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Kubota TRACTOR L3560 L4060 L4760 L5060 L5460 L6060 WORKSHOP MANUAL – PDF DOWNLOAD
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Description
Kubota TRACTOR L3560 L4060 L4760 L5060 L5460 L6060 WORKSHOP MANUAL – PDF DOWNLOAD
FILE DETAILS:
Kubota TRACTOR L3560 L4060 L4760 L5060 L5460 L6060 WORKSHOP MANUAL – PDF DOWNLOAD
Language : English
Pages : 801
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Kubota TRACTOR L3560 L4060 L4760 L5060 L5460 L6060 WORKSHOP MANUAL – PDF DOWNLOAD
TO THE READER
This Workshop Manual tells the servicing personnel about the mechanism, servicing and
maintenance of the KUBOTA Tractor L3560, L4060, L4760, L5060, L5460 and L6060. 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
Regarding the servicing of Common Rail System (CRS), refer to “DIAGNOSIS MANUAL”
(9Y120-02420) at the end of this manual.
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 TRACTOR L3560 L4060 L4760 L5060 L5460 L6060 WORKSHOP MANUAL – PDF DOWNLOAD
L3560,L4060,L4760,L5060,L5460,L6060............................................................................................................................................... 1 TO THE READER................................................................................................................................................................. 2 I INFORMATION................................................................................................................................................................. 5 INFORMATION............................................................................................................................................................... 6 1. SAFETY FIRST....................................................................................................................................................... 7 2. SAFETY DECALS...................................................................................................................................................... 10 3. SPECIFICATIONS..................................................................................................................................................... 16 [1] MANUAL TRANSMISSION........................................................................................................................................... 16 [2] GST........................................................................................................................................................... 17 [3] HST........................................................................................................................................................... 18 [4] HST with CABIN TYPE........................................................................................................................................... 20 4. TRAVELING SPEEDS................................................................................................................................................... 22 [1] MANUAL TRANSMISSION........................................................................................................................................... 22 [2] GST........................................................................................................................................................... 23 [3] HST........................................................................................................................................................... 25 5. DIMENSIONS......................................................................................................................................................... 26 G GENERAL..................................................................................................................................................................... 28 GENERAL................................................................................................................................................................... 29 1. TRACTOR IDENTIFICATION............................................................................................................................................. 30 [1] MODEL NAME AND SERIAL NUMBERS................................................................................................................................. 30 [2] E4B ENGINE.................................................................................................................................................... 31 [3] CYLINDER NUMBER............................................................................................................................................... 31 2. GENERAL PRECAUTIONS................................................................................................................................................ 32 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING............................................................................................................... 33 [1] WIRING........................................................................................................................................................ 33 [2] BATTERY....................................................................................................................................................... 35 [3] FUSE.......................................................................................................................................................... 35 [4] CONNECTOR..................................................................................................................................................... 35 [5] CIRCUIT TESTER................................................................................................................................................ 36 [6] COLOR OF WIRING............................................................................................................................................... 37 4. LUBRICANTS, FUEL AND COOLANT....................................................................................................................................... 38 5. TIGHTENING TORQUES................................................................................................................................................. 40 [1] GENERAL USE SCREWS, BOLTS AND NUTS............................................................................................................................ 40 [2] STUD BOLTS.................................................................................................................................................... 40 [3] METRIC SCREWS, BOLTS AND NUTS................................................................................................................................. 41 [4] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS.............................................................................................. 41 [5] PLUGS......................................................................................................................................................... 41 6. MAINTENANCE........................................................................................................................................................ 42 7. CHECK AND MAINTENANCE.............................................................................................................................................. 45 [1] DAILY CHECK................................................................................................................................................... 45 [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............................................................................................................................... 59 [7] CHECK POINT OF EVERY 600 HOURS................................................................................................................................ 62 [8] CHECK POINT OF EVERY 800 HOURS................................................................................................................................ 62 [9] CHECK POINTS OF EVERY 1500 HOURS.............................................................................................................................. 63 [10] CHECK POINTS OF EVERY 3000 HOURS............................................................................................................................. 63 [11] CHECK POINTS OF EVERY 1000 HOURS OR 1 YEAR................................................................................................................... 64 [12] CHECK POINTS OF EVERY 1 YEAR................................................................................................................................. 64 [13] CHECK POINTS OF EVERY 2000 HOURS OR 2 YEARS.................................................................................................................. 69 [14] CHECK POINTS OF EVERY 2 YEARS................................................................................................................................ 71 [15] CHECK POINTS OF EVERY 4 YEARS................................................................................................................................ 72 [16] OTHERS....................................................................................................................................................... 73 8. SPECIAL TOOLS...................................................................................................................................................... 79 [1] SPECIAL TOOLS FOR ENGINE...................................................................................................................................... 79 [2] SPECIAL TOOLS FOR TRACTOR..................................................................................................................................... 92 9. TIRES..............................................................................................................................................................102 [1] TIRES.........................................................................................................................................................102 [2] WHEEL ADJUSTMENT..............................................................................................................................................103 (1) Front Wheel...............................................................................................................................................103 (2) Rear Wheel................................................................................................................................................104 [3] TIRE LIQUID INJECTION.........................................................................................................................................106 10. IMPLEMENT LIMITATIONS.............................................................................................................................................109 1 ENGINE......................................................................................................................................................................114 MECHANISM.................................................................................................................................................................115 1. FEATURES...........................................................................................................................................................116 2. ENGINE BODY........................................................................................................................................................117 [1] PISTON........................................................................................................................................................117 [2] HALF-FLOATING HEAD COVER......................................................................................................................................117 3. LUBRICATING SYSTEM.................................................................................................................................................118 [1] OIL COOLER....................................................................................................................................................118 4. COOLING SYSTEM.....................................................................................................................................................119 [1] THERMOSTAT....................................................................................................................................................119 [2] BOTTOM BYPASS SYSTEM..........................................................................................................................................120 5. FUEL SYSTEM........................................................................................................................................................121 [1] OVERVIEW OF COMMON RAIL SYSTEM................................................................................................................................121 [2] SUPPLY PUMP...................................................................................................................................................124 [3] RAIL..........................................................................................................................................................127 [4] INJECTOR......................................................................................................................................................128 [5] ENGINE CONTROL SYSTEM.........................................................................................................................................132 (1) Engine ECU................................................................................................................................................133 (2) Sensor....................................................................................................................................................133 6. EGR SYSTEM.........................................................................................................................................................136 [1] OVERVIEW......................................................................................................................................................136 [2] EGR COOLER....................................................................................................................................................137 [3] EGR VALVE.....................................................................................................................................................137 [4] REED VALVE....................................................................................................................................................137 7. AFTER TREATMENT SYSTEM.............................................................................................................................................138 [1] AFTER TREATMENT DEVICES.......................................................................................................................................138 [2] DPF REGENERATION SYSTEM (INHIBIT VERSION).....................................................................................................................139 (1) Regeneration Mode (Inhibit Version).......................................................................................................................139 (2) PM Warning Level (Inhibit Version)........................................................................................................................140 [3] DPF REGENERATION SYSTEM (Default Version).....................................................................................................................141 (1) Regeneration Mode (Default Version).......................................................................................................................141 (2) PM Warning Level (Default Version)........................................................................................................................142 SERVICING.................................................................................................................................................................147 1. TROUBLESHOOTING....................................................................................................................................................148 2. SERVICING SPECIFICATIONS...........................................................................................................................................151 3. TIGHTENING TORQUES.................................................................................................................................................157 4. CHECKING AND ADJUSTING.............................................................................................................................................159 [1] ENGINE BODY...................................................................................................................................................159 [2] LUBRICATING SYSTEM............................................................................................................................................161 [3] COOLING SYSTEM................................................................................................................................................161 [4] TURBOCHARGER..................................................................................................................................................163 [5] PCV VALVE.....................................................................................................................................................164 [6] EGR COOLER....................................................................................................................................................164 5. PREPARATION........................................................................................................................................................165 [1] SEPARATING DPF MUFFLER FROM TRACTOR...........................................................................................................................165 [2] SEPARATING CLUTCH HOUSING AND ENGINE (ROPS TYPE)..............................................................................................................171 [3] SEPARATING CLUTCH HOUSING AND ENGINE (CABIN TYPE).............................................................................................................184 6. DISASSEMBLING AND ASSEMBLING.......................................................................................................................................199 [1] OUTER PARTS...................................................................................................................................................199 [2] CLUTCH ASSEMBLY...............................................................................................................................................199 [3] TURBOCHARGER AND EGR..........................................................................................................................................200 [4] COMMON RAIL...................................................................................................................................................201 [5] CYLINDER HEAD AND VALVES......................................................................................................................................203 [6] THERMOSTAT....................................................................................................................................................208 [7] SUPPLY PUMP...................................................................................................................................................209 [8] WATER PUMP AND OIL COOLER.....................................................................................................................................209 [9] GEAR CASE AND TIMING GEAR.....................................................................................................................................210 [10] PISTON AND CONNECTING ROD....................................................................................................................................213 [11] FLYWHEEL AND CRANKSHAFT......................................................................................................................................217 7. SERVICING..........................................................................................................................................................223 [1] CYLINDER HEAD AND VALVES......................................................................................................................................223 [2] TIMING GEARS..................................................................................................................................................229 [3] PISTON AND CONNECTING ROD.....................................................................................................................................232 [4] CRANKSHAFT....................................................................................................................................................234 [5] CYLINDER......................................................................................................................................................239 [6] OIL PUMP......................................................................................................................................................240 2 CLUTCH......................................................................................................................................................................241 MECHANISM.................................................................................................................................................................242 1. FEATURE............................................................................................................................................................243 SERVICING.................................................................................................................................................................245 1. TROUBLESHOOTING....................................................................................................................................................246 2. SERVICING SPECIFICATIONS...........................................................................................................................................247 3. TIGHTENING TORQUES.................................................................................................................................................248 4. CHECKING AND ADJUSTING.............................................................................................................................................249 5. PREPARATION........................................................................................................................................................250 [1] SEPARATING CLUTCH HOUSING FROM ENGINE (ROPS TYPE).............................................................................................................250 [2] SEPARATING CLUTCH HOUSING AND ENGINE (CABIN TYPE).............................................................................................................260 6. DISASSEMBLING AND ASSEMBLING.......................................................................................................................................272 7. SERVICING..........................................................................................................................................................273 [1] MANUAL TRANSMISSION AND GST...................................................................................................................................273 [2] HST...........................................................................................................................................................274 3 TRANSMISSION................................................................................................................................................................275 MECHANISM.................................................................................................................................................................276 1. STRUCTURE..........................................................................................................................................................277 [1] MANUAL TRANSMISSION...........................................................................................................................................277 [2] GLIDE SHIFT TRANSMISSION (GST)................................................................................................................................278 [3] HYDROSTATIC TRANSMISSION (HST)................................................................................................................................279 2. MANUAL TRANSMISSION................................................................................................................................................280 [1] POWER TRAIN FOR TRAVELING GEAR................................................................................................................................280 (1) Main Gear Shift Section...................................................................................................................................280 (2) Shuttle Shift Section.....................................................................................................................................280 (3) Range Gear Shift Section..................................................................................................................................281 (4) Front Wheel Drive Section.................................................................................................................................281 [2] SHIFT LINKAGE MECHANISM.......................................................................................................................................282 (1) Main Gear Shift Lever.....................................................................................................................................282 (2) Shuttle Lever.............................................................................................................................................282 (3) Range Gear Shift Lever....................................................................................................................................283 (4) Front Wheel Drive Lever...................................................................................................................................283 3. GLIDE SHIFT TRANSMISSION (GST).....................................................................................................................................284 [1] CHARACTERISTIC AND SYSTEM OUTLINE.............................................................................................................................284 [2] POWER TRAIN...................................................................................................................................................285 [3] ELECTRICAL CONTROL SYSTEM.....................................................................................................................................286 (1) Electrical Control........................................................................................................................................286 [4] HYDRAULIC CONTROL SYSTEM......................................................................................................................................287 (1) Hydraulic Circuit and System Outline......................................................................................................................287 (2) Construction and Function of Components...................................................................................................................289 [5] SHIFT LINKAGE MECHANISM.......................................................................................................................................296 4. HYDROSTATIC TRANSMISSION (HST).....................................................................................................................................297 [1] POWER TRAIN...................................................................................................................................................297 (1) Structure.................................................................................................................................................297 (2) Oil Flow..................................................................................................................................................299 (3) Function of Components....................................................................................................................................300 (4) Operation.................................................................................................................................................301 (5) Range Gear Shift Section..................................................................................................................................314 (6) Front Wheel Drive Section.................................................................................................................................315 [2] SHIFT LINKAGE MECHANISM.......................................................................................................................................315 (1) Range Gear Shift Lever....................................................................................................................................315 5. PTO SYSTEM.........................................................................................................................................................316 [1] STRUCTURE.....................................................................................................................................................316 SERVICING.................................................................................................................................................................318 1. TROUBLESHOOTING....................................................................................................................................................320 [1] GENERAL.......................................................................................................................................................320 [2] ERROR DISPLAY ON THE INTELLIPANEL.............................................................................................................................322 [3] PTO SYSTEM....................................................................................................................................................331 2. SERVICING SPECIFICATIONS...........................................................................................................................................332 3. TIGHTENING TORQUES.................................................................................................................................................335 4. CHECKING AND ADJUSTING.............................................................................................................................................339 [1] PTO CLUTCH....................................................................................................................................................339 [2] GLIDE SHIFT TRANSMISSION (GST)................................................................................................................................340 (1) Electrical Adjusting [GST Fine-adjustment with Electronic Instrument Panel (Intellipanel)]................................................................340 (2) Hydraulic Checking........................................................................................................................................342 [3] HYDROSTATIC TRANSMISSION (HST)................................................................................................................................346 (1) Electrical Adjusting [Adjustment with Electronic Instrument Panel (Intellipanel)].........................................................................346 (2) Hydraulic Checking and Adjusting..........................................................................................................................349 5. PREPARATION........................................................................................................................................................353 [1] ROPS TYPE.....................................................................................................................................................353 (1) Dismounting the step and floor seat.......................................................................................................................353 [2] CABIN TYPE....................................................................................................................................................366 (1) Separating Cabin from Tractor.............................................................................................................................366 6. DISASSEMBLING AND ASSEMBLING.......................................................................................................................................377 [1] MANUAL TRANSMISSION...........................................................................................................................................377 (1) Clutch Housing............................................................................................................................................377 (2) Mid Case..................................................................................................................................................383 (3) Transmission Case.........................................................................................................................................389 [2] GLIDE SHIFT TRANSMISSION......................................................................................................................................397 (1) Clutch Housing............................................................................................................................................397 (2) Mid Case..................................................................................................................................................402 (3) Transmission Case.........................................................................................................................................408 (4) Regulating Valve..........................................................................................................................................415 (5) GST Valve Assembly........................................................................................................................................417 [3] HYDROSTATIC TRANSMISSION......................................................................................................................................423 (1) Clutch Housing............................................................................................................................................423 (2) Mid Case..................................................................................................................................................430 (3) Transmission Case.........................................................................................................................................433 (4) Regulating Valve..........................................................................................................................................440 7. SERVICING..........................................................................................................................................................442 [1] MANUAL TRANSMISSION...........................................................................................................................................442 (1) Bearing, Gear and Shaft...................................................................................................................................442 (2) Synchronized Gear.........................................................................................................................................443 (3) PTO Clutch................................................................................................................................................444 (4) Differential Gears........................................................................................................................................445 [2] GLIDE SHIFT TRANSMISSION (GST)................................................................................................................................448 (1) Bearing, Gear and Shaft...................................................................................................................................448 (2) Synchronizer Gear.........................................................................................................................................448 (3) PTO Clutch................................................................................................................................................448 (4) Differential Gears........................................................................................................................................448 (5) GST Clutch................................................................................................................................................449 [3] HYDROSTATIC TRANSMISSION (HST)................................................................................................................................451 (1) Bearing, Gear and Shaft...................................................................................................................................451 (2) PTO Clutch................................................................................................................................................451 (3) Differential Gears........................................................................................................................................451 (4) HST.......................................................................................................................................................451 4 REAR AXLE...................................................................................................................................................................454 MECHANISM.................................................................................................................................................................455 1. STRUCTURE..........................................................................................................................................................456 SERVICING.................................................................................................................................................................458 1. TROUBLESHOOTING....................................................................................................................................................459 2. TIGHTENING TORQUES.................................................................................................................................................460 3. PREPARATION........................................................................................................................................................461 4. DISASSEMBLING AND ASSEMBLING.......................................................................................................................................465 5 BRAKES......................................................................................................................................................................466 MECHANISM.................................................................................................................................................................467 1. STRUCTURE..........................................................................................................................................................468 2. OPERATION..........................................................................................................................................................469 SERVICING.................................................................................................................................................................470 1. TROUBLESHOOTING....................................................................................................................................................471 2. SERVICING SPECIFICATIONS...........................................................................................................................................472 3. TIGHTENING TORQUES.................................................................................................................................................473 4. CHECKING AND ADJUSTING.............................................................................................................................................474 [1] BRAKE PEDAL...................................................................................................................................................474 5. DISASSEMBLING AND ASSEMBLING.......................................................................................................................................475 [1] BRAKE PEDAL...................................................................................................................................................475 [2] BRAKE CASE....................................................................................................................................................478 6. SERVICING..........................................................................................................................................................485 6 FRONT AXLE..................................................................................................................................................................486 MECHANISM.................................................................................................................................................................487 1. STRUCTURE..........................................................................................................................................................488 SERVICING.................................................................................................................................................................490 1. TROUBLESHOOTING....................................................................................................................................................491 2. SERVICING SPECIFICATIONS...........................................................................................................................................492 3. TIGHTENING TORQUES.................................................................................................................................................494 4. CHECKING AND ADJUSTING.............................................................................................................................................495 5. DISASSEMBLING AND ASSEMBLING.......................................................................................................................................497 [1] SEPARATING FRONT AXLE ASSEMBLY................................................................................................................................497 [2] DISASSEMBLING FRONT AXLE......................................................................................................................................498 6. SERVICING..........................................................................................................................................................505 7 STEERING....................................................................................................................................................................511 MECHANISM.................................................................................................................................................................512 1. STRUCTURE..........................................................................................................................................................513 2. HYDRAULIC CIRCUIT..................................................................................................................................................514 3. HYDRAULIC PUMP.....................................................................................................................................................515 4. STEERING CONTROLLER................................................................................................................................................516 5. STEERING CYLINDER..................................................................................................................................................518 SERVICING.................................................................................................................................................................519 1. TROUBLESHOOTING....................................................................................................................................................520 2. SERVICING SPECIFICATIONS...........................................................................................................................................521 3. TIGHTENING TORQUES.................................................................................................................................................522 4. CHECKING AND ADJUSTING.............................................................................................................................................523 [1] STEERING CONTROLLER...........................................................................................................................................523 5. DISASSEMBLING AND ASSEMBLING.......................................................................................................................................524 [1] STEERING CONTROLLER...........................................................................................................................................524 [2] STEERING LINKAGE..............................................................................................................................................525 [3] STEERING CYLINDER.............................................................................................................................................526 6. SERVICING..........................................................................................................................................................527 [1] STEERING CYLINDER.............................................................................................................................................527 8 HYDRAULIC SYSTEM............................................................................................................................................................528 MECHANISM.................................................................................................................................................................529 1. STRUCTURE..........................................................................................................................................................530 [1] MANUAL TRANSMISSION AND GLIDE SHIFT TRANSMISSION..............................................................................................................530 [2] HYDROSTATIC TRANSMISSION......................................................................................................................................531 2. HYDRAULIC CIRCUIT..................................................................................................................................................532 [1] MANUAL TRANSMISSION...........................................................................................................................................532 [2] GLIDE SHIFT TRANSMISSION (GST)................................................................................................................................533 [3] HYDROSTATIC TRANSMISSION (HST)................................................................................................................................534 3. HYDRAULIC PUMP.....................................................................................................................................................535 4. THREE POINT HITCH HYDRAULIC SYSTEM.................................................................................................................................536 [1] THREE POINT HITCH HYDRAULIC CIRCUIT...........................................................................................................................536 [2] REAR HYDRAULIC BLOCK..........................................................................................................................................537 [3] POSITION CONTROL VALVE........................................................................................................................................537 [4] POSITION CONTROL LINKAGE......................................................................................................................................539 [5] LOWERING SPEED ADJUSTING VALVE................................................................................................................................540 [6] HYDRAULIC CYLINDER............................................................................................................................................541 5. FRONT LOADER CONTROL VALVE ASSEMBLY................................................................................................................................542 [1] STRUCTURE.....................................................................................................................................................542 [2] FRONT LOADER HYDRAULIC CIRCUIT................................................................................................................................543 [3] OPERATION.....................................................................................................................................................544 6. AUXILIARY CONTROL VALVE (IF EQUIPPED)..............................................................................................................................551 [1] DOUBLE ACTING TYPE............................................................................................................................................551 7. OTHER..............................................................................................................................................................552 SERVICING.................................................................................................................................................................553 1. TROUBLESHOOTING....................................................................................................................................................554 2. SERVICING SPECIFICATIONS...........................................................................................................................................555 3. TIGHTENING TORQUES.................................................................................................................................................558 4. CHECKING AND ADJUSTING.............................................................................................................................................559 [1] HYDRAULIC PUMP (FOR POWER STEERING)...........................................................................................................................559 (1) Pump Test Using Flow-meter................................................................................................................................559 [2] HYDRAULIC PUMP (FOR THREE POINT HITCH)........................................................................................................................562 (1) Pump Test Using Flow-meter................................................................................................................................562 [3] RELIEF VALVE AND SAFETY VALVE.................................................................................................................................564 [4] POSITION CONTROL ROD..........................................................................................................................................566 5. DISASSEMBLING AND ASSEMBLING.......................................................................................................................................567 [1] HYDRAULIC PUMP................................................................................................................................................567 (1) Removing Hydraulic Pump Assembly..........................................................................................................................567 (2) Disassembling Hydraulic Pump..............................................................................................................................569 [2] THREE POINT HITCH HYDRAULIC BLOCK ASSEMBLY....................................................................................................................570 (1) Separating Hydraulic Block Assembly.......................................................................................................................570 (2) Disassembling Hydraulic Assembly..........................................................................................................................572 [3] POSITION CONTROL VALVE........................................................................................................................................573 (1) Separating Control Valve..................................................................................................................................573 [4] LIFT ARM SUPPORT AND HYDRAULIC CYLINDER.......................................................................................................................574 (1) Separating Hydraulic Cylinder.............................................................................................................................574 (2) Disassembling Hydraulic Cylinder..........................................................................................................................575 (3) Separating Lift Arm Support...............................................................................................................................575 (4) Disassembling Lift Arm Shaft..............................................................................................................................576 [5] FRONT LOADER CONTROL VALVE AND RELIEF VALVE...................................................................................................................577 (1) Removing Front Loader Control Valve Assembly..............................................................................................................577 (2) Disassembling Front Loader Control Valve and Relief Valve.................................................................................................580 [6] SAFETY VALVE..................................................................................................................................................581 6. SERVICING..........................................................................................................................................................582 [1] LIFT ARM......................................................................................................................................................582 [2] HYDRAULIC CYLINDER............................................................................................................................................583 [3] HYDRAULIC PUMP................................................................................................................................................584 9 ELECTRICAL SYSTEM...........................................................................................................................................................585 MECHANISM.................................................................................................................................................................586 1. WIRING DIAGRAM.....................................................................................................................................................587 [1] MANUAL TRANSMISSION (WITHOUT CCV HEATER)......................................................................................................................587 [2] MANUAL TRANSMISSION (WITH CCV HEATER).........................................................................................................................588 [3] GST (WITHOUT CCV HEATER)......................................................................................................................................589 [4] GST (WITH CCV HEATER).........................................................................................................................................590 [5] HST ROPS TYPE (WITHOUT CCV HEATER)............................................................................................................................591 [6] HST ROPS TYPE (WITH CCV HEATER)...............................................................................................................................592 [7] HST CABIN TYPE (WITHOUT CCV HEATER)...........................................................................................................................593 [8] HST CABIN TYPE (WITH CCV HEATER)..............................................................................................................................594 2. ELECTRICAL CIRCUIT.................................................................................................................................................595 [1] MANUAL TRANSMISSION (WITHOUT CCV HEATER)......................................................................................................................595 [2] MANUAL TRANSMISSION (WITH CCV HEATER).........................................................................................................................596 [3] GST (WITHOUT CCV HEATER)......................................................................................................................................597 [4] GST (WITH CCV HEATER).........................................................................................................................................598 [5] HST ROPS TYPE (WITHOUT CCV HEATER)............................................................................................................................599 [6] HST ROPS TYPE (WITH CCV HEATER)...............................................................................................................................600 [7] HST CABIN TYPE (WITHOUT CCV HEATER)...........................................................................................................................601 [8] HST CABIN TYPE (WITH CCV HEATER)..............................................................................................................................602 3. ELECTRONIC CONTROL PANEL...........................................................................................................................................603 [1] SYSTEM OUTLINE................................................................................................................................................603 [2] CONSTRUCTION AND FUNCTION OF COMPONENTS.......................................................................................................................604 (1) Instrument Panel..........................................................................................................................................604 (2) Electric Control Unit (ECU)...............................................................................................................................604 (3) Switches..................................................................................................................................................605 (4) Sensors...................................................................................................................................................609 (5) Others....................................................................................................................................................611 [3] BASIC CONTROL SYSTEM..........................................................................................................................................614 (1) Indication Items of Meter Panel...........................................................................................................................614 (2) Electronic Instrument Panel (IntelliPanel™) Display.......................................................................................................615 (3) Normal Display............................................................................................................................................617 (4) Information Display (Attention Display at Engine Starting)................................................................................................619 (5) Easy Checker™.............................................................................................................................................621 (6) Confirmation Display......................................................................................................................................622 (7) Indicator Control.........................................................................................................................................624 [4] ASSISTANT CONTROL SYSTEM......................................................................................................................................625 (1) Fail-safe Function........................................................................................................................................625 (2) Self-diagnosis Function...................................................................................................................................625 (3) Testing, Setting and adjusting Function...................................................................................................................628 (4) Glow Control..............................................................................................................................................628 4. ENGINE STARTING SYSTEM AND STOPPING SYSTEM.........................................................................................................................629 [1] MANUAL TRANSMISSION...........................................................................................................................................629 [2] GST...........................................................................................................................................................630 [3] HST...........................................................................................................................................................631 [4] RELATED SWITCHES..............................................................................................................................................632 [5] ENGINE STARTING CONDITIONS....................................................................................................................................634 [6] AUTOMATIC ENGINE STOP.........................................................................................................................................635 5. CAN (CONTROLLER AREA NETWORK) COMMUNICATION........................................................................................................................636 SERVICING.................................................................................................................................................................637 1. TROUBLESHOOTING....................................................................................................................................................639 2. SERVICING SPECIFICATIONS...........................................................................................................................................647 3. TIGHTENING TORQUES.................................................................................................................................................648 4. CHECKING AND ADJUSTING.............................................................................................................................................649 [1] BATTERY.......................................................................................................................................................649 [2] ECU AND ELECTRONIC INSTRUMENT PANEL (INTELLIPANEL)............................................................................................................652 (1) Main ECU..................................................................................................................................................652 (2) Engine ECU................................................................................................................................................652 (3) Electronic Instrument Panel...............................................................................................................................653 [3] TESTING, SETTING AND ADJUSTING BY ELECTRONIC INSTRUMENT PANEL (INTELLIPANEL)..................................................................................653 (1) Mode Selection............................................................................................................................................654 (2) Mode "A" (Test Mode)......................................................................................................................................655 (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....658 (4) Mode "C" (PTO Coefficient Number Input Mode) Input the Numeric Code Number for PTO Speed into the Electronic Instrument Panel.............................659 (5) Mode "D" (Error Information Reset Mode) Delete the Error Information from the Electronic Instrument Panel.................................................660 (6) Mode "E" (GST Lever Sensor Fine-adjustment Mode) Setting the GST Lever's Neutral Position with its Sensor.................................................661 (7) Mode "F" (GST Valve FIne-adjustment Mode) Setting the Function of Proportional Reducing Valve.............................................................662 (8) Mode "G" (GST Shift Shock Fine-adjustment Mode) Adjusting the Clutch Engaging Interval....................................................................664 (9) Mode "J" (Speed Unit Selection Mode) Input the Traveling Speed Unit to the Electronic Instrument Panel....................................................664 (10) Mode "K" (HST Pedal and Range Shift Lever Fine-adjustment Mode)..........................................................................................665 (11) Mode "L" (Throttle Sensor Fine-adjustment Mode)..........................................................................................................667 (12) Mode "M" (Mode for Factory)..............................................................................................................................667 (13) Mode "N" (Tractor Model Select Mode).....................................................................................................................668 [4] ELECTRIC CONTROL SYSTEM.......................................................................................................................................670 [5] ECU CONTROL SYSTEM............................................................................................................................................671 (1) Checking Fuse and Connector...............................................................................................................................671 (2) Checking by Electronic Instrument Panel Connector.........................................................................................................674 (3) Unit Checking.............................................................................................................................................676 (4) Checking by Main Electric Control Unit (Main ECU).........................................................................................................677 (5) Checking by Engine Electric Control Unit (ECU)............................................................................................................684 (6) Checking Sensor and Switch for Manual Transmission........................................................................................................686 (7) Checking Sensor and Switch for GST........................................................................................................................687 (8) Checking Sensor and Switch for HST........................................................................................................................691 [6] STARTING SYSTEM...............................................................................................................................................698 (1) Main Switch (ROPS Type)...................................................................................................................................698 (2) Main Switch (CABIN Type)..................................................................................................................................699 (3) Safety Switch.............................................................................................................................................700 (4) Starter...................................................................................................................................................702 (5) Relays....................................................................................................................................................704 (6) Engine ECU Power Relay, Glow Relay and Defogger Relay.....................................................................................................705 (7) Glow Control System.......................................................................................................................................706 [7] CHARGING SYSTEM...............................................................................................................................................706 [8] LIGHTING SYSTEM...............................................................................................................................................707 (1) Multi Function Combination Lever (Combination Switch).....................................................................................................707 [9] WARNING LAMPS.................................................................................................................................................710 [10] MONITOR LAMP.................................................................................................................................................711 [11] GAUGES.......................................................................................................................................................712 [12] ENGINE CONTROL SYSTEM........................................................................................................................................713 (1) Injector..................................................................................................................................................713 (2) SCV (Suction Control Valve)...............................................................................................................................714 (3) Rail Pressure Sensor......................................................................................................................................715 (4) Fuel Pump.................................................................................................................................................716 (5) Boost Sensor (If Equipped)................................................................................................................................717 (6) EGR Valve.................................................................................................................................................718 (7) Crankshaft Position Sensor................................................................................................................................719 (8) Camshaft Position Sensor..................................................................................................................................720 (9) Air Flow Sensor...........................................................................................................................................721 (10) Intake Throttle Valve....................................................................................................................................722 (11) Exhaust Temperature Sensor...............................................................................................................................723 (12) Differential Pressure Sensor.............................................................................................................................724 (13) Parked Regeneration Switch...............................................................................................................................725 (14) Auto Regeneration Switch.................................................................................................................................726 [13] CCV HEATER...................................................................................................................................................727 (1) CCV Relay.................................................................................................................................................727 (2) CCV Heater................................................................................................................................................728 5. DISASSEMBLING AND ASSEMBLING.......................................................................................................................................729 [1] STARTER.......................................................................................................................................................729 [2] ALTERNATOR....................................................................................................................................................729 6. SERVICING..........................................................................................................................................................732 [1] STARTER.......................................................................................................................................................732 [2] ALTERNATOR....................................................................................................................................................734 10 CABIN......................................................................................................................................................................736 MECHANISM.................................................................................................................................................................737 1. AIR CONDITIONER SYSTEM.............................................................................................................................................738 [1] OUTLINE OF AIR CONDITIONING SYSTEM............................................................................................................................738 [2] SYSTEM CONTROL................................................................................................................................................740 [3] ELECTRICAL SYSTEM.............................................................................................................................................741 (1) Electrical Circuit........................................................................................................................................741 (2) Compressor Relay, Blower Relays and Compressor Relay......................................................................................................742 SERVICING.................................................................................................................................................................743 1. TROUBLESHOOTING....................................................................................................................................................744 2. SERVICING SPECIFICATIONS...........................................................................................................................................748 3. TIGHTENING TORQUES.................................................................................................................................................749 4. PRECAUTIONS AT REPAIRING REFRIGERANT CYCLE.........................................................................................................................750 [1] HANDLING OF SERVICE TOOLS.....................................................................................................................................752 (1) Manifold Gauge Set........................................................................................................................................752 (2) Refrigerant Charging Hose.................................................................................................................................753 (3) Vacuum Pump Adaptor.......................................................................................................................................754 (4) Electric Gas Leak Tester..................................................................................................................................754 (5) Can Tap Valve.............................................................................................................................................754 (6) T-joint...................................................................................................................................................755 (7) R134a Refrigerant Recovery and Recycling Machine..........................................................................................................755 5. CHECKING AND CHARGING REFRIGERANT CYCLE............................................................................................................................756 [1] CHECKING WITH MANIFOLD GAUGE..................................................................................................................................756 [2] DISCHARGING, EVACUATING AND CHARGING..........................................................................................................................760 (1) Discharging the Refrigerant...............................................................................................................................760 (2) Evacuating the System.....................................................................................................................................761 (3) Charging the Refrigerant..................................................................................................................................762 (4) Checking Charge Refrigerant Amount........................................................................................................................764 6. CHECKING, DISASSEMBLING AND SERVICING..............................................................................................................................765 [1] CHECKING AND ADJUSTING........................................................................................................................................765 (1) Compressor................................................................................................................................................765 (2) Control Panel (Blower Switch, A/C Switch, Mode Control Dial and Temperature Control Dial).................................................................766 (3) Blower Resistor...........................................................................................................................................769 (4) Blower Motor..............................................................................................................................................770 (5) Temperature Motor.........................................................................................................................................770 (6) Recirculation / Fresh Air Motor Checking..................................................................................................................771 (7) Blower Relay..............................................................................................................................................771 (8) Compressor Relay..........................................................................................................................................772 (9) Pressure Switch...........................................................................................................................................773 (10) Front Wiper Switch.......................................................................................................................................774 (11) Rear Wiper Switch (If Equipped)..........................................................................................................................775 (12) Front Wiper Motor........................................................................................................................................776 (13) Rear Wiper Motor (If Equipped)...........................................................................................................................776 [2] DISASSEMBLING AND ASSEMBLING..................................................................................................................................776 (1) Separating Cabin from Tractor.............................................................................................................................776 (2) Removing Compressor Assembly..............................................................................................................................788 (3) Removing Air Conditioner Unit.............................................................................................................................790 (4) Removing Air Conditioner Pipes............................................................................................................................793 (5) Removing Heater Hoses.....................................................................................................................................794 (6) Cabin Windshields.........................................................................................................................................796 (7) Wiper Motor...............................................................................................................................................799 [3] SERVICING.....................................................................................................................................................800
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