing 13 External...

Page 326: ...ation Apply liquid gasket Three Bond 1216 or equivalent to the front differential case 1 W1045902 Pinion Bearing Case 1 Remove the pinion bearing case mounting screws 2 Remove the pinion bearing case...

Page 327: ...ferential gear case When reassembling Apply lock tight Three Bond 1324B or equivalent to the spiral bevel gear UBS screws W1072793 Tightening torque Differential bearing support mounting screw 48 1 to...

Page 328: ...f adjusting shim 2 Thickness of adjusting shims 6 Backlash changer per 0 1 mm 0 004 in shim Approx 0 05 mm 0 002 in IMPORTANT Adjust the tooth contact with shims 2 and 6 so that the spiral bevel pinio...

Page 329: ...n A replace it W1056384 Clearance between differential case and differential side gear Factory spec 0 050 to 0 091 mm 0 00197 to 0 00358 in Allowable limit 0 35 mm 0 0138 in Differential case bore I D...

Page 330: ...el Case Bushing 1 Visually inspect the DX bushing for signs of wear or damage The DX bushing tends to show concentrated wear 2 If the DX bushing is worn beyond the alloy portion A replace it W1058151...

Page 331: ...O D rubbing surface 2 Measure the O D of two needles installed diagonally in the needle bearing 3 Calculate the clearance 4 If the clearance exceeds the allowable limit replace them W1073771 Backlash...

Page 332: ...etary Gear 1 Set a dial indicator lever type on the tooth of the planetary gear 2 Hold the planetary gear support and move only the planetary gear 3 If the measurement exceeds the allowable limit chec...

Page 333: ...7 STEERING KiSC issued 03 2007 A...

Page 334: ...CONTENTS MECHANISM 1 STEERING MECHANISM 7 M1 KiSC issued 03 2007 A...

Page 335: ...magnet filter 6 etc The full hydrostatic power steering systems are divided into two types non load reaction type and load reaction type They are distinguished by whether the cylinder port is blocked...

Page 336: ...ECKING DISASSEMBLING AND SERVICING 7 S3 1 CHECKING AND ADJUSTING 7 S3 2 DISASSEMBLING AND ASSEMBLING 7 S3 1 Removing Steering Controller ROPS Type 7 S3 2 Removing Steering Controller CABIN Type 7 S4 3...

Page 337: ...ctioning Repair or replace 8 S40 Steering Wheel Turns SpontaneouslyWhen Released Control valve malfunctioning Repair or replace 8 S40 Front Wheels Wander to Right and Left Control valve malfunctioning...

Page 338: ...ower steering hose retaining nut 24 5 to 29 4 2 5 to 3 0 18 1 to 21 7 Turning delivery hose retaining nut 24 5 to 29 4 2 5 to 3 0 18 1 to 21 7 Steering controller mounting screw 48 1 to 55 9 4 9 to 5...

Page 339: ...p cable 8 at the engine side 9 Remove the rear bonnet 4 10 Remove the fuse box and cover W1011418 Piping for Power Steering 1 Disconnect the turning delivery hoses 2 2 Disconnect the main delivery pip...

Page 340: ...move the steering controller 2 When reassembling W1012404 1 Muffler 2 Bonnet Tightening torque Main delivery pipe and return pipe retaining nut 47 1 to 51 0 N m 4 8 to 5 2 kgf m 34 7 to 37 6 lbf ft Tu...

Page 341: ...ering Cylinder in 8 HYDRAULIC SYSTEM section Tightening torque Tie rod end slotted nut 156 9 to 176 5 N m 16 0 to 18 0 kgf m 115 7 to 130 2 lbf ft Tie rod joint lock nut 166 7 to 196 1 N m 17 0 to 20...

Page 342: ...8 HYDRAULIC SYSTEM KiSC issued 03 2007 A...

Page 343: ...ON 8 M5 4 PTO CLUTCH VALVE 8 M15 5 HYDRAULIC TRAILER BRAKE VALVE 8 M18 1 STRUCTURE 8 M18 2 OPERATION 8 M19 6 POWER STEERING HYDRAULIC CIRCUIT 8 M23 7 THREE POINT HYDRAULIC SYSTEM 8 M24 1 HYDRAULIC CIR...

Page 344: ...rse 5 Power Steering Controller 6 Master Cylinder Hydraulic Brake 7 Brake Oil Reservoir 8 Oil Cooler Check Valve 9 Equalizer Hydraulic Block 10 Oil Cooler 11 Hydraulic Pump for Power Steering 12 Hydra...

Page 345: ...YDRAULIC CIRCUIT 1 Auxiliary Control Valve 2 Control Valve 3 Power Steering 4 Oil Cooler Check Valve 5 Oil Cooler 6 PTO Valve 7 Shuttle Valve 8 Oil Tank Transmission Case 9 Hydraulic Oil Filter Cartri...

Page 346: ...SYSTEM 11 Trailer Brake Valve 12 Cylinder Safety Valve 13 Hydraulic Cylinder 14 Relief Valve A1 A2 To Implement Cylinder B1 B2 To Implement Cylinder N N Port X To Brake Case Pilot Pipe Y To Trailer Br...

Page 347: ...Power Steering Controller 2 Modulation Valve 3 Shuttle Shift Spool Forward Reverse 4 Proportionally Reducing Valve 5 Accumulate Valve 6 Shuttle Valve 7 PTO Control Valve 8 Oil Cooler 9 Oil Cooler Rel...

Page 348: ...8 M5 ME8200 ME9000 WSM HYDRAULIC SYSTEM 1 OPERATION Shuttle Lever at Neutral Position KiSC issued 03 2007 A...

Page 349: ...ot engage 1 Modulating Valve 2 Proportionally Reducing Valve 3 Spool Forward Reverse 4 Accumulate Valve 5 Shuttle Valve Case 1 6 Shuttle Valve Case 2 7 Shuttle Lever 8 Clutch Pedal A Check Port Modula...

Page 350: ...8 M7 ME8200 ME9000 WSM HYDRAULIC SYSTEM When Shuttle Lever is Shifting Neutral to Forward or Reverse Position Clutch Pedal is Released KiSC issued 03 2007 A...

Page 351: ...late valve 4 assists the operation of modulating valve 1 to reduce a shock 1 Modulating Valve 2 Proportionally Reducing Valve 3 Spool Forward Reverse 4 Accumulate Valve 5 Shuttle Valve Case 1 6 Shuttl...

Page 352: ...8 M9 ME8200 ME9000 WSM HYDRAULIC SYSTEM Shuttle Lever at Forward Position Clutch Pedal is Released KiSC issued 03 2007 A...

Page 353: ...port through R port and spool 3 1 Modulating Valve 2 Proportionally Reducing Valve 3 Spool Forward Reverse 4 Accumulate Valve 5 Shuttle Valve Case 1 6 Shuttle Valve Case 2 7 Shuttle Lever 8 Clutch Pe...

Page 354: ...8 M11 ME8200 ME9000 WSM HYDRAULIC SYSTEM Shuttle Lever at Reverse Position Clutch Pedal is Released KiSC issued 03 2007 A...

Page 355: ...port through F port and spool 3 1 Modulating Valve 2 Proportionally Reducing Valve 3 Spool Forward Reverse 4 Accumulate Valve 5 Shuttle Valve Case 1 6 Shuttle Valve Case 2 7 Shuttle Lever 8 Clutch Pe...

Page 356: ...8 M13 ME8200 ME9000 WSM HYDRAULIC SYSTEM When Clutch Pedal is Depressed with Shuttle Lever at Forward or Reverse Position KiSC issued 03 2007 A...

Page 357: ...ttle clutch to be set to off At the same time as the hole c and passage d are connected oil passage among the hole e hole c and T1 port are connected As a result even when the spool 1 2 does not move...

Page 358: ...inner pressure is kept in approx 2451 kPa 25 kgf cm2 355 psi by the main relief valve B Rotary Valve This valve change the oil flow to PTO clutch This is rotated by the PTO operation lever via to PTO...

Page 359: ...the clutch pack Oil entering the clutch pack pushes the piston 4 to engage the clutch pack The modulating valve absorbs the engaging shock of the clutch pack W1015150 1 PTO Clutch Valve 2 Spool 3 Plat...

Page 360: ...pack by the return spring 8 When the piston 4 is pushed back the brake plate 7 is also moved to contact the brake disc 6 so as to stop the rotation and the drag of the PTO shaft W1015494 1 PTO Clutch...

Page 361: ...essure relief element 3 with pre loaded spring 4 for limiting the trailer braking pressure Control head 6 with piston 7 and bleed valve 5 for operating the trailer brake valve through the tractor brak...

Page 362: ...reservoir through restrictor 11 throttle 9 bore 8 control spool 2 and port R Thus the pressure drop at throttle 9 holds the flow control valve 10 in the open flow position a The flow control valve 10...

Page 363: ...estrictor 11 bore 12 check valve 13 and port B The restrictor 11 is designed for the constant flow Qk A residual flow Qp Qk bypasses the flow control valve 10 and then passes to the tractor hydraulic...

Page 364: ...valve 10 is thus switched into position a and has no regulating function As in the case of the released trailer brake the delivery flow Qp from the pump passes through port N and flows as Qp Qx to the...

Page 365: ...external factor control spool 2 momentarily opens brake line B to the reservoir and avoids further increasing of the braking pressure In all control positions of the trailer brake valve the tractor h...

Page 366: ...rates and the oil passes through gerotor 4 and into steering cylinder 3 The cylinder rod then moves to control the directional movement of the front wheels Return oil from steering cylinder 3 passes t...

Page 367: ...e circuit The hydraulic cylinder 10 has a cylinder safety valve 11 to relieve shock pressure due to heavy implement bounce 5 The control valve 7 is actuated by the mechanical linkage for Position cont...

Page 368: ...or 8 does not press the spool retainer 1 the spool 5 is forced out by the return spring in the control valve feedback mechanism 4 When the spool 5 returns to the neutral position the lift arms stop ri...

Page 369: ...using the draft control lever 2 Traction load of the implement acts as torsion force to the torsion bar 5 via the top link bracket 7 When traction load increases the torsion bar is twisted depending...

Page 370: ...arms implement lower to the height set by the position control only when traction load increases slippage or engine stop may occur unless the implement is raised With the draft control only plowing d...

Page 371: ...oint Hydraulic System 8 S20 8 Three Point Hydraulic System 8 S23 2 DISASSEMBLING AND ASSEMBLING 8 S29 1 Hydraulic Shuttle System 8 S29 2 Master Cylinder and Equalizer 8 S34 3 Trailer Brake 8 S36 4 Hyd...

Page 372: ...eight Position rod and control lever improperly adjusted Adjust 8 S23 25 Draft rod and draft control rod improperly adjusted Adjust 8 S23 26 Lever stopper position improper Adjust Implement Does Not L...

Page 373: ...YDRAULIC SYSTEM W1011217 Symptom Probable Cause Solution Reference Page Draft Control Malfunctioning Draft control linkage improperly adjusted Adjust 8 S23 26 27 Torsion bar weak or broken Replace 8 S...

Page 374: ...ABIN Type Length 65 0 mm 2 56 in Main Speed Change Rod 1 ROPS Type Length 457 mm 17 99 in Auxiliary Control Lever to Stopper ROPS Type Clearance 0 to 1 mm 0 to 0 039 in Main Speed Change Rod 2 ROPS Ty...

Page 375: ...n 4 6 U S gals min 3 8 Imp gals min Housing Bore Depth of Scratch 0 09 mm 0 0035 in Bushing to Gear Shaft Clearance 0 15 mm 0 0059 in Gear Shaft O D 17 968 mm 0 7074 in Bushing Length 18 965 mm 0 7466...

Page 376: ...0 0035 in Bushing to Gear Shaft Clearance 0 15 mm 0 0059 in Gear Shaft O D 17 968 mm 0 7074 in Bushing Length 18 965 mm 0 74665 in Hydraulic Pump Delivery Above 59 1 L min 15 6 U S gals min 13 0 Imp...

Page 377: ...to 1 32 in Cylinder Safety Valve Operating Pressure 23 1 to 24 5 MPa 235 to 250 kgf cm2 3342 to 3356 psi Cylinder Bore I D 100 036 to 100 071 mm 3 93843 to 3 93980 in 100 15 mm 3 94291 in Hydraulic Ar...

Page 378: ...to 28 4 2 6 to 2 9 18 8 to 21 0 Steering cylinder guide assembly 142 2 to 152 0 14 5 to 15 5 104 9 to 112 1 Relief valve for three point hydraulic system 34 3 to 39 2 3 5 to 4 0 25 3 to 28 9 Hydrauli...

Page 379: ...d position is low check the hydraulic PTO clutch system 7 If the measurement is not within the factory specifications loosen the lock nut 7 and turn the screw 6 to adjust IMPORTANT Do not connect the...

Page 380: ...ct the port F and R for the cabin type Pressure gauge is 5 MPa 50 kgf cm2 700 psi full scale Apply Three Bond 1324N or equivalent to the plugs F R and M when install them W1013770 Shuttle Lever Clutch...

Page 381: ...fore checking and adjusting 1 Check the engine start condition as follows Position a Engine start Position b Engine does not start Position c Engine does not start 2 If the engine started at position...

Page 382: ...Neutral Position and Lever Guide Neutral Position 1 The shuttle valve spool is provided with F N and R ball detents Lift the shuttle lever 1 and slowly move it to the F and R directions until you feel...

Page 383: ...ever Free Play 1 Place the shuttle lever to the neutral position 2 Lift the shuttle lever 1 then move it back and forth and confirm the free play D of the shuttle lever 1 at neutral position W1016314...

Page 384: ...e play D toward the rear direction and slowly lower the shuttle lever 1 as shown in the figure And visually inspect the clearance Y 3 Make sure the two clearances X and Y are just the same NOTE The fi...

Page 385: ...nch to prevent the stay bends when adjust the length of the shuttle cable 4 2 If displaced too much in the F direction Clearance X Y Shorten Z 3 If displaced too much in the R direction Clearance X Y...

Page 386: ...n as follows NOTE Do not touch the shuttle lever 1 when the shuttle lever 1 is at specified position as shown in figure Reference Position A Engine start Position B Engine does not start Position C En...

Page 387: ...pressure between 2 94 to 3 24 MPa 30 to 33 kgf cm2 426 7 to 469 4 psi 5 Read the pressure P after one minute 6 After reading the pressure P wait another five minutes to read the pressure P and check t...

Page 388: ...ained due to compress the air even when the brake pedal is pressed Accordingly whenever the hydraulic brake system is disassembled be sure to bleed after reassembling W1018036 4 Trailer Brake Valve Ch...

Page 389: ...sion oil port 5 Open the flowmeter loading valve completely Turn counterclockwise 6 Start the engine and set the engine speed at 2000 to 2200 min 1 rpm 7 Slowly close the loading valve to generate pre...

Page 390: ...ations adjust the relief pressure by the adjust plug 4 IMPORTANT Air Bleeding Start the engine then turn the steering wheel slowly in both directions all the way alternately a few times and stop the e...

Page 391: ...ulic test hose to the flowmeter outlet port and to hydraulic adaptor 64 6 Open the flowmeter loading valve completely Turn counterclockwise 7 Start the engine and set the engine speed at 2000 to 2200...

Page 392: ...f cm2 2702 psi Oil temperature 50 to 60 C 122 to 140 F W1020540 Hydraulic pump delivery at no pressure Factory spec Above 41 7 L min 11 0 U S gals min 9 2 Imp gals min Hydraulic pump delivery at rated...

Page 393: ...is included in adaptor set Code No 07916 54031 7 Connect the hydraulic hose to the adaptor 61 and put the end of the hose into the transmission oil port 8 Open the flowmeter loading valve completely...

Page 394: ...nd Draft Rod Cabin Type 1 Be sure to adjust the position rod length A and draft rod length B W1021502 Hydraulic pump delivery at no pressure Factory spec Above 62 5 L min 16 5 U S gals min 13 8 Imp ga...

Page 395: ...Start the engine and set the speed at 1000 min 1 rpm 5 Move the draft control lever all the way up and measure the offset which is the distance between S1 and S2 6 If the offset is not within the fac...

Page 396: ...efer to Adjusting the Uppermost Position of Lift Arm on page 8 S24 5 Secure the position control lever 1 all the way down position to check that the floating range can be obtained Reference The specif...

Page 397: ...lower links 2 Attach the test bar 1 to the top link bracket 2 3 Start the engine and set the speed at 1000 min 1 rpm 4 Move the position control lever all the way down 5 Raise the test bar 1 until th...

Page 398: ...the draft and position control lever all the way down 5 Press the test bar 1 downward until the top link bracket 2 comes in contact with the stopper 6 Slowly shift the draft control lever 4 upward un...

Page 399: ...e Set Pressure Threaded Joint Code No 07916 50341 to the hydraulic cylinder body and then set a pressure gauge Code No 07916 50321 Cable Code No 07916 50331 2 Start the engine set at maximum speed 3 S...

Page 400: ...e System A Oil Cooler Check Valve Check Valve NOTE This is a reference when assemble the oil cooler check valve 1 When reassembling ROPS Type Arrow mark toward Up CABIN Type Arrow mark toward Down W10...

Page 401: ...xiliary control valve 6 Remove the speed change base 8 When reassembling Install the control wire 5 of first valve lower side into the rear side slot Execute the following Adjusting of Select Wire and...

Page 402: ...ire 2 to the select lever 3 W1024599 Adjusting of Control Wire for Auxiliary Control Valve 1 Valve Side Tighten the lock nut 2 so that the length B of the threaded portion become 0 mm 2 Lever Side Scr...

Page 403: ...Disconnect the 2P connector 1 for PTO safety switch 3 Disconnect the main speed change rod 2 3 from the lever 2 4 Remove the position and draft control lever grip 5 6 5 Remove the DT shift lever grip...

Page 404: ...W1026191 C Shuttle Valve CABIN Type Cover and Floor Seat Cover 1 Remove the floor mat 1 1 floor mat 2 2 cover 1 3 and cover 2 4 2 Remove the seat bracket 6 and floor seat cover 5 W1026790 Tightening...

Page 405: ...assembling the cylinder cups and O rings immerse them in clean brake oil or apply silicon grease to them Use only the brake oil or silicon grease otherwise the cylinder cups may be deteriorated It is...

Page 406: ...he equalizer in a vise remove the plug 1 to pull out the piston sub assembly When reassembling Install the piston sub assembly and plug noting the O ring Reference W1027946 Master cylinder return spri...

Page 407: ...ation and ensure that there is nothing abnormal with the hydraulic pump Removing Three Point System Hydraulic Pump and Power Steering Hydraulic Pump ME8200 1 Disconnect the delivery pipe 1 2 from the...

Page 408: ...housing cover mounting nuts and separate the power steering pump 10 from the three point system hydraulic pump 11 When reassembling W1029274 Tightening torque Hydraulic pipe mounting screw 17 7 to 20...

Page 409: ...d housing 8 3 Remove the backup elements 5 4 Take out the bushings 6 9 and gears 7 13 When reassembling Install the driven gear 13 noting its direction as shown in the figure When installing the bushi...

Page 410: ...ly 1 Remove the adjust plug 3 and draw out the spring 2 and poppet 1 When reassembling Take care not to damage the O ring IMPORTANT After disassembling and assembling the relief valve be sure to adjus...

Page 411: ...he rotor and put the spacer on it Keeping the spacer on the rotor fit it into the stator 6 with the spline bevelled side upward 4 After putting the spacer into the rotor 9 insert the splines of drive...

Page 412: ...aces and needle bearing from valve assembly When reassembling Apply transmission oil to the bearing races and needle bearing 10 Draw out the sleeve 9 and spool 11 assembly from the gerotor side with t...

Page 413: ...notch with the sleeve notch W1032024 C Steering Cylinder Disassembling Steering Cylinder 1 Carefully clamp the cylinder in a vise 2 Remove the guide assembly 1 and draw out the piston rod 4 When reass...

Page 414: ...at there is nothing abnormal with the hydraulic pump Removing Hydraulic Pump ME8200 1 Disconnect the delivery pipe 1 2 from the hydraulic pump 2 Disconnect the suction pipe 3 4 from the hydraulic pump...

Page 415: ...e to reassemble them to the each original position and direct bushing grooves to inlet side as shown in the figure Install the driven gear 8 in the correct direction as shown in the figure Take care n...

Page 416: ...ssembly mounting screws 5 Take out the hydraulic pump 5 assembly When reassembling Apply grease to the O ring and take care not to damage it W1015532 Tightening torque Hydraulic pipe mounting screw 17...

Page 417: ...be sure to reassemble them to each original position and direct bushing grooves to inlet side See figure Use care not to damage the oil seal seal element 11 backup element 12 and O rings After reasse...

Page 418: ...page 8 S30 W1034309 Rear Wheel Fender and Seat 1 See page 8 S32 W1034509 Center Frame 1 See page 8 S32 W1034566 Hydraulic Pipe and Parking Brake 1 Disconnect the delivery pipe 4 2 Remove the trailer b...

Page 419: ...d gasket NOTE Reassemble the hydraulic cylinder assembly to the tractor be sure to adjust the position control feedback rod and draft control rod W1021614 C Separating Hydraulic Cylinder Assembly CABI...

Page 420: ...lever and draft control lever W1035273 D Disassembling Position Control Valve Removing Control Valve 1 Remove the control valve mounting screws 2 Remove the control valve 1 NOTE Do not loosen adjusti...

Page 421: ...lve noting O ring and backup ring W1022351 Check Valve 1 Remove the seat plug 3 2 Draw out the spring 2 and check valve 1 When reassembling Install the plug noting O ring W1022670 Tightening torque Se...

Page 422: ...he hydraulic cylinder body 25 with the process alternately and O ring 24 is assembled into the rod As shown in figure When assemble the position connector 10 notched section 18 upward It is upward the...

Page 423: ...e the hydraulic cylinder cover 1 2 Push out the hydraulic piston 5 from the hydraulic cylinder When reassembling Install the hydraulic piston noting O ring 6 and backup ring 7 Install the hydraulic cy...

Page 424: ...ring After tightening the hydraulic arm setting screw to the specified torque insert a wire through the holes of the screw head and hydraulic arm W1025303 Hydraulic Arm and Hydraulic Rod 1 Remove the...

Page 425: ...ance between Bushing and Gear Shaft 1 Measure the gear shaft O D with an outside micrometer 2 Measure the bushing I D with an inside micrometer and calculate the clearance 3 If the clearance exceeds t...

Page 426: ...sing I D W1013805 Clearance between Bushing and Gear Shaft 1 Measure the gear shaft O D with an outside micrometer 2 Measure the bushing I D with an inside micrometer and calculate the clearance 3 If...

Page 427: ...S52 4 After adjustment tighten the lock nut firmly NOTE Use specified transmission fluid see page G 8 to test the operating pressure of the cylinder safety valve W1026531 Hydraulic Cylinder Bore 1 Ch...

Page 428: ...m 0 00551 to 0 00984 in Allowable limit 0 50 mm 0 0197 in Hydraulic arm shaft O D Right side Factory spec 59 970 to 60 000 mm 2 36102 to 2 36220 in Bushing I D After press fitted Right side Factory sp...

Page 429: ...9 ELECTRICAL SYSTEM KiSC issued 03 2007 A...

Page 430: ...ness 9 M3 3 Cabin Harness 9 M4 3 COLOR OF WIRING 9 M5 2 LIGHTING SYSTEM 9 M6 1 HAZARD FLASHER UNIT 9 M6 2 WORKING LIGHT SWITCH CABIN TYPE 9 M6 3 ROOM LAMP CABIN TYPE 9 M7 3 EASY CHECKER 9 M8 1 INDICAT...

Page 431: ...85 R 0 85 R 0 85 Y B 0 85 OR 1 25 B 0 85 G 0 5 W Y c a e b d d b e a c A 50 0 85 B 0 85 B 0 85 B 0 85 B 0 85 G 1 25 B 0 85 OR 0 85 Y B 0 85 R 0 85 R 0 85 B 0 85 Y B 0 85 G 0 85 R W 0 85 Y B 0 85 B 0 8...

Page 432: ...0 85 B 0 85 B 0 5 B 0 5 B 0 5 L W 0 5 L W 0 5 BR Y 0 5 BR Y 0 5 LG R 0 5 LG R 0 5 B 0 5 W R 0 5 W R 2 R W 0 5 R Y 2 R W 0 5 R Y 0 85 B Y 0 85 B Y 5 B W 5 B W 1 25 Y L 8 W R 5 W R 3 W 0 5 Y 0 5 LG 0 5...

Page 433: ...0 5 LG Y 1 25 L 0 85 L 0 5 BR 0 85 G W 0 5 Y 0 85 L W 0 85 L W 0 5 LG R 0 85 G 0 85 Y B 0 5 L G 0 5 L G 0 5 Y 0 85 L W 0 85 G W 0 5 L B 0 5 L B 1 25 Y L 1 25 Y L 5 W R 5 W R 5 B W 5 B W 0 85 G R 3 W 3...

Page 434: ...0 5 B 3 B 3 B 0 5 B 0 5 B 0 5 B 0 5 B 0 5 B 0 5 B 0 5 R W 0 5 Y B 0 5 Y B 0 5 G L 0 5 Y B 0 5 Y B 0 5 B LGE2 0 5 B PU 0 5 B PU 0 5 B PU 0 5 B Y 0 5 B PU 0 85 R Y 0 5 R G 1 25 L a d c d a d c b e a d c...

Page 435: ...ow G W Green White R Y Red Yellow Br Brown G Y Green Yellow W B White Black Lg Light Green L B Blue Black W G White Green Or Orange L G Blue Green W L White Blue Sb Sky Blue L Or Blue Orange W R White...

Page 436: ...Switch Front Rear When the switch 1 is pushed once the lamp 2 lights on and working light switch is set to ON position When it is pushed once more the lamp lights off and working light switch is set t...

Page 437: ...on room lamp 2 lights on at the door switch comes close position W1013629 Door Switch When the door is closed the push rod 2 is pushed by door frame so that the door switch comes open position Both R...

Page 438: ...1013833 2 CABIN Type 1 When the key is turned ON electrical charge lamp 3 air cleaner lamp 2 fuel level lamp 7 and engine oil pressure lamp 8 should come on After started the engine those lamps should...

Page 439: ...minal is shown below W1014574 Terminal Function Color of wire harness 1 Turn Signal Light LH Green White 2 3 Ground Black 4 Turn Signal Light RH Red White 5 Tail Light Sidemarker Light Parking Light Y...

Page 440: ...lternator with IC Regulator Type 2 Refer to Workshop Manual for Tractor Mechanism 3 LIGHTING SYSTEM 1 Combination Switch Type 3 Refer to Workshop Manual for Tractor Mechanism 2 Hazard Switch Refer to...

Page 441: ...TING SYSTEM 9 S12 1 Checking 9 S12 2 Disassembling and Assembling 9 S21 3 Servicing 9 S22 3 STOPPING SYSTEM 9 S24 1 Checking 9 S24 4 CHARGING SYSTEM 9 S25 1 Checking 9 S25 2 Disassembling and Assembli...

Page 442: ...attery positive terminal and alternator B terminal Repair or replace Cooling fan belt slipping Adjust tension G 21 Starter Motor Does Not Operate Battery discharged or defective Recharge or replace 9...

Page 443: ...lown Replace G 35 36 Wiring harness disconnected or improperly connected between main switch AC terminal and panel board between panel board and alternator L terminal Repair or replace Charging Lamp D...

Page 444: ...nnected or improperly connected between combination switch T terminal and tail light Repair or replace Stop Light Does Not Light Fuse blown 15 A Replace G 35 36 Brake switch defective Replace 9 S33 Bu...

Page 445: ...ot Go ON and OFF Hazard unit defective Replace 9 S33 Work Light Does Not Light CABIN Type Fuse blown Replace G 35 36 Bulb blown Replace Wiring harness disconnected or improperly connected between star...

Page 446: ...9 S37 Engine Oil Pressure Lamp Does Not Light When Main Switch Is Turned ON and Engine Is Not Running Bulb blown Replace Engine oil pressure switch defective Replace 9 S37 Wiring harness disconnected...

Page 447: ...elay 1 defective Replace 9 S16 Oil switch defective Replace 9 S37 Key stop relay defective Replace 9 S24 Fuel Gauge Does Not Function Fuel gauge defective Replace 9 S40 Fuel level sensor tank unit def...

Page 448: ...0 80 mm 0 0197 to 0 0315 in 0 2 mm 0 0079 in Brush Length 18 0 mm 0 7086 in 11 0 mm 0 4331 in Brush Length 18 5 mm 0 728 in 5 0 mm 0 197 in Slip Ring O D 22 7 mm 0 894 in 22 1 mm 0 870 in Glow Plug Re...

Page 449: ...UES Tightening torques of screws bolts and nuts on the table below are especially specified For general use screws bolts and nuts See page G 10 W1012736 Item N m kgf m lbf ft Pulley nut Alternator 58...

Page 450: ...or may result Insulate terminal of battery If this advice is disregarded damage to alternator and regulator may result 1 BATTERY 1 Checking Battery Voltage 1 Stop the engine and turn the main switch o...

Page 451: ...old the hydrometer at eye level The hydrometer reading must be taken at the highest electrolyte level Reference Specific gravity slightly varies with temperature To be exact the specific gravity decre...

Page 452: ...he specified level to prevent overflow 2 Connect the battery to the charging unit following the manufacturer s instructions 3 As the electrolyte generates gas while charging remove all port caps 4 The...

Page 453: ...st Reference Self discharge Rate W1014052 2 STARTING SYSTEM 1 Checking Main Switch ROPS Type 1 Remove the steering wheel 2 Disconnect the meter panel and disconnect the hourmeter cable and the main sw...

Page 454: ...ts of the main switch are faulty W1014641 4 Main Switch at START Position 1 Turn and hold the main switch at the START position 2 Measure the resistances with an ohmmeter across the B terminal and the...

Page 455: ...inal 6 contacts of the main switch are faulty W1015112 3 Main Switch at START Position 1 Turn and hold the main switch key at the START position 2 Measure the resistances with an ohmmeter across the 5...

Page 456: ...voltage with a voltmeter across the lead terminal and the chassis 5 If the voltage at either position differs from the battery voltage the wiring harness or main switch is faulty W1015078 Starter Rel...

Page 457: ...e the relay 1 1 2 Apply battery voltage across 1 and 3 terminals and check for continuity across 2 and 4 terminals 3 If continuity is not established across 2 and 4 terminal renew the relay 1 W1015751...

Page 458: ...minals 3 If continuity is not established across 3 and 5 terminal renew the PTO relay NOTE The key stop relay is interchangeable with PTO relay ROPS Type The key stop relay working light relay A C blo...

Page 459: ...s proper W1016424 Glow Relay 1 Connector Voltage 1 Turn the main switch off 2 Disconnect the 1P connectors and 2P connector from glow relay 1 3 Measure the voltage with a voltmeter across the 1P conne...

Page 460: ...crew 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 W1015115 PTO Clutch Safety Switch 1 Remove the safety switc...

Page 461: ...it from jumping up and down while testing the motor 1 Disconnect the battery negative cable from the battery 2 Disconnect the battery positive cable and the leads from the starter C terminal 1 3 Remov...

Page 462: ...s 9 and the 2 brush holder lock screws Take out the rear end frame 13 and the brush holder 12 3 Disconnect the armature 10 and the yoke 11 Remove also the ball 7 from the tip of the armature 4 Remove...

Page 463: ...rcut 6 If the undercut is less than the allowable limit correct it with a saw blade and chamfer the segment edges W1017092 Brush Wear 1 If the contact face of the brush is dirty or dusty clean it with...

Page 464: ...is any defect replace the overrunning clutch assembly 3 Check that the pinion turns freely and smoothly in the overrunning direction and does not slip in the cranking direction 4 If the pinion slips o...

Page 465: ...eck the continuity across the brush 2 and yoke 3 with an ohmmeter 4 If it conducts replace the yoke assembly W1018015 3 STOPPING SYSTEM 1 Checking Key Stop Relay 1 Refer to the PTO relay checking for...

Page 466: ...tch 4 7 If the plunger is not attracted the engine stop solenoid is faulty IMPORTANT Never apply the current for pulling coil more than two seconds when inspecting W1019594 4 CHARGING SYSTEM 1 Checkin...

Page 467: ...nt 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 than 100 C 212 F it drops by about 1 V W1018478 2 Disassembling a...

Page 468: ...ith its sliding face in the clockwise direction when viewed from front IMPORTANT Be sure to keep the 2 brushes deep in the brush holder Otherwise the rotor and the rear section can not be fitted into...

Page 469: ...2 If the measurement is not within factory specification replace it 3 Check the continuity across each stator coil lead and core with an ohmmeter 4 If infinity is not indicated replace it W1019964 Ro...

Page 470: ...he measurement is less than allowable limit replace it 3 Make sure that the brush moves smoothly 4 If the brush is defective replace it W1020329 Rectifier 1 Check the continuity across each diode of r...

Page 471: ...Set the light switch to the OFF position 3 Measure the resistance with an ohmmeter across the B1 terminal to the T terminal the B1 terminal to the 1 terminal and the B1 terminal to the 2 terminal 4 I...

Page 472: ...tch when Setting Switch Knob at R Position 1 Set the turn signal light switch to the R position 2 Measure the resistance with an ohmmeter across the B2 terminal to the R terminal 3 If 0 ohm is not ind...

Page 473: ...tage differ from the battery voltage the wiring harness is faulty W1046902 2 Hazard Switch Continuity 1 Measure the resistance with ohmmeter across the a terminal and c terminal and across the d termi...

Page 474: ...switch 1 2 Check the continuity with an ohmmeter across the switch terminals 3 If it does not conduct or any value is indicated when the switch is pulled the switch is faulty 4 If infinity is not indi...

Page 475: ...h PTO Switch 1 Wiring Harness 1 Disconnect the leads from the PTO switch 1 2 Connect the wiring harness lead terminals to each other and turn the main switch on 3 If the indicator do not light the fus...

Page 476: ...nector of the wiring harness side to each other by using the lead 4 If the parking brake brake oil level indicator lamp does not light on the panel board circuit or the wiring harness is faulty 2 Swit...

Page 477: ...rs from the battery voltage the wiring harness fuse or main switch is faulty 2 Working Light Switch 1 Check the continuity through the switch with an ohmmeter 2 If continuity specified below is not in...

Page 478: ...ot indicated in the normal state the switch is faulty 3 If infinity is not indicated at pressure over 4 9 kPa 0 5 kgf cm2 7 psi the switch is faulty W1026084 Charging Circuit Panel Board and Wiring Ha...

Page 479: ...logged lamp does not light the panel board circuit or wiring harness is faulty W1050130 Air Cleaner Sensor Continuity 1 Disconnect the leads from the air cleaner sensor 1 after turning the main switch...

Page 480: ...he ammeter COM lead to the sensor terminal and che lead to the coupler terminal and measure the thermistor amperage with an ammeter 3 If the measurement is less than 60 mA when the thermistor is in fu...

Page 481: ...tinuity with an ohmmeter across the FU terminal 2 and IG terminal 3 and across the FU terminal 2 and GND terminal 4 3 If infinity is indicated the fuel gauge is faulty 4 Check the continuity with an o...

Page 482: ...measure the voltage with voltmeter across the 6 terminal 1 and 3 terminal 2 2 If the voltage differs from battery voltage the wiring harness or switch for brake lights are faulty W1026040 Voltage Tur...

Page 483: ...10 CABIN KiSC issued 03 2007 A...

Page 484: ...IR CONDITIONING SYSTEM 10 M1 1 STRUCTURE 10 M1 2 SYSTEM CONTROL 10 M3 3 ELECTRICAL SYSTEM 10 M4 1 Electrical Circuit 10 M4 2 Air Conditioner Main Relay and Compressor Relay 10 M5 3 Blower Switch 10 M6...

Page 485: ...1 AIR CONDITIONING SYSTEM 1 STRUCTURE 1 Heater Hose 2 Air Conditioner Unit 3 Control Unit 4 Outer Roof 5 Air Filter 6 Air Filter 7 High Pressure Pipe and Low Pressure Pipe 8 Receiver 9 Condenser 10 Co...

Page 486: ...ning cycle and functions to lubricate the compressor But the conventional compressor oil for R12 doesn t dissolve in R134a so it doesn t circulate through the cycle and the lifespan of the compressor...

Page 487: ...he air flows to door D3 12 side passing through the heater core 3 Outlet air flow is controlled by door D3 Moving the air mode lever 1 opens and shuts door D3 and establishes the air passage according...

Page 488: ...at temperature is more than 4 C 39 2 F A C Pressure Switch 7 ON if refrigerant pressure is between 0 21 MPa 2 1 kgf cm2 30 psi and 265 MPa 27 kgf cm2 384 psi Magnetic Clutch of Compressor Engaged 1 Ba...

Page 489: ...ult in a discharged battery To protect against such trouble A C main relay 9 has been provided A C main relay 9 has been made so that when current flows through its coil the contact close to supply th...

Page 490: ...lay 9 is turned ON the current from battery 1 flows to the blower switch 12 through the blower motor 10 as follows Low Position Battery 1 Slow Blow Fuse Fuse A C Main Relay 9 Blower Motor 10 Blower Re...

Page 491: ...T CYCLE 10 S15 1 CHECKING WITH MANIFOLD GAUGE 10 S15 2 DISCHARGING EVACUATING AND CHARGING 10 S19 1 Discharging the System 10 S19 2 Evacuating the System 10 S20 3 Charging the System 10 S21 4 Checking...

Page 492: ...or replace 10 S33 Blower high relay detective Replace 10 S36 Blower motor defective Replace 10 S35 Blower switch defective Replace 10 S34 Wiring harness disconnected or improperly connected Repair Do...

Page 493: ...10 S30 Magnetic clutch defective Repair or replace 10 S29 Compressor defective Replace 10 S30 Insufficient Cooling Others Thermostat defective Replace Water valve defective Replace Condenser fin clog...

Page 494: ...10 S3 ME8200 ME9000 WSM CABIN Air Conditioning System Continued KiSC issued 03 2007 A...

Page 495: ...10 S4 ME8200 ME9000 WSM CABIN KiSC issued 03 2007 A...

Page 496: ...10 S5 ME8200 ME9000 WSM CABIN KiSC issued 03 2007 A...

Page 497: ...rating Speed Is Too Low Wiper motor defective Short circuit of motor armature worn motor brush or seized motor shaft Replace 10 S40 48 Low battery voltage Recharge or replace 9 S9 Humming occurs on mo...

Page 498: ...28 psi Pressure HI Pressure Side 1 27 to 1 66 MPa 13 to 17 kgf cm2 185 to 242 psi Pressure Switch Dual Type When pressure switch is turned OFF Setting Pressure LO Pressure Side Less than approx 0 196...

Page 499: ...en compressor and condenser High pressure pipe 1 retaining nut 19 6 to 24 5 2 0 to 2 5 14 5 to 18 1 High pressure pipe 2 between receiver and A C unit retaining nut 11 8 to 14 7 1 2 to 1 5 8 7 to 10 8...

Page 500: ...e can unless necessary When it has to be heated use warm water of 40 C 104 F or lower Do not heat using boiling water IMPORTANT If the refrigerant O rings etc for R12 are used in the R134a air conditi...

Page 501: ...ure Side Valve are Closed Two circuits are established Port C LO pressure gauge 1 Port A HI pressure gauge 2 NOTE Schrader valve D must be opened W1013376 When LO Valve is Opened and HI Valve is Close...

Page 502: ...t B Port D Schrader valve must be opened Port A LO pressure gauge 1 NOTE Schrader valve D must be opened W1013304 When LO and HI Valve are Opened Circuits are established Port A HI pressure gauge 2 LO...

Page 503: ...t connector should the sleeve 7 move before the quick link connector can be connected to the charging valve move the quick sleeve to its original position and try again When some refrigerant remains i...

Page 504: ...oid valve the valve closes to keep out the outside air and allow the vacuum to build up but when the current stops the valve opens to allow in air and end the vacuum 2 Attaching this adaptor to the R1...

Page 505: ...tem turn the handle 1 counterclockwise To stop charging turn it clockwise W1015014 6 T joint T joint 2 is used to increase efficiency of gas charging using two refrigerant containers 4 at a time 1 Ins...

Page 506: ...arging hoses at the manifold gauge connection end by utilizing the refrigerant pressure in the refrigerating cycle 3 Start the engine and set at approx 1500 min 1 rpm 4 Turn on the A C switch and set...

Page 507: ...Excessive Refrigerant or Insufficient Condenser Cooling 1 Symptoms seen in refrigerating cycle Both LO and HI pressure side 1 2 pressures too high LO pressure side 1 0 2 to 0 35 MPa 2 0 to 3 5 kgf cm2...

Page 508: ...t evacuation W1016771 Moisture Entered in the Cycle 1 Symptoms seen in refrigerating cycle The air conditioner operates normally at the beginning but over time LO pressure side 1 pressure is vacuum an...

Page 509: ...he expansion valve Replace the receiver Evacuate and charge in proper amount of new refrigerant See page 10 S20 S21 If caused by gas leakage in heat sensitizing tube replace the expansion valve W10173...

Page 510: ...10 S9 1 Discharging the System Prepare for the R134a refrigerant recovery and recycling machine 1 Connect low pressure side hose blue from the recovery and recycling machine to LO pressure side charg...

Page 511: ...the refrigerant cycle For approx 15 minutes 5 When LO pressure gauge 1 reading is more than 750 mmHg 299 in Hg stop the vacuum pump 8 and close both valves 4 10 of manifold gauge fully 6 Wait for ove...

Page 512: ...ld gauge after the system is evacuated completely 2 Connect the center charging hose 5 to the can tap valve 7 fitting and then loosen the center charging hose at the center fitting of manifold gauge u...

Page 513: ...switch Set the temperature control lever to maximum cooling position and the blower switch to HI position 4 Open the LO pressure valve 5 of manifold gauge and the can tap valve 1 on refrigerant conta...

Page 514: ...e sight glass becomes as stated below depending on refrigerant charged amount Insufficient refrigerant charge Air bubbles pass continuously the sight glass when pressure on the LO pressure side is ove...

Page 515: ...de to drain the coolant 3 Remove the radiator cap to completely drain the coolant 4 After all coolant is drained reinstall the radiator hose W1018701 Preparation 1 1 Remove the muffler 1 2 Remove the...

Page 516: ...7 6 Remove the screw 8 7 Pull out the steering joint 6 When reassembling Connecting the heater hose with blue paint one which comes from cabin to the radiator lower hose side W1019206 Preparation 3 1...

Page 517: ...ute Adjusting of Select Wire according to the ROPS type See page 3 S9 Adjust the main speed change rod 2 5 length L so that the main speed change lever become neutral position W1019675 Floor Seat Cove...

Page 518: ...e free play of the parking brake lever See page 5 S8 W1020432 Preparation 5 1 Disconnect the auxiliary speed change rod 3 2 Disconnect the DT shift rod 2 3 Disconnect the earth harness 1 When reassemb...

Page 519: ...and cap the open fittings immediately to keep moisture out of the system 4 Remove the cap stay 3 When reassembling Apply compressor oil DENSO CO ND OIL8 to the O rings and take care not to damage the...

Page 520: ...does not slip when the A C switch and blower switch are turned ON when the air conditioner is in operation 4 If anything abnormal is found repair or replace W1021678 Stator Coil 1 Measure the resista...

Page 521: ...Refer to Charging the System See page 10 S21 Apply compressor oil DENSO CO ND OIL8 or equivalent to the O rings and take care not to damage them S letter is marked on the compressor for connecting the...

Page 522: ...hand after assembling and not contact with stator and hub plate Check and adjust the air gap before tight the magnet clutch mounting screw to the specified torque W1059166 Rotor 1 Remove the cir clip...

Page 523: ...5 and the pin 4 of stator Reference Code No for circlip T1065 87440 W1059953 3 Servicing Adjustment of Air gap 1 Measure the air gap with a feeler gauge 2 When the measurement value comes off from fac...

Page 524: ...oss the 4 terminal and chassis should be approx battery voltage W1024046 2 Relay Test A C Main Relay Compressor Relay 1 Remove the relay 1 2 Connect the battery 2 and bulb 3 with the relay 1 as shown...

Page 525: ...from the battery voltage the wiring harness A C relay fuse or main switch is faulty W1021363 Blower Switch Test 1 Check the continuity through the switch with an ohmmeter 2 If the continuity specifie...

Page 526: ...6 If the blower motor does not run check the motor W1024850 D Blower Resistor Blower Resistor Check 1 Disconnect the 4P connector 2 for blower resistor 1 2 Measure the resistance with an ohmmeter acr...

Page 527: ...ssis should be approx battery voltage W1047635 2 Relay Test 1 Remove the relay 1 2 Connect the battery 2 and bulbs 3 with the relay 1 as shown in the figure left 3 If the bulb on when disconnecting th...

Page 528: ...C relay or fuse is faulty W1022722 A C Switch Check 1 Check the continuity through the switch with an ohmmeter 2 If the continuity specified below is not indicated check the switch 1 Push the A C swi...

Page 529: ...witch then set the blower switch to HI position 3 Raise pressure on the HI pressure side of the refrigerant cycle by covering the condenser front with a corrugated carboard and the dual switch 8 is ac...

Page 530: ...Connector Voltage 1 Turn the main switch ON 2 Measure the voltage with a voltmeter across the connector 4 terminal and chassis 3 If the voltage differs from the battery voltage 11 to 14 V the wiring h...

Page 531: ...g cap completely 1 Stop the engine and let cool down 2 Remove the hose 1 to drain the coolant When removing the drain plug set the hose to drain port 3 Remove the radiator cap to completely drain the...

Page 532: ...oor Control Cable Yellow Cable 1 Disconnect the air conditioner mode door control cable 3 from the def control lever 1 of A C control panel side When reassembling Set the air conditioner unit to DEF m...

Page 533: ...ive screws 7 and take off the unit 5 Remove the duct hoses When reassembling When reconnecting the cooler pipes with the unit apply compressor oil DENSO CO ND OIL8 to O rings When remounting the unit...

Page 534: ...en reassembling W1031898 B Removing Air Conditioner Pipes Discharging Refrigerant 1 Refer to Discharging the System See page 10 S19 W1032195 Muffler and Bonnet 1 Disconnect the battery s cable 4 2 Rem...

Page 535: ...ssembling Apply compressor oil DENSO CO ND OIL8 to the O rings and take care not to damage them W1032488 Inner Covers 1 Remove the inner covers 1 and 2 2 Remove the seat W1032629 Tightening torque Low...

Page 536: ...age them W1032723 C Removing Heater Hoses Draining Coolant CAUTION Never remove the radiator cap until coolant temperature is well below its boiling point Then loosen cap slightly to relieve any exces...

Page 537: ...covers 1 and 2 W1027579 Removing Heater Hoses 1 Remove the outer roof 2 Disconnect the heater hoses 1 2 3 Pull out the heater hoses 1 2 from the bottom of the cabin 4 Take out the heater hoses 1 2 Whe...

Page 538: ...el 3 and disconnect the rear wiper switch connector 2 2 Perform the following checkings 1 and 2 W1034410 1 Connector Voltage 1 Turn the main switch ON 2 Measure the voltage with a voltmeter across the...

Page 539: ...ling A Cab Windshield Preparation 1 Prepare the followings Cutter knife 1 piece Scraper 1 piece Gun for coating 1 piece Sika Tack Ultrafast or equivalent Sika cleaner No 1 Gummed tape NOTE Sika Tack U...

Page 540: ...knife 3 into the adhered part 2 Keep the edge of knife blade square to the glass edge at the part a Slide the knife blade along the glass surface and the edge Pull the part b in the direction paralle...

Page 541: ...Sika Tack Ultrafast or equivalent on the glasses as shown in the figure left NOTE Apply the Sika Tack Ultrafast or equivalent with the jig having the specified tip shape as shown in the figure left Ap...

Page 542: ...ape adhesive tape little by little to confirm the bonding condition W1036353 B Rear Windshield Wiper Rear Wiper Motor 1 Remove the wiper motor cover 5 2 Disconnect the rear wiper motor 4P connector 2...

Page 543: ...de No 9Y011 18302 2003 06 S E I E I e KUBOTA Corporation EDITOR KUBOTA FARM INDUSTRIAL MACHINERY SERVICE LTD 64 ISHIZU KITAMACHI SAKAI KU SAKAI CITY OSAKA 590 0823 JAPAN PHONE 81 72 241 1129 FAX 81 72...

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