Kubota KTH4815-2 Service Manual — TOB-0086982

About this manual

Kubota published this Service Manual for KTH4815-2. It is intended for maintenance, source-supported service, and source-supported repair, where those subjects appear in the source publication.

Use the Manual Contents below to check that the exact maintenance, inspection, service, or repair procedure you need is included in this publication.

Manual details

Manufacturer

Kubota

Manual type

Service Manual

Models

KTH4815-2

Document number

TOB-0086982

Publication year

2023

Language

English

Page count

364

Product highlights

Electrical systems

The manual includes wiring diagrams and electrical troubleshooting.

Hydraulic systems

The manual includes hydraulic circuit diagrams and hydraulic pressure-test material.

Diagnostics

The manual includes diagnostic trouble-code reference information and sensor-testing information.

Specifications and settings

The manual includes reference information for pressure specifications.

Special tools

A special-tools section is included.

Manual contents

Use these source headings to locate the task or system you need in the PDF.

• Preface — p. 3
  • Language — p. 3
  • Related documents — p. 3
  • OEM documentation overview — p. 4
  • Icons and signal words used in the document — p. 4
  • Tools — p. 5
  • Illustrations — p. 5
  • Version history — p. 5
  • Typographical conventions — p. 6
  • Abbreviations — p. 6
  • Terminology — p. 7
• 1 Safety — p. 17
  • 1.1 Service-related safety instructions — p. 17
    • 1.1.1 General safety instructions — p. 17
    • 1.1.2 Safety instructions for service on the transmission — p. 17
    • 1.1.3 Safety instructions for service below the lifting arm — p. 17
  • 1.2 Approved trainer — p. 18
  • 1.3 Approved service engineer — p. 18
• 2 Description — p. 19
  • 2.1 Engine — p. 19
    • 2.1.1 Overview — p. 19
    • 2.1.2 Lubrication system — p. 20
    • 2.1.3 Common rail system — p. 21
    • 2.1.4 Cooling system — p. 22
  • 2.2 Electrical system — p. 23
    • 2.2.1 Schematic overview — p. 23
    • 2.2.2 Electrical diagram — p. 23
    • 2.2.3 Termination resistors — p. 24
    • 2.2.4 PCU (Power Control Unit) — p. 24
    • 2.2.5 MCU (Machine Control Unit) — p. 25
    • 2.2.6 DCU (Display Control Unit) — p. 25
    • 2.2.7 LMC (Load Moment Controller) — p. 26
    • 2.2.8 ECU (Engine Control Unit) — p. 26
    • 2.2.9 Diagnostic connector — p. 27
    • 2.2.10 Service Tool — p. 28
    • 2.2.11 Fuses and relays — p. 29
    • 2.2.12 Ground and power connections — p. 31
  • 2.3 Hydraulic system — p. 35
    • 2.3.1 Hydraulic diagram — p. 35
    • 2.3.2 Overview of the drive hydraulics — p. 36
    • 2.3.3 Overview of the steering hydraulics — p. 37
    • 2.3.4 Overview of the work hydraulics — p. 38
    • 2.3.5 Overview of the fan hydraulics — p. 39
    • 2.3.6 Drive pump — p. 40
    • 2.3.7 Drive motor — p. 41
    • 2.3.8 Work pump — p. 41
    • 2.3.9 Main control valve — p. 41
    • 2.3.10 Hydraulic cylinders — p. 45
      • 2.3.10.1 Lift cylinder — p. 45
      • 2.3.10.2 Tilt cylinder — p. 45
      • 2.3.10.3 Compensation cylinder — p. 46
      • 2.3.10.4 Telescopic cylinder — p. 47
      • 2.3.10.5 Steering cylinder — p. 47
    • 2.3.11 Hydraulic steering unit — p. 48
    • 2.3.12 Manifold steering control (optional) — p. 49
    • 2.3.13 Priority valve — p. 50
    • 2.3.14 LMC hydraulic manifold — p. 51
    • 2.3.15 Attachment lock cylinder — p. 52
    • 2.3.16 6/2-diverter valve (If applicable) — p. 53
    • 2.3.17 Hydraulic 8/3 valve (optional) — p. 53
  • 2.4 Transmission and wheels — p. 55
    • 2.4.1 Overview — p. 55
    • 2.4.2 Brake and inching system — p. 57
  • 2.5 Frame — p. 58
    • 2.5.1 Overview — p. 58
• 3 Maintenance — p. 61
  • 3.1 General maintenance instructions — p. 61
  • 3.2 Performing a test drive — p. 62
  • 3.3 Ordering parts — p. 62
  • 3.4 Servicing below the lifting arm — p. 62
    • 3.4.1 Installing the safety bracket on the KTH4815-2 — p. 62
    • 3.4.2 Storing the safety bracket on the KTH4815-2 — p. 63
  • 3.5 Accessing parts — p. 63
    • 3.5.1 Opening and closing the bonnet — p. 63
    • 3.5.2 Accessing the electric area of the cabin — p. 64
    • 3.5.3 Accessing the wiring harness and frame drive hydraulics area — p. 64
    • 3.5.4 Accessing the work hydraulics (top) — p. 65
    • 3.5.5 Accessing the work hydraulics (bottom) — p. 65
    • 3.5.6 Accessing the steering unit — p. 66
    • 3.5.7 Accessing the manifold steering control — p. 66
    • 3.5.8 Accessing the telescopic lifting arm sliding plate (Rear) — p. 67
  • 3.6 Panolin synthetic hydraulic oil (If applicable) — p. 67
    • 3.6.1 Requirements — p. 68
    • 3.6.2 Sample method — p. 68
    • 3.6.3 Test intervals — p. 69
  • 3.7 Maintenance schedules — p. 69
    • 3.7.1 Maintenance: quick reference — p. 69
    • 3.7.2 Maintenance before delivery — p. 73
    • 3.7.3 Maintenance after the first 50 hours — p. 76
    • 3.7.4 Maintenance every 500 hours — p. 77
    • 3.7.5 Maintenance every 1000 hours — p. 80
    • 3.7.6 Maintenance every 1500 hours — p. 81
    • 3.7.7 Maintenance every 3000 hours — p. 81
    • 3.7.8 Maintenance every 6000 hours — p. 81
    • 3.7.9 Maintenance every 1 year — p. 81
    • 3.7.10 Maintenance every 2 years — p. 84
    • 3.7.11 Maintenance every 6 years after hydraulic hose production date — p. 84
  • 3.8 Maintenance tasks — p. 85
    • 3.8.1 Engine — p. 85
    • 3.8.2 Cooling system — p. 86
    • 3.8.3 Fuel system — p. 87
    • 3.8.4 Hydraulic system — p. 87
    • 3.8.5 Electrical system — p. 88
    • 3.8.6 Cabin and controls — p. 89
    • 3.8.7 Transmission and wheels — p. 90
    • 3.8.8 Frame — p. 92
• 4 Checks, cleaning and functional tests — p. 93
  • 4.1 Cabin and controls — p. 93
    • 4.1.1 Checking the ROPS-FOPS structure — p. 93
    • 4.1.2 Checking the windscreen wiper blades (If applicable) — p. 93
    • 4.1.3 Testing the steering system — p. 94
    • 4.1.4 Checking the steering wheel — p. 94
    • 4.1.5 Testing the steering column — p. 94
    • 4.1.6 Checking the steering column lock — p. 94
    • 4.1.7 Testing the radio (If applicable) — p. 94
    • 4.1.8 Testing the driver's seat — p. 94
    • 4.1.9 Testing the 12-V connection (If applicable) — p. 94
    • 4.1.10 Testing the rotating beacon (If applicable) — p. 95
    • 4.1.11 Testing the heater (optional) — p. 95
    • 4.1.12 Checking OPM (operator manual) presence — p. 95
  • 4.2 Engine, cooling and fuel system — p. 95
    • 4.2.1 Cleaning the main air filter — p. 95
      • 4.2.1.1 Removing the main air filter — p. 95
      • 4.2.1.2 Cleaning and inspecting the main air filter — p. 96
      • 4.2.1.3 Installing the main air valve and cover — p. 96
    • 4.2.2 Checking the exhaust system — p. 97
    • 4.2.3 Checking the fuel hoses — p. 98
    • 4.2.4 Checking the V-belt — p. 98
    • 4.2.5 Checking the cable connectors connection — p. 99
    • 4.2.6 Checking the vibration dampers — p. 99
    • 4.2.7 Regeneration — p. 100
  • 4.3 Electrical system — p. 100
    • 4.3.1 Checking the electrical wiring — p. 100
    • 4.3.2 Checking the DTCs — p. 101
    • 4.3.3 Checking the software version of the DCU/MCU — p. 101
  • 4.4 Hydraulic system — p. 102
    • 4.4.1 Checking the hydraulic cylinder scraper — p. 102
    • 4.4.2 Testing the cylinder seals — p. 102
    • 4.4.3 Testing the lifting arm displacements — p. 103
  • 4.5 Transmission and wheels — p. 104
    • 4.5.1 Checking the front axle oil level — p. 104
    • 4.5.2 Checking the rear axle oil level — p. 105
    • 4.5.3 Checking the wheel hub axle oil level — p. 106
    • 4.5.4 Checking gearbox oil level — p. 107
    • 4.5.5 Testing the braking system — p. 108
    • 4.5.6 Checking the axle breather plugs — p. 108
  • 4.6 Frame — p. 109
    • 4.6.1 Checking the paintwork — p. 109
    • 4.6.2 Checking the attachment lock position — p. 109
    • 4.6.3 Checking the cabin vibration dampers — p. 110
    • 4.6.4 Checking the hinge pin bolts — p. 111
    • 4.6.5 Checking the hinge pin spring pins — p. 112
    • 4.6.6 Checking the telescopic cylinder retaining rings — p. 113
• 5 Measurements — p. 115
  • 5.1 Cabin and controls — p. 115
    • 5.1.1 Measuring the front automotive lights inclination — p. 115
  • 5.2 Engine, cooling and fuel system — p. 115
    • 5.2.1 Measuring the coolant freezing point — p. 115
    • 5.2.2 Measuring the valve clearance — p. 116
    • 5.2.3 Measuring the V-belt tension — p. 116
    • 5.2.4 Measuring the glow plugs continuity — p. 116
    • 5.2.5 Measuring the thermostat valve opening temperature — p. 116
  • 5.3 Electrical system — p. 117
    • 5.3.1 Measuring battery voltage — p. 117
    • 5.3.2 Measuring the alternator supply voltage — p. 118
  • 5.4 Hydraulic system — p. 119
    • 5.4.1 Measuring the drive pump boost pressure — p. 119
      • 5.4.1.1 Measuring the drive pump boost pressure (With pressure gauge) — p. 119
      • 5.4.1.2 Measuring the drive pump boost pressure (With service tool) — p. 120
    • 5.4.2 Measuring the drive pump forward pressure — p. 121
      • 5.4.2.1 Measuring the drive pump forward pressure (With pressure gauge) — p. 121
      • 5.4.2.2 Measuring the drive pump forward pressure (With service tool) — p. 122
    • 5.4.3 Measuring the drive pump reverse pressure — p. 123
      • 5.4.3.1 Measuring the drive pump reverse pressure (With pressure gauge) — p. 123
      • 5.4.3.2 Measuring the drive pump reverse pressure (With service tool) — p. 124
    • 5.4.4 Measuring the main work pressure — p. 125
      • 5.4.4.1 Measuring the main work pressure (With pressure gauge) — p. 125
    • 5.4.5 Measuring the steering pressure — p. 126
  • 5.5 Transmission and wheels — p. 127
    • 5.5.1 Measuring the kingpin clearance — p. 127
    • 5.5.2 Measuring the service brake pads wear — p. 128
    • 5.5.3 Measuring the parking brake pads wear — p. 129
  • 5.6 Frame — p. 130
    • 5.6.1 Sliding plates clearance (Front: top) — p. 130
    • 5.6.2 Sliding plates clearance (Rear: bottom) — p. 131
    • 5.6.3 Sliding plates clearance (Front: left and right) — p. 132
    • 5.6.4 Sliding plates wear (Front: bottom) — p. 133
    • 5.6.5 Sliding plates wear (Front: left) — p. 134
    • 5.6.6 Sliding plates wear (Front: top and right) — p. 135
    • 5.6.7 Sliding plates wear (Rear: bottom) — p. 136
    • 5.6.8 Sliding plates wear (Rear: top, left and right) — p. 137
    • 5.6.9 Measure end stops clearance (Lifting arm) — p. 137
• 6 Adjustments — p. 139
  • 6.1 Cabin and controls — p. 139
    • 6.1.1 Adjusting the front automotive lights inclination — p. 139
  • 6.2 Engine, cooling and fuel system — p. 140
    • 6.2.1 Bleeding the fuel system — p. 140
    • 6.2.2 Draining the fuel tank — p. 141
    • 6.2.3 Adjusting the valve clearance — p. 141
    • 6.2.4 Adjusting the V-belt tension — p. 141
  • 6.3 Electrical system — p. 142
    • 6.3.1 Charging the battery — p. 142
    • 6.3.2 Updating the software of a specific control unit — p. 143
    • 6.3.3 Calibrating the drive pedal — p. 144
    • 6.3.4 Calibrating the LMC — p. 145
      • 6.3.4.1 Calibrating the load cell with the LMI — p. 145
      • 6.3.4.2 Calibrating the load cell (With service tool) — p. 148
  • 6.4 Hydraulic system — p. 149
    • 6.4.1 Adjusting the drive pump boost pressure — p. 149
    • 6.4.2 Adjusting the drive pump pressure cut-off — p. 150
    • 6.4.3 Adjusting the main work pressure — p. 151
    • 6.4.4 Adjusting the tilt cylinder load-holding valve — p. 152
    • 6.4.5 Adjusting the lift cylinder load-holding valve — p. 153
    • 6.4.6 Adjusting the telescopic cylinder load-holding valve — p. 154
  • 6.5 Transmission and wheels — p. 155
    • 6.5.1 Adding axle oil to the front axle — p. 155
    • 6.5.2 Adding axle oil to the rear axle — p. 156
    • 6.5.3 Adding axle oil to a wheel hub — p. 157
    • 6.5.4 Adding oil to the gearbox — p. 158
    • 6.5.5 Lubricating axle kingpins — p. 159
    • 6.5.6 Lubricating the hinge pins — p. 160
    • 6.5.7 Adjusting the axle steering stops — p. 161
  • 6.6 Frame — p. 161
    • 6.6.1 Adjusting sliding plates (Front: top and right) — p. 161
    • 6.6.2 Adjusting sliding plate (Rear: bottom) — p. 162
    • 6.6.3 Adjusting the end stops clearance (Lifting arm) — p. 163
• 7 Replacements — p. 165
  • 7.1 Cabin and controls — p. 165
    • 7.1.1 Replacing the steering wheel — p. 165
    • 7.1.2 Replacing the steering column — p. 166
    • 7.1.3 Replacing the joystick — p. 167
    • 7.1.4 Replacing the DCU — p. 169
    • 7.1.5 Replacing the driver's seat — p. 170
    • 7.1.6 Replacing the windscreen wiper blades (If applicable) — p. 171
    • 7.1.7 Replacing the radio (If applicable) — p. 171
  • 7.2 Engine, cooling and fuel system — p. 172
    • 7.2.1 Replacing the engine oil — p. 172
    • 7.2.2 Replacing the engine oil filter — p. 174
    • 7.2.3 Replacing the fuel filter(s) — p. 175
    • 7.2.4 Replacing the main air filter and the safety air filter — p. 176
    • 7.2.5 Replacing the complete air filter unit — p. 177
    • 7.2.6 Replacing the coolant — p. 179
    • 7.2.7 Replacing parts of the cooling system — p. 180
    • 7.2.8 Replacing the combination cooler — p. 181
    • 7.2.9 Replacing the V-belt — p. 184
    • 7.2.10 Replacing the glow plug — p. 184
    • 7.2.11 Replacing the fuel hoses — p. 186
    • 7.2.12 Replacing the fuel feed pump — p. 187
    • 7.2.13 Replacing the DOC/DPF filter unit — p. 188
    • 7.2.14 Replacing the thermostat — p. 189
    • 7.2.15 Replacing the pressure-relief valve of the combination cooler — p. 190
    • 7.2.16 Replacing the combustion engine — p. 190
    • 7.2.17 Replacing the exhaust — p. 191
    • 7.2.18 Replacing the impeller — p. 193
    • 7.2.19 Replacing the starter motor — p. 194
    • 7.2.20 Replacing the fuel tank — p. 195
  • 7.3 Electrical system — p. 196
    • 7.3.1 Replacing the battery — p. 196
    • 7.3.2 Replacing the alternator — p. 199
  • 7.4 Hydraulic system — p. 200
    • 7.4.1 Replacing the hydraulic oil tank — p. 200
    • 7.4.2 Replacing the complete hydraulic filter — p. 202
    • 7.4.3 Replacing the hydraulic suction filters — p. 203
    • 7.4.4 Replacing the hydraulic oil tank filler cap — p. 205
    • 7.4.5 Replacing the work pump — p. 205
    • 7.4.6 Replacing the drive pump — p. 207
    • 7.4.7 Replacing the drive motor — p. 209
    • 7.4.8 Replacing the steering unit — p. 215
    • 7.4.9 Replacing the hydraulic hoses — p. 217
    • 7.4.10 Replacing the main control valve — p. 217
    • 7.4.11 Replacing the hydraulic cylinders — p. 220
      • 7.4.11.1 Replacing the lift cylinder — p. 220
      • 7.4.11.2 Replacing the tilt cylinder — p. 222
      • 7.4.11.3 Replacing the compensation cylinder — p. 224
      • 7.4.11.4 Replacing the attachment lock cylinder (2/2 valve) — p. 226
    • 7.4.12 Replacing the cylinder seals — p. 227
      • 7.4.12.1 Replacing the lift cylinder seals — p. 227
      • 7.4.12.2 Replacing the tilt cylinder seals — p. 229
      • 7.4.12.3 Replacing the telescopic cylinder seals — p. 231
      • 7.4.12.4 Replacing the compensation cylinder seals — p. 233
    • 7.4.13 Replacing the telescopic cylinder load-holding valve — p. 235
    • 7.4.14 Replacing the tilt cylinder load-holding valve — p. 236
    • 7.4.15 Replacing the lift cylinder load-holding manifold — p. 237
    • 7.4.16 Replacing the load moment sensor — p. 238
  • 7.5 Transmission and wheels — p. 239
    • 7.5.1 Replacing the drive shaft — p. 239
    • 7.5.2 Replacing the monolastic elastic clutch — p. 240
    • 7.5.3 Replacing the front axle — p. 241
    • 7.5.4 Replacing the front axle oil — p. 242
    • 7.5.5 Replacing the rear axle — p. 243
    • 7.5.6 Replacing the rear axle oil — p. 245
    • 7.5.7 Replacing the wheel hubs axle oil — p. 246
    • 7.5.8 Replacing the gearbox oil — p. 248
    • 7.5.9 Replacing the brake fluid — p. 249
    • 7.5.10 Replacing the axle breather plugs — p. 250
    • 7.5.11 Replacing the service brake pads — p. 250
    • 7.5.12 Replacing the parking brake pads — p. 250
    • 7.5.13 Replacing the front steering cylinder — p. 251
      • 7.5.13.1 Replacing the front axle steering cylinder seals — p. 252
    • 7.5.14 Replacing the rear steering cylinder — p. 252
      • 7.5.14.1 Replacing the rear axle steering cylinder seals — p. 253
  • 7.6 Frame — p. 254
    • 7.6.1 Replacing the bonnet — p. 254
    • 7.6.2 Replacing sliding plates (Front: bottom) — p. 256
    • 7.6.3 Replacing sliding plates (Front: left) — p. 257
    • 7.6.4 Replacing sliding plates (Front: top or right) — p. 258
    • 7.6.5 Replacing sliding plates (Rear: bottom) — p. 259
    • 7.6.6 Replacing sliding plates (Rear: top, left and right) — p. 260
    • 7.6.7 Replacing the complete lifting arm — p. 261
    • 7.6.8 Replacing the inner telescopic boom — p. 266
      • 7.6.8.1 Removing the inner telescopic boom — p. 266
      • 7.6.8.2 Installing the inner telescopic boom — p. 268
    • 7.6.9 Replacing the fixed part of the telescopic boom — p. 269
• 8 Troubleshooting — p. 275
  • 8.1 Troubleshooting procedure — p. 275
  • 8.2 Complete machine — p. 275
    • 8.2.1 Troubleshooting table — p. 275
  • 8.3 Cabin and controls — p. 275
    • 8.3.1 Troubleshooting table — p. 275
  • 8.4 Electrical system — p. 276
    • 8.4.1 Troubleshooting table — p. 276
  • 8.5 Hydraulic system — p. 276
    • 8.5.1 Troubleshooting table — p. 276
    • 8.5.2 Forward or reverse drive pressure incorrect — p. 278
    • 8.5.3 Telescopic/tilt cylinder displacement outside of specifications — p. 279
    • 8.5.4 Lift cylinder displacement outside of specifications — p. 280
• 9 Technical Data — p. 281
  • 9.1 Consumables — p. 281
    • 9.1.1 Fluid specifications — p. 281
  • 9.2 Torque specifications — p. 282
    • 9.2.1 Torque specifications of fasteners — p. 282
    • 9.2.2 Torque specifications of special fasteners — p. 282
  • 9.3 Clearance specifications — p. 283
  • 9.4 Paint specifications — p. 283
  • 9.5 Non-Destructive Testing (NDT) inspection standards — p. 283
  • 9.6 Wear specifications — p. 283
  • 9.7 Pressure specifications — p. 284
  • 9.8 Other specifications — p. 284
  • 9.9 Special tools specifications — p. 284
• 10 OEM Documentation — p. 285
  • 10.1 Parts description — p. 285
    • 10.1.1 Front and rear axles — p. 285
      • 10.1.1.1 Front axle — p. 285
      • 10.1.1.2 Rear axle — p. 286
  • 10.2 Checks, cleaning and functional tests — p. 287
    • 10.2.1 Check V-belt — p. 287
  • 10.3 Measurements and adjustments — p. 288
    • 10.3.1 Measuring and adjusting the valve clearance — p. 288
    • 10.3.2 Measuring and adjusting the V-belt tension — p. 290
    • 10.3.3 Measuring the glow plugs continuity — p. 290
    • 10.3.4 Measuring the thermostat opening temperature — p. 291
    • 10.3.5 Measuring the alternator supply voltage — p. 291
  • 10.4 Replacements — p. 292
    • 10.4.1 Replacing parts of the cooling system — p. 292
      • 10.4.1.1 Antifreeze — p. 293
    • 10.4.2 Replacing the V-belt — p. 294
    • 10.4.3 Replacing the thermostat — p. 295
    • 10.4.4 Replacing the service brake pads — p. 296
    • 10.4.5 Replacing the parking brake pads — p. 298
    • 10.4.6 Replacing the front axle steering cylinder seals — p. 302
      • 10.4.6.1 Toe-in adjustment — p. 307
      • 10.4.6.2 Checking the hydraulic by-pass — p. 310
    • 10.4.7 Replacing the rear axle steering cylinder seals — p. 311
      • 10.4.7.1 Toe-in adjustment — p. 316
      • 10.4.7.2 Checking the hydraulic by-pass — p. 319
  • 10.5 OEM Troubleshooting — p. 320
    • 10.5.1 Electric — p. 320
      • 10.5.1.1 Bearing — p. 321
      • 10.5.1.2 Stator — p. 321
      • 10.5.1.3 Rotor — p. 322
      • 10.5.1.4 Slip ring — p. 323
      • 10.5.1.5 Brush wear — p. 324
      • 10.5.1.6 Rectifier — p. 325
      • 10.5.1.7 IC-regulator — p. 325
• 11 Diagrams — p. 327

Capabilities

The source outline indexes servicing instructions, maintenance, checking and adjustment, inspection, replacement procedures, and troubleshooting. Use these source-backed headings to locate the applicable service or repair topic in the source PDF, then confirm model-specific notes, specifications, illustrations, and operating conditions at the relevant page before carrying out service or repair work.

Keep the source's safety sequence, prerequisite steps, labels, units, configuration notes, and footnotes with the selected task; do not apply an isolated value outside the conditions stated in the manual.

Technical reference

Reference tables include pressure specifications for service specifications, limits, adjustment and repair reference data. Use the values and conditions in the PDF for the applicable model and procedure.

• Pressure reference: pressure specifications.

Delivery

This manual is supplied as a digital PDF file and is available for instant download after purchase. No physical media is shipped.

References

Kubota Service Manual for Telescopic Handler, document code TOB-0086982, PDF edition.