Kubota Wheel Loader R640 Workshop Manual
Overview
This is the Kubota Workshop Manual for the R640 model (document code RY911-29596, 2024 edition). It provides service and repair procedures powered by the Kubota V2607 engine.
Manual Details and Coverage
- Manufacturer
- Kubota
- Model
- R640
- Equipment type
- KUBOTA WHEEL LOADER
- Manual type
- Workshop Manual
- Document code
- RY911-29596
- Publication year
- 2024
- Language
- English
- Page count
- 682
- Format
Contents
The manual is structured as follows. Page references correspond to the original PDF pagination.
1. SAFETY
- SAFETY FIRST 1-
- SAFETY LABELS (1-5)
2. GENERAL
- GENERAL WORKING INSTRUCTIONS (2-1)
- PRELIMINARY WORKING INSTRUCTIONS (2-11)
- Jacking up the machine for measuring (2-13)
- Jacking up the machine for replacing the center pin and center shaft (2-15)
- Jacking up the machine for replacing the wheel
- Jacking up the machine for replacing the wheel (2-17)
- CONCLUDING WORKING INSTRUCTIONS (2-25)
- TIGHTENING TORQUES (2-31)
- GENERAL MACHINE INFORMATION (2-35)
- GENERAL ELECTRICAL INFORMATION (2-45)
- Electrical circuit diagram description (2-45)
- Electrical circuit diagram unit symbol (2-45)
- Electrical wiring color coding (2-46)
- Electrical wiring clamp (2-46)
- Bus description (2-47)
- Composite terminal description (2-47)
- Connector ha
- Connector handling precaution (2-47)
- Connector diagram description (2-47)
- TRANSPORTING THE MACHINE (2-49)
- SPECIAL TOOLS AND KITS (2-53)
3. MAINTENANCE
- MAINTENANCE INTERVALS TABLE (3-1)
- LUBRICANT QUANTITY (3-5)
- RECOMMENDED OILS (3-7)
- DAILY CHECK (3-9)
- Checking the engine oil level (3-9)
- Checking the hydraulic oil level (3-9)
- Checking the fuel level (3-10)
- Checking the coolant level (3-10)
- Checking the brake oil level (3-11)
- Greasing the lubrication points (3-11)
- Checking the air pressure of the tires (3-12)
- Checking the radiator and hydraulic oil cooler (3-13)
- Checking the steering wheel (3-13)
- Checking the parking brake (3-14)
- Checking the service brake (3-14)
- Checking the engine and engine electrical wire harness (3-14)
- Checking the fan belt (3-15)
- Draining the water separator (3-15)
- Cleaning the dust valve (3-15)
- Checking the dust level indicator (3-16)
- Checking the DPF muffler (3-16)
- Checking the bolts and nuts (3-16)
- Checking the electrical wire harness and terminals (3-16)
- Checking the warning lamps, lamps and lights (3-17)
- Checking the horn (3-20)
- Checking the oil leaks (3-21)
- Checking the machine (3-21)
- EVERY 50 HOURS (3-23)
- Checking the battery (3-21)
- EVERY 250 HOURS (3-25)
- Adjusting the fan belt (3-25)
- Checking the radiator hoses and hose clamps (3-25)
- Checking and cleaning the engine air cleaner elements (3-26)
- Checking the fuel line (3-27)
- Checking the intake air line (3-27)
- Tightening the wheel nuts (3-28)
- Replacing the water separator element (3-28)
- EVERY 500 HOURS (3-29)
- Tightening the bolts of the center shaft (3-29)
- Replacing the engine oil and engine oil filter (3-29)
- Checking the gear oil level for the front and rear axle cases (3-30)
- Replacing the return filter (3-31)
- Replacing the fuel filter (3-32)
- EVERY 1000 HOURS (3-33)
- Replacing the gear oil for the front and rear axle cases (3-33)
- Replacing the HST filter (3-33)
- Replacing the hydraulic oil and suction filter (3-34)
- Replacing the engine air cleaner element (3-35)
- Checking the valve clearance (3-36)
- EVERY 1500 HOURS (3-39)
- Checking the injector (3-39)
- Replacing the engine oil separator element (3-39)
- Checking the EGR cooler (3-40)
- EVERY 2000 HOURS (3-41)
- Checking the alternator (3-41)
- Checking the starter motor (3-41)
- EVERY 3000 HOURS (3-43)
- Checking the EGR valve (3-43)
- Checking the turbocharger (3-43)
- EVERY 6000 HOURS (3-45)
- Cleaning the DPF muffler (3-45)
- EVERY 1 YEAR (3-47)
- Checking the electrical wire harnesses and terminals (3-47)
- Checking the exhaust manifold (3-48)
- Checking the intake air line (3-48)
- Checking the AFS (3-49)
- Checking the boost sensor (3-49)
- Checking the DPF muffler (3-49)
- Checking the DPF differential pressure sensor hoses and pipings (3-50)
- Checking the DPF outlet temperature sensor (3-50)
- EVERY 2 YEARS (3-53)
- Replacing the brake oil (3-53)
- Replacing the brake hose (3-53)
- Replacing the rubber parts of the master cylinder (3-53)
- Replacing the fuel line (3-53)
- Replacing the coolant (3-54)
- Replacing the intake air line (3-56)
- Replacing the engine oil separator hoses (3-56)
- Replacing the DPF differential pressure sensor hoses (3-56)
- Replacing the AFS hoses (3-57)
- Replacing the boost sensor hose (3-57)
- Replacing the EGR cooler hoses (3-57)
- Replacing the radiator hoses and hose clamps (3-58)
- Replacing the hydraulic hoses (3-58)
- MAINTENANCE FOR CABIN SPECIFICATION (3-59)
- Checking the washer liquid level (3-59)
- Checking the air conditioning belt (3-59)
- Adjusting the air conditioning belt (3-59)
- Checking and cleaning the air conditioning filter (3-60)
- Cleaning the condenser (3-61)
- Replacing the air conditioning filter (3-61)
- Checking the air conditioning pipes and hoses (3-61)
- Replacing the air conditioning pipes and hoses (3-62)
- Checki
- Checking the refrigerant liquid (3-63)
4. MACHINE BODY
- MECHANISM (4-1)
- Coupler bucket dimensions (4-3)
- 4-in-1 bucket dimensions (4-4)
- Tilt arm dimensions (4-5)
- Tilt link dimensions (4-5)
- Lift arm dimensions (4-5)
- Front frame dimensions (4-5)
- Pin, bushing, and shim dimensions (4-5)
- Pin, bushing, and shim dimensions (4-7)
- SERVICING (4-11)
- Service specifications for machine body (4-11)
- Measuring the operating force of the pilot control lever (4-12)
- Measuring the center pin vertical play (4-12)
- Bucket (4-14)
- Removing and installing the coupler bucket (4-14)
- Removing and installing the 4-in-1 bucket (4-15)
- Quick coupler (4-16)
- Removing and installing the quick coupler (4-16)
- Tilt arm (4-19)
- Removing and installing the tilt link (4-19)
- Removing and installing the tilt arm (4-19)
- Lift arm (4-20)
- Removing and installing the lift arm (4-20)
- Counterweight (4-22)
- Removing and installing the counterweight (4-22)
- Canopy (4-23)
- Removing and installing the canopy (4-23)
- Floor frame (4-24)
- Removing and installing the floor frame (4-24)
- Cabin (4-27)
- Removing and installing the cabin (4-27)
- Seat (4-30)
- Removing and installing the seat (4-27)
- Removing and installing the seat (4-30)
- Steering wheel and column (4-31)
- Removing and installing the steering wheel and steering column (4-31)
- Accelerator pedal (4-32)
- Removing and installing the accelerator pedal (4-32)
- Center pin and center shaft (4-33)
- Removing and installing the center pin and center shaft (4-33)
- Bushings of the center shaft (4-36)
- Removing and installing bushings of the center shaft (4-36)
- Spherical bushings of the rear frame (4-37)
- Removing and installing the spherical bushing of the rear frame (4-37)
- Front wheel (4-38)
- Removing and installing the front wheel (4-38)
- Rear wheel (4-38)
- Removing and installing the rear wheel (4-38)
5. ENGINE
- MECHANISM (5-1)
- Lubricating system general description (5-10)
- Cooling system general description (5-10)
- Turbocharger system general description (5-11)
- Intake air system general description (5-11)
- EGR system general description (5-12)
- Common rail system general description (5-12)
- Common rail system general description (5-13)
- Aftertreatment system general description (5-14)
- DPF regeneration control (5-15)
- SERVICING (5-17)
- Engine troubleshooting (5-17)
- Service specifications for engine (5-19)
- Measuring the engine compression pressure (5-19)
- Measuring the engine oil pressure (5-21)
- Fuel hose and tank (5-21)
- Removing and installing the fuel tank (5-21)
- Fuel hose routing (5-23)
- Engine (5-26)
- Removing and installing the engine (5-26)
- Removing and installing the engine mount (5-28)
- Removing and installing the alternator (5-29)
- Removing and installing the starter motor (5-30)
- Removing and installing the injector (5-31)
- Removing and installing the supply pump (5-35)
- Removing and installing the common rail (5-38)
- Removing and installing the turbocharger (5-39)
- Removing and installing the EGR valve (5-41)
- Remov (5-38)
- Removing and installing the EGR cooler (5-42)
- Removing and installing the throttle valve (5-43)
- Removing and installing the SCV (5-44)
- Fuel cooler (5-45)
- Removing and installing the fuel cooler (5-45)
- Radiator (5-46)
- Removing and installing the radiator (5-46)
- DPF muffler (5-47)
- Removing and installing the DPF muffler (5-47)
6. HYDRAULIC SYSTEM
- MECHANISM (6-1)
- HST system general description (6-2)
- Front attachment system general description (6-3)
- Steering system general description (6-4)
- Pilot system general description
- Pilot system general description (6-5)
- HST pump specifications (6-6)
- HST pump hydraulic circuit (6-8)
- HST pump function and structure (6-9)
- HST pump working principles (6-9)
- Direction control solenoid valve (6-11)
- High pressure relief valve (6-11)
- Charge relief valve (6-12)
- Cut-off relief valve (6-13)
- Forward traveling circuit (6-14)
- Backward traveling circuit (6-15)
- Gear pump specifications (6-16)
- HST motor specifications (6-16)
- HST motor specifications (6-17)
- HST motor hydraulic circuit (6-18)
- HST motor function and structure (6-19)
- HST motor working principles (6-19)
- Servo regulator (6-20)
- Forward traveling circuit (6-21)
- Backward traveling circuit (6-22)
- Low speed hold circuit (6-23)
- Control valve specifications (6-24)
- Control valve hydraulic circuit (6-25)
- Control valve spool shift performance (6-26)
- Control valve function and structure (6-26)
- Main relief valve (6-26)
- Overload relief valve (6-27)
- Neutral position circuit (6-28)
- Lift arm operation circuit (6-29)
- Tilt arm operation circuit (6-30)
- AUX operation circuit (6-31)
- Float operation circuit (6-32)
- Priority valve specifications (6-33)
- Steering valve specifications (6-34)
- Steering valve hydraulic circuit (6-35)
- Steering valve
- Steering valve function and structure (6-36)
- Neutral position circuit (6-36)
- Right turn operation circuit (6-37)
- Left turn operation circuit (6-38)
- Pilot control valve specifications (6-39)
- Pilot control valve performance diagram (6-40)
- Pilot control valve function and structure (6-40)
- Inching valve specification (6-41)
- Unload valve specifications (6-42)
- Unload valve function and structure (6-43)
- Unload valve working principles (6-43)
- Hydraulic oil cooler specifications
- Hydraulic oil cooler specifications (6-44)
- Hydraulic cylinder specifications (6-45)
- Main relief valve (6-26)
- SERVICING (6-47)
- Hydraulic troubleshooting for front attachment (6-47)
- Hydraulic troubleshooting for HST system (6-48)
- Hydraulics troubleshooting for steering system (6-49)
- Service specifications for hydraulic system (6-51)
- Measuring the hydraulic devices (6-52)
- Measuring the tilt arm cylinder speed (6-52)
- Measuring the lift arm cylinder speed (6-52)
- Measuring the travel speed (6-53)
- Measuring the cylinder internal leakage (6-52)
- Measuring the cylinder internal leakage (6-53)
- Measuring the HST pump (6-54)
- Measuring the HST pump flow rate (6-54)
- Measuring the engine speed for departure (6-55)
- Measuring the cut-off relief valve pressure (6-55)
- Measuring the charge relief valve pressure (6-56)
- Measuring the HST control pressure (6-56)
- Measuring the main pump (6-57)
- Measuring the main pump flow rate (6-57)
- Measuring the charge pump (6-58)
- Measuring the charge pump flow rate (6-58)
- Measuring the HST motor (6-58)
- Measuring the HST motor flow rate (6-58)
- Measuring the control valve (6-59)
- Measuring the AUX flow rate (6-59)
- Measuring the main relief valve pressure (6-60)
- Measuring the overload relief valve pressure (6-61)
- Measuring the steering valve (6-61)
- Measuring the steering main relief valve pressure (6-61)
- Measuring the steering overload relief valve pressure (6-62)
- Measuring the pilot control valve (6-62)
- Measuring the pilot primary pressure (6-62)
- Measuring the pilot secondary pressure (6-63)
- HST pump (6-63)
- Removing and installing the HST pump (6-63)
- HST pump components (6-65)
- Disassembling the HST pump (6-66)
- Assembling the HST pump (6-73)
- Installing adapters for the HST pump
- Installing adapters for the HST pump (6-81)
- Removing and installing the pump coupling (6-83)
- Gear pump (6-83)
- Removing and installing the gear pump (6-83)
- Gear pump components (6-85)
- Disassembling the gear pump (6-86)
- Assembling the gear pump (6-86)
- Installing adapters for the gear pump (6-88)
- HST motor (6-88)
- Removing and installing the HST motor (6-88)
- HST motor components (6-90)
- Disassembling the HST motor (6-91)
- Assembling the HST motor (6-94)
- Installing adapters for the HST motor (6-98)
- Control valve (6-100)
- Removing and installing the control valve (6-100)
- Control valve components (6-100)
- Control valve components (6-102)
- Disassembling and assembling the control valve (6-103)
- Installing adapters for the control valve (6-107)
- Steering valve (6-108)
- Removing and installing the steering valve (6-108)
- Steering valve components (6-109)
- Disassembling the steering valve (6-110)
- Assembling the steering valve (6-114)
- Installing adapters for the steering valve (6-121)
- Priority valve (6-122)
- Removing and installing the priority valve (6-122)
- Priority valve components (6-122)
- Disassembling and assembling the priority valve (6-123)
- Installing adapters for the priority valve (6-124)
- Pilot control valve (6-125)
- Removing and installing the pilot control valve (6-125)
- Pilot control valve components (6-125)
- Pilot control valve components (6-127)
- Disassembling the pilot control valve (6-128)
- Assembling the pilot control valve (6-131)
- Installing adapters for the pilot control valve (6-135)
- Inching valve (6-136)
- Removing and installing the inching valve (6-136)
- Inching valve components (6-138)
- Disassembling the inching valve (6-139)
- Installing adapter for the inching valve (6-139)
- Unload valve 6-
- Removing and installing the unload valve (6-139)
- Unload valve components (6-141)
- Disassembling and assembling the unload valve (6-142)
- Installing adapters for the unload valve (6-144)
- Hydraulic oil cooler (6-145)
- Removing and installing the hydraulic oil cooler (6-145)
- Hydraulic oil tank (6-145)
- Removing and installing the hydraulic oil tank (6-145)
- Hydraulic oil tank components (6-148)
- Installing adapters for the hydraulic oil tank (6-149)
- Hydraulic cylinder (6-150)
- Hydraulic cylinder components (6-150)
- Disassembling the hydraulic cylinder (6-153)
- Assembling the hydraulic cylinder (6-155)
- Disassembling and assembling the spherical bushing of the lift arm cylinder (6-157)
- Measuring the hydraulic cylinder (6-160)
- Hydraulic hose
- Hydraulic hose (6-161)
- Metal fittings of hydraulic hoses (6-161)
- Suction and drain hose routing (6-162)
- Front hose routing (6-164)
- Delivery hose routing (6-165)
- Pilot hose routing (6-166)
- Steering hose routing (6-167)
- Brake hose routing (6-168)
7. POWER TRAIN
- MECHANISM (7-1)
- Travel system general description (7-2)
- Differential lock system general description (7-3)
- Brake system general description (7-4)
- Front axle specifications (7-4)
- Front axle specifications (7-5)
- Front axle function and structure (7-5)
- Front axle working principles (7-5)
- Rear axle specifications (7-7)
- Rear axle function and structure (7-7)
- Rear axle working principles (7-7)
- Parking brake working principles (7-9)
- Service brake working principles (7-11)
- Propeller shaft specifications (7-12)
- Master cylinder specifications (7-13)
- Parking brake solenoid valve and differential lock solenoid valve specifications (7-14)
- SERVICING (7-15)
- Power train troubleshooting (7-15)
- Service specification for power train (7-16)
- Measuring the parking brake release pressure (7-16)
- Measuring the differential lock pressure (7-17)
- Front axle (7-17)
- Removing and installing the front axle (7-17)
- Front axle components (7-19)
- Disassembling and assembling the front axle case (7-22)
- Disassembling and assembling the front flange case (7-28)
- Disassembling and assembling the front differential (7-34)
- Rear axle (7-39)
- Removing and installing the rear axle (7-39)
- Rear axle components (7-42)
- Disassembling and assembling the rear axle case (7-47)
- Disassembling and assembling the transfer case (7-47)
- Disassembling and assembling the rear differential (7-56)
- Disassembling and assembling the service brake (7-61)
- Propeller shaft (7-76)
- Removing and installing the propeller shaft (7-76)
- Brake pedal (7-76)
- Removing and installing the brake pedal (7-76)
- Inching cable (7-76)
- Inching cable (7-78)
- Removing and installing the inching cable (7-78)
- Master cylinder (7-79)
- Removing and installing the master cylinder (7-79)
- Parking brake solenoid valve and differential lock solenoid valve (7-80)
- Removing and installing the parking brake solenoid valve and differential lock solenoid
- Disassembling and assembling the parking brake solenoid valve and differential lock
- Installing adapter for the parking brake solenoid valve and differential lock solenoid valve..7-81
8. ELECTRICAL SYSTEM
- MECHANISM (8-1)
- Electrical device layout (8-1)
- Switch layout (8-4)
- Fuse and relay layout (8-6)
- Slow blow fuse layout (8-8)
- Communication port layout (8-6)
- Communication port layout (8-8)
- Ground wiring layout (8-8)
- Power supply electrical circuit diagram (cabin specification) (8-10)
- Power supply electrical circuit diagram (canopy specification) (8-12)
- Accessory electrical circuit diagram (8-14)
- Battery charge electrical circuit diagram (8-15)
- Engine start electrical circuit diagram (8-16)
- Engine stop electrical circuit diagram (8-17)
- Hydraulic unlock electrical circuit diagram (8-18)
- AUX operation electrical circuit diagram (8-19)
- Hydraulic quick coupler operation electrical circuit diagram (8-20)
- Float electrical circuit diagram (8-21)
- Headlight electrical circuit diagram (8-22)
- Work light electrical circuit diagram (8-24)
- Wiper and washer motor electrical circuit diagram (cabin specification) (8-25)
- Turn signal switch electrical circuit diagram
- Turn signal switch electrical circuit diagram (8-27)
- Hazard switch electrical circuit diagram (8-28)
- Beacon electrical circuit diagram (8-29)
- Parking brake electrical circuit diagram (8-30)
- Travel electrical circuit diagram (forward) (8-31)
- Travel electrical circuit diagram (backward) (8-32)
- Travel speed shift electrical circuit diagram (8-33)
- Differential lock electrical circuit diagram (8-34)
- Fuel indicator switch electrical circuit diagram (8-35)
- Meter panel function (8-36)
- Display mode (8-39)
- Operating normal mode (8-40)
- Operating user setting mode (8-40)
- Operating periodic check mode (8-40)
- Operating AUX flow rate setting mode (8-42)
- Operating clock setting mode (8-42)
- Service dealer mode (8-43)
- Service dealer mode list (8-43)
- Operating service dealer mode (8-45)
- Operating SET-1 (Tester mode) (8-46)
- Operating SET-2 (Reading error history) (8-49)
- Operating SET-3 (Clearing error history) (8-49)
- Operating SET-4 (Dealer setting) (8-49)
- Operating SET-4 (Dealer setting) (8-49)
- Default settings for SET-4 (Dealer setting) (8-53)
- SERVICING (8-55)
- Electrical troubleshooting (8-55)
- Error warning list (Red lamp) (8-56)
- Error warning list (Yellow lamp) (8-58)
- Engine system error (Red lamp) (8-58)
- Lamp warning list (8-61)
- Handling E:001 CAN communication error (8-62)
- Handling E:014 Hydraulic oil temperature error (8-63)
- Handling E:016 Fuel level sensor error (8-63)
- Handling E:018 Hydraulic oil temperature sensor error (8-65)
- Handling E:019 Accelerator sensor error (8-66)
- Handling E:022 Hydraulic unlock solenoid error (8-67)
- Handling E:023 Low speed hold solenoid error
- Handling E:023 Low speed hold solenoid error (8-68)
- Handling E:024 Differential lock solenoid error (8-70)
- Handling E:025 Parking brake solenoid error (8-71)
- Handling E:026 Direction control solenoid (forward) error (8-72)
- Handling E:027 Direction control solenoid (backward) error (8-73)
- Handling E:028 Direction control switch error (8-74)
- Handling E:029 AUX knob switch error (8-75)
- Handling E:031 AUX proportional solenoid RH error (8-76)
- Handling E:032 AUX proportional solenoid LH error (8-77)
- Handling E:033 Battery overcharging error (8-78)
- Handling E:034 5 V short error (8-79)
- Handling E:036 CRS CAN communication error (8-80)
- Handling E:037 Parking brake system error (8-81)
- Handling E:9118 Engine oil pressure error (8-83)
- Handling E:9119 Battery charging error (8-85)
- MECHANISM (9-1)
- Compressor specifications (9-3)
- Compressor function and structure (9-5)
- Compressor working principles (9-5)
- Magnetic clutch pulley (9-5)
- Safety valve (9-5)
- Temperature switch (9-6)
- Air conditioning unit specifications (9-7)
- Air conditioning unit function and structure (9-8)
- Evaporator (9-8)
- Heater core (9-8)
- Blower (9-8)
- Blower resistor (9-8)
- Expansion valve (9-9)
- Thermostat (9-9)
- Servomotor (9-9)
- Condenser specifications (9-10)
- Condenser function and structure (9-10)
- Receiver specifications
- Receiver specifications (9-10)
- Receiver function and structure (9-11)
- Pressure switch specifications (9-11)
- Pressure switch function and structure (9-11)
- SERVICING (9-13)
- Air conditioning and heater troubleshooting (9-13)
- Service specifications for air conditioning and heater system (9-17)
- Checking the refrigerant liquid (9-17)
- Measuring the refrigerant gas pressure (9-17)
- Checking the fan switch (9-19)
- Measuring the magnetic clutch pulley air gap (9-19)
- Checking the blower resistor 9- (9-19)
- Checking the blower resistor (9-20)
- Compressor (9-20)
- Removing and installing the compressor (9-20)
- Air conditioning unit (9-22)
- Removing and installing the air conditioning unit (9-22)
- Condenser (9-30)
- Removing and installing the condenser (9-30)
- Receiver (9-31)
- Removing and installing the receiver (9-31)
- Air conditioning and heater hoses (9-33)
- Air conditioning and heater hose routing (9-33)
10. APPENDICES
- APPENDICES (10-1)
- Service specifications for machine body (10-1)
- Service specifications for engine (10-2)
- Service specifications for
- Service specifications for hydraulic system (10-2)
- Service specification for power train (10-3)
- Service specifications for air conditioning and heater system (10-4)
- Service dealer mode (10-4)
- Tester mode list (10-4)
- Default settings for SET-4 (Dealer setting) (10-7)
- Wire harness (10-13)
- ABBREVIATIONS
- DANGER
- WARNING
- CAUTION
- IMPORTANT
- 1-2 R640
- 1-4 R640
- SAFETY LABELS
- 1-6 R640
- 1-8 R640
- 1-10 R640
- 1-12 R640
- GENERAL WORKING INSTRUCTIONS
- • T
- 2-2 R640
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.
References
Kubota Workshop Manual for KUBOTA WHEEL LOADER R640, document code RY911-29596, PDF edition.
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