Professional Documents
Culture Documents
F2880,F3680,RCK72-F36,
RCK72R-F36,RCK60-F36,
RCK60R-F36
This Workshop Manual has been prepared to provide servicing personnel with
information on the mechanism, service and maintenance of KUBOTA F2880, F3680,
KUBOTA Mower RCK72-F36, RCK72R-F36, RCK60-F36, RCK60R-F36. It is divided
into three parts, “General”, “Mechanism” and “Servicing” for each section.
■ General
Information on the tractor identification, the general precautions, maintenance check
list, check and maintenance and special tools are described.
■ Mechanism
Information on the construction and function are included. This part should be
understood before proceeding with troubleshooting, disassembling and servicing.
Refer to Diesel Engine / Tractor Mechanism Workshop Manual (Code No. 97897-
01873 / 97897-18200) for the one which has not been described to this workshop
manual.
■ Servicing
Information on the troubleshooting, servicing specification lists, tightening torque,
checking and adjusting, disassembling and assembling and servicing which cover
procedures, precautions, factory specifications and allowable limits.
All information illustrations and specifications contained in this manual are based on
the latest product information available at the time of publication.
The right is reserved to make changes in all information at any time without notice.
January 2006
© KUBOTA Corporation 2006
SAFETY INSTRUCTIONS
SAFETY FIRST
This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on
the machine itself to warn of the possibility of personal injury. Read these instructions carefully.
It is essential that you read the instructions and safety regulations before you attempt to repair or use
this unit.
DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
■ IMPORTANT : Indicates that equipment or property damage could result if instructions are not
followed.
SAFETY STARTING
• Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
• Do not alter or remove any part of machine safety
system.
• Before starting the engine, make sure that all shift
levers are in neutral positions or in disengaged
positions.
• Never start the engine while standing on the ground.
Start the engine only from operator’s seat.
SAFETY WORKING
• Do not work on the machine while under the influence
of alcohol, medication, or other substances or while
fatigued.
• Wear close fitting clothing and safety equipment
appropriate to the job.
• Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
• When servicing is performed together by two or more
persons, take care to perform all work safely.
• Do not work under the machine that is supported
solely by a jack. Always support the machine by
safety stands.
• Do not touch the rotating or hot parts while the engine
is running.
• Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise, hot
water will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressure before removing completely.
• Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury. Relieve
pressure before disconnecting hydraulic or fuel lines.
Tighten all connections before applying pressure.
AVOID FIRES
• Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
• To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first and
connect it last.
• Battery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
• Make sure that no fuel has been spilled on the engine.
SAFETY DECALS
The following safety decals are installed on the machine.
If a decal becomes damaged, illegible or is not on the machine, replace it. The decal part number is listed in
the parts list.
SPECIFICATIONS
Model F2880 F3680
Model D1105-E2-FM2-EU V1505-E2-FM3-EU
Engine gross power (SAE) *1 20.4 kW (27.3 HP) 26.3 kW (35.3 HP)
Type Indirect Injection, vertical, water-cooled, 4-cycle diesel
Number of cylinders 3 4
Bore and stroke 78.0 × 78.4 mm (3.07 × 3.09 in.)
Total displacement 1123 cm3 (68.58 cu.in.) 1498 cm3 (91.42 cu.in.)
Engine -1
Rated revolution 3000min (rpm)
Starting system Electric starter 12 V, 1.1 kW
Lubricating system Forced lubrication by gear pump
Cooling system Pressurized radiator, forced circulation with water pump
Battery 12 V, CCA : 490 A, RC : 112 min.
Diesel fuel No. 1 [below −10 °C (14 °F)]
Fuel
Diesel fuel No. 2-D
Fuel tank 61 L (16.1 U.S.gals, 13.4 Imp.gals)
Engine crankcase 3.8 L (4.0 U.S.qts., 3.3 Imp.qts)
Engine coolant 4.6 L (4.9 U.S.qts., 4.0 Imp.qts)
Capacities Recovery tank 0.6 L (0.6 U.S.qts, 0.5 Imp.qts)
Transmission case 14.0 L (14.8 U.S.qts, 12.3 Imp.qts)
Rear axle differential case 1.5 L (1.59 U.S.qts, 1.32 Imp.qts)
Rear axle gear case 0.5 L (0.53 U.S.qts, 0.44 Imp.qts)
Front 24 × 12 – 12 (4PR) Turf
Tire
Rear 18 × 9.5 – 8 (4PR) Turf
Low 0 to 9.0 km/h (0 to 5.6 mph) *2
Forward
Travelling High 0 to 20.0 km/h (0 to 12.6 mph) *2
speeds Low 0 to 4.8 km/h (0 to 3.0 mph) *2
Reverse
High 0 to 11.0 km/h (0 to 6.9 mph) *2
Overall length 2500 mm (98.4 in.)
Overall width 1370 mm (53.9 in.)
Overall height 1350 mm (53.1 in.)
Dimensions Wheel base 1300 mm (51.2 in.)
Min. ground clearance 185 mm (7.3 in.)
Front 1063 mm (41.9 in.)
Tread
Rear 1020 mm (40.2 in.)
Weight (without mower deck) 727 kg (1603 lbs) 744 kg (1640 lbs)
W1028103
DIMENSIONS
CONTENTS
1. IDENTIFICATION............................................................................................. G-1
2. GENERAL PRECAUTIONS ............................................................................ G-2
3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING .. G-3
[1] WIRING...................................................................................................... G-3
[2] BATTERY................................................................................................... G-5
[3] FUSE.......................................................................................................... G-5
[4] CONNECTOR ............................................................................................ G-5
[5] HANDLING OF CIRCUIT TESTER......................................................... G-6
4. LUBRICANTS, FUEL AND COOLANT ......................................................... G-7
5. TIGHTENING TORQUES ............................................................................... G-8
[1] GENERAL USE SCREWS, BOLTS AND NUTS................................... G-8
[2] METRIC SCREWS, BOLTS AND NUTS ............................................... G-8
[3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC
OR UNF THREADS ................................................................................. G-9
[4] PLUGS ....................................................................................................... G-9
6. MAINTENANCE CHECK LIST ..................................................................... G-10
7. CHECK AND MAINTENANCE ..................................................................... G-12
[1] DAILY CHECK ........................................................................................ G-12
[2] CHECK POINTS OF INITIAL 50 HOURS ........................................... G-17
[3] CHECK POINTS OF EVERY 50 HOURS ........................................... G-19
[4] CHECK POINTS OF EVERY 100 HOURS ......................................... G-25
[5] CHECK POINTS OF EVERY 200 HOURS ......................................... G-26
[6] CHECK POINTS OF EVERY 400 HOURS ......................................... G-29
[7] CHECK POINTS OF EVERY 1500 HOURS ....................................... G-30
[8] CHECK POINTS OF EVERY 3000 HOURS ....................................... G-30
[9] CHECK POINTS OF EVERY 1 YEAR ................................................ G-30
[10]CHECK POINTS OF EVERY 2 YEARS.............................................. G-33
[11]OTHERS .................................................................................................. G-34
8. SPECIAL TOOLS .......................................................................................... G-35
[1] SPECIAL TOOLS FOR ENGINE .......................................................... G-35
[2] SPECIAL TOOLS FOR MACHINE........................................................ G-42
9. TIRES............................................................................................................. G-43
[1] TIRE PRESSURE ................................................................................... G-43
10. IMPLEMENT LIMITATIONS.......................................................................... G-44
1. IDENTIFICATION
When contacting your local KUBOTA distributor, always specify
engine model name, engine serial number and machine serial
number.
■ Engine Serial Number
The engine serial number is an identified number for the engine.
It is marked after the engine model number.
It indicates month and year of manufacture as follows.
• Year of manufacture
Alphabet or Alphabet or
Year Year
Number Number
1 2001 F 2015
2 2002 G 2016
3 2003 H 2017
4 2004 J 2018
5 2005 K 2019
6 2006 L 2020
7 2007 M 2021
8 2008 N 2022
9 2009 P 2023
A 2010 R 2024
B 2011 S 2025
C 2012 T 2026
D 2013 V 2027
E 2014
• Month of manufacture
Engine Serial Number
Month
0001 ~ 9999 10000 ~
January A0001 ~ A9999 B0001 ~
February C0001 ~ C9999 D0001 ~
March E0001 ~ E9999 F0001 ~
April G0001 ~ G9999 H0001 ~
May J0001 ~ J9999 K0001 ~
June L0001 ~ L9999 M0001 ~
July N0001 ~ N9999 P0001 ~
August Q0001 ~ Q9999 R0001 ~
September S0001 ~ S9999 T0001 ~
October U0001 ~ U9999 V0001 ~
November W0001 ~ W9999 X0001 ~
December Y0001 ~ Y9999 Z0001 ~
e.g. D1105-5A0001
“5” indicates 2005 and “A” indicates January.
So, 5A indicates that the engine was manufactured in January,
2005.
(1) Engine Model Name (3) Machine Serial Number
(2) Engine Serial Number
W1010714
2. GENERAL PRECAUTIONS
• During disassembly, carefully arrange removed parts in a clean
area to prevent confusion later. Screws, bolts and nuts should be
installed in their original position to prevent reassembly errors.
• When special tools are required, use KUBOTA genuine special
tools. Special tools which are not frequently used should be
made according to the drawings provided.
• Before disassembling or servicing electrical wires, always
disconnect the ground cable from the battery first.
• Remove oil and dirt from parts before measuring.
• Use only KUBOTA genuine parts for parts replacement to
maintain machine performance and to assure safety.
• Gaskets and O-rings must be replaced during reassembly.
Apply grease to new O-rings or oil seals before assembling.
See the figure left side.
• When reassembling external snap rings or internal snap rings,
they must be positioned so that sharp edge faces against the
direction from which a force is applied. See the figure left side.
• When inserting spring pins, their splits must face the direction
from which a force is applied. See the figure left side.
• To prevent damage to the hydraulic system, use only specified
fluid or equivalent.
(1) Grease (A) External Snap Ring
(2) Force (B) Internal Snap Ring
(3) Sharp Edge
(4) Axial Force
(5) Rotating Movement
W10109040
[1] WIRING
• Securely tighten wiring terminals.
(1) Correct (2) Incorrect
(Securely Tighten) (Loosening Leads to Faulty Contact)
W10112160
• When installing a part, take care not to trap or damage the wiring.
(1) Wiring (A) Incorrect
W10116700
[2] BATTERY
• Take care not to confuse positive and negative terminal posts.
• When removing battery cables, disconnect negative cable first.
When installing battery cables, check for polarity and connect
positive cable first.
• Do not install any battery with capacity other than is specified
(Ah).
• After connecting cables to battery terminal posts, apply high
temperature grease to them and securely install terminal covers.
• Do not allow dirt and dust to collect on battery.
CAUTION
• Take care not to let battery liquid spill on your skin and
clothes. If contaminated, wash it off with water immediately.
• Before recharging the battery, remove it from the machine.
• Before recharging, remove cell caps.
• Recharging should take place in a well-ventilated place
where there is no open flame nearby, as hydrogen gas and
oxygen are produced, which is highly flammable.
W10118160
[3] FUSE
• Use fuses with specified capacity.
Neither too large or small capacity fuse is acceptable.
• Never use steel or copper wire in place of fuse.
• Do not install working light, radio set, etc. on machine without a
separate power supply.
• Do not install accessories if fuse capacity of reserve power
supply is exceeded.
(1) Fuse (2) Slow Blow Fuse
W10120920
[4] CONNECTOR
• For connector with lock, push lock to separate.
(A) Push
W10122110
5. TIGHTENING TORQUES
[1] GENERAL USE SCREWS, BOLTS AND NUTS
Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be tightened
according to the table below.
Indication on top of
No-grade or 4T 7T 9T
bolt
SCr435,
Material of bolt SS400, S20C S43C, S48C
SCM435
Material of opponent
Ordinariness Aluminum Ordinariness Aluminum Ordinariness
part
Unit
N·m kgf·m ft-lbs N·m kgf·m ft-lbs N·m kgf·m ft-lbs N·m kgf·m ft-lbs N·m kgf·m ft-lbs
Diameter
7.85 0.80 5.79 7.85 0.80 5.79 9.81 1.00 7.24 7.85 0.80 5.79 12.3 1.25 9.05
M6
to to to to to to to to to to to to to to to
(6 mm, 0.24 in.)
9.31 0.95 6.87 8.82 0.90 6.50 11.2 1.15 8.31 8.82 0.90 6.50 14.2 1.45 10.4
17.7 1.8 13.1 16.7 1.7 12.3 23.6 2.4 17.4 17.7 1.8 13.1 29.5 3.0 21.7
M8
to to to to to to to to to to to to to to to
(8 mm, 0.31 in.)
20.5 2.1 15.1 19.6 2.0 14.4 27.4 2.8 20.2 20.5 2.1 15.1 34.3 3.5 25.3
39.3 4.0 29.0 31.4 3.2 23.2 48.1 4.9 35.5 39.3 4.0 29.0 60.9 6.2 44.9
M10
to to to to to to to to to to to to to to to
(10 mm, 0.39 in.)
45.1 4.6 33.2 34.3 3.5 25.3 55.8 5.7 41.2 44.1 4.5 32.5 70.6 7.2 52.0
62.8 6.4 46.3 77.5 7.9 57.2 62.8 6.4 46.3 103 10.5 76.0
M12
to to to – – – to to to to to to to to to
(12 mm, 0.47 in.)
72.5 7.4 53.5 90.2 9.2 66.5 72.5 7.4 53.5 117 12.0 86.7
108 11.0 79.6 124 12.6 91.2 167 17.0 123
M14
to to to – – – to to to – – – to to to
(14 mm, 0.55 in.)
125 12.8 92.5 147 15.0 108 196 20.0 144
167 17.0 123 197 20.0 145 260 26.5 192
M16
to to to – – – to to to – – – to to to
(16 mm, 0.63 in.)
191 19.5 141 225 23.0 166 304 31.0 224
246 25.0 181 275 28.0 203 344 35.0 254
M18
to to to – – – to to to – – – to to to
(18 mm, 0.71 in.)
284 29.0 209 318 32.5 235 402 41.0 296
334 34.0 246 368 37.5 272 491 50.0 362
M20
to to to – – – to to to – – – to to to
(20 mm, 0.79 in.)
392 40.0 289 431 44.0 318 568 58.0 419
W1034542
Unit
N·m kgf·m ft-lbs N·m kgf·m ft-lbs
Nominal Diameter
M8 23.6 to 27.4 2.40 to 2.80 17.4 to 20.2 29.4 to 34.3 3.00 to 3.50 21.7 to 25.3
M10 48.1 to 55.8 4.90 to 5.70 35.5 to 41.2 60.8 to 70.5 6.20 to 7.20 44.9 to 52.1
M12 77.5 to 90.1 7.90 to 9.20 57.2 to 66.5 103.0 to 117.0 10.50 to 12.00 76.0 to 86.8
M14 124.0 to 147.0 12.60 to 15.00 91.2 to 108.0 167.0 to 196.0 17.00 to 20.00 123.0 to 144.0
M16 196.0 to 255.0 20.0 to 23.0 145.0 to 166.0 260.0 to 303.0 26.50 to 31.00 192.0 to 224.0
W1013689
Unit
N·m kgf·m ft-lbs N·m kgf·m ft-lbs
Nominal Diameter
5/16 23.1 to 27.8 2.35 to 2.84 17.0 to 20.5 32.5 to 39.3 3.31 to 4.01 24.0 to 29.0
3/8 47.5 to 57.0 4.84 to 5.82 35.0 to 42.0 61.0 to 73.2 6.22 to 7.47 45.0 to 54.0
1/2 108.5 to 130.2 11.07 to 13.29 80.0 to 96.0 149.2 to 179.0 15.22 to 18.27 110.0 to 132.0
9/16 149.2 to 179.0 15.22 to 18.27 110.0 to 132.0 217.0 to 260.4 22.14 to 26.57 160.0 to 192.0
5/8 203.4 to 244.1 20.75 to 24.91 150.0 to 180.0 298.3 to 358.0 30.44 to 36.53 220.0 to 264.0
W1022485
[4] PLUGS
Material of opponent part
Tapered R1/8 13 to 22 1.3 to 2.2 9.6 to 16.2 10 to 12 1.0 to 1.2 7.4 to 8.9
screw
0000001666E
(Continued)
Period Service Interval
Refer-
After Impor-
No. ence
50 100 150 200 250 300 350 400 450 500 550 600 since tant
page
Item
every
Check ✩ ✩ ✩ G-28
200Hr
18 Fuel line @
every 2
Replace G-33
years
every
Check ✩ ✩ ✩ G-29
200Hr
19 Intake air line @
every 2
Replace –
years
every
20 Rear axle pivot Adjust ✩ G-29
400Hr
Fuel injection nozzle every
21 Check @ G-30
(injection pressure) 1500Hr
every
22 Injection pump Check @ G-30
3000Hr
every 1
23 Radiator Clean G-31
year
every 1
24 Coolant Change @ G-31
year
25 Fuel system Bleed G-34
26 Fuse Replace Service G-34
as
27 Light bulb Replace Required G-34
28 Lift spring Adjust G-34
W1023987
CAUTION
• Always stop the engine and remove the key before checking
oil.
1. Check engine oil before starting and 5 minutes or more after the
engine has stopped.
2. Wipe dipstick (2) area clean.
3. To check the oil level, remove the dipstick (2), wipe it clean,
reinsert it, and draw it out again. Check to see that the oil level
is between the two notches.
4. Add new oil to the prescribed level at the oil inlet (1) if necessary.
5. When using a different brand or viscosity oil from the previous
one, remove all of the old oil and oil filter. Never mix two different
types of oil.
6. Use the proper Engine Oil SAE according to the ambient
temperatures. (See page G-7.)
(1) Engine Oil Inlet A : Oil level is acceptable within this
(2) Oil Level Dipstick range
W1047516
CAUTION
• Handle fuel carefully. If the engine is running, do not fill the
fuel tank. If engine is hot, let engine cool for several minutes
before adding fuel.
Do not smoke while filling the fuel tank or servicing the fuel
system. Fill fuel tank only to bottom of filler neck.
Check the fuel level. Take care that the fuel tank does not
become empty.
61 L
Fuel tank capacity 16.1 U.S.gals
13.4 Imp.gals
■ IMPORTANT
•Use Diesel Fuel Only.
1.Use No.2-D diesel fuel.
2.Use No.1-D diesel fuel if the temperature is below -10 °C (14 °F).
3.Always use a strainer when refueling to prevent fuel injection
pump contamination.
■ NOTE
• No.2-D is a distillate fuel of lower volatility for engines in
industrial and heavy mobile service.
(SAE J313 JUN87)
Grade of Diesel Fuel Oil according to ASTM D975
Water and Carbon residue
Flash point °C sediment, on, 10 percent Ash, weight %
volume % residuum %
Min Max Max Max
52 0.05 0.35 0.01
Distillation
Kinematics viscosity Saybolt viscosity, SUS
temperatures °C 90 %
cSt or mm2/S at 40 °C at 100 °F
point
Min Max Max Max Max Max
282 338 1.9 4.1 32.6 40.1
CAUTION
• Be sure to stop the engine and remove the key before
cleaning.
■ IMPORTANT
• The air intake area must be clear of debris to prevent the
engine from overheating.
Daily or after every 5 hours of operation, check to be sure the
radiator screen (1) and bonnet screen (2) are clean. Dirt or chaff on
the radiator screen (1) or bonnet screen (2) decrease cooling
performance.
1. Open the bonnet and remove the radiator screen (2).
2. Remove the dust from between the fins and the tube.
3. Tighten the fan drive belt as necessary. For this, refer to
"CHECK POINT EVERY 100 HOURS".
4. If scale forms in the tube, clean with scale inhibitor or its
equivalent.
5. Each time the bonnet screen (2) is covered with grass during
operation, remove the grass from bonnet screen by hand. Check
the radiator screen (1) from time to time if grass accumulates.
(1) Radiator Screen (2) Bonnet Screen
W1050141
WARNING
• Do not attempt to mount a tire on a rim. This should be done
by a qualified person with the proper equipment
• Always maintain the correct tire pressure.
Do not inflate tires above the recommended pressure.
CAUTION
• Never operate machine with a loose rim, wheel or axle.
• Whenever bolts are loosened, retighten to specified torque.
• Check all bolts frequently and keep them tightened.
■ Inflation Pressure
Though the inflation pressure is factory-set to the prescribed
level, it naturally drops slowly in the course of time. Thus, check it
every day and inflate as necessary.
Recommended
Tire Sizes
inflation pressure
140 kPa
Front 24 × 12-12, 4PR
(1.4 kgf/cm2, 20 psi)
200 kPa
Rear 18 × 9.5-8, 4PR
(2.0 kgf/cm2, 28 psi)
CAUTION
• Do not remove the radiator cap when the engine is hot.
Loosen cap slightly, to the stop, to relieve any excess
pressure before removing cap completely.
Check the coolant level daily both the radiator and the recovery
tank (2) before starting engine
1. Remove the radiator cap (1) and check to see that the coolant
level is just below the fill port.
2. Check to see that the coolant level is between the "FULL" and
"LOW" marks of recovery tank (2).
3. When the coolant level drops due to evaporation, add water only
up to just below the fill port of the radiator and the full level of the
recovery tank (2).
In case of leakage, add coolant and water in the specified mixing
ratio up to the full level. (See page G-7.)
■ IMPORTANT
• If the radiator cap has to be removed, follow the caution
above and securely retighten the cap.
• Use clean, distilled coolant and water to fill the radiator and
recovery tank.
(1) Radiator Cap A : FULL
(2) Recovery Tank B : LOW
W1053725
CAUTION
• Be sure to stop the engine and remove the key before
changing oil.
• Allow engine to cool down sufficiently. Oil can be hot and
may cause burns.
1. Place an oil pan underneath the engine.
2. To drain the used oil, remove the drain plugs (1) at the bottom of
the engine and drain the oil completely.
3. Screw in the drain plugs (1) and tighten.
4. Fill with new oil up to upper line on the dipstick (3).
■ IMPORTANT
• When using an oil of different manufacture or viscosity from
the previous one, remove all of the old oil.
• Never mix two different types of oil.
• Use the proper SAE Engine Oil according to ambient
temperatures.
Refer to “LUBRICANTS, FUEL AND COOLANT” (See page
G-7).
(1) Drain Plug (A) Oil level is acceptable within this
(2) Oil Inlet Plug range.
(3) Dipstick
W1030749
Replacing Engine Oil Filter Cartridge
CAUTION
• Be sure to stop the engine and remove the key before
changing the oil and the oil filter cartridge.
• Allow engine to cool down sufficiently; oil can be hot and
may cause burns.
1. Remove the oil filter cartridge (1) with the filter wrench.
2. Put a film of engine oil on the rubber seal of the new filter
cartridge.
3. Tighten the filter cartridge quickly until it contacts the mounting
surface.
4. Tighten the filter cartridge by hand an additional 1/2 turn only.
5. After the new filter is replaced, the engine oil normally decreases
a little. Check that the engine oil does not leak through the seal
and be sure to check the oil level on the dipstick.
6. Then, replenish the engine oil up to the prescribed level.
■ IMPORTANT
• To prevent serious damage to the engine. Use only a
genuine KUBOTA filter.
(1) Engine Oil Filter Cartridge
W1030949
CAUTION
• Be sure to stop the engine and remove the key before
changing the oil filter cartridge.
• Allow transmission case to cool down sufficiently; oil can be
hot and may cause burns.
1. Remove the transmission oil filter cartridge (1) with the filter
wrench.
2. Apply a slight coat of oil onto the cartridge gasket.
3. To install the new cartridge, screw it in by hand. Over tightening
may cause deformation of the rubber gasket.
4. After the new cartridge is replaced, the transmission fluid level
normally decreases a little. Add fluid if necessary.
5. Check for oil leaks around the filter gasket.
■ IMPORTANT
• To prevent serious damage to the hydraulic system,
replacement oil filter cartridge must be highly efficient. Use
only a genuine KUBOTA filter.
(1) Transmission Oil Filter Cartridge
W1031068
CAUTION
• Do not allow anyone near the machine while testing.
• If the machine does not pass a test, do not operate the
machine.
• Sit on operator’s seat for all tests except for Test 1.
1. Perform the following tests before operating the machine.
2. If the machine does not pass one of the following tests, do not
operate the machine, and check the safety switches and the
wiring harness.
■ Test 1 : Switch for the operator’s seat
1. Do not sit on the operator’s seat.
2. Depress the brake pedal (2) fully.
3. Shift the PTO lever (3) to the “DISENGAGE” position.
4. Turn the main switch (1) to the “START” position.
5. The engine must not crank.
■ Test 2 : Switch for the brake pedal
1. Sit on the operator’s seat.
2. Do not depress the brake pedal (2).
3. Shift the PTO lever (3) to the “DISENGAGE” position.
4. Turn the main switch (1) to the “START” position.
5. The engine must not crank.
■ Test 3 : Switch for the PTO lever
1. Sit on the operator’s seat.
2. Depress the brake pedal (2) fully.
3. Shift the PTO lever (3) to the “ENGAGE” position.
4. Turn the main switch (1) to the “START” position.
5. The engine must not crank.
■ Test 4 : Switch for the operator’s seat (OPC)
1. Start the engine.
2. Shift the PTO lever (3) to “DISENGAGE” position.
3. Release the brake pedal (2).
4. Stand up. (Do not get off the machine.)
5. The engine must shut off
■ Test 5 : Switch for the operator’s seat (OPC)
1. Start the engine.
2. Shift the PTO lever (3) to “ENGAGE” position.
3. Release the brake pedal (2).
4. Stand up. (Do not get off the machine.).
5. The engine must shut off.
■ Test 6 : Switch for the operator’s seat (OPC)
1. Start the engine.
2. Depress the brake pedal (2) fully and lock the parking brake.
3. Shift the PTO lever (3) to “ENGAGE” position.
4. Stand up. (Do not get off the machine).
5. The engine must shut off.
(1) Main Switch (3) PTO Lever
(2) Brake Pedal
W1050412
CAUTION
• Be sure to stop the engine and remove the key before
greasing.
(1) Speed Control Pedal Shaft (3) Differential Lock Pedal Boss
(2) Link Pivot (LH and RH) (4) Universal Joint
W1033255
CAUTION
• Be sure to stop the engine and remove the key before
greasing.
(1) Rear Wheel Drive Shaft (3) Knuckle Arm (RH)
(2) Knuckle Arm (LH)
W1033769
Oiling
1. Apply oil to the following locations as shown in the figures.
CAUTION
• Be sure to stop the engine and remove the key before oiling.
(1) Seat Adjuster (2) Accelerator Cable
W1034719
DANGER
To avoid the possibility of battery explosion:
For the refillable type battery, follow the instructions below.
• Do not use or charge the refillable type battery if the fluid
level is below the LOWER (lower limit level) mark. Otherwise,
the battery component parts may prematurely deteriorate,
which may shorten the battery's service life or cause an
explosion. Check the fluid level regularly and add distilled
water as required so that the fluid level is between the
UPPER and LOWER levels.
CAUTION
• Never remove the vent plugs while the engine is running.
• Keep electrolyte away from eyes, hands and clothes. If you
are spattered with it, immediately wash it away completely
with water and get medical attention.
• Wear eye protection and rubber gloves when working
around the battery.
1. Mishandling the battery shortens the service life and adds to
maintenance costs.
2. Machine may have a maintenance free battery. If engine cranks
slowly or lights become dim; check and clean connections,
charge battery, and load test battery.
(1) Battery
W1015551
Battery Charging
DANGER
• When the battery is being activated, hydrogen and oxygen
gases in the battery are extremely explosive. Keep sparks
and flames away from the battery at all times, especially
when charging the battery.
CAUTION
• When charging battery, remove battery vent plugs.
• When disconnecting the cable from the battery, start with
the negative terminal first.
• Never check battery charge by placing a metal object across
the posts.
• Use a voltmeter or hydrometer.
• Take care not to reverse connections (polarity) at the battery
as this could lead to electrical circuit damage, battery
damage, or battery explosion.
1. Make sure each electrolyte level is somewhere between the
markings (1) and (2). Add the correct amount of distilled water
up to the highest level as required.
2. The water in the electrolyte evaporates during recharging. Liquid
shortage damages the battery. Excessive liquid may spill over
and damages the machine body.
3. To slow charge the battery, connect the battery positive terminal
to the charge positive terminal and the negative to the negative,
then recharge in the standard fashion.
4. A boost charge is only for emergencies. It partially charges the
battery at a high rate and in a short time.
When using a boost-charged battery, it is necessary to recharge
the battery as early as possible.
Failure to do this will shorten the battery’s service life.
5. When the specific gravity of electrolyte is between 1.27 and 1.29,
charge has been completed.
6. When exchanging an old battery for a new one, use a battery of
equal specification shown in table 1 and 2.
■ Direction for Storage
1. When storing the machine for a long period, remove the battery
from the machine, adjust the electrolyte to the proper level and
store in a dry place out of direct sunlight.
2. The battery self-discharges while it is stored.
Recharge it once a month in hot seasons and once every 2
months in cold seasons.
Table 1
capacity at
Battery Type Volts (V)
5 H.R (A.H)
70D2; 3R-CF-MF 12 52
Table 2
Reverse Capacity Normal Charging Rate
Cold Cranking Amps
(min) (A)
112 490 6.5
(A) Deflection
W10356670
Adjusting Brake Pedal Free Travel
CAUTION
• Stop the engine and chock the wheels before checking
brake pedal.
■ NOTE
• If turn assist brake device and speed set device are
attached, see the instruction manuals.
1. Release the parking brake.
2. Slightly depress the main brake pedal and measure free travel
“S1” at top of pedal stroke.
3. If adjustment is needed, loosen the lock nut (2) and turn the
turnbuckle (3) to adjust the rod length within acceptable limits.
4. Retighten the lock nut.
Main brake pedal free 20 to 40 mm
Factory spec.
travel (S1) 0.8 to 1.6 in.
CAUTION
• Be sure to stop the engine before checking and changing
the transmission oil.
1. Place an oil pan underneath the transmission case.
2. Remove the drain plugs (1) at the bottom of the transmission
case.
3. Drain the transmission fluid. (See “Cleaning Transmission Oil
Strainer” below)
4. After draining, screw in the three drain plugs and tighten.
5. Fill the transmission fluid from oil inlet (3) up to the upper line on
the dipstick (2).
6. After running the engine for a few minutes, stop it and check the
fluid level again, add the fluid to the prescribed level if it is not
correct.
■ IMPORTANT
• Use only KUBOTA SUPER UDT fluid. Use of other oils may
damage the transmission or hydraulic system.
• Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page
G-7.)
• Never work the machine immediately after changing the
transmission fluid. Keeping the engine at medium speed for
a few minutes to prevents damage to the transmission.
• Do not mix different brands fluid together.
(1) Drain Plug A : Upper Level
(2) Dipstick B : Lower Level
(3) Oil Inlet
W1046657
CAUTION
• Stop the engine before attempting to carry out the work as
discribed below.
• Remember to check the fuel line periodically. The fuel line
is subject to wear and again, fuel may leak out onto the
running engine, causing a fire.
1. Check to see that all lines and hose clamps are tight and not
damaged.
2. If hoses and clamps are worn or damaged, replace or repair them
at once.
3. The fuel line is made of rubber and deteriorates regardless of
period of service. Replace the fuel hose together with the clamp
every two years and tighten securely.
4. However if the fuel hose and clamp are found damaged or
deteriorated earlier than two years, repair before running
machine.
5. After the fuel line and clamp have been changed, bleed the fuel
system.
■ IMPORTANT
• When the fuel line is disconnected for change, close both
ends of the fuel line with a piece of clean cloth or paper to
prevent dust and dirt from entering. Entrance of dust and
dirt causes malfunction of the fuel injection pump. In
addition, particular care must be taken not to admit dust and
dirt into the fuel pump.
(1) Fuel Hose (2) Hose Clamp
CAUTION
• Do not remove the radiator cap when the engine is hot.
When engine is cool, loosen cap slightly to the stop to
relieve any excess pressure before removing cap
completely.
1. Stop the engine and let it cool down.
2. To drain the coolant, open the radiator drain plug (1) and remove
the radiator cap. The radiator cap must be removed to
completely drain the coolant.
3. After all coolant is drained, install the drain plug (1).
4. Fill with clean water and cooling system cleaner.
5. Follow directions of the cleaner instruction.
6. After flushing, fill with clean water and anti-freeze until the coolant
level is just below the fill port.
7. Fill with clean water and anti-freeze up to the “FULL” mark on the
recovery tank (2).
8. Start and operate the engine for few minutes.
9. Stop the engine. Check coolant level of recovery tank (2) and
add coolant if necessary.
10.Install the radiator cap (1) securely.
■ IMPORTANT
• Do not start engine without coolant.
• Use clean, fresh water and anti-freeze to fill the radiator and
recovery tank.
Refer to “LUBRICANTS, FUEL AND COOLANT” (See page
G-7.)
• When the anti-freeze is mixed with water, the anti-freeze
mixing ratio must be less than 50 %.
• Securely tighten the radiator cap. If the cap is loose or
improperly fitted, water may leak out and the engine could
overheat.
(1) Radiator Drain Plug A : FULL
(2) Recovery Tank B : LOW
W1049995
[11] OTHERS
Bleeding Fuel System
CAUTION
• Do not bleed the fuel system when the engine is hot.
Air must removed :
1. When the fuel filter or lines are removed.
2. When tank is completely empty.
3. After the machine has not been used for a long period of time.
Bleeding procedure is as follows :
1. Fill the fuel tank with fuel.
2. Turn the key switch to the “ON” position.
3. Loosen the bleed screw (1).
When bubbles disappear from fuel coming out of the plug, tighten
the bleed screw.
(1) Bleed Screw
W1051059
Replacing Fuse
1. The electrical system is protected from potential damage by
fuses.
A blown fuse indicates that there is an overload or short
somewhere in the electrical system.
2. If any of the fuses should blow, replace with a new one of the
same capacity.
■ IMPORTANT
• Before replacing a blown fuse, determine why the fuse blew
and make any necessary repairs. Failure to follow this
procedure may result in serious damage to the electrical
system.
■ Protected circuit
Fuse No. Capacity (A) Protected Circuit
(1) 5 ACC
(2) 10 Head Light, Fuel Pump
(3) 15 Working Light
Check circuit against wrong
(4) Slow Blow Fuse 50
battery connection
W1051895
8. SPECIAL TOOLS
[1] SPECIAL TOOLS FOR ENGINE
Special Use Puller Set
Code No: 07916-09032
Application: Use exclusively for pulling out bearing, gears and other
parts with ease.
W1024050
Radiator Tester
Code No: 07909-31551
Application: Use to check of radiator cap pressure, and leaks from
cooling system.
Remarks: Adaptor (1) BANZAI Code No. RCT-2A-30S
W1024532
Nozzle Tester
Code No: 07909-31361
Application: Use to check the fuel injection pressure and spray
pattern of nozzle.
Measuring: 0 to 50 MPa
range (0 to 500 kgf/cm2, 0 to 7000 psi)
W1024653
Plastigage
Code No: 07909-30241
Application: Use to check the oil clearance between crankshaft and
bearing, etc.
Measuring: Green .... 0.025 to 0.076 mm (0.001 to 0.003 in.)
range Red ....... 0.051 to 0.152 mm (0.002 to 0.006 in.)
Blue ....... 0.102 to 0.229 mm (0.004 to 0.009 in.)
W1024719
Red Check
Code No: 07909-31371
Application: Use to check cracks on cylinder head, cylinder block,
etc.
W1024909
■ NOTE
• The following special tools are not provided, so make them referring to the figure.
Injection Pump Pressure Tester
Application: Use to check fuel tightness of injection pumps.
Pressure gauge full scale : More than 29.4 MPa (300 kgf/cm2, 4267
A
psi)
B PF 1/2
C Copper gasket
D Flange (Material : Steel)
E Hex. nut 27 mm (1.06 in.) across the plat
F Adhesive application
G Fillet welding on the enter circumference
H Retaining nut
I 17 mm dia. (0.67 in. dia.)
J 8 mm dia. (0.31 in. dia.)
K 1.0 mm (0.039 in.)
L 17 mm dia. (0.67 in. dia.)
M 6.10 to 6.20 mm dia. (0.2402 to 0.2441 in. dia.)
N 8 mm (0.31 in.)
O 4 mm (0.16 in.)
P 11.97 to 11.99 mm dia. (0.4713 to 0.4720 in. dia.)
Q PF 1/2
R 23 mm (0.91 in.)
S 17 mm (0.67 in.)
T 4 mm (0.16 in.)
U 12.00 to 12.02 mm dia. (0.4724 to 0.4732 in. dia.)
V 100 mm (3.94 in.)
W M12 × P1.5
X 5 mm (0.20 in.)
W10252400
Valve Guide Replacing Tool
Application: Use to press out and press fit the valve guide.
A 225 mm (8.86 in.)
B 70 mm (2.76 in.)
C 45 mm (1.77 in.)
D 20 mm dia. (0.79 in. dia.)
E 11.7 to 11.9 mm dia. (0.461 to 0.469 in. dia.)
F 6.5 to 6.6 mm dia. (0.256 to 0.260 in. dia.)
G 25 mm (0.98 in.)
H 6.7 to 7.0 mm dia. (0.264 to 0.276 in. dia.)
I 5 mm (0.197 in.)
J 20 mm dia. (0.787 in. dia.)
K 12.5 to 12.8 mm dia. (0.492 to 0.504 in. dia.)
L 8.9 to 9.1 mm (0.350 to 358 in.)
C1 Chamfer 1.0 mm (0.039 in.)
C2 Chamfer 2.0 mm (0.079 in.)
C0.3 Chamfer 0.3 mm (0.012 in.)
W10250170
[Press Fit]
A 135 mm (5.31 in.)
B 72 mm (2.83 in.)
C 40 mm radius (1.57 in. radius)
D 10 mm (0.39 in.)
E 24 mm (0.95 in.)
F 20 mm dia. (0.79 in. dia.)
G 68 mm dia. (2.68 in. dia.)
H 47.3 to 47.5 mm dia. (1.862 to 1.870 in. dia.)
C1 Chamfer 1.0 mm (0.039 in.)
C2 Chamfer 2.0 mm (0.079 in.)
C0.3 Chamfer 0.3 mm (0.012 in.)
W10261390
Governor Gear Holder Bushing Replacing Tool
Application: Use to press out and to press fit the governor gear
holder bushing.
A C1 : Chamfer 1.0 mm (0.039 in.)
B 73.9 to 74.0 mm dia. (29.09 to 29.13 in. dia.)
C 69.8 to 69.9 mm (2.748 to 2.751 in. dia.)
D 30 mm dia. (1.181 in. dia.)
E C2 : Chamfer 2.0 mm (0.079 in.)
F 18 mm (0.7 in.)
G 150 mm (5.9 in.)
H 188 mm (7.4 in.)
W1023337
9. TIRES
[1] TIRE PRESSURE
CAUTION
• Do not attempt to mount a tire on a rim. This should be done by a qualified person with the proper
equipment.
• Always maintain the correct tire pressure.
Do not inflate tires above the recommended pressure as shown below.
■ IMPORTANT
• Do not use tires larger than specified.
Recommended
Tire sizes Inflation Max.
Pressure
140 kPa
Front 24 × 12 - 12, 4PR
(1.4 kgf/cm2, 20 psi)
200 kPa
Rear 18 × 9.5 - 8, 4PR
(2.0 kgf/cm2, 28 psi)
W1044037
Though the tire pressure is factory-set to the prescribed level, it naturally drops slowly in the course of time.
Thus, check it everyday and inflate as necessary.
CONTENTS
1. ENGINE BODY
■ Closed Breather
Closed breather system has been adopted to prevent
the release of blow-by gas into the atmosphere.
After its oil content is filtered by oil shield (4), the blow-
by gas is fed back to the intake manifold through breather
valve (3) to be used for re-combustion.
(1) Breather Tube (4) Oil Shield
(2) Cylinder Head Cover (5) Rubber Packing
(3) Breather Valve
W1012956
2. LUBRICATING SYSTEM
(1) Rocker Arm
(2) Oil Pressure Switch
(3) Rocker Arm Shaft
(4) Valve
(5) Governor Shaft
(6) Idle Gear
(7) Crankshaft
(8) Oil Pump
(9) Oil Strainer
(10) Relief Valve
(11) Push Rod
(12) Tappet
(13) Camshaft
(14) Piston
(15) Connecting Rod
(16) Oil Filter Cartridge
W1013559
This engine's lubricating system consists of oil strainer (9), oil pump (8), relief valve (10), oil filter cartridge (16) and
oil pressure switch (2).
The oil pump sucks lubricating oil from the oil pan through the oil strainer and the oil flows down to the filter
cartridge, where it is further filtered. Then the oil is forced to crankshaft (7), connecting rods (15), idle gear (6),
governor shaft (5), camshaft (13) and rocker arm shaft (3) to lubricate each part.
Some part of oil, splashed by the crankshaft or leaking and dropping from gaps of each part, lubricates these parts
: pistons (14), cylinders, small ends of connecting rods, tappets (12), push rods (11), inlet and exhaust valves (4) and
timing gears.
3. COOLING SYSTEM
(1) Radiator
(2) Water Pump
(3) Fan
(4) Thermostat
(5) Cylinder Head
(6) Cylinder Head
The Cooling system consists of a radiator (1), centrifugal water pump (2), suction fan (3) and thermostat (4).
The coolant is cooled through the radiator core, and the fan set behind the radiator pulls cooling air through the
core to improve cooling.
The water pump (2) sucks the cooled coolant, forces it into the cylinder block and draws out the hot coolant. Then
the cooling is repeated. Furthermore, to control temperature of coolant, a thermostat is provided in the system. When
the thermostat opens, the coolant moves directly to radiator, but when it closes, the coolant moves toward the water
pump (2) through the bypass between thermostat and water pump (2).
4. FUEL SYSTEM
(1) Fuel Overflow Pipe
(2) Fuel Filter
(3) Fuel Pump
(4) Injection Nozzle
(5) Fuel Tank
(6) Fuel Filter
(7) Injection Pump
Fuel from the fuel tank (5) passes through the fuel filter (2), and then enters the injection pump (7) after impurities
such as dirt, water, etc. are removed.
The fuel pressurized by the injection pump (7) to the opening pressure (13.73 to 14.71 MPa, 140 to 150 kgf/cm2,
1991 to 2133 psi), of the injection nozzle (4) is injected into the combustion chamber.
Part of the fuel fed to the injection nozzle (4) lubricates the moving parts of the plunger inside the nozzle, then
returns to the fuel tank through the fuel overflow pipe (1) from the upper part of the nozzle holder.
[1] GOVERNOR
■ Three Lever Type Fork Lever
The governor system is a mechanical governor that
uses a governor weight (5).
The governor weight (5) is mounted on the governor
shaft that rotates at the same speed as the crankshaft.
Because the feature of this mechanism takes out the
engine speed directly as a centrifugal force of weight, the
speed control that the change in the engine rotational
speed is sensitively transmitted to fork lever assembly
(A) and high accuracy is enabled.
The fork lever assembly of this engine is composed of
fork lever 1 (6), fork lever 2 (9), and the floating lever (7).
A slide plate is installed in fork lever 1. The governor
spring (3) is hooked to fork lever 2 (9).
The floating lever (7) installs the torque pin (8) of the
output drop prevention at the overload. The start spring
(2) is hooked to a slide plate, and holds the control rack
in the direction of the full fuel position.
Fork lever 2 (9) and the floating lever are installed in
fork lever 1 (6) with the fork lever shaft (4). The max
torque limitation (1) device limits the amount of the fuel
exhalation at overload with the torque pin.
(1) Max Torque Limiter (7) Floating Lever
(2) Start Spring (8) Torque Pin
(3) Governor Spring (9) Fork Lever 2
(4) Fork Lever Shaft
(5) Governor Weight (A) Fork Lever Assembly
(6) Fork Lever 1
(Overloaded Operation)
The amount of the movement of the fork lever
assembly is limited with the fuel limitation bolt (2) and can
not be moved in the direction of the fuel increase.
As overload reduces the centrifugal force of the
governor weight, which is pressing the torque pin (5) into
the floating lever (6), the floating lever pushes the fork
lever 1 (3) in the way to increase the fuel supply with the
help of the torque spring tension.
The fuel supply increases (b) in relation to the degree
of the torque pin motion, thus preventing the engine
speed from dropping.
At this time, the maximum torque limiter (1) prevents
superfluous fuel supply and suppresses the generation
of black smoke.
(1) Max Torque Limiter (a) Distance to which torque
(2) Fuel Limitation Bolt pin (5) pushes fork lever 1
(3) Fork Lever 1 (3) out
(4) Fork Lever 2 (b) Increase of fuel
(5) Torque Pin
(6) Floating Lever
CONTENTS
1. TROUBLESHOOTING ....................................................................................1-S1
2. SERVICING SPECIFICATIONS ....................................................................1-S4
3. TIGHTENING TORQUES ............................................................................1-S10
4. CHECKING, DISASSEMBLING AND SERVICING....................................1-S11
[1] CHECKING AND ADJUSTING .............................................................1-S11
(1) Engine Body......................................................................................1-S11
(2) Lubricating System ...........................................................................1-S13
(3) Cooling System.................................................................................1-S13
(4) Fuel System ......................................................................................1-S15
[2] PREPARATION ......................................................................................1-S19
(1) Separating Engine ............................................................................1-S19
[3] DISASSEMBLING AND ASSEMBLING................................................1-S24
(1) External Components .......................................................................1-S24
(2) Cylinder Head and Valve ..................................................................1-S24
(3) Oil Pan, Timing Gears, Camshaft and Fuel Camshaft ......................1-S28
(4) Piston and Connecting Rod ..............................................................1-S32
(5) Crankshaft.........................................................................................1-S35
[4] SERVICING ............................................................................................1-S37
(1) Cylinder Head and Valves ................................................................1-S37
(2) Timing Gears, Camshaft and Governor Gear ...................................1-S43
(3) Piston and Connecting Rod ..............................................................1-S46
(4) Crankshaft.........................................................................................1-S48
(5) Cylinder .............................................................................................1-S52
(6) Oil Pump ...........................................................................................1-S53
1. TROUBLESHOOTING
Reference
Symptom Probable Solution
page
Engine Does Not No fuel Replenish fuel G-7
Start Air in the fuel system Bleed G-34
Water in the fuel system Change fuel and –
repair or replace fuel
system
Fuel pipe clogged Clean G-34
Fuel filter clogged Change G-29
Excessively high viscosity of fuel or engine oil at Use specified fuel or G-7
low temperature engine oil
Fuel with low cetane number Use specified fuel G-7
Fuel leak due to loose injection pipe retaining nut Tighten retaining nut 1-S25
Incorrect injection timing Adjust 1-S15
Fuel camshaft worn Replace –
Injection nozzle clogged Repair or replace 1-S18
Injection pump malfunctioning Repair or replace 1-S30
Seizure of crankshaft, camshaft, piston, cylinder Repair or replace –
or bearing
Compression leak from cylinder Replace head 1-S27
gasket, tighten
cylinder head screw,
glow plug and nozzle
holder
Improper valve timing Correct or replace 1-S31
timing gear
(Continued)
Reference
Symptom Probable Solution
page
Either White or Blue Excessive engine oil Reduce to specified G-7, 17
Exhaust Gas Is level
Observed Piston ring and cylinder worn or stuck Repair or replace 1-S34
Incorrect injection timing Adjust 1-S15
Deficient compression Adjust top clearance 1-S37
Either Black or Dark Overload Lessen load –
Gray Exhaust Gas Is Low grade fuel used Use specified fuel G-7
Observed
Fuel filter clogged Replace G-29
Air cleaner clogged Clean or replace G-24, 30
Deficient nozzle injection Repair or replace 1-S18, S25
nozzle
Deficient Output Incorrect injection timing Adjust 1-S15
Engine’s moving parts seem to be seizing Repair or replace –
Uneven fuel injection Replace injection 1-S30
pump
Deficient nozzle injection Repair or replace 1-S18, S25
nozzle
Compression leak Replace head 1-S25, S27
gasket, tighten
cylinder head screw,
glow plug and nozzle
holder
Excessive Lubricant Piston ring’s gap facing the same direction Shift ring gap 1-S33
Oil Consumption direction
Oil ring worn or stuck Replace 1-S34
Piston ring groove worn Replace piston 1-S34, S47
Valve stem and valve guide worn Replace 1-S28, S38
to S39
Oil leaking due to defective seals or packing Replace –
Fuel Mixed into Injection pump’s plunger worn Replace 1-S30
Lubricant Oil Deficient nozzle injection Repair or replace 1-S18, S25
nozzle
Injection pump broken Replace 1-S30
Water Mixed into Head gasket defective Replace 1-S27
Lubricant Oil Cylinder block or cylinder head flawed Replace –
W1010717
(Continued)
Reference
Symptom Probable Solution
page
Low Oil Pressure Engine oil insufficient Replenish G-7, 17
Oil strainer clogged Clean –
Relief valve stuck with dirt Clean –
Relief valve spring weaken or broken Replace –
Excessive oil clearance of crankshaft bearing Replace 1-S50, S51
Excessive oil clearance of rocker arm Replace 1-S41
Oil passage clogged Clean –
Different type of oil Use specified type of G-7
oil
Oil pump defective Repair or replace 1-S53
High Oil Pressure Different type of oil Use specified type of G-7
oil
Relief valve defective Replace –
Engine Overheated Engine oil insufficient Replenish G-7
Fan belt broken or elongated Replace or adjust G-25, 1-
S13 to S14
Cooling water insufficient Replenish G-7
Radiator net and radiator fin clogged with dust Clean –
Inside of radiator corroded Clean or replace G-31
Coolant flow route corroded Clean or replace G-31
Radiator cap defective Replace –
Overload running Loosen load –
Head gasket defective Replace 1-S27
Incorrect injection timing Adjust 1-S15
Unsuitable fuel used Use specified fuel G-7
W1012734
2. SERVICING SPECIFICATIONS
ENGINE BODY
Item Factory Specification Allowable Limit
Compression Pressure 3.72 to 4.12 MPa 2.25 MPa
38 to 42 kgf/cm2 23.0 kgf/cm2
539 to 596 psi 327 psi
Width 2.12 mm
0.0835 in.
Valve Spring Tilt – 1.0 mm
0.039 in.
Alignment – 0.01 mm
0.0004 in.
Cam Height Intake 28.80 mm 28.75 mm
1.1339 in. 1.1319 in.
Alignment – 0.02 mm
0.0008 in.
Crankpin to Crankpin Bearing Oil Clearance 0.029 to 0.091 mm 0.20 mm
0.0011 to 0.0036 in. 0.0079 in.
LUBRICATING SYSTEM
Item Factory Specification Allowable Limit
Engine Oil Pressure At Idle Speed More than 49 kPa –
0.5 kgf/cm2
7 psi
COOLING SYSTEM
Fan Belt Tension 7.0 to 9.0 mm / 98 N –
0.28 to 0.35 in. / 98 N
(10 kgf, 22 lbs)
Radiator Cap Pressure Falling 10 seconds or more –
Time 88 → 59 kPa
0.9 → 0.6 kgf/cm2
13 → 9 psi
Radiator Water Leakage No leak at specified –
Test Pressure pressure
137 kPa
1.4 kgf/cm2
20 psi
Thermostat Valve Opening 80.5 to 83.5 °C –
Temperature 176.9 to 182.3 °F
(At Beginning)
Valve Opening 95 °C –
Temperature 203 °F
(Opened
Completely)
W10135990
FUEL SYSTEM
Item Factory Specification Allowable Limit
Injection Pump Injection Timing 0.30 to 0.33 rad –
(3000 min-1 (rpm)) (17 to 19°)
before T.D.C.
Pump Element Fuel Tightness – 13.73 MPa
140 kgf/cm2
1991 psi
Delivery Valve Fuel Tightness 10 seconds 5 seconds
13.73 → 12.75 MPa 13.73 → 12.75 MPa
140 → 130 kgf/cm2 140 → 130 kgf/cm2
1991 → 1849 psi 1991 → 1849 psi
Injection Nozzle Injection Pressure 13.73 to 14.71 MPa –
140 to 150 kgf/cm2
1991 to 2134 psi
Injection Nozzle Valve Seat Valve Seat When the pressure is –
Tightness 12.75 MPa
(130 kgf/cm2, 1849 psi),
the valve seat must be
fuel tightness.
W10139730
3. TIGHTENING TORQUES
Tightening torques of screws bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-8.)
Item N·m kgf·m ft-lbs
Oil strainer 98.1 to 137.2 10.0 to 14.0 72.4 to 101.2
ROPS mounting screw 123 to 147 12.6 to 14.9 90.8 to 108.4
Seat base mounting screw 17.7 to 20.5 1.8 to 2.1 13.1 to 15.1
Drive shaft mounting screw 19.6 to 29.4 2.0 to 3.0 14.5 to 21.7
Cylinder head cover cap nut 6.9 to 8.8 0.7 to 0.9 5.1 to 6.5
Injection pipe retaining nut 24.5 to 34.3 2.5 to 3.5 18.1 to 25.3
Nozzle holder assembly 49.0 to 68.6 5.0 to 7.0 36.2 to 50.6
Nozzle holder 34.3 to 39.2 3.5 to 4.0 25.3 to 28.9
Overflow pipe assembly retaining nut 19.6 to 24.5 2.0 to 2.5 14.5 to 18.1
Glow plug 7.8 to 14.7 0.8 to 1.5 5.8 to 10.8
* Rocker arm bracket nut 21.6 to 26.5 2.2 to 2.7 15.9 to 19.5
* Cylinder head screw 63.7 to 68.6 6.5 to 7.0 47.0 to 50.6
* Fan drive pulley screw 235.4 to 245.2 24.0 to 25.0 173.6 to 180.8
* Connecting rod screw 41.2 to 46.1 4.2 to 4.7 30.4 to 34.0
* Flywheel screw 53.9 to 58.8 5.5 to 6.0 39.8 to 43.4
Bearing case cover screw 9.8 to 11.3 1.00 to 1.15 7.2 to 8.3
* Main bearing case screw 1 29.4 to 34.3 3.0 to 3.5 21.7 to 25.3
* Main bearing case screw 2 49.0 to 53.9 5.0 to 5.5 36.2 to 39.8
* Idle gear shaft 1 mounting screw 9.8 to 11.3 1.00 to 1.15 7.2 to 8.3
Oil pressure switch 14.7 to 19.6 1.5 to 2.0 10.8 to 14.5
■ NOTE
• For * marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before
tightening.
• The letter “M” in Size × Pitch means that the screw, bolt or nut dimension stands for metric. The size is
the nominal outside diameter in mm or the threads. The pitch is the nominal distance in mm between two
threads.
W1013236
Valve Clearance
■ IMPORTANT
• Valve clearance must be checked and adjusted when engine
is cold.
1. Remove the cylinder head cover and the glow plugs.
2. Align the “1TC” mark (1) on the flywheel with alignment mark (2)
on the rear end plate so that the No. 1 piston comes to the
compression top dead center.
3. Check the following valve clearance marked with “✩” using a
thickness gauge.
4. If the clearance is not within the factory specifications, adjust with
the adjusting screw.
5. Then turn the flywheel 6.28 rad (360 °), and align the “1TC” mark
(1) on the flywheel and alignment mark (2) on the rear end plate
so that the No. 1 piston comes to the overlap position.
6. Check the following valve clearance marked with “✩“ using a
feeler gauge.
Number of cylinders D1105 V1505
Valve arrangement
0.145 to 0.185 mm
Valve clearance Factory spec.
0.00571 to 0.00728 in.
(When reassembling)
• After checking the engine oil pressure, tighten the engine oil
pressure switch to the specified torque.
14.7 to 19.6 N·m
Tightening torque Oil pressure switch 1.5 to 2.0 kgf·m
10.8 to 14.5 ft-lbs
W10349520
(A) Deflection
W10356670
CAUTION
• When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down.
Otherwise, there is risk of scalding to yourself and people rearby from steam and hot water.
Radiator Cap Air Leakage
1. Install radiator cap on adaptor (2) and radiator tester (1).
2. Apply the specified pressure 88 kPa (0.9 kgf/cm2, 13 psi), and
measure the time for the pressure to fall to 59 kPa (0.6 kgf/cm2,
9 psi).
3. If the measurement is less than the factory specification, replace
the radiator cap.
More than 10 seconds
for pressure fall from
Pressure falling time Factory spec. 88 to 59 kPa
(from 0.9 to 0.6 kgf/cm2,
from 13 to 9 psi)
■ NOTE
• The liquid gasket is not required for assembling.
• Shims are available in thickness of 0.20 mm (0.0079 in.), 0.25
mm (0.0098 in.) and 0.30 mm (0.0118 in.). Combine these
shims for adjustments.
• Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or
advances the injection timing by approx. 0.0087 rad (0.5 °).
• In disassembling and replacing the injection pump, be sure
to use the same number of new shims with the same
thickness.
(1) Timing Line (5) Two-holes : 0.20 mm (0.0079 in.)
(2) Alignment Mark (6) One-hole : 0.25 mm (0.0098 in.)
(3) Delivery Valve Holder (7) Without hole : 0.30 mm (0.0118 in.)
(4) Shim (Soft Metal Gasket Shim)
W1017170
CAUTION
• If spray from injection nozzle comes in contact with human body, fuel can be injected under skin. Blood
poisoning and death may occur.
Fuel Tightness of Pump Element
1. Remove the engine stop solenoid.
2. Remove the injection pipes and glow plugs.
3. Install the injection pump pressure tester to the injection pump.
4. Install the injection nozzle (2) jetted with the proper injection
pressure to the injection pump pressure tester (1). (Refer to the
photo.)
5. Set the speed control lever to the maximum speed position.
6. Run the starter to increase the pressure.
7. If the pressure can not reach the allowable limit, replace the
pump with new one or repair with a Kubota-authorized pump
service shop.
13.73 MPa
Fuel tightness of pump
Allowable limit 140 kgf/cm2
element
1991 psi
■ NOTE
• Never try to disassemble the injection pump assembly. For
repairs, you must contact a Kubota-authorized pump
service shop.
(1) Injection Nozzle (3) Protection Cover for Jetted Fuel
(2) Injection Pump Pressure Tester
W1017430
Fuel Tightness of Delivery Valve
1. Remove the engine stop solenoid.
2. Remove the injection pipes and glow plugs.
3. Install a pressure tester to the fuel injection pump.
4. Install the injection nozzle (2) jetted with the proper injection
pressure to the injection pump pressure tester (1).
5. Run the starter to increase the pressure.
6. Stop the starter when the fuel jets from the injection nozzle. After
that, turn the flywheel by the hand and raise the pressure to
approx. 13.73 MPa (140 kgf/cm2, 1991 psi).
7. Now turn the flywheel back about half a turn (to keep the plunger
free). Maintain the flywheel at this position and clock the time
taken for the pressure to drop from 13.73 to 12.75 MPa (from 140
to 130 kgf/cm2, from 1991 to 1849 psi).
8. Measure the time lapse for fuel pressure to drop to: 12.75 MPa
(130 kgf/cm2, 1849 psi).
9. If the measurement is less than allowable limit, replace the pump
with new one or repair with a Kubota-authorized pump service
shop.
10 seconds
13.73 → 12.75 MPa
Factory spec.
140 → 130 kgf/cm2
Fuel tightness of 1991 → 1849 psi
delivery valve 5 seconds
13.73 → 12.75 MPa
Allowable limit
140 → 130 kgf/cm2
1991 → 1849 psi
■ NOTE
• Never try to disassemble the injection pump assembly. For
repairs, you must contact a Kubota-authorized pump
service shop.
(1) Injection Pump Pressure Tester (3) Protection Cover for Jetted Fuel
(2) Injection Nozzle
W1017786
KiSC issued 04, 2006 A
1-S16
F2880, F3680, RCK72-F36, RCK72R-F36, RCK60-F36, RCK60R-F36, WSM ENGINE
CAUTION
• Check the nozzle injection pressure and condition after confirming that there is nobody standing in the
direction of the fuel spray. If the spray from the nozzle directly contacts the human body, cells may be
destroyed and blood poisoning may be caused.
Nozzle Pattern
1. Set the injection nozzle to a nozzle tester, and check the nozzle
pattern.
2. If the pattern is defective, replace the nozzle piece.
(a) Good (b) Bad
W10181310
(Reference)
• Pressure variation with 0.01 mm (0.0004 in.) difference of
adjusting washer thickness.
Approx. 235 kPa (2.4 kgf/cm2, 34 psi)
(1) Adjusting Washer
W10182100
Nozzle Holder
1. Secure the nozzle retaining nut (7) with a vise.
2. Remove the nozzle holder (1), and take out parts inside.
(When reassembling)
• Assemble the nozzle in clean fuel.
• Install the push rod (4), noting its direction.
• After assembling the nozzle, be sure to adjust the fuel injection
pressure.
34.3 to 39.2 N·m
Nozzle holder 3.5 to 4.0 kgf·m
25.3 to 28.9 ft-lbs
19.6 to 24.5 N·m
Tightening torque Overflow pipe retaining nut 2.0 to 2.5 kgf·m
14.5 to 18.1 ft-lbs
49.0 to 68.6 N·m
Nozzle holder assembly 5.0 to 7.0 kgf·m
36.2 to 50.6 ft-lbs
[2] PREPARATION
(1) Separating Engine
Draining Coolant
CAUTION
• Never open the radiator cap while operating or immediately
after stopping the engine. Otherwise, hot water will spout
out from the radiator. Wait for more than ten minutes to cool
the radiator, before opening the cap.
1. Stop the engine and let it cool down.
2. Remove the drain plug (1) to drain the coolant.
3. Remove the radiator cap to completely drain the coolant.
4. After all coolant is drained, close the drain plug.
4.6 L
Capacity (without
Coolant 4.9 U.S.qts.
recovery tank)
4.0 lmp.qts.
■ IMPORTANT
• Never mix two different type of oil.
• Use the proper SAE Engine Oil according to ambient
temperatures.
Refer to “LUBIRICANTS, FUEL AND COOLANT”.
(See page G-7)
(1) Drain Plug (A) Oil level is acceptable within this
(2) Oil Inlet Plug range.
(3) Dipstick
W1019220
■ IMPORTANT
• Use only KUBOTA SUPER UDT fluid. Use of other oils may
damage the transmission or hydraulic system.
• Refer to “LUBRICANTS, FUEL AND COOLANT” (See page
G-7.).
• Do not mix different brands fluid together.
(1) Drain Plug A : Upper Level
(2) Dipstick B : Lower Level
(3) Oil Inlet
W1041483
Hydraulic Front Suction Pipe
1. Place oil pans underneath the rubber hose (4) and oil strainer (2).
2. Remove the rubber hose (4) from the front suction pipe (3).
3. Unscrew the front suction pipe mounting screw (1).
4. Unscrew the oil strainer (2), and remove the oil strainer and front
suction pipe (3).
(When reassembling)
98.1 to 137.2 N·m
Tightening torque Oil strainer 10.0 to 14.0 kgf·m
72.4 to 101.2 ft-lbs
(1) Front Suction Pipe Mounting Screw (3) Front Suction Pipe
(2) Oil Strainer (4) Rubber Hose
W1041888
Battery
CAUTION
• When disassembling the battery cables, disconnect the
negative cable from the battery first. When connecting,
connect the positive cable to the battery first.
1. Disconnect the negative cable (2) from the battery.
2. Disconnect the positive cable (1) from the battery.
(1) Positive Cable (2) Negative Cable
W1042092
Bonnet
1. Unscrew the bonnet mounting screws (2) and nuts.
2. Remove the bonnet (1) from the frame (3).
(1) Bonnet (2) Frame
(2) Bonnet Mounting Screw
W1042247
Air Cleaner
1. Remove the air cleaner (1) with hoses from the intake manifold.
(1) Air Cleaner
W1043401
Seat
1. Disconnect 2P connector from the seat switch.
2. Remove the seat (1) with the seat base.
17.7 to 20.5 N·m
Tightening torque Seat base mounting screw 1.8 to 2.1 kgf·m
13.1 to 15.1 ft-lbs
Panel
1. Separate the front panel (1) from the rear panel (4).
2. Disconnect the connectors from the easy checker, fuel gauge,
coolant temperature gauge and hour meter in front panel (1).
3. Disconnect the connectors (2), (3) from the main switch and head
light switch.
4. Remove the horn (5).
5. Remove the rear panel (4).
(1) Front Panel (4) Rear Panel
(2) 4P Connector (5) Horn
(3) 3P Connector
W1040859
Fender
1. Remove the differential lock pedal (1) and brake lock lever (3).
2. Remove the main brake pedal (2), speed control pedal (4).
3. Remove the lever grips from hydraulic lift lever (5) and PTO lever
(7).
4. Remove the lever grip from high-low gear shift lever (6).
5. Remove the lever grip from 4WD lock lever (9).
6. Remove the fender (8).
(1) Differential Lock Pedal (6) High-Low Gear Shift Lever
(2) Main Brake Pedal (7) PTO Lever
(3) Brake Lock Lever (8) Fender
(4) Speed Control Pedal (9) 4WD Lock Lever
(5) Hydraulic Lift Lever
W1047430
Fuel Tank
1. Disconnect the fuel hose and return hose from the fuel tank (1).
2. Disconnect the 1P connector from the fuel sensor.
3. Remove the fuel tank (1).
4. Remove the dust under plate (2).
5. Remove the fuel tank rear support (3).
(1) Fuel Tank (3) Fuel Tank Rear Support
(2) Dust Under Plate
W1047809
Pipe Holder
1. Remove the pipe holder (1).
(1) Pipe Holder
W1048005
Radiator
1. Unscrew the dust plate mounting screws (3).
2. Remove the radiator assembly (1) with the dust plate (4).
(1) Radiator Assembly (3) Dust Plate Mounting Screw
(2) Dust Plate Stay (4) Dust Plate
W1049330
Drive Shaft
1. Unscrew the drive shaft mounting screws (2), and disconnect the
drive shaft (3) from the fan drive pulley (1).
(When reassembling)
• Apply grease to the all splines on the drive shaft.
19.6 to 29.4 N·m
Drive shaft mounting
Tightening torque 2.0 to 3.0 kgf·m
screw
14.5 to 21.7 ft-lbs
Separating Engine
1. Unscrew the engine mounting nuts, and support the engine with
an engine lift hook and hoist.
2. Separate the engine from the frame.
W1059769
Injection Pipes
1. Loosen the screws to the pipe clamp (1).
2. Detach the injection pipes (2).
(When reassembling)
• By using compressed air, clean out the injector pipes (2). Then,
reassemble the pipes in the reverse order.
24.5 to 34.3 N·m
Tightening torque Injection pipe retaining nut 2.5 to 3.5 kgf·m
18.1 to 25.3 ft-lbs
Tappets
1. Remove the tappets (1) from the crankcase.
(When reassembling)
• Visually check the contact between tappets and cams for proper
rotation. If defect is found, replace tappets.
• Before installing the tappets, apply engine oil thinly around them.
■ IMPORTANT
• Replace the tappets (1) in the same order they were removed
from.
(1) Tappet
W1025896
Valves
1. Remove the valve caps (2).
2. Remove the valve spring collet (3) by pushing the valve spring
retainer (4) with valve spring replacer (1).
3. Remove the valve spring retainer (4), valve spring (5) and valve
stem seal (6).
4. Remove the valve (7).
(When reassembling)
• Wash the valve stem and valve guide hole, and apply engine oil
sufficiently.
• After installing the valve spring collets, lightly tap the stem to
assure proper fit with a plastic hammer.
■ IMPORTANT
• Don’t change the combination of valve and valve guide.
(1) Valve Spring Replacer (5) Valve Spring
(2) Valve Cap (6) Valve Stem Seal
(3) Valve Spring Collet (7) Valve
(4) Valve Spring Retainer
W1234567
Thermostat Assembly
1. Remove the thermostat cover mounting screws (1), and remove
the thermostat cover (2).
2. Remove the thermostat assembly (4).
(When reassembling)
• Apply a liquid gasket (Three Bond 1215 or equivalent) only at the
thermostat cover side of the gasket (3).
(1) Thermostat Cover Mounting Screw (3) Thermostat Cover Gasket
(2) Thermostat Cover (4) Thermostat Assembly
W1472583
Gear Case
1. Remove the gear case.
(When reassembling)
• Apply a thin coat of grease to the oil seal, and install it, ensuring
the lip does not get cut or rolled.
• Measure (L) when the gear case mounting bolt is inserted in the
gear case bolt hole and judge the installation position of the
mounting bolt when you do not understand the installation
position of the mounting bolt.
A : L = 18 mm (0.71 in.) (Pipe Pin Position)
B : L = 13 mm (0.51 in.) (Water Pipe Mounting)
C : L = 10 mm (0.39 in.)
D : Nut
(1) Gear Case
W1030917
Injection Pump
1. Disconnect the start spring (4) on the thrust lever side (5).
2. Align the control rack pin (2) with the notch (1) on the crankcase,
and remove the injection pump (3).
3. Remove the injection pump shims.
4. The injection pump should not be disassembled.
(When reassembling)
• When installing the injection pump, insert the control rack pin (2)
firmly into the groove (7) of the thrust lever of fork lever.
■ NOTE
• Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or
advances the injection timing by approx. 0.0087 rad (0.5 °).
• In disassembling and replacing, be sure to use the same
number or new gasket shims with the same thickness.
(1) Notch (4) Start Spring
(2) Control Rack Pin (5) Thrust Lever
(3) Injection Pump (6) Groove
W1033441
(a) Mark
W10242740
Pistons
1. Turn the flywheel and bring the piston to top dead center.
2. Draw out the piston upward by lightly tapping it from the bottom
of the crankcase with the handle of a hammer.
3. Draw out the other pistons in the same method as above.
(When reassembling)
• Before inserting the piston into the cylinder, apply enough engine
oil to the piston.
• When inserting the piston into the cylinder, face the mark on the
connecting rod to the injection pump.
■ IMPORTANT
• Do not change the combination of cylinder and piston. Make
sure of the position of each piston by marking. For example,
mark “1” on the No.1 piston.
• When installing the piston into the cylinder, place the gaps
of all the piston rings as shown in the figure.
• Carefully insert the pistons using a piston ring compressor
(1). Otherwise, their chrome-plated section may be
scratched, causing problem inside the cylinder.
(1) Piston Ring Compressor (a) 0.785 rad (45 °)
(A) Top Ring Gap (b) 0.785 rad (45 °)
(B) Second Ring Gap (c) 1.57 rad (90 °)
(C) Oil Ring Gap
(D) Piston Pin Hole
W10277450
(5) Crankshaft
Flywheel
1. Secure the flywheel to keep it from turning, using a flywheel
stopper.
2. Remove all flywheel screws (1) and then remove the flywheel (2).
(When reassembling)
• With No. 1 piston at TDC, align the “1TC” mark (a) on the outer
surface of the flywheel horizontally with the alignment mark (b)
on the rear end plate. Now fit the flywheel in position.
• Apply engine oil to the threads and the undercut surface of the
flywheel screw and fit the screw.
53.9 to 58.8 N·m
Tightening torque Flywheel screw 5.5 to 6.0 kgf·m
39.8 to 43.4 ft-lbs
Crankshaft Assembly
1. Remove the main bearing case screw 2 (1).
2. Pull out the crankshaft assembly.
■ IMPORTANT
• Take care to protect crankshaft bearing 1 from scratches,
caused by the crank gear, etc.. (Wrap the gear in vinyl tape,
etc.)
(When reassembling)
• Clean the oil passage of the crankshaft with compressed air.
• Apply oil to the main bearing case screw 2 (1).
• Install the crankshaft assembly, aligning the screw hole of main
bearing case with the screw hole of crankcase.
• Clean the oil passage of the crankshaft with compressed air.
49.0 to 53.9 N·m
Tightening torque Main bearing case screw 2 5.0 to 5.5 kgf·m
36.2 to 39.8 ft-lbs
[4] SERVICING
(1) Cylinder Head and Valves
Top Clearance
1. Remove the cylinder head. (Do not attempt to remove the
cylinder head gasket.)
2. Move the piston up and stick a strip of fuse [1.5 mm dia. (0.059
in. dia.), 5 to 7 mm long (0.197 to 0.276 in. long)] on the piston
head at three positions with grease so as to avoid the intake and
exhaust valves and the combustion chamber ports.
3. Lower the piston, and install the cylinder head and tighten the
cylinder head screws to the specified torque.
4. Turn the flywheel until the piston passes top dead center.
5. Remove the cylinder head, and measure the thickness of the
squeezed fuses.
6. If the measurement is not within the factory specifications, check
the oil clearance between the crankpin and crankpin bearing and
between the piston pin and small end bushing.
■ NOTE
• After checking the top clearance, be sure to assemble the
cylinder head with a new cylinder head gasket.
0.55 to 0.70 mm
Top clearance Factory spec.
0.0217 to 0.0276 in.
6.960 to 6.975 mm
Valve stem O.D. Factory spec.
0.2741 to 0.2746 in.
7.010 to 7.025 mm
Valve guide I.D. Factory spec.
0.2760 to 0.2765 in.
W10774950
■ IMPORTANT
• Do not hit the valve guide with a hammer during
replacement.
(A) When Removing (B) When Installing
W10278890
Valve Seat
1. Coat the valve face lightly with prussian blue and put the valve on
its seat to check the contact.
2. If the valve does not seat all the way around the valve seat or the
valve contact is less than 70 %, correct the valve seating as
follows.
3. If the valve contact does not comply with the reference value,
replace the valve or correct the contact of valve seat.
2.12 mm
Valve seat width Factory spec.
0.0835 in.
37.0 to 37.5 mm
Factory spec.
1.457 to 1.476 in.
Free length (B)
36.5 mm
Allowable limit
1.437 in.
11.973 to 11.984 mm
Rocker arm shaft O.D. Factory spec.
0.4714 to 0.4718 in.
12.000 to 12.018 mm
Rocker arm I.D. Factory spec.
0.4724 to 0.4731 in.
W10291500
19.959 to 19.980 mm
Tappet O.D. Factory spec.
0.7858 to 0.7866 in.
20.000 to 20.021 mm
Tappet guide bore I.D. Factory spec.
0.7874 to 0.7882 in.
W10293660
0.036 to 0.114 mm
Factory spec.
Backlash between idle 0.0014 to 0.0045 in.
gear 1 and cam gear 0.15 mm
Allowable limit
0.0059 in.
0.034 to 0.116 mm
Backlash between idle Factory spec.
0.0013 to 0.0046 in.
gear 1 and injection
pump gear 0.15 mm
Allowable limit
0.0059 in.
0.030 to 0.117 mm
Backlash between Factory spec.
0.0012 to 0.0046 in.
injection pump gear and
governor gear 0.15 mm
Allowable limit
0.0059 in.
W10280630
Idle Gear 1 Side Clearance
1. Set a dial indicator with its tip on the idle gear.
2. Measure the side clearance by moving the idle gear from the
front and rear.
3. If the measurement exceeds the allowable limit, replace the idle
gear collar.
0.20 to 0.51 mm
Factory spec.
Idle gear 1 side 0.0079 to 0.0201 in.
clearance 0.8 mm
Allowable limit
0.0315 in.
W10285590
Camshaft Side Clearance
1. Set a dial indicator with its tip on the camshaft.
2. measure the side clearance by moving the cam gear from the
front to rear.
3. If the measurement exceeds the allowable limit, replace the
camshaft stopper.
0.07 to 0.22 mm
Factory spec.
Camshaft side 0.0028 to 0.0087 in.
clearance 0.30 mm
Allowable limit
0.0118 in.
W10295630
Camshaft Alignment
1. Support the camshaft with V blocks on the surface plate at both
end journals.
2. Set a dial indicator with its tip on the intermediate journal.
3. Measure the camshaft alignment.
4. If the measurement exceeds the allowable limit, replace the
camshaft.
0.01 mm
Camshaft alignment Allowable limit
0.0004 in.
W10296710
29.00 mm
Factory spec.
Cam lobe height of 1.1417 in.
exhaust 28.95 mm
Allowable limit
1.1398 in.
W10297880
Oil Clearance of Camshaft Journal
1. Measure the camshaft journal O.D. with an outside micrometer.
2. Measure the cylinder block bore I.D. for camshaft with a cylinder
gauge, and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the
camshaft.
0.050 to 0.091 mm
Factory spec.
Oil clearance of 0.00197 to 0.00358 in.
camshaft journal 0.15 mm
Allowable limit
0.0059 in.
35.934 to 35.950 mm
Camshaft journal O.D. Factory spec.
1.4147 to 1.4153 in.
Camshaft bearing I.D.
36.000 to 36.025 mm
(Cylinder block bore Factory spec.
1.4173 to 1.4183 in.
I.D.)
W10299330
Oil Clearance between Idle Gear 1 Shaft and Idle Gear Bushing
1. Measure the idle gear shaft 1 O.D. with an outside micrometer.
2. Measure the idle gear bushing I.D. with an inside micrometer,
and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the
bushing.
If it still exceeds the allowable limit, replace the idle gear shaft 1.
0.020 to 0.054 mm
Oil clearance between Factory spec.
0.0008 to 0.0021 in.
idle gear shaft 1 and idle
gear bushing 0.10 mm
Allowable limit
0.0039 in.
25.967 to 25.980 mm
Idle gear shaft 1 O.D. Factory spec.
1.0223 to 1.0228 in.
26.000 to 26.021 mm
Idle gear bush I.D. Factory spec.
1.0236 to 1.0244 in.
W10301050
Replacing Idle Gear Bushing
(When removing)
1. Press out the used idle gear bushing using an idle gear bushing
replacing tool. (See page “SPECIAL TOOLS”.)
(When installing)
1. Clean a new idle gear bushing and idle gear bore, and apply
engine oil to them.
2. Press in a new bushing using an idle gear bushing replacing tool,
until it is flush with the end of the idle gear.
(A) When Removing (B) When Installing
W10302410
22.002 to 22.011 mm
Piston pin O.D. Factory spec.
0.8662 to 0.8666 in.
22.025 to 22.040 mm
Small end bushing I.D. Factory spec.
0.8671 to 0.8677 in.
W10305740
Replacing Small End Bushing
(When removing)
1. Press out the used bushing using a small end bushing replacing
tool. (See page “SPECIAL TOOLS”.)
(When installing)
1. Clean a new small end bushing and bore, and apply engine oil to
them.
2. Using a small end bushing replacing tool, press in a new bushing
(service parts) taking care to see that the connecting rod oil hole
matches the bushing hole.
0.015 to 0.075 mm
Oil clearance between Factory spec.
0.00059 to 0.00295 in.
piston pin and small end
bushing (Spare parts) 0.15 mm
Allowable limit
0.0059 in.
(A) Top Ring (Key Stone Type) (B) 2nd, Oil Ring
W10312390
(4) Crankshaft
Crankshaft Side Clearance
1. Set a dial indicator with its tip on the end of the crankshaft.
2. Measure the side clearance by moving the crankshaft to the front
and rear.
3. If the measurement exceeds the allowable limit, replace the
thrust bearings.
4. If the same size bearing is still loose because of the crankshaft
journal wear, replace it with an oversize one referring to the table
and figure.
0.15 to 0.31 mm
Factory spec.
Crankshaft side 0.0059 to 0.0122 in.
clearance 0.50 mm
Allowable limit
0.0197 in.
(Reference)
• Oversize dimensions of crankshaft journal
0.2 mm 0.4 mm
Oversize
0.008 in. 0.016 in.
51.5 to 51.7 mm 51.6 to 51.8 mm
Dimension A
2.028 to 2.035 in. 2.031 to 2.039 in.
28.20 to 28.25 mm 28.40 to 28.45 mm
Dimension B
1.1102 to 1.1122 in. 1.1181 to 1.1201 in.
2.3 to 2.7 mm radius 2.3 to 3.7 mm radius
Dimension C
0.091 to 0.106 in. radius 0.091 to 0.106 in. radius
(0.8-S)
The crankshaft journal must be fine-finished to higher than ∇∇∇∇
W10317070
Crankshaft Alignment
1. Support the crankshaft with V blocks on the surface plate at both
end journals.
2. Set a dial indicator with its tip on the intermediate journal.
3. Measure the crankshaft alignment.
4. If the measurement exceeds the allowable limit, replace the
crankshaft.
0.02 mm
Crankshaft alignment Allowable limit
0.0008 in.
W10330010
39.959 to 39.975 mm
Crankpin O.D. Factory spec.
1.5732 to 1.5738 in.
40.004 to 40.050 mm
Crankpin bearing I.D. Factory spec.
1.5750 to 1.5768 in.
(Reference)
• Undersize dimensions of crankpin
0.2 mm 0.4 mm
Undersize
0.008 in. 0.016 in.
2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
Dimension A
0.1102 to 0.1260 in. radius 0.1102 to 0.1260 in. radius
1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
*Dimension B
0.0394 to 0.0591 in. relief 0.0394 to 0.0591 in. relief
39.759 to 39.775 mm dia. 39.559 to 39.575 mm dia.
Dimension C
1.5653 to 1.5659 in. dia. 1.5574 to 1.5581 in. dia.
(0.8-S)
The crankpin must be fine-finished to higher than ∇∇∇∇
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.0394 to 0.0591 in.) relief.
W10331060
47.934 to 47.950 mm
Crankshaft journal O.D. Factory spec.
1.8872 to 1.8878 in.
Crankshaft bearing 1 47.984 to 48.048 mm
Factory spec.
I.D. 1.8891 to 1.8916 in.
(Reference)
• Undersize dimensions of crankshaft journal
0.2 mm 0.4 mm
Undersize
0.008 in. 0.016 in.
2.3 to 2.7 mm radius 2.3 to 2.7 mm radius
Dimension A
0.0906 to 0.1063 in. radius 0.0906 to 0.1063 in. radius
1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
*Dimension B
0.0394 to 0.0591 in. relief 0.0394 to 0.0591 in. relief
47.734 to 47.750 mm dia. 47.534 to 47.550 mm dia.
Dimension C
1.8793 to 1.8799 in. dia. 1.8714 to 1.8720 in. dia.
(0.8-S)
The crankshaft journal must be fine-finished to higher than ∇∇∇∇
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.0394 to 0.0591 in.) relief.
W10337170
Replacing Crankshaft Bearing 1
(When removing)
1. Press out the used crankshaft bearing 1 using a crankshaft
bearing 1 replacing tool. (See page “SPECIAL TOOLS”.)
(When installing)
1. Clean a new crankshaft bearing 1 and crankshaft journal bore,
and apply engine oil to them.
2. Using a crankshaft bearing 1 replacing tool, press in a new
bearing 1 (2) so that its seam (1) is toward the exhaust manifold
side. (See figure.)
0 to 0.3 mm
Dimension (A) Factory spec.
0 to 0.0118 in.
0.034 to 0.098 mm
Oil clearance between Factory spec.
0.0013 to 0.0039 in.
crankshaft journal and
crankshaft bearing 3 0.20 mm
Allowable limit
0.0079 in.
(5) Cylinder
Cylinder Wear
1. Measure the I.D. of the cylinder at the six positions (see figure)
with a cylinder gauge to find the maximum and minimum I.D.’s.
2. Get the difference (Maximum wear) between the maximum and
the minimum I.D.’s.
3. If the wear exceeds the allowable limit, bore and hone to the
oversize dimension. (Refer to “Correcting Cylinder”.)
4. Visually check the cylinder wall for scratches. If deep scratches
are found, the cylinder should be bored. (Refer to “Correcting
Cylinder”.)
78.000 to 78.019 mm
Factory spec.
3.0709 to 3.0716 in.
Cylinder I.D.
78.15 mm
Allowable limit
3.0768 in.
Correcting Cylinder
1. When the cylinder is worn beyond the allowable limit, bore and
hone it to the specified dimension.
78.500 to 78.519 mm
Factory spec.
Oversized cylinder liner 3.0906 to 3.0913 in.
I.D. 78.65 mm
Allowable limit
3.0965 in.
Finishing
Hone to 1.2 to 2.0 mm µR max.
∇∇∇
(0.000047 to 0.000079 in. µR max.)
2. Replace the piston and piston rings with oversize ones.
Oversize : 0.5 mm (0.0197 in.)
■ NOTE
• When the oversize cylinder is worn beyond the allowable
limit, replace the cylinder block with a new one.
(1) Cylinder I.D. (Before Correction) (2) Cylinder I.D. (Oversize)
W10344480
W10357320
CONTENTS
1. STRUCTURE
(1) Hydrostatic Transmission (2) Range Gear Shift Section (4) Differential Gear Section (5) Rear Wheel Drive Section
(HST) Section (3) PTO Section (Dual Acting Overrunning
Clutch)
2. POWER TRAIN
[1] HYDROSTATIC TRANSMISSION (HST)
(1) Structure
(1) Motor Shaft (8) Oil Seal (14) Retainer Plate (20) Check Valve Spring
(2) Needle Bearing (9) Needle Bearing (15) Thrust Plate (21) Relief Valve Spring
(3) Thrust Plate (10) Valve Plate (16) Variable Swashplate (22) Check and High Pressure
(4) Charge Relief Valve (11) Center Section (17) HST Housing Relief Valve (Forward)
(5) Cylinder Block (Motor) (12) Cylinder Block (Pump) (18) Pump Shaft (23) Check and High Pressure
(6) Valve Plate (13) Piston (19) Valve Plug Relief Valve (Reverse)
(7) Needle Bearing
The hydrostatic transmission (HST) consists of a variable displacement piston pump, a fixed displacement piston
motor, two check and high pressure relief valves and a charge relief valve.
The pump and motor have nine pistons in their cylinder blocks.
The discharge rate of the HST is 18.9 cm3/rev. (1.15 cu.in./rev.).
The speed control pedal permits simple operation of the machine, starting, stopping, increasing or decreasing
speed.
(1) Pump (5) Oil Cooler (9) Hydraulic Pump A : To PTO Control Valve
(2) Charge Relief Valve (6) Check and High Pressure (10) Check and High Pressure B : From Power Steering
(3) Oil Filter Cartridge Relief Valve Relief Valve Controller
(4) PTO Charge Relief Valve (7) Motor (11) Hydrostatic Transmission C : To Power Steering Controller
(8) Flow Priority Valve D : To Implement Control Valve
EF :EF Port
PF :PF Port
P : P Port
The closed hydraulic oil loop runs between the pump (1) and motor (7) in the hydrostatic transmission (11).
When the engine is started, the hydraulic pump (9) is rotated to drow oil from the transmission case through the
suction pipe.
The oil is forced out by the hydraulic pump (9) to the power steering controller through the flow priority valve (8).
When the control valve in the power steering controller is at “Neutral” position, the oil is delivered to the oil cooler
(5).
The oil from the oil cooler (5) is delivered to the PTO charge relief valve (4), oil filter cartridge (3) and charge relief
valve (2).
The oil is drained into the transmission case through the hydrostatic transmission housing.
(3) Operation
■ Neutral
(1) Oil Cooler (7) Cylinder Block (Motor) (13) Pump Shaft A: Port A
(2) PTO Charge Relief Valve (8) Motor Shaft (14) Swashplate B: Port B
(3) Oil Filter Cartridge (9) Piston (15) Cylinder Block (Pump) C: Port C
(4) Check and High Pressure (10) Hydraulic Pump (16) Oil Strainer D: Port D
Relief Valve (Forward) (11) Power Steering Controller (17) Transmission Case a: High Pressure
(5) Check and High Pressure (12) Flow Priority Valve (18) Implement Control Valve b: Low Pressure
Relief Valve (Reverse) c: Charge Pressure
(6) Charge Relief Valve
Engine revolution rotates the pump shaft (13) via the universal joint.
When the speed control pedal is in neutral, the swashplate (14) is at right angles to the pump piston and they only
rotate with pump cylinder block (15) without reciprocating.
Since the oil is not being pumped to the motor, the cylinder block (7) in the motor is stationary and the motor shaft
(8) does not rotate.
■ Forward
(1) Oil Cooler (7) Cylinder Block (Motor) (13) Pump Shaft A: Port A
(2) PTO Charge Relief Valve (8) Motor Shaft (14) Swashplate B: Port B
(3) Oil Filter Cartridge (9) Piston (15) Cylinder Block (Pump) C: Port C
(4) Check and High Pressure (10) Hydraulic Pump (16) Oil Strainer D: Port D
Relief Valve (Forward) (11) Power Steering Controller (17) Transmission Case a: High Pressure
(5) Check and High Pressure (12) Flow Priority Valve (18) Implement Control Valve b: Low Pressure
Relief Valve (Reverse) c: Charge Pressure
(6) Charge Relief Valve
When the speed control pedal is stepped on and in forward, the swashplate (14) is tilted as shown in the figure
above.
As the pump cylinder block (15) rotates with the pump shaft (13), oil is forced out of pump port B at high pressure.
As the pressure oil enters motor port D, the pistons, which align with port D, are pushed against the inclined thrust
plate slide down the inclined surface.
Then the motor shaft (8) rotates with the motor cylinder block (7). This drives the machine forward and the angle
of swashplate (14) determines the motor shaft speed.
■ Reverse
(1) Oil Cooler (7) Cylinder Block (Motor) (13) Pump Shaft A: Port A
(2) PTO Charge Relief Valve (8) Motor Shaft (14) Swashplate B: Port B
(3) Oil Filter Cartridge (9) Piston (15) Cylinder Block (Pump) C: Port C
(4) Check and High Pressure (10) Hydraulic Pump (16) Oil Strainer D: Port D
Relief Valve (Forward) (11) Power Steering Controller (17) Transmission Case a: High Pressure
(5) Check and High Pressure (12) Flow Priority Valve (18) Implement Control Valve b: Low Pressure
Relief Valve (Reverse) c: Charge Pressure
(6) Charge Relief Valve
When the speed control pedal is stepped on and in reverse, the swashplate (14) is tilted as shown in the figure
above.
As the pump cylinder block (15) rotates with the pump shaft (13), oil is forced out of pump port A at high pressure.
As the pressure oil enters motor port C, the pistons, which align with port C are pushed against the inclined thrust
plate and slide down the inclined surface.
Then the motor shaft (8) rotates with the motor cylinder block (7). This drives the machine backward and the angle
of swashplate (14) determines the motor shaft speed.
(1) Neutral Spring (5) Speed Control Pedal (9) Brake Rod 1 (12) Ball Bearing
(2) Speed Control Rod (6) Speed Control Bracket (10) Brake Return Spring (13) Speed Change Arm
(3) Brake Lock Lever (7) Damper Stay (11) Neutral Arm (14) Trunion Shaft
(4) Main Brake Pedal (8) Damper
The speed control pedal (5) and the trunnion shaft (14) of the variable swashplate are linked with the speed control
bracket (6), speed control rod (2), and speed change arm (13).
As the front footrest of the pedal is depressed, the swashplate rotates and forward traveling speed increases.
Depressing the rear footrest increase reverse speed.
Then, the swashplate is returned to neutral with the speed change arm (13), when the pedal is released.
The damper (8) is connected to the speed control pedal (5) linked with the speed control bracket (6) and damper
stay (7), restrict the movement of the linkage to prevent abrupt operation or reversing.
The ball bearing (12) on the neutral arm (11) seats the detent of the speed change arm (13) so that the speed
change arm (13) returns to neutral.
The dual-acting overrunning 4WD system can be engaged by simply switching the control lever. There are two
mode to choose from : full-time 4WD mode and dual-acting overrunning 4WD mode.
If the later mode is selected, the 2WD and 4WD are automatically switched from each other in both the forward
and backward runs in response to the road condition and other factors.
The dual-acting overrunning 4WD system can minimize damage to the lawn. In this mode, the wheels drag
themselves much less on the ground with repetitious forward and backward runs, this also allows small-radius turns
and in other running styles.
On slopes, the full-time 4WD mode may be selected to ensure the best possible traction, stability and safety.
■ IMPORTANT
• Do not steer the rear wheels sharply when the Dual-acting overrunning 4WD clutch lock lever is in the
“Full-time 4WD” position.
■ 2WD mode
RWD Shaft 1 (11) → Drive Cam (9) → Center Cam (16)
■ Mode 4RM
RWD Shaft 1 (11) → Drive Cam (9) → Center Cam (16) → Driven Cam (17) → RWD Shaft 2 (1)
5. PTO SECTION
■ PTO “Engage”
(1) 28T Gear (5) PTO Shaft (9) Clutch Case (13) Pressure Plate
(2) Pump Shaft (6) Coupling (10) Piston (14) 33T Gear
(3) Return Spring (7) Clutch Shaft (11) Steel Plate (15) PTO Control Valve
(4) PTO Brake Disc (8) PTO Brake Plate (12) Clutch Disc (15) Valve Lever
The main components of the PTO section are shown in the figure above.
When the PTO lever is set to “ENGAGE” position, the PTO control rod is pulled and the PTO control valve (15)
rotates.
The oil is forced out by the hydraulic pump to the hydraulic PTO clutch through the steering controller, PTO control
valve (15) and clutch shaft (7).
The piston (10) is pushed against the steel plates (11), clutch discs (12) and pressure plate (13) by this movement.
The steel plates (11) and pressure plate (13) are held between the clutch discs (12) and piston (10), and the friction
between them cause the clutch discs (12) to rotate, thus transmitting the power from the engine to the implement as
follows ;
Pump Shaft (2) → 28T Gear (1) → 33T Gear (13) → Piston (10) → Clutch Case (9) → Clutch Shaft (7) → Coupling
(6) → PTO Shaft (5).
■ PTO “Disengage”
(1) 28T Gear (5) PTO Shaft (9) Piston (13) 33T Gear
(2) Pump Shaft (6) Coupling (10) Steel Plate (14) PTO Control Valve
(3) Return Spring (7) Clutch Shaft (11) Clutch Disc (15) Valve Lever
(4) PTO Brake Disc (8) PTO Brake Plate (12) Pressure Plate
When the PTO lever is set to “DISENGAGE” position, the oil passage is closed by the PTO control valve (14).
The piston (9) is pushed against the PTO brake plates (8) and PTO brake disc (4), which creates clearance between
the steel plates (10) and clutch discs (11), causing no friction. At the same time, the PTO brake disc (4) is held
between the PTO brake plates (8), causing friction. Therefore, the power to the implement is shut off and brake
engages to prevent the PTO shaft (5) from the free-spinning.
When resistance to the right and left tires are greatly different due to ground conditions or type of work, the tire with
less resistance slips and prevents the machine from moving ahead. To compensate for this drawback, the differential
lock restricts the differential action and causes both front axles to rotate as a unit.
When the differential lock pedal is stepped on, it causes the differential lock lever (3) to rotate, which will move the
differential lock shift fork (2) and the differential lock clutch (5) toward the spiral gear (8). The differential lock clutch
(5) engaged with the teeth of the differential case (6) to cause the differential case (6) and the differential lock clutch
(5) to rotate as a unit.
Therefore, differential pinions (1) are unable to rotate around differential pinion shaft (7) and identical revolutions
are transmitted to the right and left differential gear shaft (4), (9).
CONTENTS
1. TROUBLESHOOTING ....................................................................................2-S1
2. SERVICING SPECIFICATIONS ....................................................................2-S4
3. TIGHTENING TORQUES ..............................................................................2-S6
4. CHECKING, DISASSEMBLING AND SERVICING......................................2-S7
[1] CHECKING AND ADJUSTING ...............................................................2-S7
[2] PREPARATION ......................................................................................2-S10
(1) Separating Transmission Assembly..................................................2-S10
(2) Separating Hydrostatic Transmission (HST).....................................2-S19
(3) Separating Transmission Case.........................................................2-S20
(4) Separating Differential Gear Case ....................................................2-S20
[3] DISASSEMBLING AND ASSEMBLING................................................2-S22
(1) Hydrostatic Transmission..................................................................2-S22
(2) Hydraulic PTO Clutch Assembly .......................................................2-S24
(3) RWD Case ........................................................................................2-S25
(4) Transmission Case ...........................................................................2-S26
(5) Differential Gear Case ......................................................................2-S27
[4] SERVICING ............................................................................................2-S29
(1) Hydrostatic Transmission..................................................................2-S29
(2) Hydraulic PTO Clutch .......................................................................2-S31
(3) Transmission Case ...........................................................................2-S32
(4) Differential Gear Case ......................................................................2-S33
1. TROUBLESHOOTING
HYDROSTATIC TRANSMISSION SECTION
Reference
Symptom Probable Cause Solution
Page
System Will Not Oil level is low Fill oil to proper level G-7, 2-S10
Operate in Either Control linkage defective (Speed control pedal to Repair control 2-S12, S14,
Direction speed change arm) linkage S16
Charge pressure is too • Charge relief valve Replace charge relief 2-S8, S23
low defective valve
• Oil filter cartridge Replace oil filter G-18
clogged cartridge
• PTO charge relief Replace PTO charge 2-S9, S19
valve defective relief valve
Check and high pressure relief valve defective Replace check and 2-S9, S22
high pressure relief
valve
HST component parts defective Replace HST 2-S19, S22
assembly to S23
Vibration and Noise Oil level is low Fill oil to proper level G-7, 2-S10
Control linkage defective (Speed control pedal to Repair control 2-S12, S14,
speed change arm) linkage S16
Charge pressure is too • Charge relief valve Replace charge relief 2-S8, S23
low defective valve
• Oil filter cartridge Replace oil filter G-18
clogged cartridge
• PTO charge relief Replace PTO charge 2-S9, S19
valve defective relief valve
Check and high pressure relief valve defective Replace check and 2-S9, S22
high pressure relief
valve
HST component parts defective Replace HST 2-S19, S22
assembly to S23
Loss of Power Oil level is low Fill oil to proper level G-7, 2-S10
Control linkage defective (Speed control pedal to Repair control 2-S12, S14,
speed change arm) linkage S16
Charge pressure is too • Charge relief valve Replace charge relief 2-S8, S23
low defective valve
• Oil filter cartridge Replace oil filter G-18
clogged cartridge
• PTO charge relief Replace PTO charge 2-S9, S19
valve defective relief valve
Check and high pressure relief valve defective Replace check and 2-S9, S22
high pressure relief
valve
HST component parts defective Replace HST 2-S19, S22
assembly to S23
W1022927
PTO SECTION
Reference
Symptom Probable Cause Solution
Page
Loss of PTO Power Clutch disc worn Replace 2-S24, S31
PTO Noisy PTO bearing worn Replace 2-S24
PTO Clutch Cannot Clutch disc worn Replace 2-S24, S31
be Disengaged even Improper oil pressure Check G-7, 2-S10
if Clutch Lever is
Pulled to Disengage
W1023839
2. SERVICING SPECIFICATIONS
Item Factory Specification Allowable Limit
Adjusting Screw Length Approx. 15 mm 15 to 20 mm
Approx. 0.59 in. 0.59 to 0.79 in.
Check and High Relief Pressure 34.3 MPa –
350 kgf/cm2
4975 psi
Charge Pressure 0.40 to 0.58 MPa –
4.0 to 6.0 kgf/cm2
57 to 85 psi
Cylinder Block Bore to Piston Clearance 0.02 mm 0.04 mm
0.0008 in. 0.0016 in.
Piston Slipper Thickness 3.00 mm 2.90 mm
0.118 in. 0.114 in.
PTO Brake Plate Thickness 4.35 to 4.65 mm 4.25 mm
0.1713 to 0.1830 in. 0.1673 in.
PTO Brake Disc Thickness 3.65 to 3.95 mm 3.30 mm
0.1437 to 0.1555 in. 0.1299 in.
Pressure Plate Thickness 1.95 to 2.05 mm 1.80 mm
0.0768 to 0.0807 in. 0.0709 in.
Clutch Disc Thickness 1.90 to 2.10 mm 1.60 mm
0.0748 to 0.0827 in. 0.0630 in.
Steel Plate Thickness 0.95 to 1.05 mm 0.80 mm
0.0374 to 0.0413 in. 0.0315 in.
Clutch Shaft to 16T - 33T Gear Clearance 0.007 to 0.047 mm 0.10 mm
0.0003 to 0.0018 in. 0.0039 in.
(Continued)
Item Factory Specification Allowable Limit
Differential Pinion Shaft to Differential Clearance 0.016 to 0.045 mm 0.30 mm
Pinion 0.0007 to 0.0018 in. 0.0118 in.
3. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-8)
Item N·m kgf·m ft-lbs
Holder shaft mounting screw 23.5 to 27.4 2.40 to 2.79 17.4 to 20.2
Oil strainer 98.1 to 137.2 10.0 to 14.0 72.4 to 101.2
ROPS mounting screw 123 to 147 12.6 to 14.9 90.8 to 108.4
Seat base mounting screw 17.7 to 20.5 1.8 to 2.1 13.1 to 15.1
Power steering hose mounting nut 24.6 to 29.4 2.5 to 3.0 18.1 to 21.6
Power steering pipe mounting nut 54.0 to 63.7 5.5 to 6.5 39.8 to 47.0
Delivery pipe mounting nut 39.3 to 47.0 4.0 to 5.0 28.9 to 36.1
Drive shaft mounting screw 27.5 to 29.4 2.8 to 3.0 20.3 to 21.6
Transmission mounting screw (M12) 62.8 to 72.5 6.4 to 7.4 46.3 to 53.5
Side frame mounting screw and nut 62.8 to 72.5 6.4 to 7.4 46.3 to 53.5
Front wheel mounting nut 39.3 to 44.1 4.0 to 4.5 29.0 to 32.5
PTO pipe mounting nut 54.0 to 63.7 5.5 to 6.5 39.8 to 47.0
HST mounting screw (M8) 23.6 to 27.4 2.4 to 2.8 17.4 to 20.2
HST mounting screw (M10) 39.3 to 44.1 4.0 to 4.5 29.0 to 32.5
Transmission case mounting screw and nut 39.3 to 44.1 4.0 to 4.5 29.0 to 32.5
Hydraulic cylinder mounting screw and nut 39.3 to 44.1 4.0 to 4.5 29.0 to 32.5
Front axle case mounting screw 39.3 to 44.1 4.0 to 4.5 29.0 to 32.5
Center section hex. socket screw 49.0 to 58.8 5.0 to 6.0 36.2 to 43.4
Valve plug 58.8 to 98.1 6.0 to 10.0 43.4 to 72.3
Differential bearing holder mounting screw 17.7 to 20.5 1.8 to 2.1 13.1 to 15.1
Spiral bevel gear UBS screw 29.5 to 34.3 3.0 to 3.5 21.7 to 25.3
W1012736
Charge Pressure
CAUTION
• When checking, park the machine on flat ground, apply the
parking brake.
■ NOTE
• Use a new transmission oil filter cartridge.
1. Remove the seat assembly and plate (1).
2. Remove the plug (R 1/4) from P2 port (2).
3. Assemble the adaptor 58 (Code No. 07916-52391) and threaded
joint (Code No. 07916-50341).
4. Install the assembled adaptor 58 and threaded joint to P2 port
(2).
5. Then, connect the cable (Code No. 07916-50331), threaded joint
(Code No. 07916-51301) to threaded joint in order.
6. Reinstall the seat assembly.
7. Run the engine at maximum speed.
8. Place the high-low gear shift lever in neutral.
9. Release the speed control pedal to set in neutral, and measure
the charge pressure.
10.If the charge pressure is not within the factory specifications,
change the charge relief valve assembly in HST.
(When reassembling)
• Install the plug (R 1/4) to P2 port (2) with seal tape.
Charge pressure 0.40 to 0.58 MPa
(Oil temperature at 50 to Factory spec. 4.0 to 6.0 kgf/cm2
60 °C (122 to 140 °F)) 57 to 85 psi
CAUTION
• When checking, park the machine on flat ground, apply the
parking brake.
1. Remove the seat assembly and plate (2).
2. Remove the plug (R 1/4) from P1 (1) or P3 (3) port. (P3 is for
forward and P1 is for reverse)
3. Assemble the adaptor 58 (Code No. 07916-52391) and threaded
joint (Code No. 07916-50341).
4. Install the assembled adaptor 58 and threaded joint to P3 (3) or
P1 (1) port.
5. Then, connect the cable (Code No. 07916-50331), threaded joint
(Code No. 07916-51301) and pressure gauge to threaded joint in
order.
6. Reinstall the seat assembly.
7. Run the engine at maximum speed.
8. Place the high-low gear shift lever in high.
9. Depress the speed control pedal, and measure the high relief
pressure.
10.If the measurement is not factory specification, change the check
and high relief valve assembly.
■ IMPORTANT
• Measure quickly otherwise the relief valve may not be in
operation more than 10 seconds
(When reassembling)
• Install the plug (R 1/4) to P1 (1) or P3 (3) port with seal tape.
High relief pressure 34.3 MPa
(Oil temperature at 50 to Factory spec. 350 kgf/cm2
60 °C (122 to 140 °F)) 4975 psi
CAUTION
• When checking, park the machine on flat ground, apply the
parking brake.
■ NOTE
• Use a new transmission oil filter.
1. Remove the seat assembly and plate (2).
2. Unscrew the plug (1) from the oil filter bracket.
3. Install the adaptor D. Then connect the cable and pressure
gauge to adaptor D.
4. Reinstall the seat assembly.
5. Start the engine and set at maximum speed.
6. PTO lever is set to “ENGAGE” position, and read the gauge.
7. If the pressure is not within the factory soecification, adjust with
the adjusting screw (3).
PTO charge pressure 785 to 1078 kPa
(Oil temperature at 50 to Factory spec. 8.0 to 11.0 kgf/cm2
60 °C (122 to 140 °F)) 114 to 156 psi
[2] PREPARATION
(1) Separating Transmission Assembly
Battery and Battery Support
CAUTION
• When disconnecting the battery cables, disconnect the
negative cable from the battery first.
• When connecting, connect the positive cable to the battery
first.
1. Disconnect the negative cable (4) from the battery.
2. Disconnect the positive cable (1) from the battery.
3. Unscrew the battery mounting nuts (2), and remove the battery
(3).
4. Push out the wiring clip (6) with the wiring from the hole of the
battery support (5).
5. Unscrew the battery support mounting screws, and remove the
battery support (5).
(1) Positive Cable (4) Negative Cable
(2) Battery Mounting Nut (5) Battery Support
(3) Battery (6) Wiring Clip
■ IMPORTANT
• Use only KUBOTA SUPER UDT fluid. Use of other oils may
damage the transmission or hydraulic system.
• Refer to “LUBRICANTS, FUEL AND COOLANT” (See page
G-7.).
• Do not mix different brands fluid together.
(1) Drain Plug A : Upper Level
(2) Dipstick B : Lower Level
(3) Oil Inlet
W1012046
(1) Front Suction Pipe Mounting Screw (3) Front Suction Pipe
(2) Oil Strainer (4) Rubber Hose
W1012305
Seat
1. Disconnect 2P connector from the seat switch.
2. Remove the seat (1) with the seat base.
17.7 to 20.5 N·m
Tightening torque Seat base mounting screw 1.8 to 2.1 kgf·m
13.1 to 15.1 ft-lbs
Panel
1. Separate the front panel (1) from the rear panel (4).
2. Disconnect the connectors from the easy checker, fuel gauge,
coolant temperature gauge and hour meter in front panel (1).
3. Disconnect the connectors (2), (3) from the main switch and head
light switch.
4. Remove the horn (5).
5. Remove the rear panel (4).
(1) Front Panel (4) Rear Panel
(2) 4P Connector (5) Horn
(3) 3P Connector
W1040859
Fender
1. Remove the differential lock pedal (1) and brake lock lever (3).
2. Remove the main brake pedal (2), speed control pedal (4).
3. Remove the lever grips from hydraulic lift lever (5) and PTO lever
(7).
4. Remove the lever grip from high-low gear shift lever (6).
5. Remove the lever grip from 4WD lock lever (9).
6. Remove the fender (8).
(1) Differential Lock Pedal (6) High-Low Gear Shift Lever
(2) Main Brake Pedal (7) PTO Lever
(3) Brake Lock Lever (8) Fender
(4) Speed Control Pedal (9) 4WD Lock Lever
(5) Hydraulic Lift Lever
W1041101
Fuel Tank
1. Disconnect the fuel hose and return hose from the fuel tank (1).
2. Disconnect the 1P connector from the fuel sensor.
3. Remove the fuel tank (1).
4. Remove the dust under plate (2).
5. Remove the fuel tank rear support (3).
(1) Fuel Tank (3) Fuel Tank Rear Support
(2) Dust Under Plate
W1041351
(Reference)
• Length “A” : 15 to 20 mm (0.59 to 0.78 in.)
• Length “B” (LH) : 70 mm (2.8 in.)
• Length “B” (RH) : 50 mm (2.0 in.)
(1) Side Frame (LH) (7) Lift Spring Rod
(2) Side Frame (RH) (8) Brake Return Spring
(3) Neutral Spring (9) Adjusting Nut
(4) Speed Change Arm (10) Adjusting Screw
(5) Neutral Arm (11) Adjusting Nut
(6) Holder Shaft Mounting Screw
W1043994
Support Plate
1. Remove the support plate (1) from the front frame.
(1) Support Plate
W1044828
Center Section
1. Remove the center section mounting hex. socket head screws.
2. Separate the center section (2) from HST housing.
(When reassembling)
• Cover the splines of each shaft with thin tape to protect sealing
lip.
• Apply grease to the oil seals for the pump and motor shaft.
• Place a new gasket on the housing.
• Install center section with valve plates in place.
■ IMPORTANT
• Valve plates (1), (3) may stick to the center section but they
are not fixed. Take care not to drop them.
• Be sure to tighten the hex. socket head screws to the
specified torque.
49.0 to 58.8 N·m
Center section hex. socket
Tightening torque 5.0 to 6.0 kgf·m
screw
36.2 to 43.4 ft-lbs
Input Shaft
1. Remove the internal snap ring (4) and remove the oil seal (3).
2. Remove the external snap ring (2).
3. Tap out the input shaft (1) to the cylinder block side.
(1) Input Shaft (3) Oil Seal
(2) External Snap Ring (4) Internal Snap Ring
W1034986
1. Remove the ball bearing (1) and remove the 16T-33T gear (3) with the needle bearings (2), (4).
2. Remove the external snap ring (12), and remove PTO brake plate (13), PTO brake disc (5) and thrust collar.
3. Remove the ball bearing (26), and remove the 33T gear (20) with the ball bearings (19), (24).
4. Slide out the hydraulic PTO clutch assembly from the clutch shaft (18).
5. Remove the internal snap ring (17), and remove the pressure plate (16), clutch discs (15) and steel plates (14).
6. Press the collar and remove the external snap ring (11), and remove the piston (8).
CAUTION
• Return spring (9) is under pressure and retained by external snap ring (11). Carefully compress return
spring (9) before trying to remove external snap ring (11), then carefully release pressure after external
snap ring (11) is removed.
(When reassembling)
• Apply transmission fluid to O-ring (23), D-ring (7), seal ring (27) and take care not to damage it.
• Replace O-ring, D-ring and seal ring, if it is defective.
Removing Differential
1. Remove the bearing holder mounting screws, and remove the
differential bearing holder (1).
2. Remove the differential assembly.
3. Remove the internal snap ring (5) from the differential gear case
right side.
(When reassembling)
• Install the differential assembly (3), noting the number of shims
(2), (4).
17.7 to 20.5 N·m
Differential bearing holder
Tightening torque 1.8 to 2.1 kgf·m
mounting screw
13.1 to 15.1 ft-lbs
[4] SERVICING
(1) Hydrostatic Transmission
Pump Shaft and Motor Shaft
1. Check the seal surface (1) and the bearing surface (2).
2. If the shaft is rough or grooved, replace it.
(1) Seal Surface (3) Motor Shaft
(2) Bearing Surface (4) Pump Shaft
W1024186
Valve Plate
1. Check the engagement of the valve plate (1) and the anchor pin
(2).
2. Pushing the valve plate against the anchor pin, lift it to remove.
3. Check the valve plate for foreign particles.
4. Clean the valve plate and dry with compressed air.
5. Check the valve plate for scratches, wear and erosion. (Run a
finger nail across the valve plate surface. If worn, it will be felt.)
6. If worn or scored, replace it.
■ NOTE
• After checking, coat them with hydrostatic transmission oil.
(1) Valve Plates (2) Anchor Pin
W1036339
Thrust Plate and Swashplate
1. Check the thrust plate (1) for scratches and excessive wear.
2. If worn or scored, replace it.
3. Check the bearing surface (2) of trunnion shaft (swashplate) for
scratches and excessive wear.
4. If worn or scored, replace it.
(1) Thrust Plate (2) Bearing Surface
W1036630
3.65 to 3.95 mm
Factory spec.
PTO brake disc 0.1437 to 0.1555 in.
thickness 3.30 mm
Allowable limit
0.1299 in.
W1017239
Pressure Plate, Clutch Disc and Steel Plate Wear
1. Measure the thickness of the pressure plate, clutch disc and steel
plate with the outside micrometer.
2. If the thickness is less than the allowable limit, replace it.
1.95 to 2.05 mm
Factory spec.
Thickness of pressure 0.0768 to 0.0807 in.
plate 1.80 mm
Allowable limit
0.0709 in.
1.90 to 2.10 mm
Factory spec.
0.0748 to 0.0827 in.
Thickness of clutch disc
1.60 mm
Allowable limit
0.0630 in.
0.95 to 1.05 mm
Factory spec.
0.0374 to 0.0413 in.
Thickness of steel plate
0.80 mm
Allowable limit
0.0315 in.
W1017366
26.007 to 26.028 mm
16T-33T gear I.D. Factory spec.
1.0239 to 1.0247 in.
21.987 to 22.000 mm
Clutch shaft O.D. Factory spec.
0.8657 to 0.8661 in.
1.997 to 2.000 mm
Needle O.D. Factory spec.
0.0786 to 0.0787 in.
W1026751
32.000 to 32.025 mm
Differential case I.D. Factory spec.
1.2599 to 1.2608 in.
32.000 to 32.025 mm
Spiral bevel gear I.D. Factory spec.
1.2599 to 1.2608 in.
Differential side gear 31.959 to 31.975 mm
Factory spec.
O.D. 1.2582 to 1.2589 in.
W1028123
Clearance between Differential Pinion Shaft and Differential
Pinion
1. Measure the differential pinion shaft O.D. with an outside
micrometer.
2. Measure the differential pinion I.D. with an inside micrometer,
and calculate the clearance.
3. If the clearance exceeds the allowable limit, replace faulty parts.
0.016 to 0.045 mm
Clearance between Factory spec.
0.0007 to 0.0018 in.
differential pinion shaft
and differential pinion 0.30 mm
Allowable limit
0.0118 in.
16.000 to 16.018 mm
Differential pinion I.D. Factory spec.
0.6300 to 0.6306 in.
Differential pinion shaft 15.973 to 15.984 mm
Factory spec.
O.D. 0.6289 to 0.6292 in.
W1028504
Backlash between Differential Pinion and Differential Side Gear
1. Secure the differential case with a vise.
2. Set the dial indicator (lever type) with its finger on the tooth of the
differential side gear.
3. Press differential pinion and side gear against the differential
case.
4. Hold the differential pinion and move the differential side gear to
measure the backlash.
5. If the backlash exceeds the allowable limit, adjust with differential
side gear shims.
0.1 to 0.3 mm
Backlash between Factory spec.
0.004 to 0.011 in.
differential pinion and
differential side gear 0.4 mm
Allowable limit
0.016 in.
(Reference)
• Thickness of shims :
0.8 mm (0.0315 in.), 1.0 mm (0.0394 in.), 1.2 mm (0.0472 in.)
W1028708
1. Set the dial indicator (lever type) with its finger on the end of spiral bevel pinion shaft (3).
2. Move the spiral bevel pinion back and forth to each end and measure the side clearance.
3. If the side clearance exceeds the factory specification, adjust with the shims (2) at rear end of the bevel pinion shaft
(3).
4. Set the dial indicator (lever type) with its finger on the tooth surface of spiral bevel gear (6).
5. Measure the backlash by fixing the bevel pinion shaft (3) and moving spiral bevel gear (6) by hand.
6. If the backlash is not within the factory specifications, adjust with the shims (1), (4) at bearing holder (5) and
differential case.
7. Adjust the backlash properly by repeating the above procedures.
(When adjusting)
Side clearance of Less than 0.15 mm
Factory spec.
bevel pinion shaft Less than 0.006 in.
Backlash between
bevel pinion shaft 0.10 to 0.30 mm
Factory spec.
and spiral bevel 0.0040 to 0.0118 in.
gear
W1029368
(Reference)
• Thickness of shims (1), (4) :
0.2 mm (0.008 in.), 0.5 mm (0.020 in.)
• Thickness of shims (2)
0.2 mm (0.008 in.), 0.3 mm (0.012 in.), 0.5 mm (0.020 in.)
CONTENTS
1. STRUCTURE
(1) Differential Gear Shaft (3) Front Axle Case (5) 57T Gear (7) Spiral Bevel Gear
(2) Ball Bearing (4) Front Axle (6) Ball Bearing (8) Differential Gear Assembly
The front axles are the semifloating type with ball bearings (2), (6) between the front axle (4) and the front axle case
(3) which supports the front wheel load as well as transmitting power to the front wheels.
The differential gear assembly (8) automatically controls the revolution of right and left wheels when the front
wheels encounter unequal road resistance during turning.
CONTENTS
1. TROUBLESHOOTING ....................................................................................3-S1
2. TIGHTENING TORQUES ..............................................................................3-S2
3. CEHCKING, DISASSEMBLING AND SERVICING......................................3-S3
[1] PREPARATION ........................................................................................3-S3
[2] DISASSEMBLING AND ASSEMBLING..................................................3-S4
1. TROUBLESHOOTING
Reference
Symptom Probable Cause Solution
Page
Differential Lock can Differential lock shift fork damaged Replace 3-S4
not be Set Differential lock clutch damaged Replace 3-S4
Differential Lock Differential lock pedal return spring weaken or Replace –
Pedal does not damaged
Return Differential lock fork shaft rusted Repair 3-S4, 4-S8
W1011382
2. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-8.)
Item N·m kgf·m ft-lbs
Front axle case mounting screw and nut 39.3 to 44.1 4.0 to 4.5 29.0 to 32.5
W1012736
■ IMPORTANT
• Use only KUBOTA SUPER UDT fluid. Use of other oils may
damage the transmission or hydraulic system.
• Refer to “LUBRICANTS, FUEL AND COOLANT” (See page
G-7.).
• Do not mix different brands fluid together.
(1) Drain Plug A : Upper Level
(2) Dipstick B : Lower Level
(3) Oil Inlet
W1011852
W1010993
CONTENTS
1. FEATURES
(1) Return Spring
(2) Brake Cam Lever
(3) Brake Rod 1
(4) Brake Rod 2
(5) Parking Lock Lever
(6) Main Brake Pedal
(7) Speed Control Bracket
(8) Brake Arm 1
(9) Brake Arm 2
(10) Turnbuckle
(11) Front Axle Case
W1012646
Mechanical wet disc brakes are used for the right and left travelling brakes. They are operated by the main brake
pedal (6) through the mechanical linkages and provide stable braking and require little adjustment.
The parking brake is a mechanical type which is designed to actuate the travelling brakes through the linkage.
Pulling the parking lock lever (5) results in the same state as the obtained when the main brake pedal is pressed.
2. OPERATION
(1) Front Axle Case (4) Friction Plate (6) Actuator (8) Bearing Holder
(2) Brake Cam Lever (5) Steel Ball (7) Brake Disc (9) Differential Gear Shaft
(3) Brake Cam
The brake body is incorporated in the front axle case (1) filled with transmission oil and is designed to brake when
the brake disc (7) splined with the differential gear shaft (9) is pressed against the actuator (6) by means of the cam
mechanism incorporating steel balls (5).
For greater braking force, three brake discs (7) are provided at the right and left sides respectively, and the friction
plates (4) fixed to the front axle case is arranged between the brake discs (7).
■ During Braking
When the main brake pedal is pressed, the linkage causes the brake cam lever (2) and brake cam (3) to turn into
the direction of arrow shown in the above figure.
Therefore, the actuator (6) also moves the direction of arrow. At this time, since the actuator (6) rides on the steel
balls (5) set in the grooves of the front axle case to press the brake discs (7), the differential gear shaft (9) is braked
by the frictional force generated by the actuator (6) and brake discs (7).
CONTENTS
1. TROUBLESHOOTING ....................................................................................4-S1
2. SERVICING SPECIFICATIONS ....................................................................4-S2
3. TIGHTENING TORQUES ..............................................................................4-S3
4. CHECKING, DISASSEMBLING AND SERVICING......................................4-S4
[1] CHECKING AND ADJUSTING ...............................................................4-S4
[2] DISASSEMBLING AND ASSEMBLING..................................................4-S5
(1) Brake Pedal ........................................................................................4-S5
(2) Brake Assembly ..................................................................................4-S6
[3] SERVICING ..............................................................................................4-S9
1. TROUBLESHOOTING
Reference
Symptom Probable Cause Solution
Page
Uneven Braking Brake pedal free travel unevenly adjusted Adjust 4-S4
Force Brake disc worn Replace 4-S9
Actuator warped Replace 4-S9
Brake Drags Brake pedal free travel too small Adjust 4-S4
Ball hoses of actuator for uneven wear Replace 4-S9
Brake pedal return spring weaken or broken Replace 4-S5
Brake cam lever rusted Repair 4-S9
Poor Braking Force Brake pedal free travel excessive Adjust 4-S4
Brake disc worn Replace 4-S9
Actuator warped Replace 4-S9
Brake cam lever damaged Replace 4-S9
Transmission fluid improper Change G-7, 4-S6
W1014322
2. SERVICING SPECIFICATIONS
Item Factory Specification Allowable Limit
Brake Pedal Free Travel 20 mm 20 to 30 mm
0.79 in. 0.79 to 1.18 in.
Main Brake Pedal Force 373 to 411 N –
38 to 42 kgf
84 to 92 lbs
Actuator and Bearing Holder Flatness – 0.30 mm
0.0118 in.
Actuator and Ball Height 22.89 to 22.99 mm 22.40 mm
0.9012 to 0.9051 in. 0.8819 in.
Brake Disc Thickness 3.3 to 3.5 mm 3.0 mm
0.130 to 0.137 in. 0.118 in.
Friction Plate Thickness 1.92 to 2.08 mm 1.52 mm
0.0756 to 0.0818 in. 0.0598 in.
W1013874
3. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-8.)
Item N·m kgf·m ft-lbs
Front axle case mounting screw and nut 39.3 to 44.1 4.0 to 4.5 29.0 to 32.5
W1012736
■ NOTE
• After checking brake pedal free travel, be sure to engage the
parking lock lever fully and check to see that the main brake
pedal is securely locked.
(1) Brake Rod 1 (4) Adjusting Nut
(2) Brake Rod 2 (5) Turnbuckle
(3) Main Brake Pedal
W1011243
Brake Rod 2
1. Measure the spring length “L” with vernier calipers.
2. If the measurement is not within the reference value, adjust the
brake rod 2 with the adjusting nuts (1).
3. Press the main brake pedal to lock the position of third notch, and
measure the force of main brake pedal.
4. If the measurement is not within the factory specifications, adjust
the spring length “L”.
373 to 411 MPa
Force of main brake
Factory spec. 38 to 42 kgf/cm2
pedal
84 to 92 psi
■ NOTE
• Apply grease to the rod as shown in the figure.
(Reference)
• Brake rod 2 spring length “L” : 123 to 125 mm (4.85 to 4.92 in.)
(1) Adjusting Nut (A) Grease
(B) Third Notch
W1011467
1. Remove the seat, steering post cover, pedals and fender. (Refer to page 2-S11 to S12.)
2. Remove the return springs (2) and brake rod 1 (3).
3. Remove the differential lock rod.
4. Remove the brake rod 2 (1).
5. Remove the clevis pins, brake arm 1 (4) and brake arm 2 (5) and pull out the brake shaft (6).
(When reassembling)
• Apply grease to the brake rod 2 and moving parts.
• Take care not to damage the brake switch.
■ IMPORTANT
• Use only KUBOTA SUPER UDT fluid. Use of other oils may
damage the transmission or hydraulic system.
• Refer to “LUBRICANTS, FUEL AND COOLANT” (See page
G-7.).
• Do not mix different brands fluid together.
(1) Drain Plug A : Upper Level
(2) Dipstick B : Lower Level
(3) Oil Inlet
W1014130
Front Axle
1. Remove the spring (1).
2. Draw out the differential lock clutch (3) and differential lock shift
fork (2).
3. Remove the external snap ring (5), and remove the bearing (4).
4. Draw out the 57T gear (7) from the front axle (6).
5. Tap out the front axle to the outside of front axle case.
(When reassembling)
• Apply grease to the lip of oil seal.
(1) Spring (5) External Snap Ring
(2) Shift Fork (6) Front Axle
(3) Differential Lock Clutch (7) 57T Gear
(4) Bearing
W1014606
Brake Assembly
1. Remove the internal snap ring (4).
2. Remove the differential gear shaft (2) with brake discs (5).
3. Remove the actuator (6) and steel balls (7).
(When reassembling)
• When installing the internal snap ring (4) to front axle case (3) as
shown in the figure.
• When installing the bearing holder (2) to the front axle case (3),
do not forget to install the straight pin (8).
(Refer to the figure)
(1) Bearing Holder (5) Brake Disc
(2) Differential Gear Shaft (6) Actuator
(3) Front Axle Case (7) Steel Ball
(4) Internal Snap Ring (8) Straight Pin
W1012864
[3] SERVICING
Brake Cam Lever Movement
1. Move the brake cam lever by hand to check the side to side
movement.
2. If the movement is heavy, smooth the brake cam with emery
paper.
1.92 to 2.08 mm
Factory spec.
0.0756 to 0.0818 in.
Friction plate thickness
1.52 mm
Allowable limit
0.0598 in.
W1015877
CONTENTS
1. STRUCTURE
(1) Rear Wheel Hub (7) Tie-Rod (13) Differential Gear Case (19) Differential Side Gear
(2) Rear Axle Cover (8) Differential Gear Assembly (14) Differential Yoke Shaft (Left) (20) Differential Yoke Shaft (Right)
(3) Bevel Gear (9) Differential Pinion Gear (15) Rear Axle Bracket (Front) (21) Bevel Gear
(4) Rear Axle Gear Case (10) Rear Axle Bracket (Rear) (16) Bevel Pinion Shaft (22) Bevel Gear Shaft
(5) Bevel Gear (11) Thrust Collar (17) Rear Wheel Drive Shaft (23) Bevel Gear
(6) Knuckle Arm (12) Bevel Gear (18) Coupling
The rear axle of 4WD is constructed as shown above. Power is transmitted from the transmission through the rear
wheel drive shaft (17) to the bevel pinion shaft (16), then to the bevel gear (12) and to the differential gear assembly
(8).
The power through the differential side gear (19) is transmitted to the differential yoke shaft (20), and to the bevel
gear shaft (22) through the bevel gears (21), (5) in the rear axle gear case (4).
The revolution is greatly reduced by the bevel gears (23), (3), then the power is transmitted to the rear wheel hub
(1).
The differential system allows each wheel to rotate at a different speed to make turning easier.
CONTENTS
1. TROUBLESHOOTING ....................................................................................5-S1
2. SERVICING SPECIFICATIONS ....................................................................5-S2
3. TIGHTENING TORQUES ..............................................................................5-S3
4. CHECKING, DISASSEMBLING AND SERVICING......................................5-S4
[1] CHECKING AND ADJUSTING ...............................................................5-S4
[2] PREPARATION ........................................................................................5-S5
(1) Separating Rear Axle..........................................................................5-S5
[3] DISASSEMBLING AND ASSEMBLING..................................................5-S8
[4] SERVICING ............................................................................................5-S12
1. TROUBLESHOOTING
Reference
Symptom Probable Cause Solution
Page
Rear Wheels Wander Tire pressure uneven Adjust G-43
to Right of Left Improper toe-in adjustment (improper alignment) Adjust 5-S4
Clearance between rear axle case boss and rear Replace 5-S15
axle bracket (front, rear) excessive
Rear axle rocking force too small Adjust 5-S4
Rear wheel sway excessive Replace –
Tie-rod end loose Tighten 5-S7
Air sucked in power steering circuit Bleed –
Rear Wheels Can Not Rear wheel driving gears in rear axle gear case Replace 5-S9
Be Driven broken
Rear wheel drive shaft broken Replace 5-S6
Rear wheel drive gears in transmission broken Replace 2-S20
Rear differential gear broken Replace 5-S10 to
S11
Coupling displaced Reassemble 5-S6
Noise Gear backlash excessive Adjust or replace 5-S11
Oil insufficient Replenish G-7, 5-S5
Bearings damaged or broken Replace 5-S8 to S11
Gears damaged or broken Replace 5-S8 to S11
Bevel pinion shaft turning force improper Adjust 5-S13
W1014322
2. SERVICING SPECIFICATIONS
Item Factory Specification Allowable Limit
Rear Wheel Alignment Toe-in 0 to 10 mm –
0.00 to 0.39 in.
Rear Axle Rocking Force 49.1 to 117.6 N –
5.0 to 12.0 kgf
11.1 to 26.4 lbs
Knuckle Arm Support to Knuckle Arm Clearance 0.1 to 0.3 mm –
0.0040 to 0.0118 in.
Knuckle Arm Support to Knuckle Arm Clearance 0.02 to 0.11 mm 0.40 mm
Bushing 0.0008 to 0.0118 in. 0.0157 in.
3. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-8.)
Item N·m kgf·m ft-lbs
Lock nut of rocking force adjusting screw 23.6 to 27.4 2.4 to 2.8 17.4 to 20.2
Slotted nut of drag link end 17.7 to 34.3 1.8 to 3.5 13.0 to 25.3
Rear axle bracket mounting screw and nut 124 to 147 12.6 to 15.0 91.1 to 108.4
Rear wheel mounting nut 81.8 9.0 65.1
Slotted nut of tie-end end 17.7 to 34.3 1.8 to 3.5 13.0 to 25.3
Bevel gear case mounting screw 48.1 to 55.8 4.9 to 5.7 35.5 to 41.2
Knuckle arm mounting screw M10 screw 39.3 to 64.7 4.0 to 6.6 29.0 to 47.7
Knuckle arm mounting screw M12 screw 80 to 110 8.2 to 11.2 59.1 to 81.1
Knuckle arm support mounting screw 23.6 to 27.4 2.4 to 2.8 17.4 to 20.2
Bevel support cover mounting screw 18.7 to 32.3 1.9 to 3.3 13.8 to 23.8
Axle flange mounting screw 44.2 to 63.7 4.5 to 6.5 32.6 to 47.0
W1016410
[2] PREPARATION
(1) Separating Rear Axle
Draining Rear Axle Gear Case Oil
1. Place oil pans underneath the rear axle gear case.
2. Remove the drain plug (3) with hexagonal wrench (2), and
remove the oil filler plug (1).
3. Screw in the drain plug.
(When reassembling)
• Fill new oil up to the level of the oil filter plug.
• Apply liquid gasket (Three Bond 1208D or its equivalent) to the
drain plug (3).
0.5 L
Rear axle gear case oil Capacity 0.53 U.S.qts.
0.44 Imp.qts.
■ IMPORTANT
• Use the specified oil.
Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page
G-7.)
(1) Oil Filler Plug (3) Drain Plug
(2) Hexagonal Wrench
W1011744
Draining Rear Axle Differential Case Oil
1. Place oil pans underneath the rear axle differential case.
2. Remove the drain plug (2) and oil filler plug (1) to drain oil.
3. Screw in the drain plug.
(When reassembling)
• Fill new oil up to the upper level on the oil filler plug.
1.5 L
Rear axle differential
Capacity 1.59 U.S.qts.
case oil
1.32 Imp.qts.
■ IMPORTANT
• Use the specified oil.
Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page
G-7.)
(1) Oil Filler Plug (A) Oil level is acceptable within this
(2) Drain Plug range.
W1011954
Drag Link
1. Remove the slotted nut and disconnect the drag link (2) from the
knuckle arm (1).
(When reassembling)
■ IMPORTANT
• After tightening the slotted nut to the specified torque,
install the cotter pin as shown in the figure.
17.7 to 34.3 N·m
Tightening torque Slotted nut 1.8 to 3.5 kgf·m
13.0 to 25.3 ft-lbs
Rear Axle
1. Place the jacks under the rear axle, and lift up the rear axle frame.
2. Remove the rear axle bracket mounting screws and nuts.
3. Separate the rear axle from the rear axle frame.
4. Remove the rear wheels.
5. Remove the slotted nut, and disconnect the tie-rod (2) from the
knuckle arm (1).
6. Remove the rear axle brackets (2), (4).
(When reassembling)
• Apply grease to the oil seal of rear axle bracket (Front) (4).
• Apply grease to the O-rings.
• Apply grease to the inside of rear axle brackets (3), (4) and
bosses of rear axle differential case (5).
• Apply liquid lock (Three Bond 1324 or its equivalent) to the rear
axle bracket mounting screws.
■ IMPORTANT
• Be sure to tighten the rear wheel mounting nuts to the
specified torque.
• Be sure to tighten the slotted nuts to the specified torque.
124 to 147 N·m
Rear axle bracket
12.6 to 15.0 kgf·m
mounting screw and nut
91.1 to 108.4 ft-lbs
81.8 N·m
Tightening torque Rear wheel mounting nut 9.0 kgf·m
65.1 ft-lbs
17.7 to 34.3 N·m
Slotted nut 1.8 to 3.5 kgf·m
13.1 to 25.3 ft-lbs
(1) Rear Axle Gear Case (5) Rear Axle Differential Case
(2) Tie-rod
(3) Rear Axle Bracket (Rear) A : Grease
(4) Rear Axle Bracket (Front)
W1012615
(1) Rear Axle Differential Case (3) Rear Axle Gear Case
(2) Bevel Gear Case
W1018806
Knuckle Arm and Knuckle Arm Support
1. Remove the knuckle arm (1).
2. Remove the knuckle arm support (3).
(When reassembling)
• Apply grease to the bushing.
• Install the knuckle arm (1) to the rear axle case (4), noting the
number of shims (2) between them.
39.3 to 64.7 N·m
M10 4.0 to 6.6 kgf·m
Knuckle arm mounting 29.0 to 47.7 ft-lbs
screw 80 to 110 N·m
Tightening
M12 8.2 to 11.2 kgf·m
torque
59.1 to 81.1 ft-lbs
23.6 to 27.4 N·m
Knuckle arm support mounting
2.4 to 2.8 kgf·m
screw
17.4 to 20.2 ft-lbs
[4] SERVICING
Clearance between Knuckle Arm Support and Knuckle Arm
1. Tighten the knuckle arm mounting screws to the specified torque.
2. Measure the clearance between the knuckle arm support and
knuckle arm with a feeler gauge.
3. If the measurement is not within the factory specifications, adjust
with shims between the knuckle arm and rear axle case.
Clearance between
0.1 to 0.3 mm
knuckle arm support and Factory spec.
0.0040 to 0.0118 in.
knuckle arm
(Reference)
• Thickness of shims :
0.5 mm (0.020 in.), 0.3 mm (0.012 in.), 0.2 mm (0.008 in.)
W1020280
Clearance between Knuckle Arm Support and Knuckle Arm
Bushing
1. Measure the knuckle arm support O.D. with an outside
micrometer.
2. Measure the knuckle arm bushing I.D. with an inside micrometer,
and calculate the clearance.
3. If the clearance exceeds the allowable limit, replace the bushing.
0.02 to 0.11 mm
Clearance between Factory spec.
0.0008 to 0.0043 in.
knuckle arm support and
knuckle arm bushing 0.4 mm
Allowable limit
0.0157 in.
■ NOTE
• The turning torque is figured by multiplying the radius
(distance from the center of the spiral bevel pinion shaft to a
point on the circumference from which the string is pulled)
by the reading on the spring balance.
• After turning force adjustment, be sure to stake the lock nut.
W1020967
(Reference)
• Above factory specification should be measured on the tooth of
bevel pinion. When measuring the backlash on the spline of its
shaft, factory specification will be 0.0571 to 0.1714 mm (0.00225
to 0.00675 in.).
• Thickness of adjusting collars (3), (4) :
3.4 mm (0.134 in.), 3.6 mm (0.142 in.), 3.8 mm (0.150 in.)
4.0 mm (0.157 in.), 4.1 mm (0.161 in.), 4.2 mm (0.165 in.)
4.4 mm (0.173 in.), 4.6 mm (0.181 in.)
(1) Bevel Gear (3) Adjusting Collar
(2) Bevel Pinion Shaft (4) Adjusting Collar
W1021136
(Reference)
• Thickness of adjusting shims :
0.8 mm (0.031 in.), 1.0mm (0.039 in.), 1.2mm (0.047 in.)
• Tooth contact : More than 35 %.
(1) 12T Bevel Gear (3) Shim
(2) 12T Bevel Gear
W1021372
W1017939
CONTENTS
1. STRUCTURE
(1) Steering Cylinder (4) PTO Relief Valve (7) Oil Strainer EF :EF Port
(2) Steering Controller (5) Oil Filter Cartridge (8) Hydraulic Pump PF :PF Port
(3) Oil Cooler (6) Hydrostatic Transmission (9) Flow Priority Valve P : P Port
(HST) T : T Port
A : To Implement Control Valve L : L Port
B : To PTO Control Valve R : R Port
2. STEERING CONTROLLER
The steering controller (2) consists of a control valve
(6) and a metering device (5)
■ Control Valve
The control valve is a rotating spool type. When the
steering wheel is not turned, the position of the spool (7)
and sleeve (9) is kept neutral by the centering spring (8).
This causes the forming of a "Neutral" oil circuit. When
the steering wheel is turned either clockwise or
counterclockwise, the position of the spool and sleeve
changes in relation to the centering spring. This allows
the forming of a "Right Turning" or "Left Turning" oil
circuit. At the same time, the metering device rotates
with the spool and sends the oil to the cylinder
corresponding to the rotation of the steering wheel.
■ Metering Device
The oil, sent from the hydraulic pump to the steering
cylinder, passes through the metering device (3).
Namely, when the rotor is driven, two chambers suck in
oil due to volumetric change in the pump chambers
formed between the rotor (12) and the stator (13), while
oil is discharged from other two chambers. On the other
hand, rotation of the steering wheel is directly transmitted
to the rotor through the spool (7), drive shaft (10), etc.
Accordingly, the metering device serves to supply the
steering cylinder with oil, amount of which corresponds to
the rotation of the steering wheel. The wheels are thus
turned by the angle corresponding to the rotation of the
steering wheel. When the engine stops or the hydraulic
pump malfunctions, the metering device functions as a
manual trochoid pump, which makes manual steering
possible
■ Relief Valve
The relief valve (1) is located in the steering
controller. It controls the maximum pressure of the
power steering system.
Its setting pressure is as follows.
10.8 to 11.3 MPa
110.2 to 115.2 kgf/cm2
1567 to 1638 psi
(1) Steering Cylinder A : Control Valve
(2) Steering Controller B : Metering Device
(3) Check Valve P : P Port (From Hydraulic
(4) Relief Valve Pump)
(5) Metering Device T : T Port (To Independent PTO
(6) Control Valve Clutch Valve and HST
(7) Spool Circuit)
(8) Centering Spring L : L Port
(9) Sleeve R : R Port
(10) Drive Shaft
(11) Distributor Plate
(12) Rotor
(13) Startor
W1012850
CONTENTS
1. TROUBLESHOOTING ....................................................................................6-S1
2. SERVICING SPECIFICATIONS ....................................................................6-S2
3. TIGHTENING TORQUES ..............................................................................6-S3
4. CHECKING, DISASSEMBLING AND SERVICING......................................6-S4
[1] CHECKING AND ADJUSTING ...............................................................6-S4
(1) Relief Valve.........................................................................................6-S4
[2] PREPARATION ........................................................................................6-S5
(1) Separating Power Steering Controller ................................................6-S5
(2) Separating Steering Support...............................................................6-S6
[3] DISASSEMBLING AND ASSEMBLING..................................................6-S7
(1) Steering Support .................................................................................6-S7
[4] SERVICING ..............................................................................................6-S8
(1) Steering Cylinder ................................................................................6-S8
1. TROUBLESHOOTING
Reference
Symptom Probable Cause Solution
Page
Cannot Be Steered Steering controller malfunctioning Replace 6-S6
Hose broken Replace 6-S6
Hard Steering Power steering oil improper Change with G-7
specified oil
Hydraulic pump malfunctioning Replace 7-S6
Priority valve malfunctioning Repair or replace 7-S6
Steering controller malfunctioning Replace 6-S6
Steering Force Steering controller malfunctioning Replace 6-S6
Fluctuates Priority valve malfunctioning Repair or replace 7-S6
Air sucked in pump due to lack of oil Replenish G-7
Air sucked in pump from suction circuit Repair –
Steering Wheel Turns Steering controller malfunctioning Repair or replace 6-S6
Spontaneously When
Released
Rear Wheels Wander Steering controller malfunctioning Replace 6-S6
to Right and Left Air sucked in pump due to lack of oil Replenish G-7
Air sucked in pump from suction circuit Repair –
Insufficient bleeding Bleed –
Steering cylinder malfunctioning Replace 6-S8
Improper toe-in adjustment Adjust 5-S5
Tire pressure uneven Inflate G-43
Wheels Are Turned Steering cylinder piping connected in reverse Repair 6-S8
to a Direction
Opposite to Steering
Direction
Steering Wheel Turns Insufficient bleeding Bleed –
Idle in Manual Air sucked in pump due to lack of oil Replenish G-7
Steering
Noise Air sucked in pump due to lack of oil Replenish G-7
Air sucked in pump from suction circuit Repair –
Oil Temperature Steering controller (relief valve) malfunctioning Replace 6-S6
Increases Rapidly
W1014322
2. SERVICING SPECIFICATIONS
POWER STEERING BODY
Item Factory Specification Allowable Limit
Relief Valve Setting Pressure 10.8 to 11.3 MPa –
110.2 to 115.2 kgf/cm2
1567 to 1638 psi
W1013874
STEERING CYLINDER
Cylinder Length (Rod End to Rod End) 439 to 441 mm –
17.29 to 17.36 in.
Rod End Length 15 mm –
0.59 in.
Set Angle C Angle 0.175 rad –
10 °
Set Angle D Angle 0.314 rad –
18 °
Set Angle E Angle 0.349 rad –
20 °
W1013973
3. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-8.)
Item N·m kgf·m ft-lbs
Power steering hose mounting nut 24.6 to 29.4 2.5 to 3.0 18.1 to 21.6
Power steering pipe mounting nut 54.0 to 63.7 5.5 to 6.5 39.8 to 47.0
W1012736
[2] PREPARATION
(1) Separating Power Steering Controller
Battery
CAUTION
• When disassembling the battery cables, disconnect the
negative cable from the battery first. When connecting,
connect the positive cable to the battery first.
1. Disconnect the negative cable (2) from the battery.
2. Disconnect the positive cable (1) from the battery.
(1) Positive Cable (2) Negative Cable
Seat
1. Disconnect 2P connector from the seat switch.
2. Remove the seat (1) with the seat base.
17.7 to 20.5 N·m
Tightening torque Seat base mounting screw 1.8 to 2.1 kgf·m
13.1 to 15.1 ft-lbs
Panel
1. Separate the front panel (1) from the rear panel (4).
2. Disconnect the connectors from the easy checker, fuel gauge,
coolant temperature gauge and hour meter in front panel (1).
3. Disconnect the connectors (2), (3) from the main switch and head
light switch.
4. Remove the horn (5).
5. Remove the rear panel (4).
(1) Front Panel (4) Rear Panel
(2) 4P Connector (5) Horn
(3) 3P Connector
W1013706
[4] SERVICING
(1) Steering Cylinder
Cylinder Length
1. The length between rod ends is important.
When reassembling the rod ends, set the cylinder to the shortest
position and adjust the length “A”.
439 to 441 mm
Length “A” Factory spec.
17.29 to 17.36 in.
15 mm
Length “B” Factory spec.
0.59 in.
0.175 rad
Set angle “C” Factory spec.
10 °
■ IMPORTANT
• When adjusting the cylinder length “A”, be sure to set the
direction of the rod ends (1), (4) with joint boss of cylinder
(1) as shown in figure.
0.314 rad
Set angle “D” Factory spec.
18 °
0.349 rad
Set angle “E” Factory spec.
20 °
(1) Rod End (Knuckle Arm) (4) Rod End (Main Frame)
(2) Lock Nut (5) Main Frame
(3) Lock Nut
(a) Front View
W1011546
CONTENTS
1. HYDRAULIC CIRCUIT
(1) Steering Cylinder (7) Orifice (13) Filter Cartridge EF :EF Port
(2) Steering Controller (8) Relief Valve (14) PTO Charge Relief Valve PF :PF Port
(3) Hydraulic Block Type Outlet (9) Hydraulic Pump (15) Oil Cooler P : P Port
(4) Lowering Speed Adjusting (10) Oil Strainer (16) PTO Control Valve T : T Port
Valve (11) Flow Priority Valve (17) Hydraulic PTO Clutch L : L Port
(5) Hydraulic Cylinder (12) Hydraulic Transmission R : R Port
(6) Implement Control Valve
The hydraulic system of these machines are composed of a hydraulic pump (9), hydraulic block type outlet (3),
implement control valve (6), hydraulic cylinder (5) and other components.
This system has the following functions.
Position control of the front implement connected to the lift arm.
Hydraulic power take off from the hydraulic block type outlet (3) to operate the implements such as a grass collector
and, etc..
Oil is supplied by a hydraulic pump (9) connected to the engine. When an engine is started, hydraulic pump (9)
starts running, sucks oil from a transmission case. The hydraulic pump (9) forces out the oil to the hydraulic block
type outlet (3), implement control valve (6), hydraulic cylinder (5), steering controller (2), PTO control valve (16),
hydraulic PTO clutch (17) and hydrostatic transmission (12).
2. HYDRAULIC PUMP
The hydraulic pump is composed of the case (1),
cover (3), side plate (5), and two spur gears (drive gear
(4) and driven gear (2)).
Hydraulic pump is driven by the governor shaft.
Displacement Engine speed Condition
24.0 L/min. 9.8 MPa
At 2700 min-1
6.3 U.S.gals./min. 100 kgf/cm2
(rpm)
5.2 Imp.gals./min. 1422 psi
W1013860
4. RELIEF VALVE
The implement control system circuit has a relief
valve to restrict the maximum pressure in the circuit. The
relief valve is located top of the hydraulic cylinder body.
The relief valve is of the guide piston type with
damping effect.
Among direct acting relief valves, this type is suited to
higher pressure and has large capacity. Furthermore,
this type is free from unstable operation, such as
chattering, which occurs often in direct acting relief
valves.
As shown in the figure, the guide is attached to the
poppet (5) and a valve chamber D.C. (called the damping
chamber) is formed at the bottom of the guide piston.
The inlet of the valve leads to the chamber via a
clearance between the sliding portion of the guide and
the seat (6), minimizing valve vibration with the damping
effect of the chamber.
When the oil pressure in the circuit is lower that the
setting pressure of the relief valve, the relief valve is not
operated and the oil fed to the relief valve from the
hydraulic pump flows into the implement control valve.
As the oil pressure in the circuit increases, so does
the pressure in the damping chamber D.C.. When the
pressure rises above the valve setting and overcomes
the spring force, the valve opens. Oil then flows out to
the transmission case through T port, preventing any
further rise in pressure. The valve closes again when
enough oil is released to drop pressure below the valve
setting.
(Reference)
• Relief valve setting pressure :
13.8 to 14.2 MPa
140 to 145 kgf/cm2
1992 to 2062 psi
• Engine speed : Maximum
• Oil temperature : 40 to 50 °C
104 to 122 °F
(1) Plug D.C. : Damping Chamber
(2) Washer P : Pump Port
(3) Shim T : Tank Port (To
(4) Hydraulic Cylinder BOdy Transmission Case)
(5) Poppet a : To Implement Control
(6) Seat Valve
W1013612
■ Lift
When the hydraulic control lever is set to the “LIFT”
position, the spool (2) is move to the left.
The oil forced into the implement control valve (1)
through P port flows to C port.
The oil pushes and flows into the hydraulic cylinder
through the C port to lift the implement.
(1) Implement Control Valve P : Pump Port
(2) Spool C : Cylinder Port
T1, T2 : Tank Port
W1013558
■ Down
When the hydraulic control lever is moved to
“DOWN” position, the spool (2) is moved to the right.
Oil in the hydraulic cylinder is forced out to the
transmission case through the T1 port by the weight of
the implement, causing the implement to lower.
Oil forced into the implement control valve (1) through
the P port and returns to the transmission case through
the T2 port.
(1) Implement Control Valve P : Pump Port
(2) Spool C : Cylinder Port
T1, T2 : Tank Port
W1013658
6. FEEDBACK LINKAGE
When the hydraulic control lever 1 (1) is moved to
rearward to lift the implement, the spool of the implement
control valve (7) is pulled out to form a raising circuit.
Then the lift arm (9) begins to rise.
After the lift arm (9) gets to the uppermost position,
the spool is pushed in and returned to form a neutral
circuit by the motions of the feedback pin (8), feedback
rod (3), hydraulic control lever 2 (2), control lever arm (5)
and control lever shaft (6).
(1) Hydraulic Control Lever 1 A : When the hydraulic control
(2) Hydraulic Control Lever 2 lever is moved to rearward
(3) Feedback Rod B : When the lift arm gets to the
(4) Interlocker uppermost position
(5) Control Lever Arm
(6) Control Lever Shaft
(7) Implement Control Valve
(8) Feedback Pin
(9) Lift Arm
W1014224
7. HYDRAULIC CYLINDER
(1) Lowering Speed Adjusting (4) Hydraulic Cylinder Case (7) Lift Arm (10) Back-up Ring
Shaft (5) Relief Valve (8) Implement Control Valve (11) O-ring
(2) Lowering Speed Adjusting (6) Hydraulic Arm (9) Hydraulic Rod (12) Piston
Valve
(3) Orifice
The main components of the hydraulic cylinder are shown in the figure above.
While the lift arm (7) is rising, oil from the hydraulic pump flows into the hydraulic cylinder through the implement
control valve (8). Then oil pushes out the piston (12).
While the lift arm (7) is lowering, oil in the hydraulic cylinder is discharged to the transmission case through the
implement control valve (8) by the weight of the implement. At this time, the lowering speed of the implement can be
controlled by the lowering speed adjusting valve (2) attached to the hydraulic cylinder case (4). Turning the lowering
speed adjusting knob clockwise decreases the lowering speed, and counterclockwise increases lowering speed.
When the lowering speed adjusting valve (2) is completely closed, the lift arm (7) is held at its position since oil in the
hydraulic cylinder is sealed between the piston (12) and lowering speed adjusting valve (2).
CONTENTS
1. TROUBLESHOOTING ....................................................................................7-S1
2. SERVICING SPECIFICATIONS ....................................................................7-S2
3. TIGHTENING TORQUES ..............................................................................7-S3
4. CHECKING, DISASSEMBLING AND SERVICING......................................7-S4
[1] CHECKING AND ADJUSTING ...............................................................7-S4
(1) Hydraulic Pump and Flow Priority Valve.............................................7-S4
(2) Hydraulic Cylinder Assembly ..............................................................7-S5
[2] DISASSEMBLING AND ASSEMBLING..................................................7-S6
(1) Hydraulic Pump and Flow Priority Valve.............................................7-S6
(2) Hydraulic Cylinder Assembly ..............................................................7-S7
[3] SERVICING ............................................................................................7-S11
(1) Hydraulic Pump.................................................................................7-S11
(2) Hydraulic Cylinder .............................................................................7-S12
1. TROUBLESHOOTING
Reference
Symptom Probable Cause Solution
Page
Implement Does Not Control valve broken Replace 7-S8
Rise (No Noise) Control valve improperly assembled Assemble 7-S8
Relief valve spring damaged Replace 7-S10
Spool sticks Repair 7-S8
Piston O-ring or cylinder damaged Replace 7-S9
Lowering speed adjusting valve closed Open –
(Noise) Oil strainer clogged Clean or replace G-26
Suction pipe loosen or broken Repair or replace 2-S11
Suction pipe connecting hose loosen or broken Repair or replace 2-S11
Suction pipe O-ring broken Replace 7-S6
Insufficient transmission oil Refill G-7
Relief valve setting pressure too low Adjust or replace 7-S5, S10
Hydraulic pump broken Replace 7-S6
Implement Does Not Control valve malfunctioning Repair or replace 7-S8
Lower
Implement Drops by Hydraulic cylinder worn or damaged Replace 7-S12
Its Weight Piston O-ring worn or damaged Replace 7-S9
Control valve malfunctioning Replace 7-S8
W1017660
2. SERVICING SPECIFICATIONS
HYDRAULIC PUMP
Item Factory Specification Allowable Limit
Hydraulic Pump Delivery 29.0 L/min. –
(At No Pressure) Above 7.6 U.S.GPM
6.3 Imp.GPM
Delivery
(At 9.8 MPa 24.0 L/min. 21.0 L/min.
100 kgf/cm2 Above 6.3 U.S.GPM 5.5 U.S.GPM
1422 psi) 5.2 Imp.GPM 4.6 Imp.GPM
Flow Priority Valve Delivery 10.0 L/min. –
(At No Pressure) Above 2.6 U.S.GPM
2.2 Imp.GPM
3. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-8.)
Item N·m kgf·m ft-lbs
Engine stop solenoid mounting screw 9.80 to 11.2 1.00 to 1.15 7.24 to 8.32
Flow priority valve mounting screw 17.7 to 20.6 1.8 to 2.1 13.0 to 15.2
Delivery hose mounting nut 24.6 to 29.4 2.5 to 3.0 14.5 to 21.6
Hydraulic pump mounting screw and nut 23.6 to 27.4 2.4 to 2.8 17.4 to 20.2
Cover mounting screw 39.2 to 44.1 4.0 to 4.5 28.9 to 32.5
Hydraulic cylinder assembly mounting screw and nut 39.2 to 44.1 4.0 to 4.5 28.9 to 32.5
Control valve mounting screw 23.6 to 27.4 2.4 to 2.8 17.4 to 20.2
Relief valve plug 49.0 to 68.6 5.0 to 7.0 36.2 to 50.6
W1018416
(Reference)
• Thickness of shims (3) : 0.1 mm (0.0039 in.), 0.2 mm (0.0079 in.)
(1) Plug (3) Shim
(2) Lowering Speed Adjusting Rod
W1012745
CAUTION
• When disconnecting the battery cables, disconnect the
negative cable from the battery first.
When connecting, connect the positive cable to the battery
first.
1. Disconnect the negative cable (4) from the battery.
2. Disconnect the positive cable (1) from the battery.
3. Unscrew the battery mounting nuts (2), and remove the battery
(3).
(1) Positive Cable (3) Battery
(2) Battery Mounting Nut (4) Negative Cable
W1021027
Seat
Refer to “TRANSMISSION” Section. (See page 2-S11.)
W1021463
Panel
Refer to “TRANSMISSION” Section. (See page 2-S11.)
W1021499
Fender
Refer to “TRANSMISSION” Section. (See page 2-S12.)
W1021535
Control Valve
1. Remove the control valve mounting screws, and remove the
control valve (2).
(When reassembling)
• Take care not to damage the O-rings (1).
23.6 to 27.4 N·m
Control valve mounting
Tightening torque 2.4 to 2.8 kgf·m
screw
17.4 to 20.2 ft-lbs
Hydraulic Piston
1. Use compressed air through the hydraulic cylinder oil gallery to
take out the hydraulic piston (1).
(When reassembling)
• Take care not to damage the O-ring (3) and backup ring (2).
• Apply transmission fluid to the O-ring.
• Replace the O-ring if it is defective, worn or scratched, which may
cause oil leakage.
(1) Hydraulic Piston (3) O-ring
(2) Backup Ring
W1013522
Relief Valve
1. Remove the plug (1), and remove the shims (2), (3), spring (4),
poppet (5) and the valve seat (6).
(When reassembling)
• Take care not to damage the O-ring.
49.0 to 68.6 N·m
Tightening torque Relief valve plug 5.0 to 7.0 kgf·m
36.2 to 50.6 ft-lbs
■ IMPORTANT
• After disassembling and assembling the relief valve, be sure
to adjust the relief valve setting pressure.
(1) Plug (4) Spring
(2) Shim (5) Poppet
(3) Shim (6) Valve Seat
W1013647
[3] SERVICING
(1) Hydraulic Pump
Clearance between Tip of Gear Tooth and Casing
1. Measure the gear shaft O.D. with an outside micrometer.
2. Measure the bush I.D. with a cylinder gauge, and calculate the
clearance.
3. If the clearance exceeds the allowable limit, replace the pump
assembly.
Clearance between tip 0.15 mm
Allowable limit
of gear tooth and casing 0.0059 in.
14.970 to 14.980 mm
Gear shaft O.D. Factory spec.
0.5894 to 0.5898 in.
15.005 to 15.081 mm
Bush I.D. Factory spec.
0.5908 to 0.5938 in.
W1012143
37.925 to 37.950 mm
Left Factory spec.
Hydraulic arm 1.4931 to 1.4941 in.
shaft O.D. 33.925 to 33.950 mm
Right Factory spec.
1.3356 to 1.3366 in.
37.970 to 38.035 mm
Left Factory spec.
Bushing I.D. (after 1.4949 to 1.4974 in.
press fitted) 33.970 to 34.035 mm
Right Factory spec.
1.3374 to 1.3400 in.
W1013775
CONTENTS
1. WIRING DIAGRAM
Controller
Brake Fuel PTO Switch
Horn Relay Switch Work Fuse Box
Horn Light Sensor
Brake Switch
Head Lamp Fuel Pomp 10A
0.5 YG
Seat Switch
PTO Switch
Frame Earth
Grow Plug
0.5 B
5A
Solenoid
12 V
Starter
2 RG
GND
55 W
0.85 RL
AC
0.5 RY
2 RW
2 RG
R
Y
Seat Switch
0.85 RL
M8
0.5 LW
0.5 B
0.5 B
3B
0.5 WB
0.5 RG
0.5 LW
0.5 RG
0.5 WB
0.5 RY
0.5 RY
0.5 Br
0.5 B
0.5 O
0.5 RY
0.5 YR
0.5 BrW
0.5 WB
0.5 WL
0.5 BR
0.5 YR
0.5 RY
3 BW
0.5 O
0.5 B
3 BY
Main Switch
AC
B G
ST 2 RW
3R
3 BR
3 BY
Frame Earth
0.5 RY
0.5 RY
0.5 RY
0.5 RY 3 BR
0.5 RY Glow Plug
0.5 RY
0.5 RY
Joint 0.5 RY
Connector 0.5 RY 0.5 WB
0.5 RY
0.5 RY
0.5 RY
Water Temperature
Switch
3B
0.5 B
0.5 B 0.5 WG
0.5 B
Resistance 0.5 B
Water Temperature
3B
Welding 0.5 B Sensor
0.5 B
0.5 B
0.5 B
2W
0.5 WL
Monitor Lamp
Engine Stop
RL 0.5 RY Solenoid
OIL
12
3.4 L 0.5 L
W 0.5 WR
CHG
12
3.4 RW 0.5 RY
2W
R 0.5 RY
GLOW
12
0.5 WG
Br 0.5 BrW
0.5 YG
0.5 RY
0.5 RY
0.5 RY
3.4
0.5 Br
0.5 Br
3 BW
0.5 B
0.5 B
0.5 B
0.5 L
3R
20 BR
0.5 WR
0.5 RY
3R
3R
HOUR METER S B + -
3R
12 V
50A
Hour Meter Oil Switch
+ U E + U E Starter Battery
E F C H
Alternator Slow Blow
Fuse
Color of wiring
W.....White O.....Orange RW.....Red / White BY.....Black / Yellow
R.....Red WB.....White / Black RG.....Red / Green YR.....Yellow / Red
L.....Blue WR.....White / Red RY.....Red / Yellow YG.....Yellow / Green
Y.....Yellow WG.....White / Green BW.....Black / White LW.....Blue / White
B.....Black WL.....White / Blue BR.....Black / Red BrW.....Brown / White
Br.....Brown RL.....Red / Blue
W1012663
2. STARTING SYSTEM
[1] OPERATOR PRESENCE CONTROL (OPC) SYSTEM
(1) Battery
(2) Starter
(3) Slow Blow Fuse (50A)
(4) Main Switch
(5) Fuse (5A)
(6) Glow Plug
(7) Glow Plug Lamp
(8) Seat Switch
(9) PTO Switch
(10) Brake Switch
(11) Controller
(12) Frame Earth
(13) Engine Stop Solenoid
1 to 10 :Controller Terminals
AC :AC Terminal
G : G Terminal
ST :ST Terminal
S : S Terminal
B : B Terminal
W1013395
This machine is equipped with the operator presence control (OPC) system.
This system is controlled by three safety switch (seat switch (8), PTO switch (9) and brake switch (10)) and
controller (11).
■ PTO Switch
The PTO switch (1) is located at the side frame (RH).
This switch is the open type. In normal operating
condition, the switch is open circuit.
When the PTO lever (2) is set at the “DISENGAGE”
position, the PTO switch (2) is pushed by the PTO lever
and is turned “ON”. When the PTO lever (2) is set at the
“ENGAGE” position, the PTO switch (1) is not pushed by
the PTO lever (2), and is turned “OFF”.
(1) PTO Switch (2) PTO Lever
W1013949
■ Brake Switch
The brake switch (1) is located on the front frame.
This switch is the close type. In normal operating
condition, the switch is close circuit.
When depressing the brake pedal, the brake switch
(1) is not pushed by the brake arm (2), and is turned
“ON”. When the brake pedal is free, the brake switch (1)
is pushed by the brake arm (2), and is turned “OFF”.
(1) Brake Switch (2) Brake Arm
W1014147
■ Controller
The controller (1) is located at inside the panel.
(1) Controller
W1014349
(2) Operation
■ Starting the Engine
(1) Battery (6) Glow Plug (11) Controller [A] When the main switch is
(2) Starter (7) Glow Plug Lamp (12) Frame Earth turned to the “ON” position
(3) Slow Blow Fuse (50A) (8) Seat Switch (13) Engine Stop Solenoid (AC terminal)
(4) Main Switch (9) PTO Switch (14) Holding Coil [B] When the main switch is
(5) Fuse (5A) (10) Brake Switch (15) Pulling-in Coil turned to the “START”
position (ST terminal)
When the main switch (4) is turned to the “ON” position (AC terminal) under the following condition, the electrical
current flows to the holding coil (14) of the engine stop solenoid (13). (Figure [A])
When the main switch (4) is turned to the “START” position (ST terminal), the electrical current flows to the starter
(2). Then, the electrical current flows to the pulling-in coil (15) of the engine stop solenoid (13) through the starter (2).
(Figure [B]) The engine can be started.
Seat Switch (8) PTO Switch (9) Brake Switch (10)
(Occupied : ON) (Disengaged : ON) (Pedal depressed : ON)
(Vacant : OFF) (Engaged : OFF) (Pedal free : OFF)
ON ON ON
W1014766
When the following conditions become complete, the electrical current does not flow to the holding coil (14) of the
engine stop solenoid (13) from the controller (11). Then, the engine will stop in 0.6 to 1.4 seconds.
Seat Switch (8) PTO Switch (9) Brake Switch (10)
Condition (Occupied : ON) (Disengaged : ON) (Pedal depressed : ON)
(Vacant : OFF) (Engaged : OFF) (Pedal free : OFF)
1 OFF ON OFF
2 OFF OFF ON
3 OFF OFF OFF
W1015064
CONTENTS
1. TROUBLESHOOTING ....................................................................................8-S1
2. SERVICING SPECIFICATIONS ....................................................................8-S4
3. TIGHTENING TORQUES ..............................................................................8-S5
4. CHECKING, DISASSEMBLING AND SERVICING......................................8-S6
[1] CHECKING AND ADJUSTING ...............................................................8-S6
(1) Battery.................................................................................................8-S6
(2) Main Switch.........................................................................................8-S6
(3) Starter .................................................................................................8-S8
(4) Glow Plug............................................................................................8-S9
(5) Safety Switch ......................................................................................8-S9
(6) Fuel Pump.........................................................................................8-S10
(7) Engine Stop Solenoid .......................................................................8-S11
(8) Charging System ..............................................................................8-S11
(9) Lighting System ................................................................................8-S13
(10)Cooling System.................................................................................8-S14
(11)Gauges .............................................................................................8-S14
[2] DISASSEMBLING AND ASSEMBLING................................................8-S16
(1) Starter ...............................................................................................8-S16
(2) Alternator ..........................................................................................8-S17
[3] SERVICING ............................................................................................8-S19
(1) Starter ...............................................................................................8-S19
(2) Alternator ..........................................................................................8-S22
1. TROUBLESHOOTING
Reference
Symptom Probable Cause Solution
Page
All Electrical Battery discharged or defective Recharge or replace 8-S4
Equipment Does Not Battery positive cable disconnected or Repair or replace 8-S4
Operate improperly connected
Battery negative cable disconnected or Repair or replace 8-S4
improperly connected
Slow blow fuse blown Replace G-34
Fuse Blows Short-circuited Repair or replace –
Frequently
W1014322
BATTERY
Battery Discharges Battery defective Recharge or replace 8-S4
Too Quickly Alternator defective Repair or replace 8-S11 to S12
Wiring harness disconnected or improperly Repair or replace –
connected
Cooling fan belt slipping Adjust tension G-25
W1013718
STARTING SYSTEM
Starter Does Not Work Battery discharged or defective Recharge or replace 8-S4
Slow blow fuse blown Replace G-34
Brake switch defective Replace 8-S10
PTO switch defective Replace 8-S10
Seat switch defective Replace 8-S9
Controller defective Replace G-19, 6-S6
Wiring harness disconnected or improperly Repair or replace –
connected
Starter defective Repair or replace 8-S19 to S21
Main switch defective Replace 8-S6 to S7
Glow Plug Does Not Battery discharged or defective Recharge or replace 8-S4
Glow Slow blow fuse blown Replace G-34
Wiring harness disconnected or improperly Repair or replace –
connected
Glow plug defective Replace 8-S9
Main switch defective Replace 8-S6 to S7
Engine Does Not Stop Fuse blown Replace G-34
When Main Switch Is Wiring harness disconnected or improperly Repair or replace –
Turned “OFF” connected
Position
Main switch defective Replace 8-S6 to S7
Engine stop solenoid defective Replace 8-S11
Controller defective Replace G-19, 6-S6
Engine Does Not Engine stop solenoid defective Replace 8-S11
Restart Controller defective Replace G-19, 6-S6
W1013718
KiSC issued 04, 2006 A
8-S1
F2880, F3680, RCK72-F36, RCK72R-F36, RCK60-F36, RCK60R-F36, WSM ELECTRICAL SYSTEM
CHARGING SYSTEM
Reference
Symptom Probable Cause Solution
Page
Charging Lamp Does Fuse blown Replace G-34
Not Light When Main Bulb blown Replace G-34
Switch Is Turned
“ON” Position Wiring harness disconnected or improperly Repair or replace –
connected
Charging Lamp Does Short circuit between alternator L terminal lead Repair or replace –
Not Go Off When and chassis
Engine Is Running Alternator defective Repair or replace 8-S11 to
S12
W1014322
LIGHTING SYSTEM
Head Light Does Not Fuse blown Replace G-34
Light Bulb blown Replace G-34
Head light switch defective Replace 8-S13
Wiring harness disconnected or improperly Repair or replace –
connected
Oil Pressure Engine oil pressure too low Check and repair G-7
Indicator Lamp Engine oil insufficient Replenish G-7
Lights Up When
Engine Is Running Oil pressure switch defective Replace 8-S13
Short circuit between oil pressure switch lead Repair –
(1P connector) and chassis
Oil Pressure Fuse blown Replace G-34
Indicator Lamp Does Bulb blown Replace G-34
Not Light When Main
Switch Is Turned Oil pressure switch defective Replace 8-S13
“ON” Position and Wiring harness disconnected or improperly Repair or replace –
Engine Is Not connected
Running
Main switch defective Replace 8-S6 to S7
W1013718
GAUGES
Fuel Gauge Does Not Fuel gauge defective Replace 8-S15
Function Fuel level sensor defective Replace 8-S14
Wiring harness disconnected or improperly Repair or replace –
connected
Coolant Temperature Coolant temperature gauge defective Replace 8-S15
Gauge Does Not Coolant temperature sensor defective Replace 8-S15
Function
Wiring harness disconnected or improperly Repair or replace –
connected
W1011939
2. SERVICING SPECIFICATIONS
STARTER
Item Factory Specification Allowable Limit
Commutator O.D. 28.0 mm 27.0 mm
1.10 in. 1.06 in.
ALTERNATOR
Slip Ring O.D. 14.4 mm 14.0 mm
0.567 in. 0.551 in.
Brush Length 10.5 mm 8.4 mm
0.413 in. 0.331 in.
W1013973
3. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-8)
Item N·m kgf·m ft-lbs
Starter B terminal nut 7.8 to 9.8 0.8 to 1.0 5.8 to 7.2
Starter C terminal nut 7.9 to 11.8 0.8 to 1.2 5.8 to 8.7
Starter Magnetic switch mounting nut 5.9 to 10.8 0.6 to 1.1 4.4 to 7.9
Starter Through bolt 4.42 to 7.35 0.45 to 0.75 3.23 to 5.42
Alternator Pulley nut 58.3 to 78.9 5.95 to 8.05 43.0 to 58.2
W1012736
W1012569
(3) Starter
M Terminal Voltage
1. Measure the voltage with a voltmeter between the M terminal and
the chassis.
2. If the voltage differs from the battery voltage, the battery’s
positive cable or the battery negative cable is faulty.
Voltage Factory spec. Approx. battery voltage
W1014220
Motor Test
CAUTION
• Secure the starter to prevent it from jumping up and down
while testing the motor.
1. Disconnect the battery negative cable from the battery.
2. Disconnect the battery positive cable from the battery.
3. Disconnect the leads from the starter B terminal.
4. Remove the starter from the engine.
5. Connect a jumper lead from the starter C terminal (1) to the
battery positive terminal (2).
6. Connect a jumper lead momentarily between the starter’s body
and the battery negative terminal (3).
7. If the motor does not run, starter is faulty.
Repair or replace the starter.
■ NOTE
• B terminal : It is the terminal which connect the cable from
the battery to the starter.
• C terminal : It is the terminal which connects the cable from
the motor to the magnet switch.
(1) C Terminal (3) Negative Terminal
(2) Positive Terminal
W1014468
Magnetic Switch Test
1. Disconnect the battery negative cable from the battery.
2. Disconnect the battery positive cable from the battery.
3. Disconnect the leads from the starter B terminal.
4. Remove the starter from the engine.
5. Connect a jumper lead from the starter S terminal (1) to the
battery positive terminal (2).
6. Connect a jumper lead momentarily between the starter’s body
and the battery negative terminal (3).
7. If the pinion gear does not pop out, the magnetic switch has
failed.
Repair or replace the starter.
■ NOTE
• B terminal : It is the terminal which connect the cable from
the battery to the starter.
• C terminal : It is the terminal which connects the cable from
the starter to the magnet switch.
(1) S Terminal (3) Negative Terminal
(2) Positive Terminal
W1014652
W1015086
W1020224
Connector Voltage
1. Turn the main switch OFF. Measure the voltage between the B
terminal (1) and the chassis.
2. Turn the main switch ON. Measure the voltage between the IG
terminal (3) and the chassis.
Voltage
B Terminal - Chassis Approx. battery voltage
(Main switch at OFF)
Voltage
IG Terminal - Chassis Approx. battery voltage
(Main switch at ON)
(Reference)
• Once the engine has started, the alternator temperature rises
quickly up to an ambient temperature of 70 to 90 °C (158 to 194
°F). As the temperature goes higher than 50 °C (122 °F), the
alternator voltage slowly drops ; at higher than 100 °C (212 °F),
it drops by about 1 V.
(1) Voltmeter (4) IG Terminal
(2) B Terminal (5) L Terminal
(3) Connecting Lead (6) 2P Connector
W1017026
(11) Gauges
Fuel Level Sensor
1. Remove the fuel level sensor from the fuel tank.
2. Measure the resistance with an ohmmeter across the sensor
terminal and its body.
3. If the reference value are not indicated, the sensor is faulty
Float at
upper-most 1 to 5 Ω
Resistance position
Reference
(Sensor terminal -
value Float at
Chassis)
lower-most 103 to 117 Ω
position
2) Sensor Continuity
1. Measure the resistances with an ohmmeter across the sensor
terminal and the chassis.
2. If the reference value is not indicated, the sensor is faulty.
Approx. 16.1 Ω at 120 °C (248 °F)
Resistance
Approx. 27.4 Ω at 100 °C (212 °F)
(Sensor terminal - Reference value
Approx. 51.9 Ω at 80 °C (176 °F)
Chassis)
Approx. 153.9 Ω at 50 °C (122 °F)
1. Unscrew the C terminal nut (7), and disconnect the connecting lead (12).
2. Unscrew the solenoid switch mounting nuts (1), and remove the solenoid switch (5).
3. Remove the end frame cap (17).
4. Remove the brake shoe (16), brake spring (15) and gasket (14).
5. Unscrew the through bolts (22), and remove the rear end frame (13).
6. Remove the brush from the brush holder while holding the spring up.
7. Remove the brush holder (21).
8. Draw out the yoke (19) from the starter drive housing (2).
9. Draw out the armature (10) with the drive lever (3).
■ NOTE
• Do not damage to the brush and commutator.
(When reassembling)
• Apply grease (DENSO.CO.LTD. No. 50 or equivalent) to the parts indicated in the figure.
- Joint of solenoid switch (a)
- Bushing (b)
- Drive lever (c)
- Collar (d)
- Teeth of pinion gear (e)
- Armature shaft (f)
7.8 to 9.8 N·m
Tightening torque B terminal nut 0.8 to 1.0 kgf·m
5.8 to 7.2 ft-lbs
W1012736
(2) Alternator
Pulley
1. Secure the hexagonal end of the pulley shaft with a double-
ended ratchet wrench as shown in the figure, loosen the pulley
nut with a socket wrench and remove it.
(When reassembling)
58.3 to 78.9 N·m
Tightening torque Pulley nut 5.95 to 8.05 kgf·m
43.0 to 58.2 ft-lbs
W1017282
Brush Holder
1. Unscrew the two screws holding the brush holder, and remove
the brush holder (1).
(1) Brush Holder
W1017462
IC Regulator
1. Unscrew the three screws holding the IC regulator, and remove
the IC regulator.
(1) IC Regulator
W1017539
Rectifier
1. Remove the four screws holding the rectifier and the stator lead
wires.
2. Remove the rectifier (1).
(1) Rectifier
W1017612
Rotor
1. Press out the rotor (1) from drive end frame (3).
■ IMPORTANT
• Take special care not to drop the rotor and damage the slip
ring or fan, etc.
(1) Rotor (3) Drive End Frame
(2) Block
W10194380
Retainer Plate
1. Unscrew the four screws holding the retainer plate, and remove
the retainer plate (1).
(1) Retainer Plate
W10195420
[3] SERVICING
(1) Starter
Overrunning Clutch
1. Check the pinion and if worn or damage, replace the clutch
assembly.
2. Check that the pinion turns freely and smoothly in the
overrunning direction and does not slip in the cranking direction.
3. If the pinion slips or does not turn in both directions, replace the
overrunning clutch assembly.
■ NOTE
• Do not wash off the grease in the overrunning clutch with
the chemicals or oils.
W1156799
0.50 to 0.80 mm
Factory spec.
0.0197 to 0.0315 in.
Mica under cut
0.20 mm
Allowable limit
0.0079 in.
Brush Wear
1. If the face of the brush is dirty or dusty, clean it with emery paper.
2. Measure the brush length (A) with vernier caliper.
3. If the length is than the allowable limit, replace the yoke assembly
and brush holder.
16.0 mm
Factory spec.
0.630 in.
Brush length A
10.5 mm
Allowable limit
0.413 in.
W1156360
Brush Holder
1. Check the continuity across the brush holder and the holder
support with a circuit tester.
2. If it conducts, replace the brush holder.
W1156895
Armature Coil
1. Check the continuity across the commutator and armature coil
core with resistance range of circuit tester.
2. If it conducts, replace the armature.
3. Check the continuity across the segments of the commutator with
resistance range of circuit tester.
4. If it does not conduct, replace the armature.
W1156507
Field Coil
1. Check the continuity across the lead (1) and brush (2) with a
circuit tester.
2. If it does not conduct, replace the yoke assembly.
3. Check the continuity across the brush (2) and yoke (3) with a
circuit tester.
4. If it conducts, replace the yoke assembly.
(1) Lead (3) Yoke
(2) Bush
W1156968
(2) Alternator
Bearing
1. Check the bearing for smooth rotation.
2. If it does not rotate smoothly, replace it.
W1019790
Stator
1. Measure the resistance across each lead of the stator coil with
resistance range of circuit tester.
2. If the measurement is not within factory specification, replace it.
3. Check the continuity across each stator coil lead and core with
resistance range of circuit tester.
4. If infinity is not indicated, replace it.
Resistance Factory spec. Less than 1.0 Ω
W1019964
Rotor
1. Measure the resistance across the slip rings.
2. If the resistance is not the factory specification, replace it.
3. Check the continuity across the slip ring and core with resistance
range of circuit tester.
4. If infinity is not indicated, replace it.
Resistance Factory spec. 2.9 Ω
W1020094
Slip Ring
1. Check the slip ring for score.
2. If scored, correct with an emery paper or on a lathe.
3. Measure the O.D. of slip ring with vernier calipers.
4. If the measurement is less than the allowable limit, replace it.
14.4 mm
Factory spec.
0.567 in.
Slip ring O.D.
14.0 mm
Allowable limit
0.551 in.
W1020208
Brush Wear
1. Measure the brush length with vernier calipers.
2. If the measurement is less than allowable limit, replace it.
3. Make sure that the brush moves smoothly.
4. If the brush is defective, replace it.
10.0 mm
Factory spec.
0.3937 in.
Brush length
8.4 mm
Allowable limit
0.331 in.
W1020329
Rectifier
1. Check the continuity across each diode of rectifier with resistance
range of circuit tester.
2. The rectifier is normal if the diode in the rectifier conducts in one
direction and does not conduct in the reverse direction.
W1020452
IC Regulator
1. Check the continuity across the B terminal (2) and the F terminal
(1) of IC regulator with resistance range of circuit tester.
2. The IC regulator is normal if the conducts in one direction and
does not conduct in the reverse direction.
(1) F Terminal (2) B Terminal
W1020645
SAFETY INSTRUCTIONS
SAFETY DECALS
The following safety decals are installed on the mower.
If a decal becomes damaged, illegible or is not on the mower, replace it. The decal part number is listed in
the parts list.
TERMINOLOGY
[RCK72-F36]
(1) Mower Deck (4) Center Frame (7) Discharge Deflector (10)Shield
(2) Front Roller (5) Front Gauge Wheel (8) Anti-Scalp Roller (11)Gauge Wheel Arm LH
(3) Gear Box (6) Gauge Wheel Arm RH (9) Universal Joint (12) Blade
[RCK72R-F36]
(1) Mower Deck (4) Center Frame (7) Anti-Scalp Roller (10) Gauge Wheel Arm LH
(2) Front Roller (5) Front Gauge Wheel (8) Universal Joint (11) Blade
(3) Gear Box (6) Gauge Wheel Arm RH (9) Shield
[RCK60-F36]
(1) Mower Deck (4) Center Frame (7) Discharge Deflector (10)Shield
(2) Front Roller (5) Front Gauge Wheel (8) Anti-Scalp Roller (11)Gauge Wheel Arm LH
(3) Gear Box (6) Gauge Wheel Arm RH (9) Universal Joint (12) Blade
[RCK60R-F36]
(1) Mower Deck (4) Center Frame (7) Anti-Scalp Roller (10) Gauge Wheel Arm LH
(2) Front Roller (5) Front Gauge Wheel (8) Universal Joint (11) Blade
(3) Gear Box (6) Gauge Wheel Arm RH (9) Shield
SPECIFICATIONS
Model RCK72-F36 RCK72R-F36 RCK60-F36 RCK60R-F36
Suitable front mower F2880, F3680
Mounting method 2 point linkage
Adjustment of cutting height Gauge wheel
Cutting width 1826 mm (71.9 in.) 1524 mm (60 in.)
Cutting height 25 to 129 mm (1.0 to 5.0 in.)
Discharge sirection Side Rear Side Rear
Weight (Approx.) 214 kg (472 lbs) 210 kg (463 lbs) 180 kg (397 lbs) 170 kg (375 lbs)
-1 -1
Blade spindle speed 2405 min (2405 rpm) 2695 min (2695 rpm)
Blade tip velocity 78.7 m/s (15490 fpm) 73.8 m/s (14520 fpm)
Blade length 625 mm (24.6 in.) 523 mm (20.6 in.)
Number of blades 3
Total length 1160 mm (45.7 in.) 1090 mm (42.9 in.)
2250 mm 1910 mm 1850 mm 1610 mm
Dimensions Total width
(88.6 in.) (75.2 in.) (72.8 in.) (63.4 in.)
Total height 450 mm (17.7 in.)
W1028770
CONTENTS
1. POWER TRANSMISSION
(1) Center Pulley (6) Pinion Shaft (11) Dust Cover (16) Blade Boss
(2) Bevel Gear (7) Feather Key (12) Blade (Side) (17) Dust Cover
(3) Collar (8) Side Pulley (13) Blade Boss (18) Center Pulley Holder
(4) Bevel Gear (9) Side Pulley Holder (14) Feather Key (19) Blade (Center)
(5) Bevel Gear Case (10) Blade Shaft (15) Bevel Gear Shaft
CONTENTS
1. GENERAL .......................................................................................................9-S1
[1] MOWER IDENTIFICATION .....................................................................9-S1
[2] GENERAL PRECAUTION .......................................................................9-S1
[3] LUBRICANTS ...........................................................................................9-S2
[4] TIGHTENING TORQUES ........................................................................9-S2
(1) General Use Screws, Bolt and Nuts ...................................................9-S2
(2) Metric Screws, Bolts and Nuts ............................................................9-S3
(3) American Standard Screws, Bolts and Nuts with UNC or UNF
Threads ...............................................................................................9-S3
(4) Plugs ...................................................................................................9-S3
[5] MAINTENANCE CHECK LIST................................................................9-S4
[6] CHECK AND MAINTENANCE................................................................9-S5
(1) Check Points of Daily of Each Use .....................................................9-S5
(2) Check Point of Initial 50 Hours............................................................9-S7
(3) Check Point of every 50 Hours ...........................................................9-S7
(4) Check Point of Every 150 Hours.........................................................9-S8
(5) Check Point of Every 2 Years .............................................................9-S8
2. TROUBLESHOOTING ....................................................................................9-S9
3. SERVICING SPECIFICATIONS ..................................................................9-S10
4. TIGHTENING TORQUES ............................................................................9-S11
5. CHECKING, DISASSEMBLING AND ASSEMBLING ................................9-S12
[1] CHECKING AND ADJUSTING .............................................................9-S12
[2] PREPARATION ......................................................................................9-S16
(1) Mower Tilt Up....................................................................................9-S16
(2) Dismounting Mower ..........................................................................9-S17
[3] DISASSEMBLING...................................................................................9-S18
[4] SERVICING ............................................................................................9-S22
1. GENERAL
[1] MOWER IDENTIFICATION
When contacting your local KUBOTA distributor, always specify
mower serial number.
(1) Mower Serial Number
W1010628
[3] LUBRICANTS
Capacity
Place RCK72-F36 / RCK72R-F36 Lubricants
RCK60-F36 / RCK60R-F36
0.4 L
SAE 90 gear oil
Gear box 0.43 U.S.qts.
(API Service GL-5 gear oil)
0.35 lmp.qts.
Greasing
Universal joint
Bevel gear shaft and blade shafts
Belt tension pulley
Until grease overflows SAE multi-purpose type grease
Belt tension pivot
Front gauge wheels
Front roller
Unit
N·m kgf·m ft-lbs N·m kgf·m ft-lbs
Nominal Diameter
M8 23.6 to 27.4 2.40 to 2.80 17.4 to 20.2 29.4 to 34.3 3.00 to 3.50 21.7 to 25.3
M10 48.1 to 55.8 4.90 to 5.70 35.5 to 41.2 60.8 to 70.5 6.20 to 7.20 44.9 to 52.1
M12 77.5 to 90.1 7.90 to 9.20 57.2 to 66.5 103.0 to 117.0 10.50 to 12.00 76.0 to 86.8
M14 124.0 to 147.0 12.60 to 15.00 91.2 to 108.0 167.0 to 196.0 17.00 to 20.00 123.0 to 144.0
M16 196.0 to 255.0 20.0 to 23.0 145.0 to 166.0 260.0 to 303.0 26.50 to 31.00 192.0 to 224.0
W1013689
(3) American Standard Screws, Bolts and Nuts with UNC or UNF Threads
SAE GR.5 SAE GR.8
Grade
Unit
N·m kgf·m ft-lbs N·m kgf·m ft-lbs
Nominal Diameter
5/16 23.1 to 27.8 2.35 to 2.84 17.0 to 20.5 32.5 to 39.3 3.31 to 4.01 24.0 to 29.0
3/8 47.5 to 57.0 4.84 to 5.82 35.0 to 42.0 61.0 to 73.2 6.22 to 7.47 45.0 to 54.0
1/2 108.5 to 130.2 11.07 to 13.29 80.0 to 96.0 149.2 to 179.0 15.22 to 18.27 110.0 to 132.0
9/16 149.2 to 179.0 15.22 to 18.27 110.0 to 132.0 217.0 to 260.4 22.14 to 26.57 160.0 to 192.0
5/8 203.4 to 244.1 20.75 to 24.91 150.0 to 180.0 298.3 to 358.0 30.44 to 36.53 220.0 to 264.0
W1022485
(4) Plugs
Material of opponent part
Tapered R1/8 13 to 22 1.3 to 2.2 9.6 to 16.2 10 to 12 1.0 to 1.2 7.4 to 8.9
screw
0000001666E
CAUTION
• To avoid injury, always handle the mower blade with care.
1. Dismount the mower and turn it over to expose the mower
blades.
2. Wedge a wooden block securely between the mower blade and
mower deck.
3. Retighten the mower blade screw to the specified torque.
4. If the mower blade screw is worn or broken, replace it.
98.1 to 117.7 N·m
Tightening torque Mower blade screw 10.0 to 12.0 kgf·m
72.3 to 86.8 ft-lbs
W1016076
2. TROUBLESHOOTING
Reference
Symptom Probable Cause Solution
Page
Blade Does Not Mower belt broken Replace mower belt 9-S19
Rotate PTO clutch broken Repair 2-S21, S25
Blade Speed Is Slow Mower belt loosen Replace mower belt 9-S19
or tension spring
Grass clogged Remove grass –
Cup washer flattened out or worn Replace cup washer 9-S18
Cutting Is Poor Blade worn or broken Sharpen or replace 9-S5,S18
blade
3. SERVICING SPECIFICATIONS
Item Factory Specification Allowable Limit
Maximum Front Gauge Wheel Tire Pressure 343 kPa –
3.5 kgf/cm2
49.7 psi
Recommended Front Gauge Wheel Tire Pressure 196 kPa –
2.0 kgf/cm2
28.4 psi
Pinion Shaft Turning Force 490 N
Less than 50 kgf –
110 lbs
4. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts: See page 9-S2.)
Item N·m kgf·m ft-lbs
Mower blade mounting screw 98.1 to 117.7 10.0 to 12.0 72.3 to 86.8
W1012736
WARNING
• Never exceed the tire pressure shown below (maximum
limit) when attempting to seat the bead. If bead does not
seat by the time the pressure reaches maximum limit, deflate
the assembly reposition the tire on the rim, relubricate, and
reinflate. After seating the bead, adjust inflation pressure as
recommended in the inflation pressure chart.
1. The tire pressure naturally drops slowly in the course of time.
Thus, check it every day and inflate as necessary.
343 kPa
Maximum front gauge
Factory spec. 3.5 kgf/cm2
wheel tire pressure
49.7 psi
CAUTION
• Do not attempt to mount a tire unless qualified. Use proper
equipment.
W1018550
RCK72-F36
RCK72R-F36
RCK60-F36
RCK60R-F36
W1019807
[2] PREPARATION
(1) Mower Tilt Up
Mower Tilt Up
1. Place PTO lever in “DISENGAGE” position.
2. Stop the engine, set the parking brake.
3. Place High-Low gear shift lever in “NEUTRAL” position.
4. Disconnect the universal joint from the machine.
5. [RCK72-F36 / RCK72R-F36]
Detach the tilt pipe (3) set in the mower deck, and insert the tilt
lever (4) in the tilt pipe (3).
Pull the tilt pipe (3) in the direction of the arrow, and hook the tilt
lever (4).
CAUTION
• Securely insert the tilt lever (4) in the tilt pipe (3).
• Never release the tilt pipe (3) until the tilt lever (4) is locked
to the hook securely.
6. Start the engine and raise the mower deck fully.
7. Lock the lowering speed adjusting valve.
8. Stop the engine and remove the key.
9. Pull on the lock pins (6) of the anti-scalp roller (5) and push them
upward.
10.Pull on the lock pins (7) of the lift rods (8) and lock them in the
open position.
11.Disengage the lock of the tilting pin (9).
(1) Gas Spring (6) Lock Pin
(2) Hook (7) Lock Pin
(3) Tilt Pipe (8) Lift Rod
(4) Tilt Lever (9) Lock Pin
(5) Anti-Scalp Roller
W1016339
CAUTION
• Before dismounting or mounting the mower deck, read and
understand how to use of the lowering speed adjusting
knob.
• The mower links (left hand, right hand) are spring-loaded.
Have an assistant hold the lift arm in position when
mounting and dismounting mower deck.
1. Place the PTO lever in the “DISENGAGE” position.
2. Place the High-Low gear shift lever in the “NEUTRAL” position.
3. Disconnect the universal joint from the machine.
4. Start the engine and raise the mower deck fully.
5. [RCK72-F36 / RCK72R-F36]
Unlock the tilt lever (1) with the tilt pipe.
Remove the clevis pin (3), and disconnect the gas spring (2) from
the mower lift arm (6).
6. Shut off the engine, pull the lock pins (4) of the lift rods (4) and
lock them in the open position.
7. Start the engine and down the mower deck fully, and shut off the
engine.
8. Remove the clevis pins (7), and disconnect the mower lift arms
(6) from mower deck.
(1) Tilt Lever (5) Lock Pin
(2) Gas Spring (6) Mower Lift Arm
(3) Clevis Pin (7) Clevis Pin
(4) Lift Rod
W1016795
[3] DISASSEMBLING
Universal Joint and Covers
1. Remove the screw (1), and remove the universal joint (2).
2. Remove the left and right covers.
(1) Screw (2) Universal Joint
W1021193
W1024102
[4] SERVICING
Checking Torque of Pinion Shaft
■ NOTE
• Do not remove the mower belt.
1. Wind a string around the pinion shaft and set a push-pull gauge
to the end of the string, and then slowly pull the push-pull gauge
horizontally to measure the turning force.
2. If the measurement exceeds the factory specification, check the
bearing and gears and adjust the adjusting shims (1), (2), (3).
490 N
Turning force Factory spec. Less than 50 kgf
110 lbs
5.9 N·m
Turning torque Factory spec. Less than 0.6 kgf·m
4.3 ft-lbs
(Reference)
• Thickness of adjusting shims (1), (2) : 0.2 mm (0.0079 in.)
0.3 mm (0.0118 in.)
• Thickness of adjusting shims (3) : 0.1 mm (0.0039 in.)
0.2 mm (0.0079 in.)
(1) Shim (3) Shim
(2) Shim
W1024471
W1024912