Kubota M8560 M9960 Tractor Workshop Manual – PDF DOWNLOAD

Description

Kubota M8560 M9960 Tractor Workshop Manual – PDF DOWNLOAD

DESCRIPTION:

Kubota M8560 M9960 Tractor Workshop Manual – PDF DOWNLOAD

TO THE READER
This Workshop Manual tells the servicing personnel about the mechanism, servicing and
maintenance of the M8560 and M9960. It contains 4 parts: “Information”, “General”, “Mechanism”
and “Servicing”.
? Information
This section primarily contains information below.
• Safety First
• Safety Decal
• Specification
• Dimension
? General
This section primarily contains information below.
• Engine Identification
• Model Identification
• General Precautions
• Maintenance Check List
• Check and Maintenance
• Special Tools
? Mechanism
This section contains information on the structure and the function of the unit. Before you continue
with the subsequent sections, make sure that you read this section.
Refer to the latest version of Workshop Manual (Code No. 9Y021-01870 / 9Y021-18200) for the
diesel engine / tractor mechanism that this workshop manual does not include.
? Servicing
This section primarily contains information below.
• Troubleshooting
• Servicing Specifications
• Tightening Torques
• Checking, Disassembling and Servicing
Regarding the servicing of Common Rail System (CRS), refer to “DIAGNOSIS MANUAL”
(9Y111-01920).
Regarding the servicing of Diesel Particulate Filter (DPF), refer to “DIESEL PARTICULATE FILTER
HANDLING MANUAL” (9Y111-08130).

• 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 M8560 M9960 Tractor Workshop Manual – PDF DOWNLOAD

M8560,M9960…………………………………………………………………………………………………………………………………. 1
TO THE READER……………………………………………………………………………………………………………………………. 2
I INFORMATION……………………………………………………………………………………………………………………………. 3
INFORMATION………………………………………………………………………………………………………………………….. 4
1. SAFETY FIRST…………………………………………………………………………………………………………………… 5
2. SAFETY DECALS………………………………………………………………………………………………………………….. 9
3. SPECIFICATIONS…………………………………………………………………………………………………………………. 22
4. TRAVELING SPEEDS……………………………………………………………………………………………………………….. 24
5. DIMENSIONS…………………………………………………………………………………………………………………….. 32
G GENERAL……………………………………………………………………………………………………………………………….. 35
GENERAL……………………………………………………………………………………………………………………………… 36
1. TRACTOR IDENTIFICATION………………………………………………………………………………………………………….. 38
[1] MODEL NAME AND SERIAL NUMBERS……………………………………………………………………………………………….. 38
(1) Tractor Number…………………………………………………………………………………………………………. 38
(2) Engine Number………………………………………………………………………………………………………….. 39
(3) DPF Muffler Number……………………………………………………………………………………………………… 40
[2] E4B ENGINE………………………………………………………………………………………………………………… 42
[3] CYLINDER NUMBER……………………………………………………………………………………………………………. 42
2. GENERAL PRECAUTIONS…………………………………………………………………………………………………………….. 43
3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING……………………………………………………………………………….. 44
[1] WIRING……………………………………………………………………………………………………………………. 44
[2] BATTERY…………………………………………………………………………………………………………………… 46
[3] FUSE……………………………………………………………………………………………………………………… 46
[4] CONNECTOR…………………………………………………………………………………………………………………. 46
[5] HANDLING OF CIRCUIT TESTER………………………………………………………………………………………………….. 47
[6] COLOR OF WIRING……………………………………………………………………………………………………………. 48
4. LUBRICANT, FUEL AND COOLANT……………………………………………………………………………………………………… 49
5. TIGHTENING TORQUES……………………………………………………………………………………………………………… 51
[1] GENERAL USE SCREWS, BOLTS AND NUTS…………………………………………………………………………………………… 51
[2] STUD BOLTS………………………………………………………………………………………………………………… 51
[3] HYDRAULIC FITTINGS…………………………………………………………………………………………………………. 52
(1) Hydraulic Hose Fittings…………………………………………………………………………………………………. 52
(2) Hydraulic Pipe Cap Nuts…………………………………………………………………………………………………. 52
(3) Adaptors, Elbows and Others……………………………………………………………………………………………… 52
[4] METRIC SCREWS, BOLTS AND NUTS……………………………………………………………………………………………….. 53
[5] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS………………………………………………………………… 53
[6] PLUGS…………………………………………………………………………………………………………………….. 53
6. MAINTENANCE……………………………………………………………………………………………………………………. 54
7. CHECK AND MAINTENANCE…………………………………………………………………………………………………………… 57
[1] DAILY CHECK……………………………………………………………………………………………………………….. 57
[2] CHECK POINTS OF INITIAL 50 HOURS…………………………………………………………………………………………….. 58
[3] CHECK POINTS OF EVERY 50 HOURS………………………………………………………………………………………………. 60
[4] CHECK POINTS OF EVERY 100 HOURS……………………………………………………………………………………………… 62
[5] CHECK POINTS OF EVERY 200 HOURS……………………………………………………………………………………………… 69
[6] CHECK POINTS OF EVERY 300 HOURS……………………………………………………………………………………………… 73
[7] CHECK POINTS OF EVERY 400 HOURS……………………………………………………………………………………………… 73
[8] CHECK POINTS OF EVERY 600 HOURS……………………………………………………………………………………………… 74
[9] CHECK POINT OF EVERY 800 HOURS………………………………………………………………………………………………. 75
[10] CHECK POINT OF EVERY 1500 HOURS…………………………………………………………………………………………….. 75
[11] CHECK POINTS OF EVERY 3000 HOURS……………………………………………………………………………………………. 76
[12] CHECK POINTS OF EVERY 1 YEAR……………………………………………………………………………………………….. 77
[13] CHECK POINTS OF EVERY 2 YEARS………………………………………………………………………………………………. 78
[14] OTHERS…………………………………………………………………………………………………………………… 82
8. SPECIAL TOOLS………………………………………………………………………………………………………………….. 88
[1] SPECIAL TOOLS FOR ENGINE……………………………………………………………………………………………………. 88
[2] SPECIAL TOOLS FOR TRACTOR……………………………………………………………………………………………………103
[3] SPECIAL TOOLS FOR AIR CONDITIONER UNIT………………………………………………………………………………………..122
9. TIRES………………………………………………………………………………………………………………………….125
[1] TIRE SIZE AND INFLATION PRESSURE……………………………………………………………………………………………..125
[2] TREAD ADJUSTMENT……………………………………………………………………………………………………………126
(1) Front Wheels (2WD Model)…………………………………………………………………………………………………126
(2) Front Wheels (4WD Model)…………………………………………………………………………………………………127
(3) Rear Wheels…………………………………………………………………………………………………………….128
[3] WHEEL HUB………………………………………………………………………………………………………………….129
[4] TIRE LIQUID INJECTION……………………………………………………………………………………………………….129
10. IMPLEMENT LIMITATIONS…………………………………………………………………………………………………………..133
1 ENGINE…………………………………………………………………………………………………………………………………136
MECHANISM…………………………………………………………………………………………………………………………….137
1. ENGINE…………………………………………………………………………………………………………………………138
[1] CYLINDER BLOCK……………………………………………………………………………………………………………..138
[2] HALF-FLOATING HEAD COVER…………………………………………………………………………………………………….138
[3] CYLINDER HEAD………………………………………………………………………………………………………………139
[4] PISTON…………………………………………………………………………………………………………………….139
[5] CENTER DIRECT INJECTION SYSTEM (E-CDIS)……………………………………………………………………………………….139
2. LUBRICATING SYSTEM………………………………………………………………………………………………………………141
[1] OIL COOLER…………………………………………………………………………………………………………………141
3. COOLING SYSTEM………………………………………………………………………………………………………………….142
[1] THERMOSTAT…………………………………………………………………………………………………………………142
[2] BOTTOM BYPASS SYSTEM………………………………………………………………………………………………………..143
4. COMMON RAIL SYSTEM (CRS)…………………………………………………………………………………………………………144
[1] OVERVIEW…………………………………………………………………………………………………………………..144
[2] FUEL SYSTEM………………………………………………………………………………………………………………..145
[3] SUPPLY PUMP………………………………………………………………………………………………………………..146
[4] RAIL………………………………………………………………………………………………………………………149
[5] INJECTOR…………………………………………………………………………………………………………………..150
[6] ENGINE CONTROL SYSTEM……………………………………………………………………………………………………….153
(1) Engine ECU……………………………………………………………………………………………………………..154
(2) Sensor…………………………………………………………………………………………………………………154
5. EGR SYSTEM……………………………………………………………………………………………………………………..157
[1] OVERVIEW…………………………………………………………………………………………………………………..157
[2] INTAKE AND EXHAUST SYSTEM……………………………………………………………………………………………………158
[3] EGR VALVE………………………………………………………………………………………………………………….159
[4] REED VALVE…………………………………………………………………………………………………………………159
6. AFTER TREATMENT SYSTEM…………………………………………………………………………………………………………..160
[1] AFTER TREATMENT DEVICES……………………………………………………………………………………………………..160
[2] DPF REGENERATION PROCESS…………………………………………………………………………………………………….161
(1) Auto Mode………………………………………………………………………………………………………………161
(2) Inhibit Mode……………………………………………………………………………………………………………163
SERVICING…………………………………………………………………………………………………………………………….168
1. TROUBLESHOOTING…………………………………………………………………………………………………………………169
2. SERVICING SPECIFICATIONS…………………………………………………………………………………………………………172
3. TIGHTENING TORQUES………………………………………………………………………………………………………………177
4. CHECKING, DISASSEMBLING AND SERVICING……………………………………………………………………………………………..179
[1] CHECKING AND ADJUSTING………………………………………………………………………………………………………179
(1) Engine Body…………………………………………………………………………………………………………….179
(2) Lubricating System………………………………………………………………………………………………………181
(3) Cooling System………………………………………………………………………………………………………….181
(4) Turbocharger……………………………………………………………………………………………………………183
(5) EGR System……………………………………………………………………………………………………………..184
(6) DPF System……………………………………………………………………………………………………………..185
[2] PREPARATION FOR SEPARATING ENGINE…………………………………………………………………………………………….186
(1) Lubricant and Coolant……………………………………………………………………………………………………186
(2) Bonnet and Cover………………………………………………………………………………………………………..187
(3) DPF Muffler…………………………………………………………………………………………………………….189
(4) Propeller Shaft and Power Steering Hose……………………………………………………………………………………190
[3] SEPARATING ENGINE…………………………………………………………………………………………………………..191
(1) ROPS Model……………………………………………………………………………………………………………..191
(2) CABIN Model…………………………………………………………………………………………………………….195
[4] DISASSEMBLING AND ASSEMBLING…………………………………………………………………………………………………202
(1) Damper Disk and PTO Spline Boss…………………………………………………………………………………………..202
(2) External Parts………………………………………………………………………………………………………….203
(3) Turbocharger and EGR…………………………………………………………………………………………………….203
(4) Common Rail…………………………………………………………………………………………………………….204
(5) Cylinder Head and Valves…………………………………………………………………………………………………208
(6) Thermostat……………………………………………………………………………………………………………..214
(7) Supply Pump…………………………………………………………………………………………………………….215
(8) Water Pump and Oil Cooler………………………………………………………………………………………………..217
(9) Gear Case and Timing Gear………………………………………………………………………………………………..218
(10) Piston and Connecting Rod……………………………………………………………………………………………….220
(11) Flywheel and Crankshaft…………………………………………………………………………………………………223
(12) Intake Air Heater………………………………………………………………………………………………………229
(13) Diesel Particulate Filter (DPF)………………………………………………………………………………………….229
[5] SERVICING………………………………………………………………………………………………………………….231
(1) Cylinder Head…………………………………………………………………………………………………………..231
(2) Timing Gears……………………………………………………………………………………………………………237
(3) Piston and Connecting Rod………………………………………………………………………………………………..239
(4) Crankshaft……………………………………………………………………………………………………………..242
(5) Cylinder……………………………………………………………………………………………………………….245
(6) Oil Pump……………………………………………………………………………………………………………….245
2 TRANSMISSION……………………………………………………………………………………………………………………………247
MECHANISM…………………………………………………………………………………………………………………………….248
1. STRUCTURE………………………………………………………………………………………………………………………249
[1] F8/R8 SPEED TRANSMISSION MODEL……………………………………………………………………………………………….249
[2] F12/R12 SPEED TRANSMISSION MODEL……………………………………………………………………………………………..250
[3] F24/R24 SPEED TRANSMISSION MODEL……………………………………………………………………………………………..251
2. POWER TRAIN FOR TRAVELING GEAR……………………………………………………………………………………………………252
[1] HYDRAULIC SHUTTLE SHIFT SECTION………………………………………………………………………………………………252
(1) Structure………………………………………………………………………………………………………………252
(2) Oil Flow……………………………………………………………………………………………………………….253
(3) Hydraulic Clutch Pack……………………………………………………………………………………………………254
[2] HYDRAULIC SHUTTLE VALVE SECTION………………………………………………………………………………………………255
(1) Structure………………………………………………………………………………………………………………255
(2) Operation………………………………………………………………………………………………………………256
[3] MAIN GEAR SHIFT SECTION……………………………………………………………………………………………………..261
(1) F8/R8 Speed Transmission Model……………………………………………………………………………………………261
(2) F12/R12 and F24/R24 Speed Transmission Model……………………………………………………………………………….262
[4] RANGE GEAR SHIFT SECTION…………………………………………………………………………………………………….263
(1) F8/R8 Speed Transmission Model……………………………………………………………………………………………263
(2) F12/R12 and F24/R24 Speed Transmission Model……………………………………………………………………………….264
(3) Creep Gear Shift Section (Option)…………………………………………………………………………………………265
[5] SHIFT FORK ROD AND FORK……………………………………………………………………………………………………..266
(1) F8/R8 Speed Transmission Model……………………………………………………………………………………………266
(2) F12/R12 and F24/R24 Speed Transmission Model……………………………………………………………………………….267
(3) Creep Gear Shift Section (Option)…………………………………………………………………………………………268
[6] DUAL SPEED SHIFT SECTION…………………………………………………………………………………………………….269
(1) Hydraulic Clutch Pack……………………………………………………………………………………………………269
(2) Dual Speed Valve………………………………………………………………………………………………………..270
3. LUBRICATION FOR TRANSMISSION……………………………………………………………………………………………………..271
4. POWER TRAIN FOR PTO SYSTEM……………………………………………………………………………………………………….272
[1] PTO GEAR SECTION……………………………………………………………………………………………………………272
[2] PTO HYDRAULIC CLUTCH SECTION…………………………………………………………………………………………………273
(1) PTO Hydraulic Clutch…………………………………………………………………………………………………….273
(2) PTO Solenoid Valve, Relief Valve and Oil Flow………………………………………………………………………………274
5. POWER TRAIN FOR 4WD……………………………………………………………………………………………………………..275
[1] 4WD SHIFT SECTION…………………………………………………………………………………………………………..275
(1) 2WD-4WD Section…………………………………………………………………………………………………………275
(2) 2WD-4WD Shift Linkage……………………………………………………………………………………………………276
[2] 4WD HYDRAULIC CLUTCH SECTION (DUAL SPEED MODEL)………………………………………………………………………………..277
(1) 4WD Hydraulic Clutch…………………………………………………………………………………………………….277
(2) 4WD Oil Flow……………………………………………………………………………………………………………278
6. DIFFERENTIAL LOCK……………………………………………………………………………………………………………….279
[1] PIN TYPE…………………………………………………………………………………………………………………..279
[2] HYDRAULIC ACTUATED TYPE (DUAL SPEED MODEL)…………………………………………………………………………………….280
(1) Structure………………………………………………………………………………………………………………280
(2) Oil Flow……………………………………………………………………………………………………………….281
SERVICING…………………………………………………………………………………………………………………………….282
1. TROUBLESHOOTING…………………………………………………………………………………………………………………284
2. SERVICING SPECIFICATIONS…………………………………………………………………………………………………………286
3. TIGHTENING TORQUES………………………………………………………………………………………………………………289
4. CHECKING AND ADJUSTING…………………………………………………………………………………………………………..291
[1] HYDRAULIC SHUTTLE LEVER……………………………………………………………………………………………………..291
(1) Hydraulic Shuttle Lever………………………………………………………………………………………………….291
(2) Engine Start Condition…………………………………………………………………………………………………..293
[2] CLUTCH PEDAL FREE TRAVEL…………………………………………………………………………………………………….294
[3] GEAR SHIFTING LINKAGE……………………………………………………………………………………………………….295
(1) Main Gear Shift…………………………………………………………………………………………………………295
(2) Range Gear Shift………………………………………………………………………………………………………..297
[4] ACCELERATOR SECTION…………………………………………………………………………………………………………299
(1) Checking Accelerator Lever……………………………………………………………………………………………….299
(2) Adjusting Accelerator Lever and Wire………………………………………………………………………………………301
[5] HYDRAULIC CLUTCH VALVE………………………………………………………………………………………………………303
5. DISASSEMBLING AND ASSEMBLING……………………………………………………………………………………………………..307
[1] HYDRAULIC SHUTTLE VALVE AND SOLENOID VALVE…………………………………………………………………………………….307
(1) Preparation for Disassembling and Assembling Valve………………………………………………………………………….307
(2) Hydraulic Shuttle Valve………………………………………………………………………………………………….312
(3) Solenoid Valve………………………………………………………………………………………………………….312
(4) Dual Speed Solenoid Valve………………………………………………………………………………………………..313
[2] PREPARATION FOR SEPARATING EACH BLOCK…………………………………………………………………………………………313
(1) Lubricant and Coolant……………………………………………………………………………………………………313
(2) Front Axle Rocking Restrictor…………………………………………………………………………………………….313
(3) Propeller Shaft (4WD Model) and Power Steering Hose…………………………………………………………………………314
(4) Bonnet and Cover………………………………………………………………………………………………………..315
(5) DPF Muffler…………………………………………………………………………………………………………….317
[3] SEPARATING ENGINE AND CLUTCH HOUSING CASE……………………………………………………………………………………..317
(1) ROPS Model……………………………………………………………………………………………………………..317
(2) CABIN Model…………………………………………………………………………………………………………….320
[4] SEPARATING CLUTCH HOUSING CASE AND TRANSMISSION CASE……………………………………………………………………………327
(1) Preparation for ROPS Model……………………………………………………………………………………………….327
(2) Preparation for CABIN Model………………………………………………………………………………………………336
(3) Clutch Housing Case……………………………………………………………………………………………………..339
(4) Transmission Case……………………………………………………………………………………………………….341
[5] DAMPER DISK………………………………………………………………………………………………………………..342
[6] SHUTTLE AND DUAL SPEED CLUTCH………………………………………………………………………………………………..342
(1) Removing Hydraulic Shuttle Clutch (F8/R8 and F12/R12 Speed Transmission Model)…………………………………………………342
(2) Removing Hydraulic Shuttle Clutch (F24/R24 Speed Transmission Model)………………………………………………………….344
(3) Shuttle Clutch Assembly………………………………………………………………………………………………….346
(4) Removing Dual Speed Clutch……………………………………………………………………………………………….351
[7] SHIFT COVER………………………………………………………………………………………………………………..354
[8] DISASSEMBLING CLUTCH HOUSING CASE…………………………………………………………………………………………….361
(1) Removing 1st Shaft, 2nd Shaft and 3rd Shaft………………………………………………………………………………..361
(2) 1st Shaft………………………………………………………………………………………………………………365
(3) 2nd Shaft and 3rd Shaft………………………………………………………………………………………………….369
(4) 4WD Propeller Shaft……………………………………………………………………………………………………..370
(5) Creep Gear (If Equipped)…………………………………………………………………………………………………371
[9] DISASSEMBLING TRANSMISSION CASE………………………………………………………………………………………………372
(1) Removing PTO Clutch Pack…………………………………………………………………………………………………372
(2) Disassembling PTO Clutch Pack…………………………………………………………………………………………….373
(3) Removing 4WD Clutch (Dual Speed Model)…………………………………………………………………………………….374
(4) Disassembling 4WD Clutch Pack…………………………………………………………………………………………….375
(5) Removing Differential Gear and Bevel Pinion Shaft…………………………………………………………………………..377
(6) Differential Gear……………………………………………………………………………………………………….379
(7) Differential Lock Piston (Dual Speed Model)………………………………………………………………………………..381
[10] PTO GEAR CASE……………………………………………………………………………………………………………..381
(1) 540 Type……………………………………………………………………………………………………………….381
(2) 540/540E Shift Type (If Equipped)…………………………………………………………………………………………382
(3) 540/1000 Interchangeable Type (If Equipped)………………………………………………………………………………..383
6. SERVICING………………………………………………………………………………………………………………………384
[1] BEARING……………………………………………………………………………………………………………………384
[2] SHIFT FORK AND SYNCHRONIZER………………………………………………………………………………………………….384
[3] TRAVELING CLUTCH……………………………………………………………………………………………………………385
[4] SHUTTLE CLUTCH PACK…………………………………………………………………………………………………………386
[5] DUAL SPEED CLUTCH PACK………………………………………………………………………………………………………387
[6] SHAFT AND GEAR……………………………………………………………………………………………………………..387
[7] PTO CLUTCH PACK…………………………………………………………………………………………………………….388
[8] SOLENOID VALVE……………………………………………………………………………………………………………..389
[9] 4WD CLUTCH PACK…………………………………………………………………………………………………………….389
[10] HYDRAULIC PUMP DRIVE GEAR…………………………………………………………………………………………………..391
[11] DIFFERENTIAL GEAR………………………………………………………………………………………………………….392
(1) Spiral Bevel Pinion Shaft………………………………………………………………………………………………..392
(2) Backlash and Tooth Contact……………………………………………………………………………………………….393
(3) Differential Case Differential Pinion Gear and Differential Side Gear…………………………………………………………395
3 REAR AXLE………………………………………………………………………………………………………………………………397
MECHANISM…………………………………………………………………………………………………………………………….398
1. FEATURES……………………………………………………………………………………………………………………….399
SERVICING…………………………………………………………………………………………………………………………….400
1. TROUBLESHOOTING…………………………………………………………………………………………………………………401
2. SERVICING SPECIFICATIONS…………………………………………………………………………………………………………402
3. TIGHTENING TORQUES………………………………………………………………………………………………………………403
4. DISASSEMBLING AND ASSEMBLING……………………………………………………………………………………………………..404
[1] PREPARATION FOR DISASSEMBLING AND ASSEMBLING VALVE……………………………………………………………………………..404
[2] SEPARATING REAR AXLE (ROPS MODEL)…………………………………………………………………………………………….405
[3] SEPARATING REAR AXLE (CABIN MODEL)……………………………………………………………………………………………410
[4] DISASSEMBLING REAR AXLE……………………………………………………………………………………………………..413
(1) Brake Section…………………………………………………………………………………………………………..413
(2) Rear Axle Case………………………………………………………………………………………………………….413
5. SERVICING………………………………………………………………………………………………………………………416
[1] BEARING……………………………………………………………………………………………………………………416
[2] PLANETARY GEAR……………………………………………………………………………………………………………..416
4 BRAKES…………………………………………………………………………………………………………………………………418
MECHANISM…………………………………………………………………………………………………………………………….419
1. TRAVELING BRAKE…………………………………………………………………………………………………………………420
[1] STRUCTURE………………………………………………………………………………………………………………….420
[2] MASTER CYLINDER ASSEMBLY…………………………………………………………………………………………………….421
2. PARKING BRAKE…………………………………………………………………………………………………………………..422
[1] STRUCTURE………………………………………………………………………………………………………………….422
[2] RESTRICTION DEVICE………………………………………………………………………………………………………….423
SERVICING…………………………………………………………………………………………………………………………….425
1. TROUBLESHOOTING…………………………………………………………………………………………………………………426
2. SERVICING SPECIFICATIONS…………………………………………………………………………………………………………427
3. TIGHTENING TORQUES………………………………………………………………………………………………………………428
4. CHECKING, DISASSEMBLING AND SERVICING……………………………………………………………………………………………..429
[1] CHECKING AND ADJUSTING………………………………………………………………………………………………………429
(1) Traveling Brake…………………………………………………………………………………………………………429
(2) Parking Brake…………………………………………………………………………………………………………..431
[2] DISASSEMBLING AND ASSEMBLING…………………………………………………………………………………………………434
(1) Preparation for Disassembling Master Cylinder and Brake Pedal (ROPS Model)…………………………………………………….434
(2) Preparation for Disassembling Master Cylinder and Brake Pedal (CABIN Model)……………………………………………………436
(3) Removing Master Cylinder (ROPS Model)……………………………………………………………………………………..438
(4) Removing Master Cylinder (CABIN Model)…………………………………………………………………………………….439
(5) Master Cylinder…………………………………………………………………………………………………………440
(6) Brake Pedal…………………………………………………………………………………………………………….440
(7) Brake Piston……………………………………………………………………………………………………………441
(8) Brake Disk and Plate…………………………………………………………………………………………………….442
(9) Parking Brake Gear………………………………………………………………………………………………………442
[3] SERVICING………………………………………………………………………………………………………………….445
(1) Brake Pedal…………………………………………………………………………………………………………….445
(2) Traveling Brake…………………………………………………………………………………………………………445
5 FRONT AXLE……………………………………………………………………………………………………………………………..446
MECHANISM…………………………………………………………………………………………………………………………….447
1. STRUCTURE………………………………………………………………………………………………………………………448
[1] 2 WHEEL DRIVE………………………………………………………………………………………………………………448
[2] 4 WHEEL DRIVE………………………………………………………………………………………………………………449
[3] LIMITED SLIP DIFFERENTIAL (LSD)………………………………………………………………………………………………450
SERVICING…………………………………………………………………………………………………………………………….451
1. TROUBLESHOOTING…………………………………………………………………………………………………………………452
2. SERVICING SPECIFICATIONS…………………………………………………………………………………………………………453
3. TIGHTENING TORQUES………………………………………………………………………………………………………………456
4. CHECKING, DISASSEMBLING AND SERVICING……………………………………………………………………………………………..457
[1] CHECKING AND ADJUSTING………………………………………………………………………………………………………457
[2] DISASSEMBLING AND ASSEMBLING…………………………………………………………………………………………………459
(1) Separating Front Axle [2WD Model]…………………………………………………………………………………………459
(2) Separating Front Axle [4WD Model]…………………………………………………………………………………………459
(3) Disassembling Front Axle [2WD Model]………………………………………………………………………………………461
(4) Disassembling Front Axle [4WD Model]………………………………………………………………………………………463
(5) Removing Differential Gear and Bevel Pinion Shaft…………………………………………………………………………..466
(6) Disassembling Differential Gear (LSD)……………………………………………………………………………………..467
[3] SERVICING………………………………………………………………………………………………………………….469
(1) 2WD Model………………………………………………………………………………………………………………469
(2) 4WD Model………………………………………………………………………………………………………………470
6 STEERING……………………………………………………………………………………………………………………………….479
MECHANISM…………………………………………………………………………………………………………………………….480
1. STEERING MECHANISM………………………………………………………………………………………………………………481
2. STEERING CYLINDER……………………………………………………………………………………………………………….482
SERVICING…………………………………………………………………………………………………………………………….483
1. TROUBLESHOOTING…………………………………………………………………………………………………………………484
2. SERVICING SPECIFICATIONS…………………………………………………………………………………………………………485
3. TIGHTENING TORQUES………………………………………………………………………………………………………………486
4. CHECKING, DISASSEMBLING AND SERVICING……………………………………………………………………………………………..487
[1] CHECKING AND ADJUSTING………………………………………………………………………………………………………487
(1) Steering Controller……………………………………………………………………………………………………..487
(2) Hydraulic Pump………………………………………………………………………………………………………….487
[2] PREPARATION………………………………………………………………………………………………………………..488
(1) Removing Steering Controller (ROPS Model)………………………………………………………………………………….488
(2) Removing Steering Controller (CABIN Model)…………………………………………………………………………………491
[3] DISASSEMBLING AND ASSEMBLING…………………………………………………………………………………………………493
(1) Steering Controller……………………………………………………………………………………………………..493
(2) Removing Power Steering Cylinder (2WD Model)……………………………………………………………………………….495
(3) Removing Power Steering Cylinder (4WD Model)……………………………………………………………………………….496
(4) Disassembling Steering Cylinder…………………………………………………………………………………………..498
[4] SERVICING………………………………………………………………………………………………………………….498
7 HYDRAULIC SYSTEM………………………………………………………………………………………………………………………..499
MECHANISM…………………………………………………………………………………………………………………………….500
1. STRUCTURE………………………………………………………………………………………………………………………501
[1] F8/R8, F12/R12 SPEED TRANSMISSION MODEL……………………………………………………………………………………….501
[2] F24/R24 SPEED TRANSMISSION MODEL……………………………………………………………………………………………..502
2. HYDRAULIC CIRCUIT……………………………………………………………………………………………………………….504
[1] TOTAL HYDRAULIC CIRCUIT……………………………………………………………………………………………………..504
(1) F8/R8, F12/R12 Speed Transmission Model……………………………………………………………………………………504
(2) F24/R24 Speed Transmission Model………………………………………………………………………………………….505
3. THREE POINT HYDRAULIC SYSTEM……………………………………………………………………………………………………..506
[1] OIL COOLER RELIEF VALVE (ROPS MODEL)………………………………………………………………………………………….506
[2] HYDRAULIC CIRCUIT…………………………………………………………………………………………………………..507
[3] HYDRAULIC BLOCK…………………………………………………………………………………………………………….508
[4] LINKAGE MECHANISM…………………………………………………………………………………………………………..509
(1) Position Control………………………………………………………………………………………………………..509
(2) Draft Control…………………………………………………………………………………………………………..511
(3) Mixed Control…………………………………………………………………………………………………………..514
[5] HYDRAULIC CYLINDER………………………………………………………………………………………………………….514
SERVICING…………………………………………………………………………………………………………………………….515
1. TROUBLESHOOTING…………………………………………………………………………………………………………………516
2. SERVICING SPECIFICATIONS…………………………………………………………………………………………………………517
3. TIGHTENING TORQUES………………………………………………………………………………………………………………519
4. CHECKING AND ADJUSTING…………………………………………………………………………………………………………..520
[1] HYDRAULIC PUMP……………………………………………………………………………………………………………..520
[2] RELIEF AND SAFETY VALVE……………………………………………………………………………………………………..523
[3] POSITION AND DRAFT CONTROL LINKAGE……………………………………………………………………………………………525
[4] AUXILIARY CONTROL VALVE LINKAGE………………………………………………………………………………………………532
(1) ROPS Model……………………………………………………………………………………………………………..532
(2) CABIN Model…………………………………………………………………………………………………………….533
[5] OIL COOLER RELIEF VALVE……………………………………………………………………………………………………..534
5. DISASSEMBLING AND ASSEMBLING……………………………………………………………………………………………………..535
[1] HYDRAULIC PUMP……………………………………………………………………………………………………………..535
[2] REMOVING TOP COVER (3-POINT HITCH HYDRAULIC BLOCK)……………………………………………………………………………..536
(1) ROPS Model……………………………………………………………………………………………………………..536
(2) CABIN Model…………………………………………………………………………………………………………….538
[3] HYDRAULIC LINKAGE…………………………………………………………………………………………………………..539
[4] CONTROL VALVE………………………………………………………………………………………………………………543
[5] HYDRAULIC CYLINDER………………………………………………………………………………………………………….545
[6] RELIEF VALVE……………………………………………………………………………………………………………….546
[7] SAFETY VALVE……………………………………………………………………………………………………………….547
[8] TOP LINK BRACKET……………………………………………………………………………………………………………547
[9] LIFT ARM AND LIFT ARM SHAFT………………………………………………………………………………………………….548
[10] LOWERING SPEED ADJUSTING VALVE………………………………………………………………………………………………548
6. SERVICING………………………………………………………………………………………………………………………549
[1] LIFT ARM AND TOP LINK BRACKET………………………………………………………………………………………………..549
8 ELECTRICAL SYSTEM……………………………………………………………………………………………………………………….551
MECHANISM…………………………………………………………………………………………………………………………….552
1. ELECTRICAL CIRCUIT RETAILED CHART…………………………………………………………………………………………………553
[1] ROPS MODEL…………………………………………………………………………………………………………………553
(1) Starting System and Charging System……………………………………………………………………………………….553
(2) Lighting System…………………………………………………………………………………………………………554
(3) Instrument Panel Board (Meter Panel)………………………………………………………………………………………555
(4) Main Control System (Tractor ECU)…………………………………………………………………………………………556
(5) Engine Control System 1 (Engine ECU)………………………………………………………………………………………557
(6) Engine Control System 2 (Engine ECU)………………………………………………………………………………………558
[2] CABIN MODEL………………………………………………………………………………………………………………..559
2. STARTING SYSTEM…………………………………………………………………………………………………………………566
[1] SYSTEM OUTLINE AND ELECTRICAL CIRCUIT…………………………………………………………………………………………566
(1) ROPS Model……………………………………………………………………………………………………………..566
(2) CABIN Model…………………………………………………………………………………………………………….567
[2] COMPONENTS…………………………………………………………………………………………………………………568
(1) Intake Air Heater……………………………………………………………………………………………………….568
(2) Heater Relay……………………………………………………………………………………………………………568
3. INSTRUMENT PANEL………………………………………………………………………………………………………………..569
[1] INDICATION ITEMS OF METER PANEL………………………………………………………………………………………………569
[2] EASY CHECKER™………………………………………………………………………………………………………………570
[3] LCD MONITOR INDICATION………………………………………………………………………………………………………571
(1) ERROR Mode……………………………………………………………………………………………………………..572
(2) Setting Mode……………………………………………………………………………………………………………573
(3) Testing Mode……………………………………………………………………………………………………………573
[4] ECO 40 km/h FUNCTION………………………………………………………………………………………………………..574
(1) Structure………………………………………………………………………………………………………………574
(2) Components……………………………………………………………………………………………………………..575
[5] PTO SPEED LIMITER (IF EQUIPPED 540ECONOMY)…………………………………………………………………………………….576
(1) Structure………………………………………………………………………………………………………………576
(2) Components……………………………………………………………………………………………………………..577
[6] CONSTANT RPM MANAGEMENT SWITCH WITH INDICATOR (WORK CRUISE)……………………………………………………………………..579
(1) Structure………………………………………………………………………………………………………………579
4. LIGHTING SYSTEM…………………………………………………………………………………………………………………580
[1] COMPONENTS…………………………………………………………………………………………………………………580
(1) Flasher Unit……………………………………………………………………………………………………………580
5. TRAILER SOCKET………………………………………………………………………………………………………………….581
SERVICING…………………………………………………………………………………………………………………………….582
1. TROUBLESHOOTING…………………………………………………………………………………………………………………584
2. SERVICING SPECIFICATIONS…………………………………………………………………………………………………………589
3. TIGHTENING TORQUES………………………………………………………………………………………………………………590
4. CHACKING AND ADJUSTING…………………………………………………………………………………………………………..591
[1] BATTERY, FUSE, GROUNDING AND CONNECTOR………………………………………………………………………………………..591
(1) Battery………………………………………………………………………………………………………………..591
(2) Checking Fuse…………………………………………………………………………………………………………..593
(3) Checking Grounding Wires…………………………………………………………………………………………………597
(4) Connector………………………………………………………………………………………………………………598
[2] MAIN SWITCH………………………………………………………………………………………………………………..598
(1) Main Switch (ROPS Model)…………………………………………………………………………………………………598
(2) Main Switch (CABIN Model)………………………………………………………………………………………………..599
[3] INTAKE AIR HEATER…………………………………………………………………………………………………………..601
[4] STARTER MOTOR………………………………………………………………………………………………………………601
[5] ALTERNATOR…………………………………………………………………………………………………………………602
[6] THROTTLE SENSOR…………………………………………………………………………………………………………….604
[7] METER PANEL………………………………………………………………………………………………………………..606
(1) Setting Mode……………………………………………………………………………………………………………606
(2) Adjusting Meter Panel……………………………………………………………………………………………………607
(3) Adjusting Throttle Sensor………………………………………………………………………………………………..608
(4) Testing Mode……………………………………………………………………………………………………………610
(5) Checking the Error Code………………………………………………………………………………………………….611
(6) Selecting the Tractor Specification……………………………………………………………………………………….612
[8] TRACTOR ECU………………………………………………………………………………………………………………..615
(1) Tractor ECU…………………………………………………………………………………………………………….615
(2) Connector Pin (44 Pin)…………………………………………………………………………………………………..617
[9] TRAVELING SWITCH AND SENSOR………………………………………………………………………………………………….618
[10] ENGINE SENSOR……………………………………………………………………………………………………………..623
[11] RELAYS……………………………………………………………………………………………………………………625
(1) Starter Relay…………………………………………………………………………………………………………..625
(2) Intake Air Heater Relay………………………………………………………………………………………………….626
(3) Relays…………………………………………………………………………………………………………………627
[12] LIGHTING SWITCHES AND FLASHER UNIT…………………………………………………………………………………………..629
(1) Combination Switch (ROPS Model)…………………………………………………………………………………………..629
(2) Lever Combination Switch and Horn Switch (CABIN Model)………………………………………………………………………630
(3) Hazard Switch…………………………………………………………………………………………………………..631
(4) Flasher Unit……………………………………………………………………………………………………………632
(5) Front Work Light Switch (ROPS Model)………………………………………………………………………………………633
(6) Front/Rear Work Light (CABIN Model)……………………………………………………………………………………….634
[13] SOLENOID VALVE…………………………………………………………………………………………………………….635
(1) PTO, 4WD and Rear Differential Lock……………………………………………………………………………………….635
(2) Dual Speed (F24/R24 Speed Transmission Model)………………………………………………………………………………636
[14] OPC (OPERATOR PRESENCE CONTROL) SYSTEM……………………………………………………………………………………….636
5. DISASSEMBLING AND ASSEMBLING……………………………………………………………………………………………………..638
[1] STARTER MOTOR………………………………………………………………………………………………………………638
[2] ALTERNATOR…………………………………………………………………………………………………………………638
[3] FUSE (SLOW BLOW 100 A) FOR CABIN MODEL………………………………………………………………………………………..640
6. SERVICING………………………………………………………………………………………………………………………641
[1] STARTER……………………………………………………………………………………………………………………641
[2] ALTERNATOR…………………………………………………………………………………………………………………643
9 CABIN………………………………………………………………………………………………………………………………….645
MECHANISM…………………………………………………………………………………………………………………………….646
1. AIR CONDIITIONING SYSTEM…………………………………………………………………………………………………………647
[1] STRUCTURE………………………………………………………………………………………………………………….647
[2] COMPRESSOR…………………………………………………………………………………………………………………648
[3] AIR CONDITIONER UNIT………………………………………………………………………………………………………..649
[4] SYSTEM CONTROL……………………………………………………………………………………………………………..650
[5] AIR FLOW…………………………………………………………………………………………………………………..651
[6] AIR CONTROL VENT……………………………………………………………………………………………………………651
[7] ELECTRICAL SYSTEM…………………………………………………………………………………………………………..652
(1) Electrical Circuit………………………………………………………………………………………………………652
(2) Blower Relay and Compressor Relay…………………………………………………………………………………………653
(3) Blower 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……………………………………………………………………………………………………663
(1) Manifold Gauge Set………………………………………………………………………………………………………663
(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 Recover and Recycling Machine…………………………………………………………………………….667
5. CHECKING AND CHARGING REFRIGERANT CYCLE……………………………………………………………………………………………668
[1] CHECKING WITH MANIFOLD GAUGE…………………………………………………………………………………………………668
[2] DISCHARGING, EVACUATING AND CHARGING………………………………………………………………………………………….673
(1) Discharging the Refrigerant………………………………………………………………………………………………673
(2) Evacuating the System……………………………………………………………………………………………………674
(3) Charging the Refrigerant…………………………………………………………………………………………………675
(4) Checking Charge Refrigerant Amount………………………………………………………………………………………..677
6. CHECKING, DISASSEMBLING AND SERVICING……………………………………………………………………………………………..678
[1] CHECKING AND ADJUSTING………………………………………………………………………………………………………678
(1) Compressor……………………………………………………………………………………………………………..678
(2) Relay (A/C Compressor, Front Working Light, Front Wiper, Blower, Blower Hi, ACC, Auxiliary Power)………………………………..678
(3) Wiper Relay…………………………………………………………………………………………………………….679
(4) Control Panel (Blower Switch, A/C Switch, Mode Control Dial, Temperature Control Dial and Recirculation/Fresh Air Selection Switch)….680
(5) Blower Resistor…………………………………………………………………………………………………………683
(6) Blower Motor……………………………………………………………………………………………………………683
(7) Temperature Motor……………………………………………………………………………………………………….684
(8) Mode Motor……………………………………………………………………………………………………………..684
(9) Recirculation/Fresh Air Motor…………………………………………………………………………………………….685
(10) Pressure Switch………………………………………………………………………………………………………..686
(11) Front Wiper Switch……………………………………………………………………………………………………..687
(12) Front Wiper Motor………………………………………………………………………………………………………687
(13) Rear Wiper Switch (If equipped)………………………………………………………………………………………….688
(14) Rear Wiper Motor (If equipped)…………………………………………………………………………………………..688
[2] DISASSEMBLING AND ASSEMBLING…………………………………………………………………………………………………689
(1) Separating Cabin from Tractor…………………………………………………………………………………………….689
(2) Removing Compressor Assembly……………………………………………………………………………………………..698
(3) Removing Air Conditioner Unit…………………………………………………………………………………………….701
(4) Removing Air Conditioner Hose…………………………………………………………………………………………….705
(5) Removing Heater Hoses……………………………………………………………………………………………………708
(6) Cab Windshield………………………………………………………………………………………………………….709
(7) Wiper Motor…………………………………………………………………………………………………………….712
[3] SERVICING………………………………………………………………………………………………………………….713
ELECTRIC CIRCUIT………………………………………………………………………………………………………………………….714

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