Kubota R540 Workshop Manual — RY911-29302

About this manual

Kubota published this Workshop Manual for the R540 wheel loader models. It brings the documented service and technical-reference material for those named wheel loaders into a single publication.

The manual is especially useful for work that crosses electrical and hydraulic systems: it includes electrical troubleshooting with connector views and pinouts, alongside hydraulic diagrams, pressure-test evidence, and valve-adjustment information.

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

Manual details

Manufacturer

Kubota

Manual type

Workshop Manual

Models

R540

Document number

RY911-29302

Language

English

Page count

649

Product highlights

Manual contents

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

• CONTENTS — p. 4
• 1. SAFETY — p. 17
  • SAFETY FIRST — p. 18
    • 1. Working precautions — p. 18
    • 2. Preparing for emergencies — p. 18
    • 3. Working cautions — p. 19
    • 4. Starting machine safely — p. 19
    • 5. Preventing fires — p. 20
    • 6. Preventing acid burns — p. 20
    • 7. Avoiding high pressure fluid — p. 20
    • 8. Avoiding hot exhaust — p. 21
    • 9. Cleaning exhaust filter — p. 21
  • SAFETY LABELS — p. 22
    • 1. Safety labels placement — p. 22
    • 2. Safety labels maintenance — p. 28
• 2. GENERAL — p. 29
  • GENERAL WORKING INSTRUCTIONS — p. 30
    • 1. General working precautions — p. 30
    • 2. Tightening bolts and nuts — p. 30
    • 3. Applying thread-locking fluid — p. 30
    • 4. Installing circlips — p. 31
    • 5. Installing spring pins — p. 31
    • 6. Handling split pin — p. 31
    • 7. Handling chain joint and split pin — p. 31
    • 8. Handling liquid gasket — p. 32
    • 9. Replacing O-rings — p. 32
    • 10. Replacing oil seals — p. 32
    • 11. Replacing floating seals — p. 33
    • 12. Connecting hydraulic hoses — p. 33
    • 13. Wrapping thread seal tape — p. 33
    • 14. Installing elbows with male seat — p. 33
    • 15. Connecting and disconnecting quick hose couplings — p. 34
    • 16. Handling the battery — p. 34
    • 17. Handling wire harness — p. 34
    • 18. Handling fuses — p. 36
    • 19. Handling connectors — p. 36
    • 20. Wiring color — p. 37
    • 21. Washing the machine with a high pressure washer — p. 37
    • 22. Dispose fluids correctly — p. 38
  • PRELIMINARY WORKING INSTRUCTIONS — p. 40
    • 1. Vacuuming the hydraulic oil tank — p. 40
    • 2. Releasing residual pressure of the hydraulic circuit — p. 40
    • 3. Removing the battery — p. 41
    • 4. Locking the lift arm — p. 42
    • 5. Locking the front and rear frames — p. 42
    • 6. Jack up the machine — p. 42
      • 6.1 Jacking up the machine for measuring — p. 42
      • 6.2 Jacking up the machine for replacing the center pin and center shaft — p. 44
      • 6.3 Jacking up the machine for replacing the wheel — p. 46
    • 7. Vacuuming the refrigerant gas — p. 48
    • 8. Connecting Diagmaster — p. 50
    • 9. Removing the bonnet, column cover, and floor plate — p. 50
    • 10. Removing the side cover RH — p. 51
    • 11. Removing and installing the air duct — p. 52
    • 12. Removing and installing the engine air cleaner element — p. 53
  • CONCLUDING WORKING INSTRUCTIONS — p. 54
    • 1. Bleeding the air from the hydraulic cylinder — p. 54
    • 2. Bleeding the air from the HST line — p. 54
    • 3. Bleeding the air from the brake oil line — p. 55
    • 4. Setting the new main ECU — p. 56
    • 5. Charging the refrigerant gas — p. 56
  • TIGHTENING TORQUES — p. 60
    • 1. Bolts and nuts tightening torque — p. 60
    • 2. Stud bolts tightening torque — p. 60
    • 3. Hydraulic hose fitting tightening torque — p. 61
    • 4. Hydraulic hoses tightening torque (taper thread) — p. 61
    • 5. Locknuts of adapters with O-ring tightening torque (straight thread) — p. 61
    • 6. Adapters tightening torque (taper thread) — p. 62
    • 7. Hose clamps tightening torque — p. 62
  • GENERAL MACHINE INFORMATION — p. 64
    • 1. Machine model identification — p. 64
    • 2. Engine model identification — p. 64
    • 3. DPF muffler model identification — p. 65
    • 4. Injector code identification — p. 66
    • 5. Specifications — p. 68
    • 6. Machine dimensions — p. 70
    • 7. Machine mass table — p. 72
  • GENERAL ELECTRICAL INFORMATION — p. 74
    • 1. Electrical circuit general description — p. 74
      • 1.1 Electrical circuit diagram description — p. 74
      • 1.2 Electrical circuit diagram unit symbol — p. 74
      • 1.3 Electrical wiring color coding — p. 75
      • 1.4 Electrical wiring clamp — p. 75
      • 1.5 Bus description — p. 76
      • 1.6 Composite terminal description — p. 76
    • 2. Connector — p. 76
      • 2.1 Connector handling precaution — p. 76
      • 2.2 Connector diagram description — p. 76
  • TRANSPORTING THE MACHINE — p. 78
    • 1. Loading and unloading the machine on a truck — p. 78
    • 2. Towing the inoperable machine — p. 79
  • SPECIAL TOOLS AND KITS — p. 82
    • 1. Special tools for the general section — p. 82
    • 2. Special tools for the machine body section — p. 85
    • 3. Special kit for the engine section — p. 88
    • 4. Special tools for the hydraulic system section — p. 88
    • 5. Special tools for the power train section — p. 91
• 3. MAINTENANCE — p. 99
  • MAINTENANCE INTERVALS TABLE — p. 100
  • LUBRICANT QUANTITY — p. 104
  • RECOMMENDED LUBRICANTS — p. 106
  • DAILY CHECK — p. 108
    • 1. Checking the engine oil level — p. 108
    • 2. Checking the hydraulic oil level — p. 108
    • 3. Checking the fuel level — p. 109
    • 4. Checking the coolant level — p. 109
    • 5. Checking the brake oil level — p. 110
    • 6. Greasing the lubrication points — p. 110
    • 7. Checking the air pressure of the tires — p. 111
    • 8. Checking the radiator and hydraulic oil cooler — p. 112
    • 9. Checking the steering wheel — p. 112
    • 10. Checking the parking brake — p. 113
    • 11. Checking the service brake — p. 113
    • 12. Checking the engine and engine electrical wire harness — p. 113
    • 13. Checking the fan belt — p. 114
    • 14. Draining the water separator — p. 114
    • 15. Cleaning the dust valve — p. 114
    • 16. Checking the dust level indicator — p. 115
    • 17. Checking the DPF muffler — p. 115
    • 18. Checking the bolts and nuts — p. 115
    • 19. Checking the electrical wire harness and terminals — p. 115
    • 20. Checking the warning lamps, lamps and lights — p. 116
    • 21. Checking the horn — p. 119
    • 22. Checking the oil leaks — p. 120
    • 23. Checking the machine — p. 120
  • EVERY 50 HOURS — p. 122
    • 1. Checking the battery — p. 122
  • EVERY 250 HOURS — p. 124
    • 1. Adjusting the fan belt — p. 124
    • 2. Checking the radiator hoses and hose clamps — p. 124
    • 3. Checking and cleaning the engine air cleaner elements — p. 125
    • 4. Checking the fuel line — p. 126
    • 5. Checking the intake air line — p. 126
    • 6. Tightening the wheel nuts — p. 127
    • 7. Replacing the water separator element — p. 127
  • EVERY 500 HOURS — p. 128
    • 1. Tightening the bolts of the center shaft — p. 128
    • 2. Replacing the engine oil and engine oil filter — p. 128
    • 3. Checking the gear oil level for the front and rear axle cases — p. 129
    • 4. Replacing the return filter — p. 130
    • 5. Replacing the fuel filter — p. 131
  • EVERY 1000 HOURS — p. 132
    • 1. Replacing the gear oil for the front and rear axle cases — p. 132
    • 2. Replacing the HST filter — p. 132
    • 3. Replacing the hydraulic oil and suction filter — p. 133
    • 4. Replacing the engine air cleaner element — p. 134
    • 5. Adjusting the valve clearance — p. 135
  • EVERY 1500 HOURS — p. 138
    • 1. Checking the injector — p. 138
    • 2. Replacing the engine oil separator element — p. 138
    • 3. Checking the EGR cooler — p. 139
  • EVERY 2000 HOURS — p. 140
    • 1. Checking the alternator — p. 140
    • 2. Checking the starter motor — p. 140
  • EVERY 3000 HOURS — p. 142
    • 1. Checking the EGR valve — p. 142
  • EVERY 6000 HOURS — p. 144
    • 1. Cleaning the DPF muffler — p. 144
  • EVERY 1 YEAR — p. 146
    • 1. Checking the electrical wire harnesses and terminals — p. 146
    • 2. Checking the exhaust manifold — p. 147
    • 3. Checking the intake air line — p. 147
    • 4. Checking the AFS — p. 148
    • 5. Checking the DPF muffler — p. 148
    • 6. Checking the DPF differential pressure sensor hoses and pipings — p. 148
    • 7. Checking the DPF outlet temperature sensor — p. 149
    • 8. Checking the EGR and EGR piping — p. 149
    • 9. Checking the CCV heater — p. 150
    • 10. Checking the brake hose — p. 151
  • EVERY 2 YEARS — p. 152
    • 1. Replacing the brake oil — p. 152
    • 2. Replacing the brake hose — p. 152
    • 3. Replacing the rubber parts of the master cylinder — p. 152
    • 4. Replacing the fuel line — p. 152
    • 5. Replacing the coolant — p. 153
    • 6. Replacing the intake air line — p. 155
    • 7. Replacing the engine oil separator hoses — p. 155
    • 8. Replacing the DPF differential pressure sensor hoses — p. 155
    • 9. Replacing the AFS hoses — p. 156
    • 10. Replacing the EGR cooler hoses — p. 156
    • 11. Replacing the radiator hoses and hose clamps — p. 156
    • 12. Replacing the hydraulic hoses — p. 157
  • MAINTENANCE FOR CABIN SPECIFICATION — p. 158
    • 1. Daily check — p. 158
      • 1.1 Checking the washer liquid level — p. 158
      • 1.2 Checking the air conditioning belt — p. 158
    • 2. Every 250 hours — p. 158
      • 2.1 Adjusting the air conditioning belt — p. 158
      • 2.2 Checking and cleaning the air conditioning filter — p. 159
      • 2.3 Cleaning the condenser — p. 160
    • 3. Every 1000 hours — p. 160
      • 3.1 Replacing the air conditioning filter — p. 160
    • 4. Every 1 year — p. 160
      • 4.1 Checking the air conditioning pipes and hoses — p. 160
    • 5. Every 2 years — p. 161
      • 5.1 Replacing the air conditioning pipes and hoses — p. 161
    • 6. Service as required — p. 162
      • 6.1 Checking the refrigerant liquid — p. 162
• 4. MACHINE BODY — p. 163
  • MECHANISM — p. 164
    • 1. Machine device layout — p. 164
    • 2. Bucket — p. 166
      • 2.1 Coupler bucket dimensions — p. 166
      • 2.2 4-in-1 bucket dimensions — p. 167
    • 3. Tilt arm — p. 168
      • 3.1 Tilt arm dimensions — p. 168
      • 3.2 Tilt link dimensions — p. 168
    • 4. Lift arm — p. 168
      • 4.1 Lift arm dimensions — p. 168
    • 5. Front frame — p. 168
      • 5.1 Front frame dimensions — p. 168
    • 6. Pins, bushings, and shims — p. 170
      • 6.1 Pin, bushing, and shim dimensions — p. 170
  • SERVICING — p. 174
    • 1. Service specifications — p. 174
      • 1.1 Service specifications for machine body — p. 174
    • 2. Testing — p. 175
      • 2.1 Measuring the operating force of the pilot control lever — p. 175
      • 2.2 Measuring the center pin vertical play — p. 175
    • 3. Repairing — p. 177
      • 3.1 Bucket — p. 177
        • 3.1.1 Removing and installing the coupler bucket — p. 177
        • 3.1.2 Removing and installing the 4-in-1 bucket — p. 178
      • 3.2 Tilt arm — p. 179
        • 3.2.1 Removing and installing the tilt link — p. 179
        • 3.2.2 Removing and installing the tilt arm — p. 180
      • 3.3 Lift arm — p. 180
        • 3.3.1 Removing and installing the lift arm — p. 180
      • 3.4 Counterweight — p. 182
        • 3.4.1 Removing and installing the counterweight — p. 182
      • 3.5 Canopy — p. 183
        • 3.5.1 Removing and installing the canopy — p. 183
      • 3.6 Floor frame — p. 184
        • 3.6.1 Removing and installing the floor frame — p. 184
      • 3.7 Cabin — p. 187
        • 3.7.1 Removing and installing the cabin — p. 187
      • 3.8 Seat — p. 190
        • 3.8.1 Removing and installing the seat — p. 190
      • 3.9 Steering wheel and column — p. 191
        • 3.9.1 Removing and installing the steering wheel and steering column — p. 191
      • 3.10 Accelerator pedal — p. 192
        • 3.10.1 Removing and installing the accelerator pedal — p. 192
      • 3.11 Center pin and center shaft — p. 193
        • 3.11.1 Removing and installing the center pin and center shaft — p. 193
      • 3.12 Bushings of the center shaft — p. 196
        • 3.12.1 Removing and installing bushings of the center shaft — p. 196
      • 3.13 Spherical bushings of the rear frame — p. 197
        • 3.13.1 Removing and installing the spherical bushing of the rear frame — p. 197
      • 3.14 Front wheel — p. 198
        • 3.14.1 Removing and installing the front wheel — p. 198
      • 3.15 Rear wheel — p. 198
        • 3.15.1 Removing and installing the rear wheel — p. 198
• 5. ENGINE — p. 200
  • MECHANISM — p. 201
    • 1. Engine device layout — p. 201
    • 2. Engine specifications — p. 205
    • 3. Engine dimensions — p. 207
    • 4. Engine performance curves — p. 208
    • 5. Lubricating system — p. 210
      • 5.1 Lubricating system general description — p. 210
    • 6. Cooling system — p. 210
      • 6.1 Cooling system general description — p. 210
    • 7. Intake air system — p. 211
      • 7.1 Intake air system general description — p. 211
    • 8. EGR system — p. 212
      • 8.1 EGR system general description — p. 212
    • 9. Common rail system — p. 213
      • 9.1 Common rail system general description — p. 213
    • 10. Aftertreatment system — p. 214
      • 10.1 Aftertreatment system general description — p. 214
      • 10.2 DPF regeneration control — p. 215
  • SERVICING — p. 217
    • 1. Troubleshooting — p. 217
      • 1.1 Engine troubleshooting — p. 217
    • 2. Service specifications — p. 219
      • 2.1 Service specifications for engine — p. 219
    • 3. Testing — p. 219
      • 3.1 Measuring the engine compression pressure — p. 219
      • 3.2 Measuring the engine oil pressure — p. 220
    • 4. Repairing — p. 221
      • 4.1 Fuel hose and tank — p. 221
        • 4.1.1 Removing and installing the fuel tank — p. 221
        • 4.1.2 Fuel hose routing — p. 223
      • 4.2 Engine — p. 226
        • 4.2.1 Removing and installing the engine — p. 226
        • 4.2.2 Removing and installing the engine mount — p. 228
        • 4.2.3 Removing and installing the alternator — p. 229
        • 4.2.4 Removing and installing the starter motor — p. 230
        • 4.2.5 Removing and installing the injector — p. 231
        • 4.2.6 Removing and installing the supply pump — p. 235
        • 4.2.7 Removing and installing the common rail — p. 237
        • 4.2.8 Removing and installing the EGR valve — p. 238
        • 4.2.9 Removing and installing the EGR cooler — p. 240
        • 4.2.10 Removing and installing the throttle valve — p. 241
        • 4.2.11 Removing and installing the SCV — p. 242
      • 4.3 Fuel cooler — p. 243
        • 4.3.1 Removing and installing the fuel cooler — p. 243
      • 4.4 Radiator — p. 244
        • 4.4.1 Removing and installing the radiator — p. 244
      • 4.5 DPF muffler — p. 245
        • 4.5.1 Removing and installing the DPF muffler — p. 245
• 6. HYDRAULIC SYSTEM — p. 248
  • MECHANISM — p. 249
    • 1. Hydraulic device layout — p. 249
    • 2. Hydraulic system general description — p. 250
      • 2.1 HST system general description — p. 250
      • 2.2 Front attachment system general description — p. 251
      • 2.3 Steering system general description — p. 252
      • 2.4 Pilot system general description — p. 253
    • 3. HST pump — p. 254
      • 3.1 HST pump specifications — p. 254
      • 3.2 HST pump hydraulic circuit — p. 255
      • 3.3 HST pump function and structure — p. 256
        • 3.3.1 HST pump working principles — p. 256
        • 3.3.2 DA valve — p. 258
        • 3.3.3 Direction control solenoid valve — p. 259
        • 3.3.4 High pressure relief valve — p. 259
        • 3.3.5 Charge relief valve — p. 260
        • 3.3.6 Forward traveling circuit — p. 261
        • 3.3.7 Backward traveling circuit — p. 262
    • 4. Gear pump — p. 263
      • 4.1 Gear pump specifications — p. 263
    • 5. HST motor — p. 264
      • 5.1 HST motor specifications — p. 264
      • 5.2 HST motor hydraulic circuit — p. 265
      • 5.3 HST motor function and structure — p. 266
        • 5.3.1 HST motor working principles — p. 266
        • 5.3.2 Servo regulator — p. 267
        • 5.3.3 Forward traveling circuit — p. 268
        • 5.3.4 Backward traveling circuit — p. 269
        • 5.3.5 Low speed hold circuit — p. 270
    • 6. Control valve — p. 271
      • 6.1 Control valve specifications — p. 271
      • 6.2 Control valve hydraulic circuit — p. 272
      • 6.3 Control valve spool shift performance — p. 273
      • 6.4 Control valve function and structure — p. 273
        • 6.4.1 Main relief valve — p. 273
        • 6.4.2 Overload relief valve — p. 274
        • 6.4.3 Neutral position circuit — p. 275
        • 6.4.4 Lift arm operation circuit — p. 276
        • 6.4.5 Tilt arm operation circuit — p. 277
        • 6.4.6 AUX operation circuit — p. 278
        • 6.4.7 Float operation circuit — p. 279
    • 7. Priority valve — p. 280
      • 7.1 Priority valve specifications — p. 280
    • 8. Steering valve — p. 281
      • 8.1 Steering valve specifications — p. 281
      • 8.2 Steering valve hydraulic circuit — p. 282
      • 8.3 Steering valve function and structure — p. 283
        • 8.3.1 Neutral position circuit — p. 283
        • 8.3.2 Right turn operation circuit — p. 284
        • 8.3.3 Left turn operation circuit — p. 285
    • 9. Pilot control valve — p. 286
      • 9.1 Pilot control valve specifications — p. 286
      • 9.2 Pilot control valve performance diagram — p. 287
      • 9.3 Pilot control valve function and structure — p. 287
    • 10. Unload valve — p. 289
      • 10.1 Unload valve specifications — p. 289
      • 10.2 Unload valve function and structure — p. 290
        • 10.2.1 Unload valve working principles — p. 290
    • 11. Hydraulic oil cooler — p. 291
      • 11.1 Hydraulic oil cooler specifications — p. 291
    • 12. Hydraulic cylinder — p. 292
      • 12.1 Hydraulic cylinder specifications — p. 292
  • SERVICING — p. 293
    • 1. Troubleshooting — p. 293
      • 1.1 Hydraulic troubleshooting for front attachment — p. 293
      • 1.2 Hydraulic troubleshooting for HST system — p. 294
      • 1.3 Hydraulics troubleshooting for steering system — p. 295
    • 2. Service specifications — p. 297
      • 2.1 Service specifications for hydraulic system — p. 297
    • 3. Testing — p. 299
      • 3.1 Measuring the hydraulic devices — p. 299
        • 3.1.1 Measuring the tilt arm cylinder speed — p. 299
        • 3.1.2 Measuring the lift arm cylinder speed — p. 299
        • 3.1.3 Measuring the travel speed — p. 299
        • 3.1.4 Measuring the cylinder internal leakage — p. 300
      • 3.2 Measuring the HST pump — p. 300
        • 3.2.1 Measuring the HST pump flow rate — p. 300
        • 3.2.2 Measuring the engine speed for departure — p. 301
        • 3.2.3 Measuring the high pressure relief valve pressure — p. 302
        • 3.2.4 Measuring the charge relief valve pressure — p. 303
        • 3.2.5 Measuring the HST control pressure — p. 303
      • 3.3 Measuring the main pump — p. 304
        • 3.3.1 Measuring the main pump flow rate — p. 304
      • 3.4 Measuring the charge pump — p. 305
        • 3.4.1 Measuring the charge pump flow rate — p. 305
      • 3.5 Measuring the HST motor — p. 305
        • 3.5.1 Measuring the HST motor flow rate — p. 305
      • 3.6 Measuring the control valve — p. 306
        • 3.6.1 Measuring the AUX flow rate — p. 306
        • 3.6.2 Measuring the main relief valve pressure — p. 307
        • 3.6.3 Measuring the overload relief valve pressure — p. 308
      • 3.7 Measuring the steering valve — p. 309
        • 3.7.1 Measuring the steering main relief valve pressure — p. 309
        • 3.7.2 Measuring the steering overload relief valve pressure — p. 309
      • 3.8 Measuring the pilot control valve — p. 310
        • 3.8.1 Measuring the pilot primary pressure — p. 310
        • 3.8.2 Measuring the pilot secondary pressure — p. 310
    • 4. Repairing — p. 311
      • 4.1 HST pump — p. 311
        • 4.1.1 Removing and installing the HST pump — p. 311
        • 4.1.2 HST pump components — p. 313
        • 4.1.3 Disassembling the HST pump — p. 314
        • 4.1.4 Assembling the HST pump — p. 319
        • 4.1.5 Installing adapters for the HST pump — p. 325
        • 4.1.6 Removing and installing the pump coupling — p. 327
      • 4.2 Gear pump — p. 327
        • 4.2.1 Removing and installing the gear pump — p. 327
        • 4.2.2 Gear pump components — p. 329
        • 4.2.3 Disassembling the gear pump — p. 330
        • 4.2.4 Assembling the gear pump — p. 332
        • 4.2.5 Installing adapters for the gear pump — p. 334
      • 4.3 HST motor — p. 334
        • 4.3.1 Removing and installing the HST motor — p. 334
        • 4.3.2 HST motor components — p. 336
        • 4.3.3 Disassembling the HST motor — p. 337
        • 4.3.4 Assembling the HST motor — p. 340
        • 4.3.5 Installing adapters for the HST motor — p. 344
      • 4.4 Control valve — p. 346
        • 4.4.1 Removing and installing the control valve — p. 346
        • 4.4.2 Control valve components — p. 348
        • 4.4.3 Disassembling and assembling the control valve — p. 349
        • 4.4.4 Installing adapters for the control valve — p. 353
      • 4.5 Steering valve — p. 354
        • 4.5.1 Removing and installing the steering valve — p. 354
        • 4.5.2 Steering valve components — p. 355
        • 4.5.3 Disassembling the steering valve — p. 356
        • 4.5.4 Assembling the steering valve — p. 360
        • 4.5.5 Installing adapters for the steering valve — p. 367
      • 4.6 Priority valve — p. 368
        • 4.6.1 Removing and installing the priority valve — p. 368
        • 4.6.2 Priority valve components — p. 368
        • 4.6.3 Disassembling and assembling the priority valve — p. 369
        • 4.6.4 Installing adapters for the priority valve — p. 370
      • 4.7 Pilot control valve — p. 371
        • 4.7.1 Removing and installing the pilot control valve — p. 371
        • 4.7.2 Pilot control valve components — p. 373
        • 4.7.3 Disassembling the pilot control valve — p. 374
        • 4.7.4 Assembling the pilot control valve — p. 377
        • 4.7.5 Installing adapters for the pilot control valve — p. 381
      • 4.8 Unload valve — p. 382
        • 4.8.1 Removing and installing the unload valve — p. 382
        • 4.8.2 Unload valve components — p. 383
        • 4.8.3 Disassembling and assembling the unload valve — p. 384
        • 4.8.4 Installing adapters for the unload valve — p. 386
      • 4.9 Hydraulic oil cooler — p. 387
        • 4.9.1 Removing and installing the hydraulic oil cooler — p. 387
      • 4.10 Hydraulic oil tank — p. 387
        • 4.10.1 Removing and installing the hydraulic oil tank — p. 387
        • 4.10.2 Hydraulic oil tank components — p. 390
        • 4.10.3 Installing adapters for the hydraulic oil tank — p. 391
      • 4.11 Hydraulic cylinder — p. 392
        • 4.11.1 Hydraulic cylinder components — p. 392
        • 4.11.2 Disassembling the hydraulic cylinder — p. 395
        • 4.11.3 Assembling the hydraulic cylinder — p. 397
        • 4.11.4 Disassembling and assembling the spherical bushing of the lift arm cylinder — p. 399
        • 4.11.5 Measuring the hydraulic cylinder — p. 402
      • 4.12 Hydraulic hose — p. 403
        • 4.12.1 Metal fittings of hydraulic hoses — p. 403
        • 4.12.2 Suction and drain hose routing — p. 404
        • 4.12.3 Front hose routing — p. 406
        • 4.12.4 Delivery hose routing — p. 407
        • 4.12.5 Pilot hose routing — p. 408
        • 4.12.6 Steering hose routing — p. 409
        • 4.12.7 Brake hose routing — p. 410
• 7. POWER TRAIN — p. 411
  • MECHANISM — p. 412
    • 1. Power train device layout — p. 412
    • 2. Power train general description — p. 413
      • 2.1 Travel system general description — p. 413
      • 2.2 Differential lock system general description — p. 414
      • 2.3 Brake system general description — p. 415
    • 3. Front axle — p. 416
      • 3.1 Front axle specifications — p. 416
      • 3.2 Front axle function and structure — p. 416
        • 3.2.1 Front axle working principles — p. 416
    • 4. Rear axle — p. 418
      • 4.1 Rear axle specifications — p. 418
      • 4.2 Rear axle function and structure — p. 418
        • 4.2.1 Rear axle working principles — p. 418
        • 4.2.2 Parking brake working principles — p. 420
        • 4.2.3 Service brake working principles — p. 422
    • 5. Propeller shaft — p. 423
      • 5.1 Propeller shaft specifications — p. 423
    • 6. Master cylinder — p. 424
      • 6.1 Master cylinder specifications — p. 424
    • 7. Parking brake solenoid valve and differential lock solenoid valve — p. 425
      • 7.1 Parking brake solenoid valve and differential lock solenoid valve specifications — p. 425
  • SERVICING — p. 426
    • 1. Troubleshooting — p. 426
      • 1.1 Power train troubleshooting — p. 426
    • 2. Service specifications — p. 427
      • 2.1 Service specification for power train — p. 427
    • 3. Testing — p. 427
      • 3.1 Measuring the parking brake release pressure — p. 427
      • 3.2 Measuring the differential lock pressure — p. 428
    • 4. Repairing — p. 428
      • 4.1 Front axle — p. 428
        • 4.1.1 Removing and installing the front axle — p. 428
        • 4.1.2 Front axle components — p. 430
        • 4.1.3 Disassembling and assembling the front axle case — p. 433
        • 4.1.4 Disassembling and assembling the front flange case — p. 439
        • 4.1.5 Disassembling and assembling the front differential — p. 445
      • 4.2 Rear axle — p. 450
        • 4.2.1 Removing and installing the rear axle — p. 450
        • 4.2.2 Rear axle components — p. 453
        • 4.2.3 Disassembling and assembling the rear axle case — p. 458
        • 4.2.4 Disassembling and assembling the transfer case — p. 458
        • 4.2.5 Disassembling and assembling the rear differential — p. 467
        • 4.2.6 Disassembling and assembling the service brake — p. 472
      • 4.3 Propeller shaft — p. 487
        • 4.3.1 Removing and installing the propeller shaft — p. 487
      • 4.4 Brake pedal — p. 487
        • 4.4.1 Removing and installing the brake pedal — p. 487
      • 4.5 Inching cable — p. 489
        • 4.5.1 Removing and installing the inching cable — p. 489
      • 4.6 Master cylinder — p. 490
        • 4.6.1 Removing and installing the master cylinder — p. 490
      • 4.7 Parking brake solenoid valve and differential lock solenoid valve — p. 492
        • 4.7.1 Removing and installing the parking brake solenoid valve and differential lock solenoid valve — p. 492
        • 4.7.2 Disassembling and assembling the parking brake solenoid valve and differential lock solenoid valve — p. 492
        • 4.7.3 Installing adapter for the parking brake solenoid valve and differential lock solenoid valve — p. 492
• 8. ELECTRICAL SYSTEM — p. 493
  • MECHANISM — p. 494
    • 1. Electrical device — p. 494
      • 1.1 Electrical device layout — p. 494
      • 1.2 Switch layout — p. 497
      • 1.3 Fuse and relay layout — p. 499
      • 1.4 Slow blow fuse layout — p. 501
      • 1.5 Communication port layout — p. 501
      • 1.6 Ground wiring layout — p. 501
    • 2. Functional electrical circuit — p. 503
      • 2.1 Power supply electrical circuit diagram (cabin specification) — p. 503
      • 2.2 Power supply electrical circuit diagram (canopy specification) — p. 505
      • 2.3 Accessory electrical circuit diagram — p. 507
      • 2.4 Battery charge electrical circuit diagram — p. 508
      • 2.5 Engine start electrical circuit diagram — p. 509
      • 2.6 Engine stop electrical circuit diagram — p. 510
      • 2.7 Hydraulic unlock electrical circuit diagram — p. 511
      • 2.8 AUX operation electrical circuit diagram — p. 512
      • 2.9 Hydraulic quick coupler operation electrical circuit diagram — p. 513
      • 2.10 Float electrical circuit diagram — p. 514
      • 2.11 Headlight electrical circuit diagram — p. 515
      • 2.12 Work light electrical circuit diagram — p. 517
      • 2.13 Wiper and washer motor electrical circuit diagram (cabin specification) — p. 518
      • 2.14 Turn signal switch electrical circuit diagram — p. 520
      • 2.15 Hazard switch electrical circuit diagram — p. 521
      • 2.16 Beacon electrical circuit diagram — p. 522
      • 2.17 Parking brake electrical circuit diagram — p. 523
      • 2.18 Travel electrical circuit diagram (forward) — p. 524
      • 2.19 Travel electrical circuit diagram (backward) — p. 525
      • 2.20 Travel speed shift electrical circuit diagram — p. 526
      • 2.21 Differential lock electrical circuit diagram — p. 527
      • 2.22 Fuel indicator switch electrical circuit diagram — p. 528
    • 3. Meter panel — p. 529
      • 3.1 Meter panel function — p. 529
      • 3.2 Display mode — p. 532
      • 3.3 Operating normal mode — p. 533
      • 3.4 Operating user setting mode — p. 533
        • 3.4.1 Operating periodic check mode — p. 533
        • 3.4.2 Operating AUX flow rate setting mode — p. 535
        • 3.4.3 Operating clock setting mode — p. 535
      • 3.5 Service dealer mode — p. 536
        • 3.5.1 Service dealer mode list — p. 536
        • 3.5.2 Operating service dealer mode — p. 538
        • 3.5.3 Operating SET-1 (Tester mode) — p. 539
        • 3.5.4 Operating SET-2 (Reading error history) — p. 542
        • 3.5.5 Operating SET-3 (Clearing error history) — p. 542
        • 3.5.6 Operating SET-4 (Dealer setting) — p. 542
        • 3.5.7 Default settings for SET-4 (Dealer setting) — p. 546
  • SERVICING — p. 548
    • 1. Troubleshooting — p. 548
      • 1.1 Electrical troubleshooting — p. 548
      • 1.2 Error warning list (Red lamp) — p. 549
      • 1.3 Error warning list (Yellow lamp) — p. 551
      • 1.4 Engine system error (Red lamp) — p. 551
      • 1.5 Lamp warning list — p. 554
    • 2. Handling error warning — p. 555
      • 2.1 Handling E:001 CAN communication error — p. 555
      • 2.2 Handling E:014 Hydraulic oil temperature error — p. 556
      • 2.3 Handling E:016 Fuel level sensor error — p. 556
      • 2.4 Handling E:018 Hydraulic oil temperature sensor error — p. 558
      • 2.5 Handling E:019 Accelerator sensor error — p. 559
      • 2.6 Handling E:022 Hydraulic unlock solenoid error — p. 560
      • 2.7 Handling E:023 Low speed hold solenoid error — p. 561
      • 2.8 Handling E:024 Differential lock solenoid error — p. 563
      • 2.9 Handling E:025 Parking brake solenoid error — p. 564
      • 2.10 Handling E:026 Direction control solenoid (forward) error — p. 565
      • 2.11 Handling E:027 Direction control solenoid (backward) error — p. 566
      • 2.12 Handling E:028 Direction control switch error — p. 567
      • 2.13 Handling E:029 AUX knob switch error — p. 568
      • 2.14 Handling E:031 AUX proportional solenoid RH error — p. 569
      • 2.15 Handling E:032 AUX proportional solenoid LH error — p. 570
      • 2.16 Handling E:033 Battery overcharging error — p. 571
      • 2.17 Handling E:034 5 V short error — p. 572
      • 2.18 Handling E:036 CRS CAN communication error — p. 573
      • 2.19 Handling E:037 Parking brake system error — p. 574
      • 2.20 Handling E:9118 Engine oil pressure error — p. 576
      • 2.21 Handling E:9119 Battery charging error — p. 578
• 9. AIR CONDITIONING AND HEATER SYSTEM — p. 580
  • MECHANISM — p. 581
    • 1. Air conditioning device layout — p. 581
    • 2. Air conditioning and heater system general description — p. 582
    • 3. Compressor — p. 583
      • 3.1 Compressor specifications — p. 583
      • 3.2 Compressor function and structure — p. 585
        • 3.2.1 Compressor working principles — p. 585
        • 3.2.2 Magnetic clutch pulley — p. 585
        • 3.2.3 Safety valve — p. 585
        • 3.2.4 Temperature switch — p. 586
    • 4. Air conditioning unit — p. 587
      • 4.1 Air conditioning unit specifications — p. 587
      • 4.2 Air conditioning unit function and structure — p. 588
        • 4.2.1 Evaporator — p. 588
        • 4.2.2 Heater core — p. 588
        • 4.2.3 Blower — p. 588
        • 4.2.4 Blower resistor — p. 588
        • 4.2.5 Expansion valve — p. 589
        • 4.2.6 Thermostat — p. 589
        • 4.2.7 Servomotor — p. 589
    • 5. Condenser — p. 590
      • 5.1 Condenser specifications — p. 590
      • 5.2 Condenser function and structure — p. 590
    • 6. Receiver — p. 590
      • 6.1 Receiver specifications — p. 590
      • 6.2 Receiver function and structure — p. 591
    • 7. Pressure switch — p. 591
      • 7.1 Pressure switch specifications — p. 591
      • 7.2 Pressure switch function and structure — p. 591
  • SERVICING — p. 593
    • 1. Troubleshooting — p. 593
      • 1.1 Air conditioning and heater troubleshooting — p. 593
    • 2. Service specifications — p. 597
      • 2.1 Service specifications for air conditioning and heater system — p. 597
    • 3. Testing — p. 597
      • 3.1 Checking the refrigerant liquid — p. 597
      • 3.2 Measuring the refrigerant gas pressure — p. 597
      • 3.3 Checking the fan switch — p. 599
      • 3.4 Measuring the magnetic clutch pulley air gap — p. 599
      • 3.5 Checking the blower resister — p. 600
    • 4. Repairing — p. 600
      • 4.1 Compressor — p. 600
        • 4.1.1 Removing and installing the compressor — p. 600
      • 4.2 Air conditioning unit — p. 602
        • 4.2.1 Removing and installing the air conditioning unit — p. 602
      • 4.3 Condenser — p. 610
        • 4.3.1 Removing and installing the condenser — p. 610
      • 4.4 Receiver — p. 611
        • 4.4.1 Removing and installing the receiver — p. 611
      • 4.5 Air conditioning and heater hoses — p. 612
        • 4.5.1 Air conditioning and heater hose routing — p. 612
• 10. APPENDICES — p. 616
  • APPENDICES — p. 617
    • 1. Servicing information — p. 617
      • 1.1 Service specifications for machine body — p. 617
      • 1.2 Service specifications for engine — p. 618
      • 1.3 Service specifications for hydraulic system — p. 618
      • 1.4 Service specification for power train — p. 619
      • 1.5 Service specifications for air conditioning and heater system — p. 620
      • 1.6 Service dealer mode — p. 620
        • 1.6.1 Tester mode list — p. 620
        • 1.6.2 Default settings for SET-4 (Dealer setting) — p. 623
    • 2. Normal mode and user setting mode flow chart — p. 625
    • 3. Service dealer mode flow chart — p. 626
    • 4. Hydraulic circuit diagram — p. 629
      • 4.1 Hydraulic circuit diagram — p. 629
    • 5. Wire harness — p. 630
      • 5.1 Wire harness — p. 630
• ELECTRICAL CIRCUIT DIAGRAM — p. 638
• INDEX — p. 639

Capabilities

The source outline separates mechanism explanations from servicing instructions for 4. Machine Body, 5. Engine, 6. Hydraulic System, 7. Power Train, 8. Electrical System, and 9. Air Conditioning And Heater System. Use these indexed headings to locate the applicable system in the source PDF, then confirm model-specific notes, specifications, illustrations, and operating conditions at the relevant page before carrying out service 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 torque settings, wear limits, fluid and system capacities, speed ratings, and emission data for service checks, adjustment work, and specification lookup. Use the values and conditions in the PDF for the applicable model and procedure.

• Service limits and settings: torque settings and wear limits.
• Fluid reference: fluid and system capacities.
• Machine specifications: speed ratings.
• Electrical and emissions: emission data.

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 Workshop Manual for Wheel Loader, document code RY911-29302, PDF edition.