Kubota M5N-091 M5N-111 Tractor Workshop Manual – PDF DOWNLOAD

Kubota M5N-091 M5N-111 Tractor Workshop Manual – PDF DOWNLOAD

FILE DETAILS:

Kubota M5N-091 M5N-111 Tractor Workshop Manual – PDF DOWNLOAD

Language : English
Pages : 1210
Downloadable : Yes
File Type : PDF
Size: 220 MB

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Kubota M5N-091 M5N-111 Tractor Workshop Manual – PDF DOWNLOAD

TO THE READER
This Workshop Manual tells the servicing personnel about the mechanism, servicing and maintenance of the
M5N-091 and M5N-111 . It contains 4 parts: “Information”, “General”, “Mechanism” and “Servicing”.
Information
This section primarily contains information below.
• Safety First
• Safety Decal
• Specification
• Dimension
General
This section primarily contains information below.
• Engine Identification
• Model Identification
General Precautions
Maintenance Check List
• Check and Maintenance
Special Tools
Mechanism
This section contains information on the structure and the function of the unit. Before you continue with the
subsequent sections, make sure that you read this section.
Refer to the latest version of Workshop Manual (Code No. 9Y021-01870 I 9Y021-18200) for the Diesel engine
mechanism I Tractor mechanism that this Workshop Manual does not include.
Servicing
This section primarily contains information below.
Troubleshooting
Servicing Specifications
Tightening Torques
Checking, Disassembling and Servicing
Regarding the servicing of Common Rail System (CRS), refer to “Diagnosis Manual” (9Y120-03140).
Regarding the servicing of Diesel Particulate Filter (DPF), refer to “Diesel particulate filter handling manuaf’
(9Y121-08130).
All illustrations, photographs and specifications contained in this manual are of the newest information available at the
time of publication.
KUBOTA reserves the right to change all information at any time without notice.
Since this manual includes many models, information or illustrations and photographs can show more than one
model.

TABLE OF CONTENTS:

Kubota M5N-091 M5N-111 Tractor Workshop Manual – PDF DOWNLOAD

1 INFORMATION
SAFETY FIRST 1-1
1 Safety first 1-1
2 Before you start service 1-2
3 Start safely 1-2
4 Operate safely 1-2
5 Avoiding high pressure fluid 1-3
6 Avoiding hot exhaust 1-3
7 Cleaning exhaust filter 1-4
8 Prevent a fire 1-4
9 Keep a good airflow in the work area 1-4
10 Discard fluids correctly 1-4
11 Prevent acid burns 1-5
12 Preparing for emergencies 1-5
SAFETY DECALS 1-7
1 Care of danger, warning and caution labels 1-17
SPECIFICATIONS 1-19
1 Wheel model 1-19
1 1 Specification table (ROPS model) 1-19
1 2 Specification table (Cabin model) 1-21
2 Crawler model 1-23
2 1 Specification table (Power crawler model) 1-23
TRAVELING SPEEDS 1-25
1 Wheel model 1-25
1 1 Traveling speeds (ROPS model) 1-25
1 2 Traveling speeds (Cabin model) 1-27
2 Crawler model 1-29
2 1 Traveling speeds 1-29
DIMENSIONS 1-31
1 Wheel model 1-31
1 1 Dimension for ROPS model 1-31
1 2 Dimension for Cabin model 1-32
2 Crawler model 1-33
2 1 Dimension for Crawler model 1-33
2 GENERAL
TRACTOR IDENTIFICATION 2-1
1 Model name and serial number 2-1
1 1 Tractor number 2-1
1 2 Engine serial number 2-2
1 3 DPF muffler serial number 2-4
1 4 SCR muffler serial number 2-4
1 5 EF4B engine 2-4
1 6 Cylinder number 2-5
GENERAL WORKING PRECAUTIONS 2-7
1 Tightening bolts and nuts 2-7
2 Applying thread-locking fluid 2-7
3 Installing circlips 2-8
4 Installing spring pins 2-8
5 Handling split pin 2-8
6 Handling chain joint and split pin 2-8
7 Handling liquid gasket 2-9
8 Replacing O-rings 2-9
9 Replacing oil seals 2-9
MSN-09 1 MSN-111 iii
KiSC issued 01, 2022 A
10 Replacing floating seals 2-10
11 Connecting hydraulic hoses 2-10
12 Wrapping thread seal tape 2-10
13 Installing elbows with male seat 2-10
14 Connecting and disconnecting quick hose couplings 2-11
15 Handling the battery 2-11
16 Handling wire harness 2-11
17 Handling fuses 2-13
18 Handling connectors 2-13
19 Wiring color 2-14
20 Washing the machine with a high pressure washer 2-14
21 Dispose fluids correctly 2-15
LUBRICANTS, FUEL AND COOLANT 2-17
1 Wheel model 2-17
1 1 Lubricants, fuel and coolant 2-17
2 Crawler model 2-19
2 1 Lubricants, fuel and coolant 2-19
3 Note 2-21
3 1 Engine oil 2-21
3 2 Fuel 2-21
3 3 DEF/AdBlue® 2-21
3 3 1 Handling DEF (AdBlue) 2-21
3 3 2 Quality of DEF (AdBlue) 2-21
3 3 3 Warning indication and countermeasures 2-22
3 3 4 Adding DEF (AdBlue) 2-25
3 3 5 Draining DEF (AdBlue) 2-25
3 3 6 Storing purchased DEF (AdBlue) 2-25
3 3 7 Storing DEF (AdBlue) in the DEF tank 2-26
3 3 8 Disposing of DEF (AdBlue) 2-26
3 3 9 Handling precautions after stopping the engine 2-26
3 3 10 Precautions when using in cold regions 2-26
3 4 Transmission oil 2-27
3 5 Biodiesel fuel (BDF) B0-B5 2-27
TIGHTENING TORQUES 2-29
1 General use screws, bolts and nuts 2-29
2 Stud bolts 2-30
3 Hydraulic fitting 2-31
3 1 Hydraulic hose fittings 2-31
3 2 Hydraulic pipe cap nuts 2-31
3 3 Adapters, elbows and others 2-31
4 Metric screws, bolts and nuts 2-33
5 American standard screws, bolts and nuts with UNC or UNF threads 2-33
6 Plugs 2-33
MAINTENANCE 2-35
1 Service intervals 2-35
1 1 Wheel model 2-35
1 1 1 Service intervals 2-35
1 2 Crawler model 2-38
1 2 1 Service intervals 2-38
1 3 Maintenance items chart 2-41
CHECK AND MAINTENANCE 2-43
1 Wheel model 2-43
1 1 Periodic service 2-43
1 1 1 Daily check 2-43
1 1 2 Check points of initial 50 hours 2-43
1 1 3 Check points every 50 hours 2-44
1 1 4 Check points of every 100 hours 2-46
1 1 5 Check points of every 200 hours 2-51
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KiSC issued 01, 2022 A
1 1 6 Check points of every 400 hours 2-53
1 1 7 Check point of every 500 hours 2-54
1 1 8 Check points of every 600 hours 2-59
1 1 9 Check point of every 1000 hours 2-59
1 1 10 Check points of every 1000 hours or 1 year 2-63
1 1 11 Check points of every 1500 hours 2-63
1 1 12 Check points of every 2000 hours or 2 years 2-65
1 1 13 Check points of every 3000 hours 2-67
1 1 14 Check points of every 8000 hours 2-70
1 1 15 Every 3 months 2-70
1 1 16 Check points of every 1 year 2-70
1 1 17 Check points of every 2 years 2-72
1 1 18 Check point of every 3 years 2-73
1 1 19 Check point of every 4 years 2-73
1 1 20 Others 2-76
2 Crawler model 2-82
2 1 Periodic service 2-82
2 1 1 Daily check 2-82
2 1 2 Check points of initial 50 hours 2-85
2 1 3 Check points every 50 hours 2-86
2 1 4 Check points of every 100 hours 2-88
2 1 5 Check points of every 200 hours 2-94
2 1 6 Check points of every 400 hours 2-96
2 1 7 Check point of every 500 hours 2-97
2 1 8 Check points of every 600 hours 2-102
2 1 9 Check point of every 1000 hours 2-102
2 1 10 Check points of every 1000 hours or 1 year 2-107
2 1 11 Check points of every 1500 hours 2-107
2 1 12 Check points of every 2000 hours or 2 years 2-109
2 1 13 Check points of every 3000 hours 2-111
2 1 14 Check points of every 1 year 2-114
2 1 15 Check points of every 2 years 2-115
2 1 16 Check point of every 3 years 2-116
2 1 17 Check point of every 4 years 2-117
2 1 18 Others 2-119
SPECIAL TOOLS 2-129
1 Special tools for engine 2-129
1 1 Diesel engine compression tester 2-129
1 2 Oil pressure tester 2-129
1 3 Small end bushing replacing tool 2-129
1 4 Idle gear bushing replacing tool 2-130
1 5 Gear case cover oil seal press fit tool 2-130
1 6 Valve guide replacing tool 2-130
1 7 Crankshaft sleeve press fit tool 2-131
1 8 Supply pump gear puller 2-132
1 9 Supply pump gear reinstall jig 2-132
1 10 Flywheel stopper 2-133
1 11 Crankcase 1 and 2 aligning tool 2-134
1 12 Compression tester adapter 2-135
1 13 Jig 1 for measuring air gap of the crankshaft position sensor 2-137
1 14 Jig 2 for measuring air gap of the crankshaft position sensor 2-138
1 15 Rotation sensor signal interface unit 2-139
1 16 Balancer bushing replacing tool 1 assembly 2-140
1 17 Balancer bushing replacing tool 1 components parts 2-140
1 18 Balancer bushing replacing tool 2 2-141
1 19 Balancer bushing replacing tools 3, 4, 5 2-141
1 20 Balancer bushing tool components parts 2-142
1 21 Engine stand 2-145
MSN-091 ,MSN-111 V
KiSC issued 01, 2022 A
1 22 Nozzle adaptor for measuring cylinder compression pressure 2-14 7
1 23 DEF header unit replacing tool 2-149
2 Special tools for tractor 2-149
2 1 Tie rod end lifter 2-149
2 2 Steering wheel puller 2-149
2 3 Relief valve pressure tester 2-149
2 4 Flowmeter 2-150
2 5 Adaptor set for flowmeter 2-150
2 6 Toe-in gauge 2-150
2 7 Injector CH3 2-150
2 8 Brake air bleeder 2-151
2 9 Relief valve setting pressure adaptor G 2-151
2 10 Pressure gauge 50 2-151
2 11 Power steering adaptor 2-151
2 12 Front axle rocking restrictor 2-151
2 13 Sliding hammer 2-152
2 14 Adaptor (M6) for sliding hammer 2-153
2 15 Hydraulic clutch spring compressor 2-154
2 16 Locking wrench 2-158
2 17 Bevel gear shaft tool for front axle 2-158
2 18 Bevel gear shaft tool for rear axle 2-159
2 19 Hydraulic arm shaft bushing press-fitting tool 2-159
2 20 Draft control test bar 2-159
2 21 Hydraulic cylinder piston sealing tool 2-160
2 22 Cylinder safety valve setting pressure adaptor 2-161
2 23 Oil cooler relief valve setting pressure adaptor 2-163
2 24 Valve adaptor 2-164
2 25 Hydraulic brake adaptor 2-165
2 26 Tools for dismounting cabin 2-166
3 Special tools for air conditioner unit 2-172
3 1 Air conditioner service tool 2-172
3 2 Electric gas leak tester 2-173
3 3 Vacuum pump 2-173
3 4 Magnetic clutch stopper (for NC compressor) 2-174
3 5 Stopper bolt (for A/C compressor) 2-175
4 Special tools for crawler 2-175
4 1 Idler rocking restrictor 2-175
4 2 Track roller separator 2-175
TIRES 2-177
1 Tire size and inflation pressure 2-177
2 Wheel adjustment 2-178
2 1 Front wheels (4WD model) 2-178
2 2 Rear wheels (ROPS model) 2-179
2 3 Rear wheels 2-181
3 Wheel hub 2-183
4 Tire liquid injection 2-183
4 1 Preparation of calcium chloride solution 2-184
4 2 Attaching injector 2-184
4 3 Injecting liquid 2-184
4 4 Draining water or solution 2-185
IMPLEMENT LIMITATIONS 2-187
1 Implement limitations 2-187
2 Implement capacity 2-188
3 ENGINE
MECHANISM 3-1
1 Engine 3-1
1 1 Feature of cylinder block 3-1
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1 2 Feature of cylinder head 3-1
1 3 Feature of piston 3-1
2 Lubricating system 3-2
2 1 Feature of oil cooler 3-2
3 Cooling system 3-2
3 1 Feature of thermostat 3-2
3 2 Feature of bottom bypass system 3-3
4 Common rail system (CRS) 3-3
4 1 Overview of common rail system 3-3
4 2 Supply pump 3-4
4 2 1 Function of supply pump 3-4
4 2 2 Function of feed pump 3-4
4 2 3 Function of pre-stroke control valve (PCV) 3-4
4 2 4 Function of pump unit 3-5
4 2 5 Function of delivery valve 3-5
4 3 Function of rail for common rail system 3-6
4 4 Injector 3-6
4 4 1 Function of injector 3-6
4 4 2 Operation of injector 3-7
4 4 3 Function of injector drive circuit 3-9
4 4 4 Function of injector QR/ID codes 3-9
4 4 5 When replacing an injector 3-9
4 4 6 When replacing the engine ECU 3-9
4 5 Structure of engine control system 3-10
4 5 1 Function of engine ECU 3-12
4 5 2 Function of crankshaft position sensor 3-12
4 5 3 Function of camshaft position sensor 3-13
4 5 4 Pulse chart of the crankshaft position sensor output signal and camshaft position sensor
output signal 3-13
4 5 5 Function of temperature sensors 3-14
4 5 6 Function of boost sensor 3-14
5 EGR system 3-15
5 1 Overview of EGR system 3-15
5 2 EGR valve 3-16
5 2 1 Function of water cooled EGR valve 3-16
5 2 2 Function of EGR valve lift sensor 3-16
5 3 Function of reed valve 3-16
6 Aftertreatment system 3-17
6 1 Overview of after treatment devices 3-17
6 2 Outline of the SCR system 3-18
6 3 DPF regeneration process 3-19
6 4 PM warning level 3-20
6 5 Auto regeneration mode 3-21
6 6 Regeneration inhibit mode 3-22
6 7 Function of diesel oxidation catalyst (DOC) 3-23
6 8 Function of diesel particulate filter (DPF) 3-23
6 9 Function of diesel particulate filter (DPF) 3-23
6 10 Function of intake throttle valve 3-24
6 11 Function of air flow sensor 3-24
6 12 Function of temperature sensor 3-24
6 13 Function of differential pressure sensor 3-24
6 14 Function of oil separator 3-25
6 15 Function of selective catalytic reduction (SCR) 3-25
6 16 Function of diesel exhaust fluid (DEF) pump 3-26
6 17 Function of DEF injector 3-26
6 18 Function of DEF tank 3-26
6 19 Function of coolant valve 3-27
6 20 Function of after treatment control unit (ACU) 3-27
MSN-091 MSN-111 vii
KiSC issued 01 2022 A
SERVICING 3-29
1 Troubleshooting for engine 3-29
2 Servicing specifications for engine 3-33
3 Tightening torques for engine 3-37
4 Checking, disassembling, and servicing 3-40
4 1 Checking and adjusting 3-40
4 1 1 Engine body 3-40
4 1 2 Lubricating system 3-42
4 1 3 Cooling system 3-43
4 1 4 Turbocharger ······ ··· ·· ···· ······· ···· ······· ······ ········ ··· •··· ··· ···· ··· ···· ··· ···· ···•··· ···•· ····· •· ·· ·· ··· ··· ···· ··· ···· ··· ·· ·· 3-44
4 1 5 EGR system 3-45
4 1 6 DPF system 3-45
4 2 Preparation for separating engine 3-45
4 2 1 Lubricant and coolant 3-45
4 2 2 Front axle rocking restrictor 3-4 7
4 2 3 Propeller shaft and power steering hose 3-4 7
4 2 4 ROPS model 3-48
4 2 5 Cabin model 3-55
4 3 Separating engine from clutch housing 3-61
4 3 1 ROPS model 3-61
4 3 2 Cabin model 3-71
4 4 Separating engine from front axle frame 3-80
4 4 1 ROPS model 3-80
4 4 2 Cabin model 3-81
4 5 Disassembling and assembling 3-82
4 5 1 Damper disk 3-82
4 5 2 External parts 3-82
4 5 3 Oil separator 3-83
4 5 4 Turbocharger and EGR 3-87
4 5 5 Common rail 3-88
4 5 6 Cylinder head and valve 3-92
4 5 7 Thermostat 3-99
4 5 8 Supply pump 3-99
4 5 9 Water pump and oil cooler 3-101
4 5 10 Gear case and timing gear 3-102
4 5 11 Piston and connecting rod 3-105
4 5 12 Flywheel and crankshaft 3-108
4 5 13 Intake air heater 3-11 3
4 6 Servicing 3-113
4 6 1 Cylinder head 3-113
4 6 2 Timing gears 3-120
4 6 3 Piston and connecting rod 3-124
4 6 4 Crankshaft 3-126
4 6 5 Cylinder 3-130
4 6 6 Oil pump 3-131
4 6 7 Replacing 3-132
4 TRANSMISSION
MECHANISM 4-1
1 Structure 4-1
1 1 Structure of F12/R12 speed transmission model 4-1
1 2 Structure of F24/R24 speed transmission model 4-2
2 Power train for traveling gear 4-3
2 1 Hydraulic shuttle shift section 4-3
2 1 1 Structure of hydraulic shuttle 4-3
2 1 2 Oil flow of hydraulic shuttle 4-4
2 1 3 Power train of shuttle shift section 4-4
2 2 Main gear shift section 4-6
viii M5N-091,M5N-1 11
KiSC issued 01, 2022 A
2 2 1 Power train of main gear shift section 4-6
2 3 Range gear shift section 4-7
2 3 1 Structure of range gear shift section 4-7
2 3 2 Range / creep gear shift section (Option) 4-8
2 4 Shift fork rod and fork 4-9
2 4 1 Structure of shift fork rod and fork 4-9
2 4 2 Structure of creep gear shift section (Option) 4-10
2 5 Dual speed shift section 4-11
2 5 1 Structure of dual speed section 4-11
2 5 2 Structure of dual speed valve 4-12
3 Lubrication for transmission 4-14
4 Power train for PTO system 4-15
4 1 Structure of PTO gear section 4-15
4 2 PTO hydraulic clutch section 4-16
4 2 1 Structure of PTO hydraulic clutch 4-16
4 2 2 Structure of PTO solenoid valve, relief valve and oil flow 4-17
5 Power train for 2WD, 4WD and Bi-speed turn 4-20
5 1 4WD / Bi-speed turn hydraulic clutch section 4-20
5 1 1 Structure of 4WD and Bi-speed turn clutch 4-20
5 1 2 Operation mechanism of 2WD – 4WD – Bi-speed turn system 4-20
5 1 3 Oil flow of 4WD / Bi-speed turn solenoid valve 4-21
6 Differential lock 4-23
6 1 Pin type 4-23
SERVICING 4-25
1 Troubleshooting for transmission 4-25
2 Servicing specifications for transmission 4-29
3 Tightening torques for transmission 4-32
3 1 Wheel model and crawler model 4-32
3 1 1 Tightening torques for transmission 4-32
3 2 Crawler model 4-35
3 2 1 Tightening torques for transmission 4-35
4 Checking and adjusting 4-36
4 1 Clutch pedal free travel 4-36
4 1 1 Adjusting clutch pedal free travel 4-36
4 2 Gear shifting linkage 4-36
4 2 1 Main gear shift 4-36
4 2 2 Range / creep gear shift 4-38
4 3 Accelerator section 4-39
4 3 1 Checking hand accelerator lever operating force 4-39
4 3 2 Checking accelerator pedal 4-40
4 3 3 Adjusting hand accelerator lever rod (ROPS model) 4-41
4 4 Hydraulic clutch valve 4-42
4 4 1 Checking shuttle clutch valve system pressure 4-42
4 4 2 Checking PTO clutch operating pressure 4-44
4 4 3 Checking 4WD and Bi-speed turn clutch valve operating pressure 4-44
4 4 4 Checking dual speed clutch valve operating pressure (F24/R24 speed transmission model)4-46
5 Disassembling and assembling 4-47
5 1 Wheel model 4-47
5 1 1 Hydraulic shuttle valve 4-47
5 1 2 Solenoid valve 4-53
5 1 3 Dual speed solenoid valve 4-54
5 1 4 Preparation for separating each block 4-54
5 1 5 Clutch housing case 4-90
5 1 6 Transmission case 4-91
5 1 7 Damper disk 4-94
5 1 8 Shift cover 4-94
5 1 9 Shuttle and dual speed clutch 4-97
5 1 10 Disassembling clutch housing case 4-109
M5N-091 M5N-111 ix
KiSC issued 01 2022 A
5 1 11 Disassembling transmission case 4-117
5 1 12 PTO gear case 4-130
5 2 Crawler model 4-132
5 2 1 Hydraulic shuttle valve 4-132
5 2 2 Solenoid valve 4-139
5 2 3 Dual speed solenoid valve 4-140
5 2 4 Preparation for separating cabin 4-140
5 2 5 Clutch housing case 4-164
5 2 6 Transmission case 4-166
5 2 7 Damper disk 4-172
5 2 8 Shift cover 4-172
5 2 9 Shuttle and dual speed clutch 4-175
5 2 10 Disassembling clutch housing case 4-187
5 2 11 Disassembling transmission case 4-195
5 2 12 PTO gear case 4-208
6 Servicing 4-211
6 1 Bearing 4-211
6 1 1 Checking ball bearing 4-211
6 1 2 Checking split type needle bearing 4-211
6 1 3 Checking taper roller bearing 4-211
6 2 Shift fork and synchronizer 4-211
6 2 1 Checking clearance between shift fork and shifter groove 4-211
6 2 2 Checking smooth sliding and moving of coupling and shifter 4-211
6 2 3 Checking wear on synchronizer key and spring 4-212
6 3 Travelling clutch 4-212
6 3 1 Checking displacement around damper disc edge 4-212
6 3 2 Checking clearance between inching lever pin and lever bushing 4-212
6 4 Shuttle clutch pack 4-213
6 4 1 Checking clearance between internal circlip and belleville washer (Cupped spring
washer) for shuttle clutch pack 4-213
6 5 Dual speed clutch pack 4-214
6 5 1 Checking clearance between internal circlip and pressure plate for dual speed clutch pack4-214
6 6 Shaft and gear 4-215
6 6 1 Checking side clearance of 1 st shaft 4-215
6 7 PTO clutch pack 4-215
6 7 1 Checking PTO clutch disc wear 4-215
6 7 2 Checking PTO steel plate wear 4-216
6 7 3 Checking flatness of PTO piston and PTO steel plate 4-216
6 7 4 Checking PTO clutch back plate 4-216
6 7 5 Checking piston return spring free length 4-216
6 7 6 Checking seal ring thickness of PTO clutch pack 4-217
6 8 Solenoid valve 4-217
6 8 1 Checking dual speed solenoid valve (F24/R24 speed transmission model) 4-217
6 8 2 Checking PTO, 4WD and Bi-speed turn solenoid valve 4-218
6 9 4WD/Bi-speed turn clutch pack 4-218
6 9 1 Checking clutch disk wear 4-218
6 9 2 Checking steel plate and pressure plate wear 4-219
6 9 3 Checking flatness of piston, steel plate and pressure plate 4-219
6 9 4 Checking thickness of seal ring 4-219
6 10 Differential gear 4-219
6 10 1 Spiral bevel pinion shaft 4-219
6 10 2 Backlash and tooth contact 4-220
6 10 3 Differential case differential pinion gear and differential side gear 4-221
5 REAR AXLE
MECHANISM 5-1
1 Wheel model 5-1
1 1 Features of rear axle 5-1
X M5N-091 ,M5N-111
KiSC issued 01, 2022 A
2 Crawler model 5-2
2 1 Structure of crawler 5-2
2 2 Advantage of crawler track comparing wheel 5-4
2 3 Advantage of swing shaft center moved forward 5-4
2 4 Structure of final gear assembly 5-5
SERVICING 5-7
1 Troubleshooting for rear axle 5-7
1 1 Wheel model and crawler model 5-7
1 1 1 Troubleshooting for rear axle 5-7
1 2 Crawler model 5-8
1 2 1 Troubleshooting for rear axle 5-8
2 Servicing specifications 5-9
2 1 Wheel model and crawler model 5-9
2 1 1 Servicing specifications for rear axle 5-9
2 2 Crawler model 5-10
2 2 1 Servicing specifications for rear axle 5-10
3 Tightening torques for rear axle 5-11
3 1 Wheel model and crawler model 5-11
3 1 1 Tightening torques for rear axle 5-11
3 2 Crawler model 5-12
3 2 1 Tightening torques for rear axle 5-12
4 Checking and adjusting 5-13
4 1 Adjusting tension of crawler track 5-13
5 Disassembling and assembling 5-13
5 1 Wheel model 5-13
5 1 1 Preparation for disassembling and assembling valve 5-13
5 1 2 Separating rear axle 5-15
5 1 3 Disassembling rear axle 5-24
5 2 Crawler model 5-28
5 2 1 Preparation for disassembling and assembling valve 5-28
5 2 2 Separating rear axle 5-29
5 2 3 Disassembling rear axle 5-40
6 Servicing 5-46
6 1 Wheel model 5-46
6 1 1 Bearing 5-46
6 1 2 Planetary gear 5-4 7
6 2 Crawler model 5-48
6 2 1 Bearing 5-48
6 2 2 Checking slider external width 5-48
6 2 3 Checking spring length 5-49
6 2 4 Checking sprocket pin wear 5-49
6 2 5 Checking crawler track 5-49
6 2 6 Checking track roller wear 5-50
6 2 7 Checking idler wear 5-51
6 2 8 Checking swing shaft bracket wear 5-51
6 2 9 Checking final gear case 5-52
6 BRAKES
MECHANISM 6-1
1 Traveling brake 6-1
1 1 Structure of traveling brake 6-1
1 2 Function of master cylinder assembly 6-2
2 Parking brake 6-3
2 1 Structure of gear locked parking brake 6-3
SERVICING 6-5
1 Troubleshooting for brakes 6-5
2 Servicing specifications for brakes 6-7
3 Tightening torques for brakes 6-8
M5N-091 ,M5N-111 xi
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4 Checking, disassembling, and servicing 6-9
4 1 Checking and adjusting 6-9
4 1 1 Traveling brake 6-9
4 1 2 Parking brake 6-11
4 2 Disassembling and assembling 6-12
4 2 1 Wheel model 6-12
4 2 2 Crawler model 6-26
4 3 Servicing 6-33
4 3 1 Brake pedal 6-33
4 3 2 Traveling brake 6-34
7 FRONT AXLE
MECHANISM 7-1
1 Structure 7-1
1 1 Structure of front axle (4WD model) 7-1
SERVICING 7-3
1 Troubleshooting for front axle 7-3
2 Servicing specifications for front axle 7-4
3 Tightening torques for front axle 7-6
4 Checking, disassembling, and servicing 7-7
4 1 Checking and adjusting 7-7
4 1 1 Checking toe-in 7-7
4 1 2 Adjusting toe-in 7-7
4 1 3 Checking axial sway of front wheel 7-7
4 1 4 Adjusting front axle pivot 7-7
4 1 5 Adjusting front wheel steering angle 7-8
4 2 Disassembling and assembling 7-8
4 2 1 Separating front axle 7-8
4 2 2 Disassembling front axle 7-11
4 2 3 Removing differential gear and bevel pinion shaft (4WD model) 7-16
4 2 4 Disassembling differential gear 7-17
4 3 Servicing 7-18
4 3 1 Checking ball bearing 7-18
4 3 2 Checking backlash and tooth contact between bevel pinion shaft and bevel gear 7-18
4 3 3 Checking clearance between differential case and differential side gear 7-20
4 3 4 Checking clearance between differential pinion shaft and pinion gear 7-21
4 3 5 Checking backlash between differential pinion and differential side gear 7-21
4 3 6 Checking turning torque of spiral bevel pinion shaft (pinion shaft only) 7-21
4 3 7 Checking front bracket and rear bracket bushing 7-22
4 3 8 Checking bearing retainer and front wheel case support bushing 7-23
4 3 9 Checking bevel gear case and front wheel case bushing 7-23
4 3 10 Checking backlash of bevel gear in bevel gear case 7-23
4 3 11 Checking backlash of bevel gear in front wheel case 7-24
8 STEERING
MECHANISM 8-1
1 Mechanism of steering 8-1
2 Feature of steering cylinder 8-2
SERVICING 8-3
1 Troubleshooting for steering 8-3
2 Servicing specifications for steering 8-5
3 Tightening torques for steering 8-6
3 1 Wheel model and crawler model 8-6
3 1 1 Tightening torques for steering 8-6
3 2 Crawler model 8-7
3 2 1 Tightening torques for steering 8-7
4 Checking, disassembling, and servicing 8-8
4 1 Checking and adjusting 8-8
xii M5N-091,M5N-111
KiSC issued 01 , 2022 A
4 1 1 Steering controller 8-8
4 2 Disassembling and assembling 8-8
4 2 1 Removing steering controller 8-8
4 2 2 Steering controller 8-56
4 2 3 Removing power steering cylinder 8-59
4 2 4 Disassembling steering cylinder 8-61
4 3 Servicing 8-62
4 3 1 Checking steering cylinder I D 8-62
4 3 2 Checking clearance between rod and bushing 8-62
9 HYDRAULIC SYSTEM
MECHANISM 9-1
1 Outline 9-1
1 1 Outline of whole hydraulic system 9-1
2 Structure 9-3
2 1 Structure of F12/R 12 speed transmission model hydraulic system 9-3
2 2 Structure of F24/R24 speed transmission model hydraulic system 9-4
3 Hydraulic circuit 9-5
3 1 Hydraulic circuit of F12/R12 speed transmission model 9-5
3 2 Hydraulic circuit of F24 / R24 speed model hydraulic system 9-7
4 Three point hitch hydraulic system 9-9
4 1 Outline of three point hitch hydraulic system 9-9
4 2 Structure of hydraulic block 9-11
4 3 Linkage mechanism 9-12
4 3 1 Function of position control 9-12
4 3 2 Outline of draft control 9-14
4 3 3 Function of mixed control 9-17
4 4 Feature of hydraulic cylinder 9-17
5 Auxiliary control valve 9-18
5 1 Self canceling detent (SCD) valve 9-18
5 1 1 Structure of inlet valve 9-18
5 1 2 Function of SCD valve 9-20
5 2 Floating detent (FD) valve 9-25
5 2 1 Structure of FD (Floating De tent) valve 9-25
5 2 2 Function of FD valve 9-27
5 3 Inlet valve 9-31
5 3 1 Structure of inlet valve 9-31
5 3 2 Function 9-32
SERVICING 9-35
1 Troubleshooting for hydraulic system 9-35
2 Servicing specifications for hydraulic system 9-38
3 Tightening torques for hydraulic system 9-40
4 Checking and adjusting 9-41
4 1 Hydraulic pump 9-41
4 1 1 Testing hydraulic flow of power steering pump 9-41
4 1 2 Testing hydraulic flow of 3-point hitch pump 9-42
4 2 Relief and safety valve 9-43
4 2 1 Checking relief valve setting pressure with pressure tester 9-43
4 2 2 Checking safety valve setting pressure using injection nozzle tester 9-43
4 3 Position and draft control linkage 9-44
4 3 1 Adjusting position feedback rod and draft feedback rod 9-44
4 3 2 Adjusting position control rod and draft control rod 9-45
4 3 3 Adjusting position control 9-45
4 3 4 Adjusting uppermost position of lift arm 9-46
4 3 5 Adjusting draft control 9-4 7
4 3 6 Adjusting draft lever free range 9-48
4 3 7 Adjusting draft floating range 9-49
4 3 8 Adjusting position and draft control lever operating force 9-49
MSN-091 ,MSN-111 xiii
KiSC issued 01, 2022 A
4 4 Auxiliary control valve linkage 9-51
4 4 1 Adjusting wire length of auxiliary control valve (Lever side) 9-51
4 4 2 Adjusting wire of auxiliary control (Valve side) 9-51
4 4 3 Adjusting oil flow control wire 9-52
4 5 Oil cooler check valve 9-52
4 5 1 Checking operating pressure of oil cooler check valve 9-52
5 Disassembling and assembling 9-53
5 1 Hydraulic pump 9-53
5 1 1 ROPS model 9-53
5 1 2 Cabin model 9-54
5 1 3 Disassembling hydraulic pump 9-55
5 2 Removing top cover (3-point hitch hydraulic block) 9-56
5 2 1 ROPS model 9-56
5 2 2 Cabin model 9-58
5 3 Hydraulic linkage 9-60
5 3 1 Removing position lever and draft lever linkage 9-60
5 3 2 Removing linkage bracket 9-61
5 3 3 Removing draft lever rod and position lever rod 9-61
5 3 4 Removing draft lever 3 and position lever 3 9-61
5 3 5 Removing position feedback rod and draft rod 9-62
5 3 6 Removing draft spool lever and position spool lever 9-62
5 4 Control valve 9-63
5 4 1 Removing control valve 9-63
5 4 2 Removing plug and unload valve 9-64
5 4 3 Removing spool and poppet valve 9-64
5 4 4 Removing check valve 9-64
5 5 Hydraulic cylinder 9-65
5 5 1 Removing hydraulic cylinder 9-65
5 5 2 Disassembling hydraulic cylinder 9-65
5 5 3 Installing piston seal 9-66
5 6 Removing position and draft control shaft and position and draft feedback shaft 9-66
5 7 Reliefvalve 9-67
5 7 1 Disassembling relief valve 9-67
5 8 Safety valve 9-68
5 8 1 Disassembling safety valve 9-68
5 9 Top link bracket 9-68
5 9 1 Disassembling top link bracket 9-68
5 10 Lift arm and lift arm shaft 9-69
5 10 1 Removing lift arm and lift arm shaft 9-69
5 11 Lowering speed adjusting valve 9-69
5 11 1 Removing lowering speed adjusting valve (ROPS model) 9-69
5 11 2 Removing lowering speed adjusting valve (Cabin model) 9-70
6 Servicing 9-71
6 1 Lift arm and top link bracket 9-71
6 1 1 Checking lift arm support bushing 9-71
6 1 2 Checking torsion bar and top link bracket 9-72
10 ELECTRICAL SYSTEM
MECHANISM 10-1
1 Electrical circuit related chart and connectors 10-1
1 1 ROPS model 10-1
1 1 1 Starting system and charging system (ROPS model) 10-1
1 1 2 Engine control system (Engine ECU) (ROPS model) 10-2
1 1 3 Engine control system (ACU) (ROPS model) 10-3
1 1 4 Lighting system (ROPS model) 10-4
1 1 5 Instrument panel (ROPS model) 10-5
1 1 6 Main control system (Tractor ECU) (ROPS model) 10-6
1 2 Cabin model 10-7
xiv M5N-091 ,M5N-111
KiSC issued 01, 2022 A
1 2 1 Starting system and charging system (Cabin model) 10-7
1 2 2 Engine control system (Engine ECU) (Cabin model) 10-8
1 2 3 Engine control system (ACU) (Cabin model) 10-9
1 2 4 Lighting system (Cabin model) 10-10
1 2 5 Instrument panel (Cabin model) 10-11
1 2 6 Main control system (Tractor ECU) 10-12
1 2 7 Air conditioner system (Cabin model) 10-13
1 2 8 Connectors (Cabin model) 10-14
2 Travel speed limiterfunction 10-15
2 1 Wheel model 10-15
2 1 1 Structure of travel speed limiter function 10-15
2 2 Crawler model 10-17
2 2 1 Structure of travel speed limiter function 10-17
2 3 Components 10-18
2 3 1 Function of tractor ECU 10-18
2 3 2 Function of range gear shift switch (Hi) and main gear shift switch (6th) 10-18
2 3 3 Function of shuttle rotation sensor 10-18
2 3 4 Function of traveling speed sensor 10-18
2 3 5 Function of throttle sensor 10-19
2 3 6 Function of engine ECU 10-19
2 3 7 Function of crankshaft position sensor 10-19
2 3 8 Meter ECU 10-19
3 Starting system 10-20
3 1 System outline and electrical circuit 10-20
3 1 1 Electrical circuit of starting system (ROPS model) 10-20
3 1 2 Electrical circuit of starting system (Cabin model) 10-22
3 2 Components 10-24
3 2 1 Function of intake air heater 10-24
3 2 2 Intake air heater relay 10-24
4 Instrument panel 10-25
4 1 Indication items of meter panel 10-25
4 1 1 Instrument panel 10-25
4 1 2 Easy Checker™ 10-26
4 1 3 Fuel gauge 10-27
4 1 4 DEF/AdBlue® gauge 10-27
4 1 5 Coolant temperature gauge 10-27
4 1 6 Function of tachometer 10-27
4 1 7 LCD monitor 10-28
5 Constant RPM management switch with indicator (Work cruise) 10-34
5 1 Structure of constant RPM management switch with indicator (Work cruise) 10-34
5 1 1 Constant RPM management mechanism 10-35
6 Electronic hydraulic shuttle 10-36
6 1 Structure of electronic hydraulic shuttle 10-36
6 2 Components 10-37
6 2 1 Function of tractor ECU 10-37
6 2 2 Function of shuttle shift indicator on meter panel 10-38
6 2 3 Function of shuttle sensor 10-39
6 2 4 Function of shuttle switch 10-39
6 2 5 Function of gear lock parking lever switch 10-39
6 2 6 Function of gear lock parking detect switch 10-39
6 2 7 Function of clutch off switch 10-40
6 2 8 Function of shuttle valve spool neutral switch 10-40
6 2 9 Function of buzzer 10-40
7 Bi-speed turn system 10-41
7 1 Structure of Bi-speed turn control 10-41
7 2 Components 10-42
7 2 1 Function of tractor ECU 10-42
7 2 2 Function of 4WD indicator on meter panel 10-43
MSN-09 1 MSN-111 xv
KiSC issued 01 , 2022 A
7 2 3 Bi-speed turn mode indicator on meter panel 10-44
7 2 4 Function of 4WD / Bi-speed turn switch 10-45
7 2 5 Function of turning angle switch 10-45
7 2 6 Function of traveling speed sensor 10-45
8 PTO speed limiter 10-46
8 1 Function of PTO speed limiter 10-46
8 2 Components 10-46
8 2 1 Function of tractor ECU 10-46
8 2 2 Function of PTO speed select switch 10-47
8 2 3 PTO switch 10-47
8 2 4 Function of throttle sensor 10-4 7
8 2 5 PTO relay 10-48
8 2 6 Function of engine ECU 10-48
8 2 7 Function of crankshaft position sensor 10-48
8 2 8 Function of meter ECU 10-48
9 Lighting system 10-48
9 1 Components 10-48
9 1 1 Flasher unit 10-48
10 Trailer socket 10-49
SERVICING 10-51
1 Troubleshooting for electrical system 10-51
2 Servicing specifications for electrical system 10-58
3 Tightening torques for electrical system 10-60
4 Checking and adjusting 10-61
4 1 Checking, setting and adjusting by using instrument panel 10-61
4 1 1 Mode and item selection 10-62
4 1 2 Mode [TST] 10-64
4 1 3 Mode [CHK] 10-67
4 1 4 Mode [SEL] 10-71
4 1 5 Mode [ADJ] 10-75
4 1 6 Various setting mode 10-78
4 2 Battery, fuses, grounding and connector 10-80
4 2 1 Battery 10-81
4 2 2 Fuse 10-82
4 2 3 Checking grounding wires 10-86
4 2 4 Connector 10-88
4 3 Starting system 10-88
4 3 1 Main switch 10-88
4 3 2 Starter motor 10-92
4 3 3 Shuttle lever neutral switch 10-93
4 3 4 Shuttle valve spool neutral switch 10-94
4 3 5 PTO switch 10-95
4 4 Intake air heater 10-96
4 4 1 Checking intake air heater 10-96
4 5 Alternator 10-96
4 5 1 Preparing for checking alternator 10-96
4 5 2 Measuring connector voltage for alternator 10-96
4 5 3 Measuring connector voltage for alternator (No load) 10-96
4 6 ECU 10-97
4 6 1 Meter ECU 10-97
4 6 2 Tractor ECU 10-98
4 6 3 Engine ECU and ACU 10-102
4 7 Traveling switch and sensor 10-112
4 7 1 Main gear shift (6th) switch 10-112
4 7 2 Range gear shift (High) switch 10-113
4 7 3 Shuttle valve spool neutral switch 10-114
4 7 4 Foot brake switch 10-115
4 7 5 Parking lock lever switch 10-115
xvi M5N-091 M5N-1 11
KiSC issued 01 2022 A
4 7 6 Gear lock parking brake switch 10-116
4 7 7 4WD I Bi-speed turn switch 10-117
4 7 8 Wheel angle switch 10-120
4 7 9 Main shift lever switch (F24/R24 speed transmission model) 10-121
4 7 10 Dual speed switch 10-122
4 7 11 Traveling speed sensor 10-123
4 7 12 Shuttle lever sensor 10-123
4 7 13 Shuttle rotation sensor 10-124
4 8 Engine control system 10-125
4 8 1 Injector 10-125
4 8 2 Pre-stroke control valve (PCV) 10-126
4 8 3 Rail pressure sensor 10-126
4 8 4 Pressure reducing valve (PRV) 10-127
4 8 5 Fuel pump 10-128
4 8 6 Sedimenter 10-129
4 8 7 Boost pressure sensor 10-129
4 8 8 Intake air temperature sensor 10-130
4 8 9 EGR valve 10-130
4 8 10 Camshaft position sensor 10-131
4 8 11 Crankshaft position sensor 10-131
4 8 12 Air flow sensor 10-132
4 8 13 Coolant temperature sensor 10-133
4 8 14 Intake throttle valve 10-134
4 8 15 Exhaust gas temperature sensor 10-134
4 8 16 Differential pressure sensor 10-135
4 8 17 Throttle sensor 10-136
4 8 18 Parked regeneration switch 10-138
4 8 19 DPF INHIBIT switch 10-138
4 8 20 Constant RPM management switch 10-139
4 8 21 RPM dual memory switch 10-141
4 8 22 Fuel level sensor 10-143
4 8 23 NOx sensor 10-143
4 8 24 SCR temperature sensor 10-144
4 8 25 DEF tank unit 10-145
4 8 26 DEF pump unit 10-146
4 8 27 DEF tank heater coolant valve 10-147
4 9 Relays 10-147
4 9 1 Intake air heater relay 10-147
4 9 2 Relays 10-148
4 10 Lighting switches and flasher unit 10-152
4 10 1 Combination switch and lever (ROPS model) 10-152
4 10 2 Combination switch and lever (Cabin model) 10-153
4 10 3 Hazard switch 10-154
4 10 4 Flasher unit 10-155
4 10 5 Front work light switch (ROPS model) 10-156
4 10 6 Front/ Rear work light (Cabin model) 10-156
4 11 Solenoid valve 10-157
4 11 1 Shuttle valve 10-157
4 11 2 PTO, 4WD and Bi-speed turn solenoid valve 10-158
4 11 3 Dual speed (F24/R24 speed transmission model) 10-160
4 12 Operator presence control (OPC) system 10-161
4 12 1 Checking OPC system 10-161
4 12 2 Checking seat switch 10-161
4 13 Other 10-161
4 13 1 Display select switch 10-161
4 13 2 PTO speed select switch 10-163
4 13 3 Buzzer 10-164
4 13 4 CCV heater (If equipped) 10-165
MSN-091 ,MSN-111 xvii
KiSC issued 01, 2022 A
5 Disassembling and assembling 10-168
5 1 Starter motor 10-168
5 1 1 Disassembling starter motor 10-168
5 2 Alternator 10-168
5 2 1 Disassembling front bracket 10-168
5 2 2 Disassembling pulley 10-168
5 2 3 Disassembling rotor 10-169
5 2 4 Disassembling brush 10-169
5 2 5 Reassembling brush 10-169
5 2 6 Disassembling bearing at slip ring side 10-170
5 3 Fuse (Slow blow 100 A) for Cabin model 10-170
5 3 1 Removing fuse 10-170
6 Servicing 10-171
6 1 Starter 10-171
6 1 1 Checking mica undercut of starter commutator 10-171
6 1 2 Measuring brush wear 10-171
6 1 3 Checking armature coil 10-172
6 1 4 Checking overrunning clutch 10-172
6 1 5 Checking brush holder 10-172
6 1 6 Checking field coil 10-172
6 2 Alternator 10-173
6 2 1 Checking bearing 10-173
6 2 2 Checking stator 10-173
6 2 3 Checking rotor 10-173
6 2 4 Checking slip ring 10-174
6 2 5 Checking brush wear 10-174
6 2 6 Checking rectifier 10-174
11 CABIN
MECHANISM 11-1
1 Air condiitioning system 11-1
1 1 Structure of air conditioning system 11-1
1 2 Structure of compressor 11-3
1 2 1 Operation of compressor 11-3
1 2 2 Property of compressor oil 11-3
1 3 Feature of air conditioner unit 11-3
1 3 1 Feature of A/C blower 11-4
1 4 System control of air conditioner 11-5
1 5 Airflow 11-6
1 5 1 Outline of air flow 11-6
1 6 Electrical system 11-7
1 6 1 Electrical circuit of air conditioner 11-7
1 6 2 Operation of blower function 11-8
1 6 3 Function of blower relay and compressor relay 11-10
1 6 4 Blower relay 11-13
SERVICING 11-15
1 Troubleshooting for cabin 11-15
2 Servicing specifications for cabin 11-20
3 Tightening torques for cabin 11-21
3 1 Wheel model and crawler model 11-21
3 1 1 Tightening torques for cabin 11-21
3 2 Crawler model 11 -23
3 2 1 Tightening torques for cabin 11-23
4 Precautions at repairing refrigerant cycle 11-24
4 1 Setting manifold gauge 11-25
4 2 Refrigerant charging hose 11-26
4 3 Objective of vacuum pump adaptor 11-27
4 4 Outline of electric gas leak tester 11-28
xviii M5N-091 ,M5N-111
KiSC issued 01, 2022 A
4 5 Operating can tap valve 11-28
4 6 Installing T-joint 11-28
4 7 Necessity of R134a refrigerant recovery and recycling machine 11-28
5 Checking and charging refrigerant cycle 11-29
5 1 Checking refrigerant cycle with manifold gauge 11-29
5 1 1 Connecting manifold gauge for test preparation 11-29
5 1 2 Outline of normal operating 11-29
5 1 3 Insufficient refrigerant 11-30
5 1 4 Excessive refrigerant or insufficient condenser cooling 11-30
5 1 5 Air entered in cycle 11-31
5 1 6 Moisture entered in cycle 11-31
5 1 7 Refrigerant fails to circulate 11-32
5 1 8 Expansion valve opens too far or improper installation of heat sensitizing tube 11-32
5 1 9 Damaged compression of compressor 11-32
5 2 Discharging, evacuating and charging 11-33
5 2 1 Discharging refrigerant 11-33
5 2 2 Evacuating system 11-35
5 2 3 Charging refrigerant 11-36
5 2 4 Checking charging refrigerant amount 11-37
6 Checking, disassembling, and servicing 11-38
6 1 Checking and adjusting 11-38
6 1 1 Compressor 11-38
6 1 2 Relay (A/C compressor, blower, work light, defoger and auxiliary power) 11-40
6 1 3 Control panel (Blower switch, A/C switch, mode control dial, temperature control dial,
and recirculation / fresh air selection switch) 11-42
6 1 4 Blower resistor 11-44
6 1 5 Blower motor 11-45
6 1 6 Temperature motor 11-46
6 1 7 Mode motor 11-46
6 1 8 Pressure switch 11-46
6 1 9 Front wiper switch 11-48
6 1 10 Front wiper motor 11 -48
6 1 11 Rear wiper switch (If equipped) 11-49
6 1 12 Rear wiper motor (If equipped) 11-50
6 1 13 Defogger switch (If equipped) 11-50
6 2 Disassembling and assembling 11-50
6 2 1 Wheel model 11-50
6 2 2 Crawler model 11-90
6 3 Servicing 11-131
6 3 1 Adjusting air gap of magnetic clutch (between hub plate and rotor) 11-131