Kubota L3240-3 L3540-3 L3940-3 L4240-3 L4740-3 L5040-3 L5240-3 L5740-3 Tractor Workshop Manual – PDF DOWNLOAD

Description

Kubota L3240-3 L3540-3 L3940-3 L4240-3 L4740-3 L5040-3 L5240-3 L5740-3 Tractor Workshop Manual – PDF DOWNLOAD

DESCRIPTION:

Kubota L3240-3 L3540-3 L3940-3 L4240-3 L4740-3 L5040-3 L5240-3 L5740-3 Tractor Workshop Manual – PDF DOWNLOAD

TO THE READER
This Workshop Manual tells the servicing personnel about the mechanism, servicing and
maintenance of the KUBOTA Tractor L3240-3, L3540-3, L3940-3, L4240-3, L4740-3, L5040-3, L5240-3
and L5740-3. It contains 4 parts: “Information”, “General”, “Mechanism” and “Servicing”.
? Information
This section contains information below.
• Safety First
• Safety Decal
• Specification
• Dimension
? General
This section contains information below.
• Engine Identification
• Model Identification
• General Precautions
• Maintenance Check List
• Check and Maintenance
• Special Tools
? Mechanism
This section contains information on the struction and the function of the unit. Before you continue
with the subsequent sections, make sure that you read this section.
Refer to the latest version of the Workshop Manual (Code No. 9Y021-01870 / 9Y021-18200) for the
diesel engine / tractor mechanism that this workshop manual does not include.
? Servicing
This section contains information below.
• Troubleshooting
• Servicing Specifications
• Tightening Torques
• Checking, Disassembling and Servicing
All illustrations, photographs and specifications contained in this manual are of the newest
information available at the time of publication.
KUBOTA reserves the right to change all information at any time without notice.
Since this manual includes many models, information or illustrations and photographs can show
more than one model.

TABLE OF CONTENTS:

Kubota L3240-3 L3540-3 L3940-3 L4240-3 L4740-3 L5040-3 L5240-3 L5740-3 Tractor Workshop Manual – PDF DOWNLOAD

L3240-3,L3540-3,L3940-3,L4240-3,L4740-3,L5040-3,L5240-3,L5740-3……………………………………………………………………………………………………. 1
TO THE READER…………………………………………………………………………………………………………………………………………….. 2
I INFORMATION…………………………………………………………………………………………………………………………………………….. 3
INFORMATION…………………………………………………………………………………………………………………………………………… 4
1. SAFETY FIRST……………………………………………………………………………………………………………………………………. 5
2. SAFETY DECALS…………………………………………………………………………………………………………………………………… 8
3. SPECIFICATIONS………………………………………………………………………………………………………………………………….. 14
[1] MANUAL TRANSMISSION MODEL……………………………………………………………………………………………………………………. 14
[2] GST MODEL………………………………………………………………………………………………………………………………….. 16
[3] HST MODEL………………………………………………………………………………………………………………………………….. 18
[4] HST MODEL with CABIN………………………………………………………………………………………………………………………… 20
4. TRAVELLING SPEEDS……………………………………………………………………………………………………………………………….. 22
[1] MANUAL TRANSMISSION MODEL……………………………………………………………………………………………………………………. 22
[2] GST MODEL………………………………………………………………………………………………………………………………….. 23
[3] HST MODEL………………………………………………………………………………………………………………………………….. 24
5. DIMENSIONS……………………………………………………………………………………………………………………………………… 25
G GENERAL………………………………………………………………………………………………………………………………………………… 26
GENERAL………………………………………………………………………………………………………………………………………………. 27
1. TRACTOR IDENTIFICATION…………………………………………………………………………………………………………………………… 28
[1] MODEL NAME AND SERIAL NUMBERS………………………………………………………………………………………………………………… 28
[2] E3 ENGINE………………………………………………………………………………………………………………………………….. 29
[3] CYLINDER NUMBER…………………………………………………………………………………………………………………………….. 29
2. GENERAL PRECAUTIONS……………………………………………………………………………………………………………………………… 30
3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING………………………………………………………………………………………………… 31
[1] WIRING…………………………………………………………………………………………………………………………………….. 31
[2] BATTERY……………………………………………………………………………………………………………………………………. 33
[3] FUSE………………………………………………………………………………………………………………………………………. 33
[4] CONNECTOR………………………………………………………………………………………………………………………………….. 33
[5] CIRCUIT TESTER……………………………………………………………………………………………………………………………… 34
[6] COLOR OF WIRING…………………………………………………………………………………………………………………………….. 35
4. LUBRICANTS, FUEL AND COOLANT……………………………………………………………………………………………………………………… 36
5. TIGHTENING TORQUES………………………………………………………………………………………………………………………………. 41
[1] GENERAL USE SCREWS, BOLTS AND NUTS……………………………………………………………………………………………………………. 41
[2] STUD BOLTS…………………………………………………………………………………………………………………………………. 41
[3] METRIC SCREWS, BOLTS AND NUTS………………………………………………………………………………………………………………… 42
[4] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS…………………………………………………………………………………. 42
[5] PLUGS……………………………………………………………………………………………………………………………………… 42
6. MAINTENANCE…………………………………………………………………………………………………………………………………….. 43
7. CHECK AND MAINTENANCE……………………………………………………………………………………………………………………………. 46
[1] DAILY CHECK………………………………………………………………………………………………………………………………… 46
[2] CHECK POINTS OF INITIAL 50 HOURS……………………………………………………………………………………………………………… 50
[3] CHECK POINTS OF EVERY 50 HOURS……………………………………………………………………………………………………………….. 52
[4] CHECK POINTS OF EVERY 100 HOURS………………………………………………………………………………………………………………. 55
[5] CHECK POINTS OF EVERY 200 HOURS………………………………………………………………………………………………………………. 58
[6] CHECK POINTS OF EVERY 400 HOURS………………………………………………………………………………………………………………. 62
[7] CHECK POINT OF EVERY 600 HOURS……………………………………………………………………………………………………………….. 64
[8] CHECK POINT OF EVERY 800 HOURS……………………………………………………………………………………………………………….. 64
[9] CHECK POINT OF EVERY 1500 HOURS………………………………………………………………………………………………………………. 64
[10] CHECK POINTS OF EVERY 3000 HOURS…………………………………………………………………………………………………………….. 65
[11] CHECK POINTS OF EVERY 1 YEAR………………………………………………………………………………………………………………… 65
[12] CHECK POINTS OF EVERY 2 YEAR………………………………………………………………………………………………………………… 65
[13] OTHERS……………………………………………………………………………………………………………………………………. 70
8. SPECIAL TOOLS…………………………………………………………………………………………………………………………………… 74
[1] SPECIAL TOOLS FOR ENGINE…………………………………………………………………………………………………………………….. 74
[2] SPECIAL TOOLS FOR TRACTOR……………………………………………………………………………………………………………………. 84
9. TIRES………………………………………………………………………………………………………………………………………….. 92
[1] TIRE PRESSURE………………………………………………………………………………………………………………………………. 92
[2] TREADS ADJUSTMENT…………………………………………………………………………………………………………………………… 93
(1) Front Wheels (2WD Type)………………………………………………………………………………………………………………….. 93
(2) Front Wheels (4WD Type)………………………………………………………………………………………………………………….. 94
(3) Rear Wheels…………………………………………………………………………………………………………………………….. 94
[3] TIRE LIQUID INJECTION……………………………………………………………………………………………………………………….. 96
[4] IMPLEMENT LIMITATIONS……………………………………………………………………………………………………………………….. 99
1 ENGINE………………………………………………………………………………………………………………………………………………….106
MECHANISM……………………………………………………………………………………………………………………………………………..107
1. FEATURES………………………………………………………………………………………………………………………………………..108
2. EGR (EXHAUST GAS RECIRCULATION) SYSTEM (IF EQUIPPED)…………………………………………………………………………………………………109
[1] EGR VALVE…………………………………………………………………………………………………………………………………..110
[2] EGR COOLER………………………………………………………………………………………………………………………………….110
SERVICING……………………………………………………………………………………………………………………………………………..111
1. TROUBLESHOOTING………………………………………………………………………………………………………………………………….112
2. SERVICING SPECIFICATIONS………………………………………………………………………………………………………………………….115
3. TIGHTENING TORQUES……………………………………………………………………………………………………………………………….121
[1] ROPS Model………………………………………………………………………………………………………………………………….121
[2] CABIN Model…………………………………………………………………………………………………………………………………121
[3] Engine……………………………………………………………………………………………………………………………………..122
4. CHECKING AND ADJUSTING……………………………………………………………………………………………………………………………123
[1] ENGINE BODY…………………………………………………………………………………………………………………………………123
[2] LUBRICATING SYSTEM…………………………………………………………………………………………………………………………..125
[3] COOLING SYSTEM………………………………………………………………………………………………………………………………126
[4] FUEL SYSTEM…………………………………………………………………………………………………………………………………128
[5] TURBOCHARGER ( IF EQUIPPED)…………………………………………………………………………………………………………………..132
5. PREPARATION……………………………………………………………………………………………………………………………………..133
[1] SEPARATING ENGINE FROM TRACTOR (ROPS MODEL)…………………………………………………………………………………………………….133
[2] SEPARATING ENGINE FROM TRACTOR (CABIN MODEL)……………………………………………………………………………………………………142
6. DISASSEMBLING AND ASSEMBLING………………………………………………………………………………………………………………………154
[1] OUTER PARTS…………………………………………………………………………………………………………………………………154
[2] EGR VALVE AND EGR COOLER (IF EQUIPPED)…………………………………………………………………………………………………………155
[3] CYLINDER HEAD AND VALVES……………………………………………………………………………………………………………………..156
[4] TIMING GEARS, CAMSHAFT AND FUEL CAMSHAFT……………………………………………………………………………………………………….161
[5] PISTON AND CONNECTING ROD…………………………………………………………………………………………………………………….167
[6] CRANKSHAFT………………………………………………………………………………………………………………………………….170
7. SERVICING……………………………………………………………………………………………………………………………………….173
[1] CYLINDER HEAD AND VALVES……………………………………………………………………………………………………………………..173
[2] TIMING GEARS, CAMSHAFT AND FUEL CAMSHAFT……………………………………………………………………………………………………….179
[3] PISTON AND CONNECTING ROD…………………………………………………………………………………………………………………….183
[4] CRANKSHAFT………………………………………………………………………………………………………………………………….185
[5] CYLINDER……………………………………………………………………………………………………………………………………189
[6] OIL PUMP……………………………………………………………………………………………………………………………………190
2 CLUTCH………………………………………………………………………………………………………………………………………………….192
MECHANISM……………………………………………………………………………………………………………………………………………..193
1. FEATURE…………………………………………………………………………………………………………………………………………194
SERVICING……………………………………………………………………………………………………………………………………………..195
1. TROUBLESHOOTING………………………………………………………………………………………………………………………………….196
2. SERVICING SPECIFICATIONS………………………………………………………………………………………………………………………….197
3. TIGHTENING TORQUES……………………………………………………………………………………………………………………………….198
4. CHECKING AND ADJUSTING……………………………………………………………………………………………………………………………199
5. PREPARATION……………………………………………………………………………………………………………………………………..200
[1] SEPARATING CLUTCH HOUSING AND ENGINE (ROPS MODEL)……………………………………………………………………………………………….200
[2] SEPARATING CLUTCH HOUSING AND ENGINE (CABIN MODEL)………………………………………………………………………………………………206
6. DISASSEMBLING AND ASSEMBLING………………………………………………………………………………………………………………………216
7. SERVICING……………………………………………………………………………………………………………………………………….217
3 TRANSMISSION…………………………………………………………………………………………………………………………………………….219
MECHANISM……………………………………………………………………………………………………………………………………………..220
1. STRUCTURE……………………………………………………………………………………………………………………………………….221
[1] MANUAL TRANSMISSION MODEL…………………………………………………………………………………………………………………….221
[2] GLIDE SHIFT TRANSMISSION (GST) MODEL…………………………………………………………………………………………………………..222
[3] HYDROSTATIC TRANSMISSION (HST) MODEL…………………………………………………………………………………………………………..223
2. MANUAL TRANSMISSION MODEL…………………………………………………………………………………………………………………………224
[1] POWER TRAIN FOR TRAVELING GEAR………………………………………………………………………………………………………………..224
(1) Main Gear Shift Section…………………………………………………………………………………………………………………..224
(2) Shuttle Shift Section…………………………………………………………………………………………………………………….225
(3) Range Gear Shift Section………………………………………………………………………………………………………………….225
(4) Front Wheel Drive Section (For Four Wheel Drive Model)……………………………………………………………………………………….226
[2] SHIFT LINKAGE MECHANISM………………………………………………………………………………………………………………………227
(1) Main Gear Shift Lever…………………………………………………………………………………………………………………….227
(2) Shuttle Lever……………………………………………………………………………………………………………………………227
(3) Range Gear Shift Lever……………………………………………………………………………………………………………………228
(4) Front Wheel Drive Lever (For Four Wheel Drive Model)…………………………………………………………………………………………228
3. GLIDE SHIFT TRANSMISSION (GST) MODEL……………………………………………………………………………………………………………….229
[1] CHARACTERISTIC AND SYSTEM OUTLINE……………………………………………………………………………………………………………..229
[2] POWER TRAIN…………………………………………………………………………………………………………………………………230
[3] ELECTRICAL CONTROL SYSTEM…………………………………………………………………………………………………………………….231
(1) Electrical Control……………………………………………………………………………………………………………………….231
[4] HYDRAULIC CONTROL SYSTEM……………………………………………………………………………………………………………………..232
(1) Hydraulic Circuit and System Outline……………………………………………………………………………………………………….232
(2) Construction and Function of Components…………………………………………………………………………………………………….234
[5] SHIFT LINKAGE MECHANISM………………………………………………………………………………………………………………………241
4. HYDROSTATIC TRANSMISSION (HST) MODEL……………………………………………………………………………………………………………….242
[1] POWER TRAIN…………………………………………………………………………………………………………………………………242
(1) Structure……………………………………………………………………………………………………………………………….242
(2) Oil Flow………………………………………………………………………………………………………………………………..244
(3) Function of Components……………………………………………………………………………………………………………………245
(4) Operation……………………………………………………………………………………………………………………………….246
(5) Range Gear Shift Section………………………………………………………………………………………………………………….259
(6) Front Wheel Drive Section…………………………………………………………………………………………………………………259
[2] SHIFT LINKAGE MECHANISM………………………………………………………………………………………………………………………260
(1) Range Gear Shift Lever……………………………………………………………………………………………………………………260
5. PTO SYSTEM………………………………………………………………………………………………………………………………………261
[1] STRUCTURE…………………………………………………………………………………………………………………………………..261
[2] AUTO THROTTLE ADVANCE (ATA)…………………………………………………………………………………………………………………..263
SERVICING……………………………………………………………………………………………………………………………………………..264
1. TROUBLESHOOTING………………………………………………………………………………………………………………………………….266
[1] GENERAL…………………………………………………………………………………………………………………………………….266
[2] MANUAL TRANSMISSION MODEL…………………………………………………………………………………………………………………….268
[3] GST SYSTEM………………………………………………………………………………………………………………………………….270
[4] HST SYSTEM………………………………………………………………………………………………………………………………….276
[5] PTO SYSTEM………………………………………………………………………………………………………………………………….283
2. SERVICING SPECIFICATIONS………………………………………………………………………………………………………………………….284
[1] ALL MODEL…………………………………………………………………………………………………………………………………..284
[2] GLIDE SHIFT TRANSMISSION (GST) MODEL…………………………………………………………………………………………………………..285
[3] HST MODEL…………………………………………………………………………………………………………………………………..286
[4] PTO CLUTCH………………………………………………………………………………………………………………………………….286
3. TIGHTENING TORQUES……………………………………………………………………………………………………………………………….287
4. CHECKING AND ADJUSTING……………………………………………………………………………………………………………………………290
[1] PTO CLUTCH………………………………………………………………………………………………………………………………….290
[2] GLIDE SHIFT TRANSMISSION (GST) MODEL…………………………………………………………………………………………………………..291
(1) Electrical Adjusting [GST Fine-adjustment with Electronic Instrument Panel (Intellipanel)]……………………………………………………….291
(2) Hydraulic Checking……………………………………………………………………………………………………………………….294
[3] HYDROSTATIC TRANSMISSION (HST) MODEL…………………………………………………………………………………………………………..297
(1) Electrical Adjusting [Adjustment with Electronic Instrument Panel (Intellipanel)]……………………………………………………………….297
(2) Hydraulic Checking and Adjusting…………………………………………………………………………………………………………..301
5. PREPARATION……………………………………………………………………………………………………………………………………..305
[1] ROPS MODEL………………………………………………………………………………………………………………………………….305
(1) Dismount the step and floor seat…………………………………………………………………………………………………………..305
[2] CABIN MODEL…………………………………………………………………………………………………………………………………315
(1) Separating Cabin from Tractor……………………………………………………………………………………………………………..315
6. DISASSEMBLING AND ASSEMBLING………………………………………………………………………………………………………………………323
[1] MANUAL TRANSMISSION MODEL…………………………………………………………………………………………………………………….323
(1) Clutch Housing…………………………………………………………………………………………………………………………..323
(2) Mid Case………………………………………………………………………………………………………………………………..328
(3) Transmission Case………………………………………………………………………………………………………………………..333
[2] GLIDE SHIFT TRANSMISSION MODEL………………………………………………………………………………………………………………..341
(1) Clutch Housing…………………………………………………………………………………………………………………………..341
(2) Mid Case………………………………………………………………………………………………………………………………..348
(3) Transmission Case………………………………………………………………………………………………………………………..353
(4) Regulating Valve…………………………………………………………………………………………………………………………360
(5) GST Valve Assembly……………………………………………………………………………………………………………………….362
[3] HYDROSTATIC TRANSMISSION MODEL………………………………………………………………………………………………………………..368
(1) Clutch Housing…………………………………………………………………………………………………………………………..368
(2) Mid Case………………………………………………………………………………………………………………………………..376
(3) Transmission Case………………………………………………………………………………………………………………………..378
(4) Regulating Valve…………………………………………………………………………………………………………………………384
7. SERVICING……………………………………………………………………………………………………………………………………….386
[1] MANUAL TRANSMISSION MODEL…………………………………………………………………………………………………………………….386
(1) Bearing, Gear and Shaft…………………………………………………………………………………………………………………..386
(2) Synchronized Gear………………………………………………………………………………………………………………………..387
(3) PTO Clutch………………………………………………………………………………………………………………………………388
(4) Differential Gears……………………………………………………………………………………………………………………….389
[2] GLIDE SHIFT TRANSMISSION (GST) MODEL…………………………………………………………………………………………………………..394
(1) Bearing, Gear and Shaft…………………………………………………………………………………………………………………..394
(2) Synchronizer Gear………………………………………………………………………………………………………………………..394
(3) PTO Clutch………………………………………………………………………………………………………………………………394
(4) Differential Gears……………………………………………………………………………………………………………………….394
(5) GST Clutch………………………………………………………………………………………………………………………………394
[3] HYDROSTATIC TRANSMISSION (HST) MODEL…………………………………………………………………………………………………………..396
(1) Bearing, Gear and Shaft…………………………………………………………………………………………………………………..396
(2) PTO Clutch………………………………………………………………………………………………………………………………396
(3) Differential Gears……………………………………………………………………………………………………………………….396
(4) HST…………………………………………………………………………………………………………………………………….396
4 REAR AXLE……………………………………………………………………………………………………………………………………………….399
MECHANISM……………………………………………………………………………………………………………………………………………..400
1. STRUCTURE……………………………………………………………………………………………………………………………………….401
SERVICING……………………………………………………………………………………………………………………………………………..403
1. TROUBLESHOOTING………………………………………………………………………………………………………………………………….404
2. TIGHTENING TORQUES……………………………………………………………………………………………………………………………….405
3. PREPARATION……………………………………………………………………………………………………………………………………..406
4. DISASSEMBLING AND ASSEMBLING………………………………………………………………………………………………………………………410
5 BRAKES………………………………………………………………………………………………………………………………………………….411
MECHANISM……………………………………………………………………………………………………………………………………………..412
1. STRUCTURE……………………………………………………………………………………………………………………………………….413
2. OPERATION……………………………………………………………………………………………………………………………………….414
SERVICING……………………………………………………………………………………………………………………………………………..415
1. TROUBLESHOOTING………………………………………………………………………………………………………………………………….416
2. SERVICING SPECIFICATIONS………………………………………………………………………………………………………………………….417
3. TIGHTENING TORQUES……………………………………………………………………………………………………………………………….418
4. CHECKING AND ADJUSTING……………………………………………………………………………………………………………………………419
[1] BRAKE PEDAL…………………………………………………………………………………………………………………………………419
5. DISASSEMBLING AND ASSEMBLING………………………………………………………………………………………………………………………420
[1] BRAKE PEDAL…………………………………………………………………………………………………………………………………420
[2] BRAKE CASE………………………………………………………………………………………………………………………………….422
6. SERVICING……………………………………………………………………………………………………………………………………….427
6 FRONT AXLE………………………………………………………………………………………………………………………………………………428
MECHANISM……………………………………………………………………………………………………………………………………………..429
1. STRUCTURE……………………………………………………………………………………………………………………………………….430
[1] 2WD TYPE……………………………………………………………………………………………………………………………………430
[2] 4WD TYPE……………………………………………………………………………………………………………………………………431
SERVICING……………………………………………………………………………………………………………………………………………..433
1. TROUBLESHOOTING………………………………………………………………………………………………………………………………….434
2. SERVICING SPECIFICATIONS………………………………………………………………………………………………………………………….435
3. TIGHTENING TORQUES……………………………………………………………………………………………………………………………….438
4. CHECKING AND ADJUSTING……………………………………………………………………………………………………………………………439
5. DISASSEMBLING AND ASSEMBLING………………………………………………………………………………………………………………………441
[1] SEPARATING FRONT AXLE ASSEMBLY………………………………………………………………………………………………………………..441
[2] DISASSEMBLING 2WD TYPE FRONT AXLE……………………………………………………………………………………………………………..443
[3] DISASSEMBLING 4WD TYPE FRONT AXLE……………………………………………………………………………………………………………..445
6. SERVICING……………………………………………………………………………………………………………………………………….452
[1] 2WD TYPE……………………………………………………………………………………………………………………………………452
[2] 4WD TYPE……………………………………………………………………………………………………………………………………453
7 STEERING………………………………………………………………………………………………………………………………………………..459
MECHANISM……………………………………………………………………………………………………………………………………………..460
1. STRUCTURE……………………………………………………………………………………………………………………………………….461
2. HYDRAULIC CIRCUIT………………………………………………………………………………………………………………………………..462
3. HYDRAULIC PUMP…………………………………………………………………………………………………………………………………..463
4. STEERING CONTROLLER………………………………………………………………………………………………………………………………464
5. STEERING CYLINDER………………………………………………………………………………………………………………………………..466
SERVICING……………………………………………………………………………………………………………………………………………..467
1. TROUBLESHOOTING………………………………………………………………………………………………………………………………….468
2. SERVICING SPECIFICATIONS………………………………………………………………………………………………………………………….469
3. TIGHTENING TORQUES……………………………………………………………………………………………………………………………….470
4. CHECKING AND ADJUSTING……………………………………………………………………………………………………………………………471
[1] STEERING CONTROLLER………………………………………………………………………………………………………………………….471
5. DISASSEMBLING AND ASSEMBLING………………………………………………………………………………………………………………………472
[1] STEERING CONTROLLER………………………………………………………………………………………………………………………….472
[2] STEERING CYLINDER……………………………………………………………………………………………………………………………473
(1) 2 Wheel Drive……………………………………………………………………………………………………………………………473
(2) 4 Wheel Drive……………………………………………………………………………………………………………………………475
[3] STEERING LINKAGE…………………………………………………………………………………………………………………………….477
6. SERVICING……………………………………………………………………………………………………………………………………….478
[1] STEERING CYLINDER……………………………………………………………………………………………………………………………478
8 HYDRAULIC SYSTEM…………………………………………………………………………………………………………………………………………479
MECHANISM……………………………………………………………………………………………………………………………………………..480
1. STRUCTURE……………………………………………………………………………………………………………………………………….481
[1] MANUAL TRANSMISSION AND GLIDE SHIFT TRANSMISSION………………………………………………………………………………………………..481
[2] HYDROSTATIC TRANSMISSION……………………………………………………………………………………………………………………..482
2. HYDRAULIC CIRCUIT………………………………………………………………………………………………………………………………..483
[1] MANUAL TRANSMISSION………………………………………………………………………………………………………………………….483
[2] GLIDE SHIFT TRANSMISSION (GST)………………………………………………………………………………………………………………..484
[3] HYDROSTATIC TRANSMISSION (HST)………………………………………………………………………………………………………………..485
3. HYDRAULIC PUMP…………………………………………………………………………………………………………………………………..486
4. THREE POINT HITCH HYDRAULIC SYSTEM…………………………………………………………………………………………………………………487
[1] THREE POINT HITCH HYDRAULIC CIRCUIT……………………………………………………………………………………………………………487
[2] REAR HYDRAULIC BLOCK…………………………………………………………………………………………………………………………488
[3] POSITION CONTROL LINKAGE……………………………………………………………………………………………………………………..489
[4] LOWERING SPEED ADJUSTING VALVE………………………………………………………………………………………………………………..490
[5] HYDRAULIC CYLINDER…………………………………………………………………………………………………………………………..491
5. FRONT LOADER CONTROL VALVE ASSEMBLY………………………………………………………………………………………………………………..492
[1] STRUCTURE…………………………………………………………………………………………………………………………………..492
[2] FRONT LOADER HYDRAULIC CIRCUIT………………………………………………………………………………………………………………..493
[3] OPERATION…………………………………………………………………………………………………………………………………..494
6. AUXILIARY CONTROL VALVE (IF EQUIPPED)………………………………………………………………………………………………………………501
[1] DOUBLE ACTING TYPE…………………………………………………………………………………………………………………………..501
7. OTHER…………………………………………………………………………………………………………………………………………..502
[1] Safety Valve………………………………………………………………………………………………………………………………..502
SERVICING……………………………………………………………………………………………………………………………………………..503
1. TROUBLESHOOTING………………………………………………………………………………………………………………………………….504
2. SERVICING SPECIFICATIONS………………………………………………………………………………………………………………………….505
3. TIGHTENING TORQUES……………………………………………………………………………………………………………………………….507
4. CHECKING AND ADJUSTING……………………………………………………………………………………………………………………………508
[1] HYDRAULIC PUMP (FOR POWER STEERING)……………………………………………………………………………………………………………508
(1) Pump Test Using Flow-meter………………………………………………………………………………………………………………..508
[2] HYDRAULIC PUMP (FOR THREE POINT HITCH)…………………………………………………………………………………………………………511
(1) Pump Test Using Flow-meter………………………………………………………………………………………………………………..511
[3] RELIEF VALVE AND SAFETY VALVE…………………………………………………………………………………………………………………513
[4] POSITION CONTROL ROD…………………………………………………………………………………………………………………………515
5. DISASSEMBLING AND ASSEMBLING………………………………………………………………………………………………………………………516
[1] HYDRAULIC PUMP………………………………………………………………………………………………………………………………516
(1) Removing Hydraulic Pump Assembly…………………………………………………………………………………………………………..516
(2) Disassembling Hydraulic Pump………………………………………………………………………………………………………………518
[2] THREE POINT HITCH HYDRAULIC BLOCK ASSEMBLY……………………………………………………………………………………………………..519
(1) Separating Hydraulic Block Assembly………………………………………………………………………………………………………..519
(2) Disassembling Hydraulic Assembly…………………………………………………………………………………………………………..521
[3] POSITION CONTROL VALVE……………………………………………………………………………………………………………………….522
(1) Separating Control Valve………………………………………………………………………………………………………………….522
[4] LIFT ARM SUPPORT AND HYDRAULIC CYLINDER………………………………………………………………………………………………………..523
(1) Separating Hydraulic Cylinder……………………………………………………………………………………………………………..523
(2) Disassembling Hydraulic Cylinder…………………………………………………………………………………………………………..524
(3) Separating Lift Arm Support……………………………………………………………………………………………………………….524
(4) Disassembling Lift Arm Shaft………………………………………………………………………………………………………………525
[5] FRONT LOADER CONTROL VALVE AND RELIEF VALVE…………………………………………………………………………………………………….526
(1) Removing Front Loader Control Valve Assembly (ROPS Model)…………………………………………………………………………………….526
(2) Removing Front Loader Control Valve Assembly (CABIN Model)……………………………………………………………………………………527
(3) Disassembling Front Loader Control Valve and Relief Valve…………………………………………………………………………………….529
[6] SAFETY VALVE………………………………………………………………………………………………………………………………..530
6. SERVICING……………………………………………………………………………………………………………………………………….531
[1] LIFT ARM……………………………………………………………………………………………………………………………………531
[2] HYDRAULIC CYLINDER…………………………………………………………………………………………………………………………..532
[3] HYDRAULIC PUMP………………………………………………………………………………………………………………………………533
9 ELECTRICAL SYSTEM………………………………………………………………………………………………………………………………………..534
MECHANISM……………………………………………………………………………………………………………………………………………..535
1. WIRING DIAGRAM…………………………………………………………………………………………………………………………………..536
[1] ROPS TYPE…………………………………………………………………………………………………………………………………..536
(1) Manual Transmission Model…………………………………………………………………………………………………………………536
(2) GST Model……………………………………………………………………………………………………………………………….537
(3) HST Model……………………………………………………………………………………………………………………………….538
[2] CABIN TYPE………………………………………………………………………………………………………………………………….539
(1) HST Model (Main Harness)………………………………………………………………………………………………………………….539
(2) HST Model (Cabin Harness)…………………………………………………………………………………………………………………540
2. ELECTRONIC CONTROL PANEL………………………………………………………………………………………………………………………….541
[1] SYSTEM OUTLINE AND ELECTRICAL CIRCUIT………………………………………………………………………………………………………….541
(1) System Outline…………………………………………………………………………………………………………………………..541
(2) Control Items……………………………………………………………………………………………………………………………542
[2] CONSTRUCTION AND FUNCTION OF COMPONENTS………………………………………………………………………………………………………..543
[3] BASIC CONTROL SYSTEM…………………………………………………………………………………………………………………………553
(1) Normal Display…………………………………………………………………………………………………………………………..553
(2) Attention Display (At Engine Starting)……………………………………………………………………………………………………..554
(3) Service Interval Alert……………………………………………………………………………………………………………………557
(4) Warning Display or Warning Information……………………………………………………………………………………………………..557
(5) Lamp Control…………………………………………………………………………………………………………………………….559
[4] ASSISTANT CONTROL SYSTEM……………………………………………………………………………………………………………………..560
(1) Fail-safe Function……………………………………………………………………………………………………………………….560
(2) Self-diagnosis Function…………………………………………………………………………………………………………………..560
(3) Testing, Setting and adjusting Function…………………………………………………………………………………………………….562
(4) Glow Control…………………………………………………………………………………………………………………………….563
3. ENGINE STARTING SYSTEM AND STOPPING SYSTEM………………………………………………………………………………………………………….564
[1] MANUAL TRANSMISSION MODEL…………………………………………………………………………………………………………………….564
[2] GST MODEL…………………………………………………………………………………………………………………………………..565
[3] HST MODEL…………………………………………………………………………………………………………………………………..566
(1) Related Switches…………………………………………………………………………………………………………………………567
(2) Engine Starting Conditions………………………………………………………………………………………………………………..570
(3) Automatic Engine Stop…………………………………………………………………………………………………………………….571
SERVICING……………………………………………………………………………………………………………………………………………..572
1. TROUBLESHOOTING………………………………………………………………………………………………………………………………….574
2. SERVICING SPECIFICATIONS………………………………………………………………………………………………………………………….585
3. TIGHTENING TORQUES……………………………………………………………………………………………………………………………….586
4. CHECKING AND ADJUSTING……………………………………………………………………………………………………………………………587
[1] BATTERY…………………………………………………………………………………………………………………………………….587
(1) Checking………………………………………………………………………………………………………………………………..587
[2] ECU AND ELECTRONIC INSTRUMENT PANEL (INTELLIPANEL)………………………………………………………………………………………………590
(1) ECU…………………………………………………………………………………………………………………………………….590
(2) Electronic Instrument Panel……………………………………………………………………………………………………………….591
[3] TESTING, SETTING AND ADJUSTING BY ELECTRONIC INSTRUMENT PANEL (INTELLIPANEL)……………………………………………………………………….592
(1) Mode Selection…………………………………………………………………………………………………………………………..592
(2) Mode “A” (Test Mode)……………………………………………………………………………………………………………………..594
(3) Mode “B” (Traveling Speed Coefficient Input Mode) Input the 4 Digit Tire Code for Correct Travel Speed to the Electronic Instrument Panel Memory Panel….596
(4) Mode “C” (PTO Coefficient Number Input Mode) Input the Numeric Code Number for PTO Speed into the Electronic Instrument Panel………………………..597
(5) Mode “D” (Error Information Reset Mode) Delete the Error Information from the Electronic Instrument Panel………………………………………….597
(6) Mode “E” (GST Lever Sensor Fine-adjustment Mode) Setting the GST Lever’s Neutral Position with its Sensor………………………………………….598
(7) Mode “F” (GST Valve FIne-adjustment Mode) Setting the Function of Proportional Reducing Valve…………………………………………………….599
(8) Mode “G” (GST Shift Shock Fine-adjustment Mode) Adjusting the Clutch Engaging Interval…………………………………………………………..600
(9) Mode “H” (Error Information Display Mode) Confirming or Reviewing the Error Information………………………………………………………….600
(10) Mode “I” (Transmission Model Input Mode) Input the Transmission Model into Electronic Instrument Panel……………………………………………601
(11) Mode “J” (Speed Unit Selection Mode) Input the Traveling Speed Unit to the Electronic Instrument Panel……………………………………………601
(12) Mode “K” (HST Pedal, Range Shift Lever, Cruise Control Lever, HST Response Dial, Fine-adjustment Mode)……………………………………………602
(13) Mode “L” (Throttle Sensor Fine-adjustment Mode)…………………………………………………………………………………………….604
(14) Mode “M” (Mode for Factory)………………………………………………………………………………………………………………605
(15) Mode “N” (Tractor Model Select Mode)………………………………………………………………………………………………………605
[4] ELECTRIC CONTROL SYSTEM………………………………………………………………………………………………………………………606
(1) Checking Fuse and Connector……………………………………………………………………………………………………………….607
(2) Checking by Electronic Instrument Panel Connector……………………………………………………………………………………………609
(3) Unit Checking……………………………………………………………………………………………………………………………612
[5] ECU CONTROL SYSTEM (GST MODEL AND HST MODEL)……………………………………………………………………………………………………613
(1) Checking Fuse and Connector……………………………………………………………………………………………………………….613
(2) Checking by Electric Control Unit (ECU)…………………………………………………………………………………………………….615
(3) Checking Sensor and Switch for GST Model……………………………………………………………………………………………………618
(4) Checking Sensor and Switch for HST Model……………………………………………………………………………………………………619
[6] STARTING SYSTEM……………………………………………………………………………………………………………………………..627
(1) Main Switch (ROPS Type)…………………………………………………………………………………………………………………..627
(2) Main Switch (CABIN Type)………………………………………………………………………………………………………………….628
(3) Safety Switch……………………………………………………………………………………………………………………………629
(4) Starter and Starter Relay…………………………………………………………………………………………………………………631
(5) Glow Control System………………………………………………………………………………………………………………………632
(6) Engine Stop Solenoid……………………………………………………………………………………………………………………..633
(7) OPC Controller…………………………………………………………………………………………………………………………..634
[7] CHARGING SYSTEM……………………………………………………………………………………………………………………………..635
[8] LIGHTING SYSTEM……………………………………………………………………………………………………………………………..636
(1) Multi Function Combination Lever (Combination Switch)………………………………………………………………………………………..636
[9] WARNING LAMPS……………………………………………………………………………………………………………………………….638
(1) Checking………………………………………………………………………………………………………………………………..638
[10] MONITOR LAMP……………………………………………………………………………………………………………………………….639
(1) Checking………………………………………………………………………………………………………………………………..639
[11] GAUGES…………………………………………………………………………………………………………………………………….640
(1) Checking………………………………………………………………………………………………………………………………..640
(2) Coolant Temperature Sensor………………………………………………………………………………………………………………..640
5. DISASSEMBLING AND ASSEMBLING………………………………………………………………………………………………………………………641
[1] STARTER…………………………………………………………………………………………………………………………………….641
[2] ALTERNATOR………………………………………………………………………………………………………………………………….641
6. SERVICING……………………………………………………………………………………………………………………………………….644
[1] STARTER…………………………………………………………………………………………………………………………………….644
[2] ALTERNATOR………………………………………………………………………………………………………………………………….646
10 CABIN………………………………………………………………………………………………………………………………………………….648
MECHANISM……………………………………………………………………………………………………………………………………………..649
1. AIR CONDITIONER SYSTEM……………………………………………………………………………………………………………………………650
[1] OUTLINE OF AIR CONDITIONING SYSTEM…………………………………………………………………………………………………………….650
[2] SYSTEM CONTROL………………………………………………………………………………………………………………………………652
[3] ELECTRICAL SYSTEM……………………………………………………………………………………………………………………………653
(1) Electrical Circuit……………………………………………………………………………………………………………………….653
(2) Air Conditioner Relay, Blower Relays and Compressor Relay…………………………………………………………………………………….654
SERVICING……………………………………………………………………………………………………………………………………………..655
1. TROUBLESHOOTING………………………………………………………………………………………………………………………………….656
2. SERVICING SPECIFICATIONS………………………………………………………………………………………………………………………….660
3. TIGHTENING TORQUES……………………………………………………………………………………………………………………………….661
4. PRECAUTIONS AT REPAIRING REFRIGERANT CYCLE………………………………………………………………………………………………………….662
[1] HANDLING OF SERVICE TOOLS…………………………………………………………………………………………………………………….664
(1) Manifold Gauge Set……………………………………………………………………………………………………………………….664
(2) Refrigerant Charging Hose…………………………………………………………………………………………………………………665
(3) Vacuum Pump Adaptor………………………………………………………………………………………………………………………666
(4) Electric Gas Leak Tester………………………………………………………………………………………………………………….666
(5) Can Tap Valve……………………………………………………………………………………………………………………………666
(6) T-joint…………………………………………………………………………………………………………………………………667
(7) R134a Refrigerant Recovery and Recycling Machine…………………………………………………………………………………………….667
5. CHECKING AND CHARGING REFRIGERANT CYCLE…………………………………………………………………………………………………………….668
[1] CHECKING WITH MANIFOLD GAUGE………………………………………………………………………………………………………………….668
[2] DISCHARGING, EVACUATING AND CHARGING…………………………………………………………………………………………………………..672
(1) Discharging the Refrigerant……………………………………………………………………………………………………………….672
(2) Evacuating the System…………………………………………………………………………………………………………………….673
(3) Charging the Refrigerant………………………………………………………………………………………………………………….674
(4) Checking Charge Refrigerant Amount…………………………………………………………………………………………………………676
6. CHECKING, DISASSEMBLING AND SERVICING………………………………………………………………………………………………………………677
[1] CHECKING AND ADJUSTING……………………………………………………………………………………………………………………….677
(1) Compressor………………………………………………………………………………………………………………………………677
(2) Control Panel (Blower Switch, A/C Switch, Mode Control Dial and Temperature Control Dial)………………………………………………………..678
(3) Blower Resistor………………………………………………………………………………………………………………………….680
(4) Blower Motor…………………………………………………………………………………………………………………………….681
(5) Temperature Motor………………………………………………………………………………………………………………………..681
(6) Mode Motor………………………………………………………………………………………………………………………………682
(7) Air Conditioner Relay and Blower Relay……………………………………………………………………………………………………..682
(8) Pressure Switch………………………………………………………………………………………………………………………….683
(9) Front Wiper Switch……………………………………………………………………………………………………………………….684
(10) Front Wiper Motor……………………………………………………………………………………………………………………….685
[2] DISASSEMBLING AND ASSEMBLING………………………………………………………………………………………………………………….686
(1) Separating Cabin from Tractor……………………………………………………………………………………………………………..686
(2) Removing Compressor Assembly………………………………………………………………………………………………………………693
(3) Removing Air Conditioner Unit……………………………………………………………………………………………………………..695
(4) Removing Air Conditioner Pipes…………………………………………………………………………………………………………….698
(5) Removing Heater Hoses…………………………………………………………………………………………………………………….700
(6) Cabin Windshields………………………………………………………………………………………………………………………..702
(7) Wiper Motor……………………………………………………………………………………………………………………………..705
[3] SERVICING…………………………………………………………………………………………………………………………………..705

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