Kubota M5-091, M5-111 Workshop Manual

Overview

This is the Kubota Workshop Manual for the M5-091, M5-111 (document code 9Y111-12857, 2021 edition). It provides service and repair procedures for Kubota M5-091, M5-111 tractor. Powered by the Kubota V3800 engine.

Manual Details and Coverage

Manufacturer

Kubota

Models

M5-091, M5-111

Equipment type

Tractor

Applicability

Kubota M5-091 and M5-111 series tractors

Manual type

Workshop Manual

Document code

9Y111-12857

Publication year

2021

Language

English

Page count

1,071

Format

PDF

Selected Technical Specifications

Torque Specifications

Clearances

Manual Revisions

• July 2020 — Adding information how to handling DEF/AdBlue ®; Adding information about outline of the SCR system; Change and adding some maintenance items about DEF/AdBlue®
• July 2021 — Added the procedure for removing the cam gear

Delivery (Instant Download)

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

Contents

The manual is structured as follows. Page references correspond to the original PDF pagination.

1. INFORMATION

• SAFETY FIRST (1-1)
  • Before you start service (1-2)
  • Start safely (1-2)
  • Operate safely (1-2)
  • Avoiding high pressure fluid (1-3)
  • Avoiding hot exhaust (1-3)
  • Cleaning exhaust filter (1-4)
  • Prevent a fire (1-4)
  • Keep a good airflow in the work area (1-4)
  • Discard fluids correctly (1-4)
  • Prevent acid burns (1-5)
  • Preparing for emergencies (1-5)
• SAFETY DECALS (1-7)
  • Care of danger, warning and caution labels (1-20)
• SPECIFICATIONS (1-7)
• SPECIFICATIONS (1-21)
  • Specification table (1-21)
  • Specification table (ROPS Low Profile model) (1-23)
• TRAVELING SPEEDS (1-25)
  • Traveling speeds for ROPS model (1-25)
  • Traveling speeds for Cabin model (1-27)
  • Traveling speeds (ROPS Low Profile model) (1-31)
• DIMENSIONS (1-33)
  • Dimension for ROPS model (1-33)
  • Dimension for Cabin model (1-34)
  • Dimension for ROPS Low profile model (1-35)

2. GENERAL

• TRACTOR IDENTIFICATION (2-1)
  • Tractor number (2-1)
  • Engine serial number (2-3)
  • DPF muffler serial number (2-1)
  • DPF muffler serial number (2-4)
  • SCR muffler serial number (2-4)
  • EF4B engine (2-4)
  • Cylinder number (2-5)
• GENERAL WORKING PRECAUTIONS (2-7)
• LUBRICANTS, FUEL AND COOLANT (2-17)
  • Engine oil (2-20)
  • Fuel (2-20)
  • DEF/AdBlue® (2-20)
    • Handling DEF (AdBlue) (2-20)
    • Quality of DEF (AdBlue) (2-20)
    • Warning indication and countermeasures (2-21)
    • Adding DEF (AdBlue) (2-24)
    • Draining DEF (AdBlue) (2-2)
    • Draining DEF (AdBlue) (2-24)
    • Storing purchased DEF (AdBlue) (2-24)
    • Storing DEF (AdBlue) in the DEF tank (2-25)
    • Disposing of DEF (AdBlue) (2-25)
    • Handling precautions after stopping the engine (2-25)
    • Precautions when using in cold regions (2-25)
  • Transmission oil (2-26)
• TIGHTENING TORQUES (2-27)
  • Hydraulic hose fittings (2-29)
  • Hydraulic pipe cap nuts (2-29)
  • Adapters, elbows and others (2-29)
• MAINTENANCE (2-33)
  • Service intervals (ROPS model) (2-33)
  • Service intervals (Cabin model) (2-36)
  • Maintenance items chart (2-39)
• CHECK AND MAINTENANCE (2-41)
  • Daily check (2-41)
    • Warning (2-41)
    • Walk around inspection (2-41)
    • Checking and refueling (2-41)
    • Checking the DEF (AdBlue) level and adding fluid (2-42)
    • Checking water separator (2-43)
    • Checking engine oil level (2-43)
    • Checking transmission fluid level
    • Checking transmission fluid level (2-44)
    • Checking coolant level (2-44)
    • Cleaning evacuator valve (2-45)
    • Checking dust indicator (2-45)
    • Cleaning grill, radiator screen, oil cooler, fuel cooler, air conditioner condenser and
    • Checking DPF muffler / SCR device (2-46)
    • Checking brake pedal (2-47)
    • Checking parking brake (2-47)
    • Checking gauges, meter and Easy Checker (2-47)
    • Checking headlight, turn signal light, hazard light, and so on (2-47)
    • Checking seat belt (2-47)
    • Checking movable parts (2-47)
  • Check points of initial 50 hours (2-47)
    • Checking engine oil level (2-47)
    • Replacing engine oil filter (2-48)
  • Check points every 50 hours (2-49)
    • Checking engine start system (2-49)
    • Checking wheel bolt torque (2-49)
    • Checking tie-rod dust cover (2-50)
  • Check points of every 100 hours (2-51)
    • Lubricating grease fittings (2-51)
    • Cleaning air cleaner primary element (2-54)
    • Adjusting fan belt tension (2-55)
    • Adjusting brake pedal (2-55)
    • Checking gear locked parking brake (2-58)
    • Checking battery condition (2-58)
    • Charging battery (2-58)
    • Adjusting air conditioner belt tension (2-58)
    • Adjusting air conditioner belt tension (2-59)
  • Check points of every 200 hours (2-60)
    • Adjusting toe-in (2-60)
    • Draining fuel tank water (2-60)
    • Cleaning inner air filter (2-61)
    • Cleaning fresh air filter (2-61)
    • Cleaning air conditioner condenser (2-62)
  • Check points of every 400 hours (2-62)
    • Cleaning water separator (2-62)
    • Lubricating grease fitting (2WD model) (2-63)
  • Check point of every 500 hours (2-63)
    • Changing engine oil (2-63)
    • Replacing engine oil filter (2-64)
    • Replacing fuel filter (2-65)
    • Replacing hydraulic oil filter (2-65)
    • Checking power steering line (2-66)
    • Checking radiator hose and hose clamp (2-65)
    • Checking radiator hose and hose clamp (2-67)
    • Checking fuel line (2-68)
    • Checking intake air line (2-69)
    • Checking air conditioner pipe and hose (2-69)
  • Check points of every 600 hours (2-69)
    • Adjusting front axle pivot (2-69)
  • Check point of every 1000 hours (2-69)
    • Changing transmission fluid (2-69)
    • Changing front differential case oil (2-70)
    • Changing front axle gear case oil (2-71)
    • Adjusting valve clearance (2-71)
  • Check points of every 1000 hours or 1 year (2-72)
    • Replacing air cleaner primary element and secondary element (2-72)
    • Checking exhaust manifold (2-72)
  • Check points of every 1500 hours (2-73)
    • Checking fuel injector nozzle tip (2-73)
    • Checking DEF/AdBlue® injector tip (2-73)
    • Checking DEF/AdBlue® injector tip (2-73)
    • Checking DEF/AdBlue® line (2-73)
    • Replacing oil separator element (2-73)
    • Checking positive crankcase ventilation (PCV) valve (2-74)
    • Checking and cleaning EGR cooler (2-74)
  • Check points of every 2000 hours or 2 years (2-75)
    • Flushing cooling system and changing coolant (2-75)
    • Antifreeze (2-76)
  • Check points of every 3000 hours (2-76)
    • Checking exhaust gas leakage of turbine side (2-76)
    • Checking air leakage of compressor side (2-77)
    • Checking radial clearance (2-77)
    • Checking supply pump (2-77)
    • Checking intake air heater (2-77)
    • Checking and cleaning EGR system (2-77)
    • Cleaning DPF muffler (2-78)
    • Checking DEF/AdBlue® injector (2-78)
    • Replacing DEF/AdBlue® pump filter (ROPS model) (2-79)
    • Replacing DEF/AdBlue® pump filter (Cabin model) (2-79)
  • Check points of every 8000 hours (2-80)
    • Replacing DEF/AdBlue® tank filter (2-80)
  • Every 3 months (2-80)
    • Checking the quality of DEF (AdBlue) (2-80)
  • Check points of every 1 year (2-80)
    • Checking antifrost heater of oil separator (if equipped) (2-80)
    • Checking CAB isolation cushion (CAB model) (2-81)
    • Checking DPF related pipe (2-81)
    • Checking EGR pipe (2-81)
    • Checking EGR pipe (2-82)
  • Check points of every 2 years (2-82)
    • Cleaning master cylinder filter (2-82)
    • Replacing oil separator related rubber pipe (2-82)
    • Replacing DPF related rubber pipe (2-83)
    • Replacing EGR cooler rubber pipe (2-84)
    • Replacing boost sensor hose (2-84)
  • Check point of every 4 years (2-84)
    • Replacing radiator hose (Water pipes) (2-84)
    • Replacing fuel hose (2-86)
    • Replacing intake air line (2-86)
    • Replacing power steering hose (2-87)
    • Replacing lift cylinder hose (2-87)
    • Replacing master cylinder kit (2-87)
    • Replacing brake seal 1 and (2-87)
    • Replacing air conditioner hose (2-87)
  • Others (2-87)
  • Others (2-87)
    • Bleeding fuel system (ROPS model) (2-87)
    • Bleeding fuel system (Cabin model) (2-88)
    • Bleeding brake system (2-89)
    • Draining clutch housing water (ROPS model) (2-90)
    • Draining clutch housing water (Cabin model) (2-90)
    • Checking fuse (ROPS model) (2-90)
    • Checking slow blow fuse (ROPS model) (2-91)
    • Checking fuse (Cabin model) (2-92)
    • Checking slow blow fuses (Cabin model) (2-94)
    • Replacing light bulb (ROPS model) (2-95)
    • Replacing light bulb (Cabin model) (2-95)
    • Replacing head lamp (2-95)
    • Lubricating points (Cabin model) (2-96)
    • Adding washer liquid (Cabin model) (2-96)
    • Checking the amount of refrigerant (Gas) (2-96)
• SPECIAL TOOLS (2-97)
  • Diesel engine compression tester (2-97)
  • Oil pressure tester (2-97)
  • Small end bushing replacing tool (2-97)
  • Idle gear bushing replacing tool (2-98)
  • Gear case cover oil seal press fit tool (2-98)
  • Valve guide replacing tool (2-98)
  • Crankshaft sleeve press fit tool (2-99)
  • Supply pump gear puller (2-100)
  • Supply pump gear reinstall jig (2-100)
  • Flywheel stopper (2-101)
  • Compression tester adapter (2-103)
  • Jig 1 for measuring air gap of the crankshaft position sensor (2-105)
  • Jig 2 for measuring air gap of the crankshaft position sensor (2-106)
  • Rotation sensor signal interface unit (2-107)
  • Balancer bushing replacing tool 1 assembly (2-108)
  • Balancer bushing replacing tool 1 components parts (2-108)
  • Balancer bushing replacing tool (2-109)
  • Balancer bushing replacing tools 3, 4, (2-109)
  • Balancer bushing tool components parts (2-110)
  • Engine stand (2-113)
  • Nozzle adaptor for measuring cylinder compression pressure (2-115)
  • DEF header unit replacing tool (2-117)
• Tie rod end lifter (2-117)
• Steering wheel puller (2-117)
• Relief valve pressure tester (2-117)
• Flowmeter (2-118)
• Adaptor set for flowmeter (2-118)
• Toe-in gauge (2-118)
• Injector CH3 (2-118)
• Brake air bleeder (2-119)
• Relief valve setting pressure adaptor G (2-119)
• Pressure gauge (2-119)
• Power steering adaptor (2-119)
• Front axle rocking restrictor (2-119)
• Sliding hammer (2-120)
• Adaptor (M6) for sliding hammer (2-121)
• LSD adaptor (2-120)
• LSD adaptor (2-121)
• Hydraulic clutch spring compressor (2-123)
• Locking wrench (2-127)
• Bevel gear shaft (8T) tool (2-127)
• Hydraulic arm shaft bushing press-fitting tool (2-128)
• Draft control test bar (2-128)
• Hydraulic cylinder piston sealing tool (2-128)
• Cylinder safety valve setting pressure adaptor (2-129)
• Oil cooler relief valve setting pressure adaptor (2-132)
• Valve adaptor (2-133)
• Hydraulic brake adaptor (2-134)
• Tools for dismounting cabin (2-135)
• Propeller shaft sleeve fitting tool (2-142)
• Arbor for oil seal of propeller shaft (2-142)
• Propeller shaft oil seal fitting tool (2-142)
  • Air conditioner service tool
  • Air conditioner service tool (2-144)
  • Electric gas leak tester (2-145)
  • Vacuum pump (2-145)
  • Magnetic clutch stopper (for A/C compressor) (2-146)
  • Stopper bolt (for A/C compressor) (2-147)
• Front wheels (2WD model) (2-150)
• Front wheels (4WD model) (2-152)
• Rear wheels (2-154)
  • Preparation of calcium chloride solution 2-
  • Attaching injector (2-157)
  • Injecting liquid (2-158)
  • Draining water or solution (2-159)
• IMPLEMENT LIMITATIONS (2-161)

3. ENGINE

• MECHANISM (3-1)
  • Feature of cylinder block (3-1)
  • Feature of cylinder head (3-1)
  • Feature of piston (3-1)
  • Feature of oil cooler (3-1)
  • Feature of oil cooler (3-2)
• Feature of thermostat (3-2)
• Feature of bottom bypass system (3-3)
  • Overview of common rail system (3-3)
  • Supply pump (3-4)
    • Function of supply pump (3-4)
    • Function of feed pump (3-4)
    • Function of pre-stroke control valve (PCV) (3-4)
    • Function of pump unit (3-5)
    • Function of delivery valve (3-5)
  • Function of rail for common rail system (3-6)
  • Injector (3-6)
    • Function of injector (3-6)
    • Operation of injector (3-6)
    • Operation of injector (3-7)
    • Function of injector drive circuit (3-9)
    • Function of injector QR/ID codes (3-9)
    • When replacing an injector (3-9)
    • When replacing the engine ECU (3-9)
  • Structure of engine control system (3-10)
    • Function of engine ECU (3-12)
    • Function of crankshaft position sensor (3-12)
    • Function of camshaft position sensor (3-13)
    • Pulse chart of the crankshaft position sensor output signal and camshaft position sensor
    • Function of temperature sensors (3-14)
    • Function of boost sensor (3-14)
  • Overview of EGR system (3-15)
  • EGR valve (3-16)
    • Function of water cooled EGR valve (3-15)
    • Function of water cooled EGR valve (3-16)
    • Function of EGR valve lift sensor (3-16)
  • Function of reed valve (3-16)
  • Overview of after treatment devices (3-17)
  • Outline of the SCR system (3-18)
  • DPF regeneration process (3-19)
  • PM warning level (3-20)
  • Auto regeneration mode (3-21)
  • Regeneration inhibit mode (3-22)
  • Function of diesel oxidation catalyst (DOC) (3-23)
  • Function of diesel particulate filter (DPF) (3-23)
  • Function of diesel particulate filter (DPF) (3-23)
  • Function of intake throttle valve (3-24)
  • Function of air flow sensor (3-24)
  • Function of temperature sensor (3-24)
  • Function of differential pressure sensor (3-24)
  • Function of oil separator (3-25)
  • Function of selective catalytic reduction (SCR) (3-25)
  • Function of diesel exhaust fluid (DEF) pump (3-26)
  • Function of DEF injector (3-26)
  • Function of DEF tank (3-26)
  • Function of coolant valve (3-27)
  • Function of after treatment control unit (ACU) (3-27)
• SERVICING (3-29)
  • Checking and adjusting (3-40)
    • Engine body (3-40)
    • Lubricating system (3-42)
    • Cooling system (3-43)
    • Turbocharger (3-44)
    • EGR system (3-45)
    • DPF system (3-45)
  • Preparation for separating engine (3-46)
    • Lubricant and coolant (3-46)
    • Propeller shaft (3-47)
    • ROPS model (3-48)
    • Cabin model (3-55)
    • ROPS - Low Profile model (3-48)
    • ROPS - Low Profile model (3-61)
  • Separating engine from clutch housing (3-66)
    • ROPS model (3-66)
    • Cabin model (3-72)
    • ROPS - Low Profile model (3-80)
  • Separating engine from front axle frame (3-88)
    • Separating engine from front axle frame (Cabin model) (3-88)
    • Separating engine from front axle frame (ROPS Low Profile model) (3-88)
  • Disassembling and assembling (3-89)
    • Damper disk (3-89)
    • External parts (3-89)
    • Oil separator (3-90)
    • Turbocharger and EGR (3-94)
    • Common rail (3-95)
    • Cylinder head and valve (3-99)
    • Thermostat (3-106)
    • Supply pump (3-99)
    • Supply pump (3-106)
    • Water pump and oil cooler (3-108)
    • Gear case and timing gear (3-109)
    • Piston and connecting rod (3-112)
    • Flywheel and crankshaft (3-116)
    • Intake air heater (3-120)
  • Servicing (3-121)
    • Cylinder head (3-121)
    • Timing gears (3-128)
    • Piston and connecting rod (3-132)
    • Crankshaft (3-135)
    • Cylinder (3-138)
    • Oil pump (3-139)
    • Replacing (3-140)

4. TRANSMISSION

• MECHANISM (4-1)
  • F8/R8 speed transmission model (4-2)
  • F12/R12 speed transmission model (4-3)
  • F24/R24 speed transmission model (4-4)
  • Hydraulic shuttle shift section (4-5)
    • Structure of hydraulic shuttle (4-5)
    • Oil flow of hydraulic shuttle (4-6)
    • Power train of shuttle shift section (4-6)
  • Main gear shift section (4-8)
    • Main gear shift section (F8/R8 speed transmission model) (4-8)
    • Main gear shift section (F12/R12, F24/R24 speed transmission model) (4-10)
  • Range gear shift section (4-8)
  • Range gear shift section (4-11)
    • Range gear shift section (F8/R8 speed transmission model) (4-11)
    • Structure of range gear shift section (4-12)
    • Range / creep gear shift section (Option) (4-13)
  • Shift fork rod and fork (4-14)
    • Shift fork rod and fork (F8/R8 speed transmission model) (4-14)
    • Structure of shift fork rod and fork (4-15)
    • Structure of creep gear shift section (Option) (4-16)
  • Dual speed shift section (4-17)
    • Structure of dual speed section (4-17)
    • Structure of dual speed valve (4-18)
• Structure of PTO gear section (4-21)
• PTO hydraulic clutch section (4-23)
  • Structure of PTO hydraulic clutch (4-23)
    • Structure of PTO s
    • Structure of PTO solenoid valve, relief valve and oil flow (4-23)
  • 4WD shift section (4-24)
    • 2WD - 4WD section (4-24)
    • 2WD - 4WD shift linkage (4-25)
  • 4WD hydraulic clutch section (Dual speed model) (4-26)
    • 4WD hydraulic clutch (4-26)
    • 4WD oil flow (4-27)
  • Pin type (4-28)
  • Hydraulic actuated type (4-29)
    • Structure of differential lock (Hydraulic actuated type) (4-29)
    • Oil flow of differential lock (Hydraulic actuated type) (4-31)
• SERVICING (4-33)
• Clutch pedal free travel (4-41)
  • Adjusting clutch pedal free travel (4-41)
• Gear shifting linkage (4-42)
  • Main gear shift (4-42)
    • Range / creep gear shift (4-45)
• Accelerator section (4-47)
  • Checking hand accelerator lever operating force (4-47)
    • Checking accelerator pedal (4-48)
• Hydraulic clutch valve (4-49)
  • Checking shuttle clutch valve system pressure (4-49)
    • Checking PTO clutch valve operating pressure (4-52)
    • Checking 4WD clutch valve operating pressure (F24/R24 speed transmission model)
    • Checking dual speed clutch valve operating pressure (F24/R24 speed transmission model)4-54
  • Hydraulic shuttle valve (4-55)
    • Preparation for disassembling and assembling valve (4-55)
    • Accessing hydraulic shuttle valve (4-57)
    • Removing hydraulic shuttle valve assembly (4-63)
  • Solenoid valve (4-63)
    • Removing solenoid valve assembly (F8/R8, F12/R12 speed transmission model) (4-63)
    • Removing solenoid valve assembly (F24/R24 speed transmission model) (4-64)
  • Dual speed solenoid valve (4-64)
    • Removing dual speed solenoid valve assembly (F24/R24 speed transmission model) (4-64)
  • Preparation for separating each block (4-65)
    • Lubricant and coolant
    • Lubricant and coolant (4-65)
    • Front axle rocking restrictor (4-66)
    • Removing propeller shaft (4WD model) (4-67)
  • Separating engine and clutch housing case (4-67)
    • ROPS model (4-67)
    • Cabin model (4-78)
    • ROPS - Low Profile model (4-91)
  • Separating clutch housing case and transmission case (4-103)
    • Preparation for ROPS model (4-103)
    • Preparation for Cabin model (4-113)
    • Preparation for ROPS - Low Profile model (4-114)
    • Clutch housing case (4-125)
    • Transmission case (4-129)
  • Shuttle and dual speed clutch (4-132)
    • Removing hydraulic shuttle clutch (4-132)
    • Shuttle clutch assembly (4-136)
    • Removing dual speed clutch
    • Removing dual speed clutch (4-141)
  • Shift cover (4-143)
    • Removing shift cover (4-143)
    • Disassembling main shift fork (F8/R8 speed transmission model) (4-144)
    • Disassembling main shift fork (F12/R12, F24/R24 speed transmission model) (4-145)
    • Disassembling range gear shift fork (4-146)
    • Removing main shift arm (4-146)
    • Disassembling range shift arm (4-147)
    • Disassembling creep gear assembly (option) (4-148)
  • Disassembling clutch housing case (4-148)
    • Removing 1st shaft, 2nd shaft and 3rd shaft (4-148)
    • 1st shaft (4-152)
    • 2nd shaft and 3rd shaft (4-159)
    • 4WD propeller shaft (4-160)
    • Creep gear (4-162)
  • Disassembling transmission case (4-163)
    • Removing PTO clutch pack (4-162)
    • Removing PTO clutch pack (4-163)
    • Disassembling PTO clutch pack (4-163)
    • Removing 4WD clutch (4-167)
    • Disassembling 4WD clutch pack (4-167)
    • Removing differential gear and bevel pinion shaft (4WD model) (4-169)
    • Differential gear (4-171)
    • Differential lock piston (4-173)
  • PTO gear case (4-173)
    • Disassembling PTO gear case (540 type) (4-173)
    • Disassembling PTO gear case (540/540E shift type) (4-174)
    • Disassembling PTO gear case (540/1000 interchangeable type) (4-176)
  • Bearing (4-176)
    • Checking ball bearing (4-176)
    • Checking split type needle bearing (4-176)
    • Checking taper roller bearing (4-176)
  • Shift fork and synchronizer (4-177)
    • Checking clearance between shift fork and shifter groove (4-177)
    • Checking smooth sliding and moving of coupling and shifter (4-177)
    • Checking wear on synchronizer key and spring (4-177)
  • Travelling clutch (4-177)
    • Checking displacement around damper disc edge (4-177)
    • Checking clearance between inching lever pin and lever bushing (4-178)
  • Shuttle clutch pack (4-178)
    • Checking clearance between internal circlip and belleville washer (Cupped spring
  • Dua (4-178)
  • Dual speed clutch pack (4-179)
    • Checking clearance between internal circlip and pressure plate for dual speed clutch pack4-179
  • Shaft and gear (4-180)
    • Checking side clearance of 1st shaft (4-180)
  • PTO clutch pack (4-181)
    • Checking PTO clutch disc wear (4-181)
    • Checking PTO steel plate wear (4-181)
    • Checking flatness of PTO piston and PTO steel plate (4-182)
    • Checking PTO clutch back plate (4-182)
    • Checking piston return spring free length (4-182)
    • Checking seal ring thickness of PTO clutch pack (4-182)
  • Solenoid valve (4-183)
    • Checking PTO solenoid valve (F8/R8, F12/R12 speed transmission model) (4-183)
    • Checking PTO, 4WD and rear differential lock solenoid valve (F24/R24 speed
    • Checking dual speed solenoid valve (F24/R24 speed transmission model) (4-184)
  • 4WD clutch pack (4-185)
    • Checking clutch disk (4-184)
    • Checking clutch disk wear (4-185)
    • Checking steel plate and pressure plate wear (4-185)
    • Checking flatness of piston, steel plate and pressure plate (4-185)
    • Checking thickness of seal ring (4-185)
  • Hydraulic pump drive gear (4-186)
    • Checking backlash between 18T bevel gear and 19T bevel gear (4-186)
  • Differential gear (4-186)
    • Spiral bevel pinion shaft (4-186)
    • Backlash and tooth contact (4-187)
    • Differential case differential pinion gear and differential side gear (4-188)

5. REAR AXLE

• MECHANISM (5-1)
• SERVICING (5-3)
  • Preparation for disassembling and assembling valve (5-6)
    • Draining transmission fluid (5-6)
    • Draining fuel (5-6)
    • Disconnecting battery negative cable (5-7)
    • Installing front axle rocking restrictor (5-7)
  • Separating rear axle (5-7)
    • ROPS model (5-7)
    • Cabin model (5-11)
    • Low Profile model (5-16)
  • Disassembling rear axle (5-21)
    • Brake section (5-21)
    • Rear axle case (5-23)
• Bearing (5-25)
  • Checking ball bearing (5-25)
    • Checking needle bearing (5-25)
• Planetary gear (5-25)
  • Checking backlash between internal gear and planetary gear (5-25)
    • Measuring thrust collar thickness (5-25)
    • Measuring clearance between planetary gear and planetary gear shaft (5-25)

6. BRAKES

• MECHANISM
• MECHANISM (6-1)
  • Structure of traveling brake (6-1)
  • Function of master cylinder assembly (6-2)
  • Structure of gear locked parking brake (6-3)
• SERVICING (6-5)
  • Checking and adjusting (6-9)
    • Traveling brake (6-9)
    • Parking brake (6-12)
  • Disassembling and assembling (6-14)
    • Preparation
    • Preparation for disassembling master cylinder and brake pedal (6-14)
    • Removing master cylinder (6-18)
    • Master cylinder (6-20)
    • Brake pedal (6-21)
    • Brake piston (6-22)
    • Brake disc and plate (6-22)
    • Parking brake gear (6-25)
  • Servicing (6-26)
    • Brake pedal (6-26)
    • Traveling brake (6-27)

7. FRONT AXLE

• MECHANISM (7-1)
  • Structure (2WD model) (7-2)
  • Structure of 4 wheel drive (7-3)
  • Function of limited slip differential (LSD) (7-4)
• SERVICING
• SERVICING (7-5)
  • Checking and adjusting (7-9)
    • Checking toe-in (7-9)
    • Adjusting toe-in (7-9)
    • Checking axial sway of front wheel (7-9)
    • Adjusting front axle pivot (7-10)
    • Adjusting between bevel gear case and stopper (4WD model) (7-10)
  • Disassembling and assembling (7-11)
    • Separating front axle (7-11)
    • Disassembling front axle (7-14)
    • Removing differential gear and bevel pinion shaft (4WD model) (7-19)
    • Disassembling differential gear (LSD) (4WD model) (7-20)
  • Servicing (7-22)
    • Servicing front axle (2WD model) (7-22)
    • Servicing front axle (4WD model) (7-23)

8. STEERING

• MECHANISM (8-1)
• SERVICING (8-3)
  • Checking and adjusting (8-7)
    • Steering controller (8-7)
  • Disassembling and assembling (8-7)
    • Removing steering controller (8-7)
    • Steering controller (8-13)
    • Removing power steering cylinder (8-16)
    • Disassembling steering cylinder (8-19)
  • Servicing (8-19)
    • Checking steering cylinder I.D (8-19)
    • Checking clearance between rod and bushing (8-20)

9. HYDRAULIC SYSTEM

• MECHANISM (9-1)
  • F8/R8, F12/R12 speed transmission model (ROPS model) (9-1)
  • F8/R8, F12/R12 speed transmission model (ROPS model) (9-2)
  • F8/R8, F12/R12 speed transmission model (Cabin model) (9-3)
  • F24/R24 speed transmission model (9-4)
  • Total hydraulic circuit (9-6)
    • F8/R8, F12/R12 speed transmission model (9-6)
    • F24/R24 speed transmission model (9-7)
  • Three point hitch hydraulic system (9-8)
    • Outline of three point hitch hydraulic circuit diagram (9-8)
    • Structure of hydraulic block (9-9)
    • Linkage mechanism (9-10)
    • Feature of hydraulic cylinder (9-15)
• SERVICING (9-17)
  • Hydraulic pump (9-21)
    • Checking hydraulic flow (Hydraulic pump for power steering) (9-21)
    • Checking hydraulic flow (Hydraulic pump for 3-point hitch) (9-21)
  • Relief and safety valve (9-22)
    • Checking relief valve setting pressure with pressure tester (9-22)
    • Checking safety valve setting pressure using injection nozzle tester (9-23)
  • Position and draft control linkage (9-24)
    • Adjusting position and draft control cable (9-24)
    • Adjusting position and draft lever rods (ROPS Low Profile model) (9-25)
    • Adjusting position feedback rod and draft feedback rod
    • Adjusting position control (9-25)
    • Adjusting uppermost position of lift arm (9-26)
    • Adjusting draft control (9-27)
    • Adjusting draft lever free range (9-28)
    • Adjusting draft floating range (9-29)
    • Adjusting position and draft control lever operating force (9-30)
  • Auxiliary control valve linkage (9-31)
    • ROPS model (9-31)
    • Cabin model (9-31)
  • Oil cooler check valve (9-32)
    • Checking operating pressure of oil cooler check valve (9-32)
  • Hydraulic pump
  • Hydraulic pump (9-33)
    • Removing hydraulic pump assembly (9-33)
    • Disassembling hydraulic pump (9-34)
  • Removing top cover (3-point hitch hydraulic block) (9-34)
    • ROPS model (9-34)
    • Cabin model (9-36)
  • Hydraulic linkage (9-39)
    • Removing position linkage and draft linkage (9-39)
    • Removing linkage bracket (9-40)
    • Removing draft lever rod and position lever rod (9-40)
    • Removing draft lever 3 and position lever (9-40)
    • Removing position feedback rod and draft rod (9-41)
    • Removing draft spool lever and position spool lever (9-41)
    • Removing position and draft control shaft and position and draft feedback shaft (9-42)
  • Control valve (9-42)
    • Removing control valve (9-42)
    • Removing plug and unload valve (9-42)
    • Removing plug and unload valve (9-43)
    • Removing spool and poppet valve (9-44)
    • Removing check valve (9-44)
  • Hydraulic cylinder (9-45)
    • Removing hydraulic cylinder (9-45)
    • Disassembling hydraulic cylinder (9-45)
    • Installing piston seal (9-46)
  • Relief valve (9-46)
    • Disassembling relief valve (9-46)
  • Safety valve (9-47)
    • Disassembling safety valve (9-47)
  • Top link bracket (9-47)
    • Disassembling top link bracket (9-47)
  • Lift arm and lift arm shaft (9-48)
    • Removing lift arm and lift arm shaft (9-48)
  • Lowering speed adjusting valve (9-48)
    • Removing lowering s
    • Removing lowering speed adjusting valve (ROPS model) (9-48)
    • Removing lowering speed adjusting valve (Cabin model) (9-49)
  • Lift arm and top link bracket (9-50)
    • Checking lift arm support bushing (9-50)
    • Checking torsion bar and top link bracket (9-51)

10. ELECTRICAL SYSTEM

• MECHANISM (10-1)
  • ROPS model (10-2)
    • Electrical component location on main harness 1 (ROPS model) (10-2)
    • Electrical component location on main harness 2 (ROPS model) (10-3)
    • Electrical component location on head light harness (ROPS model) (10-4)
    • Electrical component location on body harness (ROPS model) (10-5)
  • Cabin model (10-6)
    • Electrical component location on engine harness 1 (Cabin model) (10-6)
    • Electrical component location on engine harness 2 (Cabin model) (10-7)
    • Electrical component location on main harness (Cabin model) (10-8)
    • Electrical component location on body harness (Cabin model) (10-9)
    • Electrical component location on cabin harness (Cabin model) (10-10)
  • ROPS model (10-11)
    • Starting system and charging system (ROPS model) (10-11)
    • Engine control system (Engine ECU) (ROPS model) (10-12)
    • Engine control system (ACU) (ROPS model) (10-13)
    • Lighting system (ROPS model) (10-14)
    • Instrument panel (ROPS model)
    • Instrument panel (ROPS model) (10-15)
    • Main control system (Tractor ECU) (ROPS model) (10-16)
  • Cabin model (10-17)
    • Starting system and charging system (Cabin model) (10-17)
    • Starting system and charging system (Option) (Cabin model) (10-19)
    • Engine control system (Engine ECU) (Cabin model) (10-21)
    • Engine control system (ACU) (Cabin model) (10-22)
    • Lighting system (Cabin model) (10-23)
    • Instrument panel (Cabin model) (10-24)
    • Main control system (Tractor ECU) (F8/R8, F12/R12 speed transmission model) (Cabin
    • Main contorl system (Tractor ECU) (F24/R24 speed transmission model) (Cabin model) (10-26)
    • Air conditioner system (Cabin model) (10-27)
  • System outline and electrical circuit (10-29)
    • Electrical circuit of starting system (ROPS model) (10-29)
    • Electrical circuit of starting system (Cabin model) (10-30)
  • Components
  • Components (10-32)
    • Function of intake air heater (10-32)
    • Intake air heater relay (10-32)
  • Indication items of meter panel (10-33)
    • Instrument panel (10-33)
    • Easy Checker™ (10-34)
    • Fuel gauge (10-35)
    • DEF/AdBlue® gauge (10-35)
    • Coolant temperature gauge (10-35)
    • Function of tachometer (10-35)
    • LCD monitor (10-36)
  • ECO 40 km/h function (10-42)
    • Structure of ECO 40 km/h function (10-42)
    • Components (10-42)
    • Components (10-44)
  • Constant RPM management switch with indicator (Work cruise) (10-47)
    • Structure of constant RPM management switch with indicator (Work cruise) (10-47)
    • Constant RPM management mechanism (10-48)
  • Electronic hydraulic shuttle (10-49)
    • Structure of electronic hydraulic shuttle (10-49)
    • Components (10-50)
  • PTO speed limiter (If equipped 540 Economy) (10-51)
    • Checking PTO speed limiter (If equipped 540 Economy) (10-51)
    • Components (10-52)
  • Components (10-54)
    • Flasher unit (10-54)
• SERVICING (10-57)
  • Diagnostic trouble code for VCU (10-63)
  • Diagnostic trouble code for ECU (10-64)
  • Diagnostic trouble code for ACU (10-79)
  • Checking, setting and adjusting by using instrument panel (10-100)
    • Mode and item selection
    • Mode and item selection (10-101)
    • Mode [TST] (10-103)
    • Mode [CHK] (10-105)
    • Mode [SEL] (10-108)
    • Mode [ADJ] (10-112)
    • Various setting mode (10-115)
  • Checking, setting and adjusting by using diagnostic tool (10-118)
    • Connection port of diagnostic tool (10-118)
  • Battery, fuses, grounding and connector (10-118)
    • Battery (10-118)
    • Fuse (10-120)
    • Checking grounding wires (10-125)
    • Connector (10-126)
  • Starting system (10-126)
    • Main switch (10-126)
    • Starter motor (10-126)
    • Starter motor (10-130)
    • Shuttle lever neutral switch (10-131)
    • Shuttle valve spool neutral switch (10-132)
    • PTO switch (10-133)
  • Intake air heater (10-134)
    • Checking intake air heater (10-134)
  • Alternator (10-135)
    • Preparing for checking alternator (10-135)
    • Measuring connector voltage for alternator (10-135)
    • Measuring connector voltage for alternator (No load) (10-136)
  • ECU (10-137)
    • Meter ECU (10-137)
    • Tractor ECU (10-137)
    • Engine ECU (10-140)
    • ACU (10-146)
  • Traveling switch and sensor (10-149)
    • Main gear shift (6th) switch (10-146)
    • Main gear shift (6th) switch (10-149)
    • Range gear shift (High) switch (10-149)
    • Shuttle valve spool neutral switch (10-150)
    • Rear differential lock switch (F24/R24 speed transmission model) (10-151)
    • Foot brake switch (F24/R24 speed transmission model) (10-153)
    • Gear lock parking lever switch (10-153)
    • Gear lock parking brake switch (10-154)
    • 4WD ON-OFF switch (except F24/R24 speed transmission model) (10-156)
    • 4WD switch (F24/R24 speed transmission model) (10-157)
    • Main shift lever switch (F24/R24 speed transmission model) (10-159)
    • Traveling speed sensor (10-160)
    • Shuttle lever sensor (10-161)
    • Shuttle rotation sensor (F12/R12, F24/R24 speed transmission model) (10-161)
  • Engine control system (10-162)
    • Injector (10-162)
    • Pre-stroke control valve (PCV) (10-163)
    • Rail pressure sensor (10-164)
    • Pressure reducing valve (PRV) (10-165)
    • Fuel pump (10-165)
    • Sedimenter (10-166)
    • Boost pressure sensor (10-166)
    • Intake air temperature sensor (10-167)
    • EGR valve (10-168)
    • Crankshaft position sensor (10-168)
    • Camshaft position sensor (10-169)
    • Air flow sensor (10-169)
    • Coolant temperature sensor (10-170)
    • Intake throttle valve (10-171)
    • Exh (10-169)
    • Exhaust gas temperature sensor (10-172)
    • DPF differential pressure sensor (10-173)
    • Throttle sensor (10-173)
    • Parked regeneration switch (10-175)
    • DPF INHIBIT switch (10-176)
    • Constant RPM management switch (10-176)
    • RPM dual memory switch (ROPS model) (10-177)
    • RPM dual memory switch (Cabin model) (10-179)
    • Fuel level sensor (10-180)
    • NOx sensor (10-181)
    • SCR temperature sensor (10-182)
    • DEF tank unit (10-183)
    • DEF pump unit (10-183)
    • DEF tank heater coolant valve (10-184)
    • CCV heater (10-185)
  • Relays (10-186)
    • Intake air heate (10-185)
    • Intake air heater relay (10-186)
    • Relays (10-187)
  • Lighting switches and flasher unit (10-191)
    • Combination switch and lever (ROPS model) (10-191)
    • Combination switch and lever (Cabin model) (10-192)
    • Hazard switch (10-193)
    • Flasher unit (10-195)
    • Front work light switch (ROPS model) (10-196)
    • Front / Rear work light (Cabin model) (10-196)
  • Solenoid valve (10-197)
    • Shuttle valve (10-197)
    • PTO (F8/R8, F12/R12 speed transmission model) (10-198)
    • PTO, 4WD and rear differential lock (F24/R24 speed transmission model) (10-200)
    • Dual speed (F24/R24 speed transmission model) (10-201)
  • Operator presence control (OPC) (10-202)
    • Checking OPC system (10-202)
    • Checking seat switch (10-202)
    • Checking seat switch (10-203)
  • Others (10-203)
    • Display select switch (10-203)
    • PTO speed select switch (10-204)
    • Buzzer (10-205)
  • Starter motor (10-206)
    • Disassembling starter motor (10-206)
  • Alternator (10-207)
    • Disassembling front bracket (10-207)
    • Disassembling pulley (10-207)
    • Disassembling rotor (10-207)
    • Disassembling brush (10-207)
    • Reassembling brush (10-208)
    • Disassembling bearing at slip ring side (10-208)
  • Fuse (Slow blow 100 A) for Cabin model (10-209)
    • Removing fuse (10-209)
  • Starter (10-209)
    • Checking mica undercut of starter commutator (10-209)
    • Measuring brush wear (10-210)
    • Checking armature coil (10-210)
    • Checking overrunning clutch (10-210)
    • Checking brush holder (10-211)
    • Checking field coil (10-211)
  • Alternator (10-211)
  • Alternator (10-211)
    • Checking bearing (10-211)
    • Checking stator (10-211)
    • Checking rotor (10-212)
    • Checking slip ring (10-212)
    • Checking brush wear (10-212)
    • Checking rectifier (10-213)

11. CABIN

• MECHANISM (11-1)
  • Structure of air conditioning system (11-1)
  • Structure of compressor (11-3)
    • Operation of compressor (11-3)
    • Property of compressor oil (11-3)
  • Feature of air conditioner unit (11-3)
    • Feature of A/C blower (11-4)
  • System control of air conditioner (11-3)
  • System control of air conditioner (11-5)
  • Air flow (11-6)
    • Outline of air flow (11-6)
  • Air control vent (11-6)
    • Feature of dashboard air outlet (11-6)
  • Electrical system (11-7)
    • Electrical circuit of air conditioner (11-7)
    • Outline of blower relay and compressor relay (11-8)
    • Blower relay (11-9)
• SERVICING (11-11)
  • Setting manifold gauge (11-19)
  • Refrigerant charging hose (11-18)
  • Refrigerant charging hose (11-20)
  • Objective of vacuum pump adaptor (11-21)
  • Outline of electric gas leak tester (11-22)
  • Operating can tap valve (11-22)
  • Installing T-joint (11-22)
  • Necessity of R134a refrigerant recovery and recycling machine (11-22)
  • Checking refrigerant cycle with manifold gauge (11-23)
    • Connecting manifold gauge for test preparation (11-23)
    • Outline of normal operating (11-23)
    • Insufficient refrigerant (11-24)
    • Excessive refrigerant or insufficient condenser cooling
    • Air entered in cycle (11-25)
    • Moisture entered in cycle (11-25)
    • Refrigerant fails to circulate (11-26)
    • Expansion valve opens too far or improper installation of heat sensitizing tube (11-26)
    • Damaged compression of compressor (11-26)
  • Discharging, evacuating and charging (11-27)
    • Discharging refrigerant (11-27)
    • Evacuating system (11-29)
    • Charging refrigerant (11-30)
    • Checking charging refrigerant amount (11-31)
  • Checking and adjusting (11-32)
    • Compressor (11-32)
    • Relay (A/C compressor, blower, work light, defoger and auxiliary power) (11-33)
    • Control panel (Blower switch, A/C switch, mode control dial, temperature control dial,
    • Blower resistor (11-39)
    • Blower motor (11-39)
    • Temperature motor (11-40)
    • Mode motor (11-40)
    • Recirculation / fresh air motor (11-41)
    • Pressure switch (11-41)
    • Front wiper switch (11-42)
    • Front wiper motor (11-43)
    • Rear wiper switch (If equipped) (11-44)
    • Rear wiper motor (If equipped) (11-44)
  • Disassembling and assembling (11-45)
    • Separating cabin from tractor (11-45)
    • Removing compressor assembly (11-62)
    • Removing air conditioner unit (11-67)
    • Removing air conditioner hose (11-72)
    • Removing heater hoses
    • Removing heater hoses (11-76)
    • Cab windshield (11-79)
    • Wiper motor (11-81)
  • Servicing (11-83)
    • Adjusting air gap of magnetic clutch (between hub plate and rotor) (11-83)
• DANGER
• WARNING
• CAUTION
• IMPORTANT
• SAFETY DECALS

References

Kubota Workshop Manual for Tractor, document code 9Y111-12857, PDF edition.