WSM 60
WSM 60
WSM 60
COMBINE HARVESTER
DC-60-PH
Q General
Information on the machine body and engine identifications, the general precautions, tightening
torque and special tools are described.
Q Mechanism
Information on the construction and function are included.This part should be understood before
proceeding with troubleshooting, disassembling and servicing.
Q Servicing
Information on the troubleshooting, checking and adjusting, disassembling and assembling, and
servicing which cover procedures, precautions, factory specifications and allowable limits.
All information illustrations and specifications contained in this manual are based on the latest
product information available at the time of publication.
Specifications and other content contained in this manual are subject to change without prior notice.
August 2010
© KUBOTA Corporation 2010
CONTENTS
1. SAFETY FIRST
SAFETY FIRST
• This symbol, the Safety Alert Symbol, is used throughout this manual and on labels on the machine
itself to warn of the possibility of personal injury. Read these instructions carefully.
• It is essential that you read the instructions and safety regulations before you attempt to repair this unit.
DANGER
• Indicates an imminently hazardous situation which will result in death or serious injury if you do not
follow the instruction.
WARNING
• Indicates a potentially hazardous situation which could result in death or serious injury if you do not
follow the instruction.
CAUTION
• Indicates a potentially hazardous situation which may result in injury if you do not follow the
instruction.
IMPORTANT
• Indicates that machinery damage or failure could be caused if you do not follow the instruction.
NOTE
• Indicates useful information for operation.
(Reference)
• Indicates other suggestions for your reference.
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CONTENTS
1. MECHANISM................................................................................................................................ G-1
[1] SPECIFICATIONS.................................................................................................................. G-1
[2] POWER TRAIN ...................................................................................................................... G-2
2. FOR SAFE OPERATION.............................................................................................................. G-3
[1] IDENTIFICATION ................................................................................................................... G-3
[2] GENERAL PRECAUTIONS ................................................................................................... G-3
[3] HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING .............................. G-6
[4] TIGHTENING TORQUE ......................................................................................................... G-8
[5] SPECIAL TOOLS ................................................................................................................. G-10
1. MECHANISM
[1] SPECIFICATIONS
Model name DC-60
Type Grain hopper
Overall length 4800 mm
Dimensions Overall width 2175 mm
Overall height 2500 mm (Pre-cleaner)
Body weight 2450 kg
Name V2403-M-DI-TE2-CKMS1
Type Water-cooled 4 stroke cycle 4 cylinder form diesel engine
Total displacement 2.434 L (2434 cc)
Output / Speed 44.1 kW (60 PS) / 2700 rpm
Engine
Applicable fuel Diesel fuel (light oil)
Tank capacity 60 L
Starting system Starter
Battery 12 V, 52 Ah
Center
1150 mm
distance
Width ×
Ground 400 × 1545 mm
Crawler contact length
Average
ground
Running 19.7 kPa (0.20 kgf/cm2)
contact
portion pressure
Minimum ground clearance 255 mm (Transmission case bottom to ground)
Speed shift system Hydrostatic transmission system (HST)
Number of speed shift steps Forward stepless, Backward stepless (Each sub-shift consists of 2 traveling speeds)
Forward
Travel speed (sub-shift) Low speed (L): 0 to 1.30 m/s, High speed (H): 0 to 1.80 m/s
Reverse
Turning system Brake turning
Pick-up system Reel pick-up
Turning circle
diameter × 900 × 1828 mm
Width
Reel
Height
Reaping adjustment Hydraulic
portion system
Reaping width (Distance
2000 mm
between edge of dividers)
Width of reaping blade 1905 mm
Range of reaping height
−19 to 800 mm (At the tip of reaping blade)
(Raising and lowering)
Threshing system Axial flow type (threshing tooth type)
Type of
threshing Round-bar, tooth bar
Threshing tooth blade
Threshing drum Diameter ×
620 × 1615 mm
portion Width
Turning speed 560 rpm
Tailings return system Auger
Grain sorting system Shaking, wind selection (3 different airflow selection)
Concave area (4 pieces) 1.456 m2
Grain output Grain hopper 420 L
Applicable crop Rice
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G-1
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G-2
G-3
Oil Seals
• Packings and O-rings must be replaced during reassembly.
• Generally, oil seal lips should be attached in the direction of the
object that must be airtight. (for exceptional cases, different
instructions will be given.)
• Apply grease to new O-rings or oil seals before assembling.
(1) Apply Grease
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Snap Rings
• When reassembling external snap rings or internal snap rings,
as shown left, they must be positioned so that cornered section
faces against the force direction.
(1) Face the Sharp Edge Against the (A) For External snap rings
Direction from which Force is (B) For Internal snap rings
Applied.
9Y1210019GEG0007US0
Spring Pin
• When inserting spring pins, as shown left, the split (alignment
mark) must face the force direction.
(1) For Moving in Parallel (2) For Rotating
9Y1210019GEG0008US0
Split Pin
• Replace with a new split pin and fully split to prevent pulling out.
In general, single side splits are used, and the instruction
isgiven separately if a double split (anchor split) must be used.
• Tighten a grooved nut in the specified torque, align the hole of
the split pin to the tighten direction and use an S sp.
(1) Single split (3) S split
(2) double split
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G-4
CAUTION
• Be sure to set the nozzle to dispersion and then wash the
combine harvester at a distance of 2 meters or more to
prevent damage. If washed with direct projection or at an
improper distance;
1. Electrical wiring damage or disconnection could result,
causing fire.
2. Hydraulic hose damage could result, causing injury when
high-pressure oil gushes out.
3. May lead to equipment damage, breakdown or malfunction.
(Example)
1. Seals or warning labels may be peeled off.
2. If water enters electronic components, the engine or
transmission, a malfunction may result.
3. Rubber products including oil seals, resin products and
glass products may be damaged.
4. Coatings and gildings may be peeled off.
(1) Direct Shoot is Strictly Prohibited. (A) Direct Shoot
(2) Improper Distance is Strictly (B) Dispersion Projection
Prohibited. (C) Less than 2 m
(D) More than 2 m
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G-5
Wiring
• Securely tighten wiring terminals. Loose connections may lead
to malfunction or fire.
• Wiring must be kept away from rotating parts or hot parts.
• A protective cover should be installed over places of potential
damage.
• Damaged wiring must be fixed with electrical insulating tape or
mouse-proof tape; otherwise, replace with new wiring.
(1) Check Contact Portion without Rust (3) Contacted
(2) Loose Connections May Cause
Malfunction
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G-6
Cleaning
• Do not throw water on electrical parts such as connectors, the
main switch and starter motor.
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G-7
G-8
G-9
Adaptor C1
Application
• Use for checking the relief valve set pressure.
Adaptor C1
• For raising and lowering valve of the reaper and the reel
A 50 mm
B 16 mm
C 25 mm
D 3 mm
E 30 °
F 30 °
G 30 °
H 5.5 mm dia.
I PF 1/4
J PF 1/8 Threaded depth 10 mm, Drill depth 12 mm
K PF 1/4 Threaded depth 15 mm, Drill depth 18 mm
L 90 °
M 23 mm dia.
N 23 mm
O 90 °
P 26.6 mm
Q 9 mm dia.
C1 Chamfer 1 mm
R1 1 mm radius
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G-10
Adaptor 58
• For HST charge relief valve
A 35 mm
B 15 mm
C 10 mm
D 4 mm dia.
E 45 °
F 30 °
G 45 °
H PF 1/4 Threaded depth 15 mm, Drill depth 20 mm
I PT 1/4
J 21 mm
K 24.2 mm
R0.5 0.5 mm radius
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G-11
A 180 mm H 38 mm dia.
B 119.6 to 120.4 mm I 4.5 mm
C 65 mm J 9 mm
D 10 mm dia. (for 2 places) K M8 × 1.25
E Welding 4 points (20 mm) L Flange nut
F 65 mm dia. M Length : More than 80 mm
G 42 mm dia.
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G-12
A 27 mm O 14.5 mm dia.
B 23 mm P 80 mm dia.
C M14 × 2.0 Q 40 mm radius
D 25 mm R 30 mm radius
E 25 mm S 10 mm radius
F 60 mm T 5 mm
G M16 × 1.5 U 120 mm
H M14 × 2.0
I M14 × 2.0 V M14 x 2.0 Threaded depth 30 mm
J 25 mm
K 25 mm W 50 mm dia.
L 450 mm X 25 mm dia.
M 54 mm dia. Y 10 mm
N 40 mm dia. Z 110 mm
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G-13
CONTENTS
*The intervals shown in the above table may vary depending on operation conditions, crops and maintenance
service (repair, check).
IMPORTANT
• After replacing a belt, chain, or wire, be sure to check and make adjustments after a break-in.
1-S1
Check, Refer-
Check and replacement intervals
Check item Measures ence
(Indication or hourmeter)
/ change page
Traveling, operating portion
Initial or after replacement: After 20 hours, every 100 hours
Adjust
Traveling (transmission) drive belt thereafter 1-S24
Replace Every 300 hours
Power brake wire Replace Every 300 hours –
Transmission drive belt tension pulley Replace Every 800 hours –
Initial: After 50 hours, every 300 hours thereafter (Replace when
HST oil filter cartridge Replace 1-S22
replacing the hydraulic oil tank)
Initial: After 50 hours, every 300 hours thereafter (Replace when
Cleaning
Hydraulic oil tank filter replacing the hydraulic oil tank) 1-S22
Replace Every 600 hours
Initial or after replacement: After 20 hours, every 100 hours
Adjust
Crawler thereafter 1-S35
Replace Every 500 hours
Reassem-
Every 200 hours
Crawler drive sprocket ble –
Replace Every 400 hours
Rear wheels, track rollers, carrier rollers Replace Every 800 hours –
Crawler guide (front, rear) Replace Every 800 hours –
*The intervals shown in the above table may vary depending on operation conditions, crops and maintenance
service (repair, check).
IMPORTANT
• After replacing a belt, chain, or wire, be sure to check and make adjustments after a break-in.
1-S2
Check, Refer-
Check and replacement intervals
Check item Measures ence
(Indication or hourmeter)
/ change page
Reaper portion
Initial or after replacement: After 20 hours, every 100 hours
Adjust
Reaper drive belt thereafter 1-S25
Replace Every 300 hours
Initial or after replacement: After 20 hours, every 100 hours
Adjust
Feeder conveyor counter drive belt thereafter 1-S25
Replace Every 300 hours
Feeder conveyor counter drive belt tension
Replace Every 300 hours –
roller
Initial or after replacement: After 20 hours, every 100 hours
Adjust
Reel drive belt thereafter 1-S26
Replace Every 300 hours
Initial or after replacement: After 20 hours, every 100 hours
Adjust
Auger drum drive chain thereafter 1-S28
Replace Every 500 hours
Initial or after replacement: After 20 hours, every 100 hours
Adjust
Reel counter chain thereafter 1-S28
Replace Every 500 hours
Reel counter chain tension roller Replace Every 300 hours –
Initial or after replacement: After 20 hours, every 100 hours
Adjust
Reaper drive chain thereafter 1-S30
Replace Every 500 hours
Initial or after replacement: After 20 hours, every 100 hours
Adjust
Feeder conveyor chain thereafter 1-S29
Replace Every 500 hours
Adjust Every 100 hours
Reaping blade 1-S32
Replace Every 500 hours
Collecting finger shaft, finger guide, bracket Adjust Every 300 hours –
Reaper clutch wire Replace Every 400 hours 1-S31
*The intervals shown in the above table may vary depending on operation conditions, crops and maintenance
service (repair, check).
IMPORTANT
• After replacing a belt, chain, or wire, be sure to check and make adjustments after a break-in.
1-S3
Check, Refer-
Check and replacement intervals
Check item Measures ence
(Indication or hourmeter)
/ change page
Threshing portion
Initial or after replacement: After 20 hours, every 100 hours
Adjust
Thresher drive belt thereafter 1-S24
Replace Every 300 hours
Initial or after replacement: After 20 hours, every 100 hours
Adjust
Threshing drum drive belt thereafter 1-S26
Replace Every 300 hours
Initial or after replacement: After 20 hours, every 100 hours
Adjust
Grain and tailings auger drive belt thereafter 1-S27
Replace Every 300 hours
Grain and tailings auger drive belt tension
Replace Every 300 hours –
roller
Adjust Initial or after replacement: after 20 hours, every 100 hours thereafter
Shaking drive belt 1-S27
Replace Every 300 hours
Shaking drive belt tension roller Replace Every 300 hours –
Tailings auger drive chain Replace Every 500 hours –
Exchange Every 250 hours
Threshing tooth, threshing tooth bar Adjust Every 250 hours –
Replace Every 500 hours
Exchange Every 250 hours –
Concave
Replace Every 750 hours –
Grain vertical and horizontal auger shafts Replace Every 500 hours –
Tailings vertical and horizontal auger shafts Replace Every 500 hours –
Each auger shaft vane Replace Every 500 hours –
Each plate Replace Every 500 hours –
Each liner Replace Every 500 hours –
Each seal cloth, sponge Replace Every 300 hours –
All tension arms, fulcrum bushings Replace Every 500 hours –
Hopper
Discharge port boot Replace Every 500 hours –
Electrical portion
Charge When the engine becomes difficult to start
Battery G-6
Replace When the engine will not start
Check Every 50 hours
Wire harness, battery cable –
Replace If damaged
Check Every 100 hours
Fuse, slow blow fuse –
Replace If damaged
Check Every 100 hours
Lamp (bulb) –
Replace If damaged
Check Every 100 hours
Horn switch –
Replace If damaged
*The intervals shown in the above table may vary depending on operation conditions, crops and maintenance
service (repair, check).
IMPORTANT
• After replacing a belt, chain, or wire, be sure to check and make adjustments after a break-in.
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1-S4
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Pre-cleaner
• Keep it clean and protect against dirt or dust. Dirt or dust must
not be allowed to pile up higher than the white line (3) on the
collector (2) side.
(1) Knob Nut (3) White Line
(2) Collector (4) Dirt or Dust
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Dustproof Screen
• Open the dustproof cover (1) and clean the dustproof screen (2)
from the inside using compressed air.
IMPORTANT
• Do not use hard materials such as the spatula or the screw
driver, and do not use in a high-pressure washing machine.
(1) Dustproof Cover (2) Dustproof Screen
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1-S5
1-S6
1-S7
1-S8
1-S9
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1-S10
Engine Oil
1. Remove the rear engine cover (3).
2. Remove the oil gauge (2) and check the engine oil amount. It
should be between the upper limit and the lower limit on the oil
gauge.
[Replacement]
1. Remove the rear engine cover (3).
2. Remove the oil supply plug (4).
3. Remove the oil drain plug (5) and drain the oil.
Type SAE15W-40 CF
Capacity 9L
1-S11
1-S12
Reaper Drive Chain, Front Auger Drum Drive Chain and Reel
Drive Counter Chain Lubrication
1. Apply oil to the chain from the lubricating ports (1), (2), (3) of the
reaper right side cover top (4), bottom (5) and the feeder
conveyor right side cover (6).
(1) Lubricating Port of Reaper Drive (4) Top of Reaper Right Side Cover
Chain (5) Bottom of Reaper Right Side Cover
(2) Lubricating Port of Front Auger (6) Feeder Conveyor Right Side Cover
Drive Chain
(3) Lubricating Port of Reel Drive
Counter Chain
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1-S13
1-S14
1-S15
1-S16
1-S17
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1-S18
Fuel Strainer
• Remove the fuel cap (1) and clean the fuel strainer (2) with
diesel fuel or spray the compressed air if dirty or clogged.
IMPORTANT
• During replenishing fuel, the fuel strainer (2) should be
attached.
(1) Fuel Cap (2) Fuel Strainer
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1-S19
1-S20
(1) Inlet Hose 1 for Air Cleaner (2) Inlet Hose 2 for Air Cleaner
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Radiator Hose
1. Check the radiator hose (1), (2) and the water drain hose (3) for
deterioration and the hose clamp for loose connections.
Part Name Part No.
(1) Radiator hose 1 5H473-25560
(2) Radiator hose 2 5H473-25570
(3) Water drain hose 5T051-25541
1-S21
1-S22
[4] BELT
IMPORTANT
• Use only KUBOTA genuine parts for the belt replacement.
Check and
Size (Number of Reference
Part name Code No. replacement intervals
belts) page
(Time: Hour)
Inspection: 50 hours for
the first time. Every 100
Engine cooling fan drive belt 17111-97010 A40.5 (1) hours thereafter. 1-S23
Replacement: Every
500 hours
Engine room
Thresher drive belt 5T051-11571 SC54 cog (2) Inspection: 20 hours for 1-S24
the first time. Every 100
Traveling (transmission) hours thereafter.
5T051-11421 SB59 Cog (2) Replacement: Every 1-S24
drive belt
300 hours
Reaper drive belt 5T051-64651 SB54 (1) Inspection: 20 hours for 1-S25
the first time. Every 100
Feeder conveyor counter
Reaper portion 5T051-56461 SB46 (1) hours thereafter. 1-S25
drive belt
Replacement: Every
Reel drive belt 5T051-54551 SB107 (1) 300 hours 1-S26
Threshing drum drive belt 5T051-65852 SC96 (2) Inspection: 20 hours for 1-S26
the first time. Every 100
Threshing Grain auger and tailings
5T051-66351 SB104 (1) hours thereafter. 1-S27
portion reprocessing auger drive belt
Replacement: Every
Shaking drive belt 5T051-64571 SB66 (1) 300 hours 1-S27
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Engine Cooling Fan Drive Belt
1. Remove the front engine cover.
2. To check the amount of deflection (A), push your finger against
the center of the engine cooling fan drive belt (1).
3. If the measurement is not within factory specifications, loose the
mounting bolt (3) of the alternator (2) and the adjustment bolt
(4), and then adjust the belt tension of the engine cooling fan
drive belt (1) pulling the alternator (2).
7 to 9 mm / pushing with
Amount of deflection (A) Factory specification Approx. 60 to 70 N
(6 to 7 kgf)
1-S23
(1) Traveling (Transmission) Drive Belt (A) Inner Distance of Belt Tension
(2) Belt Tension Spring Spring Hooks
(3) Adjustment Nut
(4) Belt Tension Bolt
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1-S24
1-S25
(1) Threshing Drum Drive Belt (A) Inner Distance of Belt Tension
(2) Belt Tension Spring Spring Hooks
(3) Adjustment Nut
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1-S26
(1) Grain Auger and Tailings (A) Inner Distance of Belt Tension
Reprocessing Auger Drive Belt Spring Hooks
(2) Belt Tension Spring
(3) Adjustment Nut
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(1) Sieve Case Shaking Drive Belt (A) Inner Distance of Belt Tension
(2) Belt Tension Spring Spring Hooks
(3) Adjustment Nut
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1-S27
[5] CHAIN
IMPORTANT
• Use only KUBOTA genuine parts for the chain replacement.
Number
Reference
Part Name Part No. of Cleaning time (Time: Hour)
Page
chains
Front auger drum drive chain 5T051-49301 1 Inspection : 20 hours for the 1-S28
Reel drive counter chain 5T051-49401 1 first time. Every 100 hours for 1-S28
Reaper portion the second time or later.
Feeder conveyor chain 5T051-46301 1 Replacement : Every 500 1-S29
Reaper drive chain 5T051-46401 1 hours 1-S30
Threshing Tailings reprocessing vertical Replacement : Every 500
5T051-68610 1 3-S17
portion auger drive chain hours
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Front Auger Drum Drive Chain
1. Remove the right chain cover.
2. Measure the inner distance (A) of the chain tension spring (2)
hooks.
3. If the measurement is not within factory specifications, adjust
with the adjustment nut (3).
4. If the inner distance (A) of chain tension spring hooks can not
be adjusted by the adjustment nuts (3) due to much stretch of
the front auger drum drive chain (1), remove the half chain.
Inner distance (A) of belt
Factory specification 149 to 151 mm
tension spring hooks
(1) Front Auger Drum Drive Chain (A) Inner Distance of Chain Tension
(2) Chain Tension Spring Spring Hooks
(3) Adjustment Nut
(4) Chain Joint Part
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1-S28
1-S29
[6] WIRE
IMPORTANT
• Use only KUBOTA genuine parts for the wire replacement.
Check and replacement Reference
Part Name Part No.
intervals Page
Engine acceleration wire 5T051-32551 Inspection : Every 50 hours 1-S30
Engine stop wire 5T051-36251 Replacement : Every 300 hours 1-S31
Around driver's
Inspection : 50 hours for the first
seat
time. Every 100 hours for the
Reaper clutch wire 5T051-32541 1-S25
second time or later.
Replacement : Every 500 hours
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Engine Acceleration Wire
1. When the speed adjustment lever (1) on the engine side is set
to the lowest speed (a), the engine acceleration lever (2) should
be set in the lowest speed position (b) at the cover long hole (3).
Use the adjustment nut (4) to adjust.
2. When the engine acceleration lever (2) is set to the highest
speed, the clearance (d) between the engine acceleration lever
and the cover long hole should be 5 to 8 mm. Use the
adjustment nut (4) to adjust. (If measurement is not within the
factory specification 5 to 8 mm, adjust the clearance to 8 mm as
close as possible.)
(1) Speed Adjustment Lever on Engine (a) Lowest Speed Position
Side (b) Lowest Speed Position
(2) Engine Acceleration Lever (c) Highest Speed Position
(3) Cover Long Hole (d) Clearance
(4) Adjustment Nut
9Y1210019MAS0057US0
1-S30
1-S31
DANGER
• Do not touch the blade.
• For detaching and attaching the reaping blade, wear
protective gloves and hold both ends with other people.
1. Remove the reaping blade as one unit.
2. Remove dirt, rust, etc. using a wire brush.
3. Adjust the clearance (A) between the reaping blade (1) and
knife clip (2) by adding or removing a shim (4).
4. Lubricate the entire reaping blade and confirm that it moves to
the left and right smoothly.
Clearance (A) between
the reaping blade and Factory specification 0.3 to 1.0 mm
knife clip
1-S32
1-S33
1-S34
1-S35
(1) Chaff Sieve Adjustment Arm (A) Clearance between chaff sieve
(2) Bolt
(3) Chaff Sieve
(4) Step 1 (Fully Closed)
(5) Step 2
(6) Step 3
(7) Step 4 (Standard Position when
Shipped)
(8) Step 5 (Fully Open)
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1-S36
CONTENTS
1. MECHANISM.............................................................................................................................. 2-M1
[1] STRUCTURE ....................................................................................................................... 2-M1
1. MECHANISM
[1] STRUCTURE
Feeder Conveyor
(1) Feeder Conveyor Drum (4) Feeder Conveyor Chain (7) 27T Sprocket (10) Feeder Conveyor Drive Shaft
(2) Feeder Conveyor Drum Shaft (5) Feeder Conveyor Counter (8) Feeder Conveyor Drive Shaft (11) Feeder Conveyor Drive Pulley
(3) Feeder Conveyor Plate Drive Pulley Cover
(6) 22T Sprocket (9) 27T Sprocket
9Y1210019RPM0001US0
Front Auger Drum
(1) Drum Bracket (3) Crankshaft Bracket (5) Crankshaft (7) Crankshaft Bracket
(2) Fixed Shaft (4) Finger Bracket (6) Front Auger Drum Finger (8) Front Auger Drum Drive
Sprocket
9Y1210019RPM0002US0
2-M1
CONTENTS
DANGER
• Do not touch the blade.
• For detaching and attaching the reaping blade, wear
protective gloves and hold both ends with other people.
1. Remove the reaping blade as one unit.
2. Remove dirt, rust, etc. using a wire brush.
3. Adjust the clearance (A) between the reaping blade (1) and
knife clip (2) by adding or removing a shim (4).
4. Lubricate the entire reaping blade and confirm that it moves to
the left and right smoothly.
Clearance (A) between
the reaping blade and Factory specification 0.3 to 1.0 mm
knife clip
2-S1
2-S2
[3] REEL
Clearance between the Reel Tine and the Tip of Spiral Plate on
Front Auger Drum
1. Lower the reel to its lowest position and mount in the bolt hole
(5) position.
2. Remove the upper right reel cover.
3. Measure the clearance (A) between the tip of reel tine (1) and
the tip of spiral plate (2) on front auger drum.
4. If the measurement is not within factory specifications, loosen
the bolt (4) on the right side of the reel and adjust the tine angle.
5. After making adjustments, make sure the tip of the tine (1) is not
touching the received blade (7).
Clearance (A) between
reel tine and tip of spiral Factory specification 20 to 40 mm
plate on front auger drum
2-S3
9Y1210019RPS0006US0
2-S4
3. Remove 2 pairs of mounting bolts and nuts (5) from the rod ends
(4).
4. Remove the mounting bolt (7) on the reaping blade drive arm
(6). Remove the reaping blade drive arm (6).
(4) Rod Ends (6) Reaping Blade Drive Arm
(5) Bolt, Nut (7) Bolt
(When reassembling)
• When reassembling the rod ends, install the bolt stopper
parts (projections) (8) facing outwards as shown in the
diagram.
• Assemble in a manner so that the oil seal (15) groove faces
outwards.
(8) Bolt Stopper Parts (Projections) (15) Oil Seal
(To be continued)
2-S5
(When reassembling)
• When assembling the reaping blade drive arm (11), ensure
that it is parallel to the rod end (12).
Projection (A) Reference value 10.5 mm
5. Slide the reaping blade (13) to the right to pull out the entire
reaping blade unit.
9Y1210019RPS0008US0
2-S6
2. Remove the external snap ring (2) and then remove reaping
blade drive shaft 2 (4).
3. Remove the front auger drum drive chain (3).
(When reassembling)
Internal dimensions of
front auger drum drive Factory specification 149 to 151 mm
chain tension spring
(When reassembling)
• Ensure that the bearing holder part (5) of reaping blade
drive shaft 2 (4) is set to its correct position.
As shown in the left picture, the pin (6) must be assembled
inside from the center of the bearing holder (5).
Assemble the bearing holder part (5) so that the internal
snap ring (12) faces outside.
(4) Reaping Blade Drive Shaft 2 (6) Pin
(5) Bearing Holder Part
6. Remove the mounting bolts (10) of the reaping blade drive shaft
1 (9).
7. Remove the reaping blade drive shaft 1 (9).
(When reassembling)
• If the reaping blade drive cam (11) has been removed,
tighten with the prescribed tightening torque.
230 to 250 N·m
Tightening torque Reaping blade drive cam
23.50 to 25.40 kgf·m
(9) Reaping Blade Drive Shaft 1 (11) Reaping Blade Drive Cam
(10) Bolt
9Y1210019RPS0009US0
2-S7
3. Remove the front and rear adjustment bolts (2) for the left and
right reel positions.
(When reassembling)
• Apply grease to the inside of the front and rear adjustment
part for the reel position.
(2) Bolt
2-S8
(1) Front Auger Drum Drive Chain (2) Reel Drive Counter Chain
5. Remove the mounting bolt (4) and then remove the front auger
drum drive gear (3).
(When reassembling)
• Apply loctite bond to the threads of the mounting bolt (4) of the
front auger drive gear before reassembling.
(3) Front Auger Drum Drive Gear (4) Bolt
6. Remove the left and right drum covers (5) and (6).
7. Remove the left and right dividers (7).
8. Remove the left and right side covers (8) of the front auger
drum.
(5) Right Drum Cover (7) Divider
(6) Left Drum Cover (8) Drum Side Cover
[Right side]
1. Remove 3 mounting bolts (1) of the bearing holder for the front
auger drum shaft.
2. Remove the front auger drum height adjustment bolt (2).
3. Remove the hydraulic piping (3) for the reel cylinder.
(1) Bolt (3) Hydraulic Piping
(2) Front Auger Drum Height
Adjustment Bolt
2-S9
[Left side]
1. Remove the mounting bolt and nut (1) of the crankshaft.
(1) Bolt, Nut
5. Remove 8 mounting nuts (5) from the front auger drum height
adjustment plate and then remove the front auger drum height
adjustment plate (6).
(5) Nut (6) Front Auger Drum Height
Adjustment Plate
(To be continued)
2-S10
2-S11
2-S12
2. Remove the mounting bolt and nut (2) on the left side
crankshaft.
(2) Bolt, Nut
3. Remove the finger mounting bolts (3) and then remove the front
auger drum fingers (4).
4. Remove the finger guide (5).
(When reassembling)
• Apply the screw lock tight bond to the finger mounting
bolts (3) and reassemble.
(3) Finger Mounting Bolt (5) Finger Guide
(4) Front Auger Drum Finger
2-S13
2-S14
4. Remove the reaper drive belt and the feeder conveyor counter
drive belt.
5. Remove the wire harness (6) and hydraulic hose (5).
6. Remove the eight feeder mounting bolts and nuts (7).
7. Remove the joint pin of the front side of the cylinder for raising
and lowering the reaper portion.
(4) Reaper Drive Chain (6) Wire Harness
(5) Hydraulic Hose (7) Bolt, Nut
2-S15
(When reassembling)
• Use the chain tension bolt (2) to adjust the clearance (A)
between the feeder conveyor plate (4) and the bottom plate.
Measure the clearance (A) at the 3rd feeder conveyor plate
(4) position from the front of the reaper (a) as shown in the
left diagram.
• When assembling the feeder conveyor plate (4), be sure to
assemble it in the rotation direction shown in the drawing.
• Apply loctite bond to the feeder conveyor plate mounting
nuts.
Clearance (A) between
feeder conveyor and Factory specification 0.5 to 2 mm
bottom plate
2-S16
(When reassembling)
• Tighten the nut (5) of the feeder conveyor chain so that the
length (B) is set to between 25.2 and 25.8 mm.
9Y1210019RPS0015US0
(When reassembling)
• When reassembling the feeder conveyor drum, ensure that
the drum joint surface (4) is set in relation to the rotation
direction as shown in the drawing.
(4) Drum Joint Surface
9Y1210019RPS0016US0
2-S17
1. Remove the pulley mounting nuts and then remove the pulley
(1).
2. Remove the key (2).
3. Remove the pulley mounting nuts and then remove the pulley
(6).
4. Remove the internal snap ring (7).
5. Remove the cover guide (10) rivets (11) and then place the
cover guide (10) on the pipe cover L (9) side.
6. Remove the pipe cover (8) and then remove the 2 mounting
bolts (3) for the 27T gears (4).
7. Push out the feeder conveyor drive shaft (5) in the direction of
the arrow and remove the 27T gears (4), pipe cover L (9), and
cover guide (10).
(When reassembling)
• Apply loctite bond to the mounting bolts (3) and
reassemble.
• Apply grease on the entire circumference around the arrow
(A) section.
• Assemble the pipe cover (8) on the left side of the machine.
• After assembling the pipe cover (8), fill the notch with PVC
adhesive.
• Assemble the pipe cover L (9) and cover guide (10).
• Move the cover guide (10) to the left side of the machine.
• Attach the pipe cover L (9) and cover guide (10) using rivets
(11).
(1) Pulley (7) Internal Snap Ring
(2) Key (8) Pipe Cover
(3) Bolt (9) Pipe Cover L
(4) 27T Gear (10) Cover Guide
(5) Feeder Conveyor Drive Shaft (11) Rivet
(6) Pulley
9Y1210019RPS0017US0
2-S18
CONTENTS
1. MECHANISM.............................................................................................................................. 3-M1
[1] STRUCTURE ....................................................................................................................... 3-M1
1. MECHANISM
[1] STRUCTURE
Grain Auger
(1) Grain Vertical Auger Vane (3) Grain Auger Bevel Gear Case (5) Grain Auger Drive Pulley (6) Bearing Case
(2) Grain Vertical Auger Shaft (4) Grain Horizontal Auger Shaft
9Y1210019THM0001US0
3-M1
(1) Tailings Reprocessing Vertical (3) Tailings Reprocessing Vertical (4) Tailings Reprocessing (5) Tailings Reprocessing Auger
Auger Shaft Auger Drive Chain Case Horizontal Auger Shaft Drive Pulley
(2) Tailings Reprocessing Vertical
Auger Bevel Gear Case
9Y1210019THM0002US0
Winnower Fan
(1) Thresher Drive Pulley (2) Winnower Fan Plate (3) Thresher Drive Counter Pulley
9Y1210019THM0003US0
3-M2
(1) Front Twine Prevention Plate (2) Threshing Tooth (3) Rear Twine Prevention Plate (4) Deformed Threshing Tooth
9Y1210019THM0004US0
Sieve Case Shaking
(1) Sieve Case Shaking Drive (3) Shaking Arm Shaft 2 (4) Shaking Arm (5) Shaking Arm Shaft 1
Pulley
(2) Balance Weight
9Y1210019THM0005US0
3-M3
(1) Feeder Conveyor Counter (3) Feeder Conveyor Counter (4) Threshing Drum Drive Shaft 2 (5) Threshing Drum Drive Shaft 1
Drive Pulley Drive Shaft
(2) Shim
9Y1210019THM0006US0
3-M4
CONTENTS
Threshing Tooth
1. Remove 3 mounting bolts of the top roof, and open the top roof.
2. Remove the mounting bolts of the threshing tooth complete unit
(1), and then remove the threshing tooth complete unit (1).
(1) Threshing Tooth Complete Unit
9Y1210019THS0002US0
3-S1
6. Remove the retainer 1 (9) and the retainer 2 (10) of the feeder
conveyor counter drive belt (11), and then remove the feeder
conveyor counter drive belt (11).
(9) Retainer 1 (11) Feeder Conveyor Counter Drive
(10) Retainer 2 Belt
(12) Bolt
9Y1210019THS0003US0
3-S2
(1) Feeder Conveyor Counter (3) Feeder Conveyor Counter (4) Threshing Drum Drive Shaft 2 (5) Threshing Drum Drive Shaft 1
Drive Pulley Drive Shaft
(2) Shim
9Y1210019THS0004US0
CAUTION
• Be sure to install the flat washer (1) as shown in the picture
when removing the threshing drum drive pulley (3) by the
gear puller. It is dangerous the threshing drum drive pulley
(3) may come rushing out without a flat washer (1) pulling
by the gear puller.
1. Remove the mounting nut (2) of the threshing drum drive pulley
(3), and then remove the spring washer.
2. With the flat washer (1) set, install the nut (2), and then remove
the threshing drum drive pulley (3) using the gear puller.
(1) Flat Washer (3) Threshing Drum Drive Pulley
(2) Nut
IMPORTANT
• When removing the feeder conveyor counter drive shaft,
never hammer the shaft because it is made of soft material.
1. Remove the mounting nut of the feeder conveyor counter drive
pulley, and remove the spring washer.
2. With the flat washer set, install the nut. Remove the feeder
conveyor counter drive pulley using the gear puller.
3. Remove the oil seal, and remove the internal snap ring.
4. Check whether the shim is mounted.
5. Use the slide hammer (4) to remove the feeder conveyor
counter drive shaft.
(When reassembling)
• If the shim is mounted, be sure to install it in the original
position.
Type of Shims (0.2 mm, 0.8 mm, 1.0 mm and 1.2 mm).
Bevel gear backlash Factory specification 0.1 to 0.3 mm
3-S3
(When reassembling)
• Tighten the mounting bolts of the threshing drum drive gear case cover to the prescribed tightening
torque.
Mounting bolt of threshing 54.1 to 58.2 N·m
Tightening torque
drum drive gear case cover 5.30 to 5.70 kgf·m
9Y1210552THS0001US0
3-S4
2. Open the top panel (3) and remove the lower fulcrum of the gas
spring (4).
3. Close the top panel (3) and remove the 6 mounting bolts of the
top panel, and then remove the top panel (3).
(3) Top Panel (4) Gas Spring
4. Remove the thresher drum drive belt, reaper drive belt, and
feeder reversing drive belt. (See page 3-S2.)
5. Remove the threshing drum drive gear case (5) as complete
unit.
(When reassembling)
Mounting bolts of threshing 87.8 to 91.8 N·m
Tightening torque
drum drive gear case 8.60 to 9.00 kgf·m
3-S5
(A) Clearance
(When reassembling)
• Apply loctite bond to the threads of bolts (1) and (3) before assembly.
54.1 to 58.1 N·m
Tightening torque Bolts (1), (2), and (3)
5.30 to 5.70 kgf·m
9Y1210552THS0004US0
3-S6
CAUTION
• Use 2 persons to remove the sieve case.
1. Remove the sieve case shaking drive belt (1).
(1) Sieve Case Shaking Drive Belt
3. Remove 6 mounting bolts (3) of the sieve case for left and right
sides.
(When reassembling)
24.5 to 32.4 N·m
Tightening torque Sieve case mounting bolts
2.40 to 3.20 kgf·m
(3) Bolt
3-S7
2. Install the rubber sheets 3 (3) and 4 (4) as shown in the picture.
(3) Rubber Sheet 3 (4) Rubber Sheet 4
3. Install the rubber sheet 5 (5) to the side of the tailings horizontal
auger, and install rubber sheet 6 (6) to the external side of
rubber sheet 5 (5).
(1) Rubber Sheet 1 (5) Rubber Sheet 5
(2) Rubber Sheet 2 (6) Rubber Sheet 6
9Y1210019THS0009US0
3-S8
5. Remove the left and right side of the bearing at the front side of
the sieve case (2) by the puller.
(1) Straw Rack Frame (4) Chaff Sieve Assembly
(2) Sieve Case (5) Grain Sieve
(3) Chaff Sieve Adjustment Arm (6) Chaff Sieve
9Y1210325THS0001US0
3-S9
[Left Side]
1. Remove the threshing drum drive belt (1).
(1) Threshing Drum Drive Belt
(To be continued)
3-S10
3-S11
3. Remove 4 mounting bolts (3) for fixing the outside plate and the
bearing case.
4. Remove the grain horizontal auger towards the left side of the
machine.
(3) Bolt
9Y1210019THS0012US0
3-S12
3-S13
3-S14
Grain auger bevel gear case can be disassembled according to the figure below.
(1) Vertical Bevel Gear Shaft
(2) Oil Seal
(3) Internal Snap Ring
(4) Bearing
(5) Bevel Gear
(6) Grain Auger Bevel Gear
Case
(7) Bearing
(8) Bevel Gear
(9) Bearing
(10) Internal Snap Ring
(11) Oil Seal
(12) Horizontal Bevel Gear Shaft
(13) Grain Horizontal Auger Shaft
(14) Grain Vertical Auger Shaft
(When reassembling)
• Apply grease to the splines of vertical bevel gear shaft (1) and horizontal bevel gear shaft (12).
• Apply grease to the internal and external surfaces of the oil seal (2), (11).
• Add 35 to 45 g grease to the inside of the grain auger bevel gear case (6).
9Y1210019THS0015US0
3-S15
3-S16
(When reassembling)
• Apply grease to chain (2), 14T sprocket (3) and 13T sprocket (12).
• Add 15 to 25 g grease to the inside of the tailings reprocessing vertical auger bevel gear case (16).
• Apply grease to the splines of the 14T sprocket (3) and 13T sprocket (12).
• Apply grease to the internal and external surfaces of the oil seals (8), (17).
9Y1210552THS0003US0
3-S17
3-S18
(When reassembling)
• Add 15 to 25 g grease to the tailings reprocessing vertical auger bevel gear case (11).
• Apply grease to the spline of the tailings reprocessing vertical auger drive shaft (3).
• Apply grease to the internal and external surfaces of the oil seal (7) and secure.
9Y1210019THS0019US0
3-S19
CONTENTS
1. MECHANISM.............................................................................................................................. 4-M1
[1] STRUCTURE ....................................................................................................................... 4-M1
1. MECHANISM
[1] STRUCTURE
Structure
(1) Crawler Drive Sprocket (6) Right Brake Piston (11) Left Brake Piston (16) Parking Brake Claw
(2) 14T Gear (7) Axle Shaft (12) Steering Clutch Shaft (17) Parking Brake Plate
(3) HST Output Shaft (8) 19T-24T Gear (13) 16T-35T Gear (18) Thrust Collar
(4) 25T Gear (9) 1st Shaft (14) Intermediate Shaft (19) Brake Disk
(5) 40T-45T Gear (10) Steering Clutch 16T Gear (15) 39T Gear
9Y1210019TPM0001US0
4-M1
4-M2
Low-speed Position
4-M3
CONTENTS
4-S1
(2) Collar
(3) Bearing
(4) Bolt
(5) Track Roller Shaft
(6) Oil Seal
(7) Track Roller
(8) Shaft Collar
(9) Flat Washer
(10) Plug
(11) Internal Snap Ring
(12) Bolt
9Y1210019TPS0003US0
4-S2
(2) Collar
(3) Bearing
(4) Bolt
(5) Carrier Roller Shaft
(6) Oil Seal
(7) Carrier Roller
(8) Shaft Collar
(9) Flat Washer
(10) Plug
(11) Internal Snap Ring
(12) Bolt
9Y1210019TPS0004US0
4-S3
4-S4
[2] TRANSMISSION
Separating Left Side Case of Transmission Case
1. Remove the reaper and the feeder conveyor.
2. Remove the crawlers.
3. Discharge the transmission case oil and the hydraulic oil tank
oil.
4. Remove the traveling (transmission) drive belt (1).
5. Remove the HST drive pulley (2).
6. Remove the return hose 1 (6) and 2 (5) for the direction
hydraulic unit (4), and the hose (7).
7. Remove the axle shaft holder (8).
8. Remove the brake case (10).
9. Set the steering clutch spring assembling jig (11) and remove
the external snap ring (12).
10. Remove the assembling jig (11), the outside collar (one with the
smaller inside diameter) and the inside collar (one with the
larger inside diameter) of the steering clutch return spring.
(When reassembling)
• Apply the screw lock tight bond to the HST drive pulley
mounting nut (3) and tighten.
• Apply the screw lock tight bond to the axle shaft holder
mounting bolts (9) and tighten.
• Before reassembling, apply grease to the O-ring of the
brake case (10) to avoid damaging.
• When assembling the brake case (10), set the sub-shift
lever to the parking brake position, and then assemble in
meshing engagement with the brake disks and the spline
part of the steering clutch 16T gear by turning the brake
case (10). Do not assemble by tapping with a hammer, etc.
• Set the assembling jig (11) to push the steering clutch
return spring for installing the external snap ring.
(For the assembling jig, see page G-12.)
HST drive pulley mounting 59 to 61 N·m
Tightening torque
nut 6.0 to 6.2 kgf·m
4-S5
4-S6
(1) Right Side Transmission Case (5) Steering Clutch Shaft (9) Needle Bearing (12) Axle Shaft
(2) 14T Gear (6) Intermediate Shaft (10) Thrust Collar (13) Crawler Drive Sprocket Boss
(3) Sub-shift Shift Fork (7) Left Brake Case (11) Left Side Transmission Case (14) Crawler Drive Sprocket
(4) 1st Shaft (8) Left Brake Piston
9Y1210019TPS0007US0
(When reassembling)
• Apply oil to the brake piston (1), the O-ring (2) and the
sliding part of the transmission case (3) before
reassembling the brake piston (1).
• When reassembling the thrust needle bearing (4), the cover
(5) side should be faced to the brake piston (1) side.
• Surface A (6) of the thrust needle bearing (4) should be
faced to the thrust collar (7) side.
(1) Brake Piston (5) Cover
(2) O-ring (6) Surface A
(3) Transmission Case (7) Thrust Collar
(4) Thrust Needle Bearing
9Y1210019TPS0008US0
4-S7
4-S8
CONTENTS
1. MECHANISM.............................................................................................................................. 5-M1
[1] GENERAL ............................................................................................................................ 5-M1
[2] REAPER AND REEL RAISING AND LOWERING HYDRAULIC UNIT................................ 5-M3
(1) Neutral (Reaper and Reel Portions) ............................................................................... 5-M4
(2) Raising (Reaper and Reel Portions)............................................................................... 5-M5
(3) Lowering (Reaper and Reel Portions) ............................................................................ 5-M6
[3] DIRECTION HYDRAULIC UNIT........................................................................................... 5-M7
1. MECHANISM
[1] GENERAL
General (Hydraulic Circuit)
The hydraulic devices for the combine harvesters can be classified into the following 4 main functions.
• Raising and lowering the reaper portion
• Raising and lowering the reel
• Direction correction and turning the combine harvester
• HST (Hydrostatic transmission)
The dedicated hydraulic pump D is equipped for turning on and off the steering clutch and the steering brake, and
the hydraulic pump HR for raising and lowering the reaper portion and the reel portion.
As the hydraulic unit, there are 2 units as the direction hydraulic unit and the reaper and reel raising and lowering
unit.
To raise and lower the reaper or the reel and to turn the machine, use each operating lever to move the hydraulic
spool in the hydraulic unit so that oil flow can be switched to each hydraulic actuator.
9Y1210019HYM0001US0
Hydraulic Pump
5-M1
Reaper Cylinder
Reel Cylinder
5-M2
(1) Reaper Cylinder (4) Hydraulic Pump HR (8) Power Steering Lever (12) Reel Raising and Lowering
(2) Reaper and Reel Raising and (5) Hydraulic Oil Tank (9) Reel Cylinder Lever
Lowering Hydraulic Unit (6) Check Valve (10) Relief Valve (13) Raising Position
(3) Reaper Raising and Lowering (7) Check Valve (11) Reel Raising and Lowering (14) Neutral Position
Valve Valve (15) Lowering Position
9Y1210019HYM0008US0
Relief Valve
The relief valve of 14.7 to 15.7 MPa (150 to
160 kgf/cm2) is provided to set the maximum pressure
for actuating the hydraulic cylinder. If becoming the
overload situation in the hydraulic circuit, the relief valve
is opened to leak the hydraulic oil for protecting the
hydraulic devices.
(1) From Hydraulic Pump HR (3) To Reaper and Reel Raising
(2) To Hydraulic Oil Tank and Lowering Spool
9Y1210019HYM0009US0
5-M3
Relief Valve
5-M4
5-M5
5-M6
(1) Direction Change Spool (4) Left Brake Piston (6) Power Steering Lever (8) Hydraulic Oil Tank
(2) Hydraulic Pump D (5) Right Brake Piston (7) Direction Hydraulic Unit (9) Variable Relief Valve
(3) Check Valve
9Y1210019HYM0019US0
Variable Relief Valve
The variable relief valve regulates the hydraulic oil
pressure to activate the brake piston (see 4-M2 page)
controlling the hydraulic oil flow coming to B port of the
direction hydraulic unit from the brake pistons which are
existed in the transmission case.
When inclining the power steering lever to right or
left, the turning arm (6) moves in conjunction with the
power steering lever, and pushes the spring holder (5)
constantly. (At the same time, the turning arm (6) makes
to move the direction change spool (7) to right or left.)
The inclined amount of the power steering lever is
directly proportional to the moving amount of the spring
holder (5) pushing by the turning arm (6).
If the spring holder (5) is pushed much, the relief
spring (4) and the valve spring (3) are compressed so
that the valve opening pressure of the poppet (2) is
higher, causing the high pressure of the hydraulic oil in
the hydraulic oil circuit
The variable relief valve of 17.6 to 19.6 MPa (18 to
20 kgf/cm2) is provided to set the maximum pressure for
actuating the brake pistons.
(1) Valve P: From Hydraulic Pump D
(2) Poppet R: To Right Brake Piston
(3) Valve Spring L: To Left Brake Piston
(4) Relief Spring B: From Brake Piston
(5) Spring Holder T: To Hydraulic Oil Tank
(6) Turning Arm
(7) Direction Change Spool
9Y1210552HYM0003US0
5-M7
5-M8
5-M9
CONTENTS
5-S1
CONTENTS
1. MECHANISM.............................................................................................................................. 6-M1
[1] GENERAL ............................................................................................................................ 6-M1
1. MECHANISM
[1] GENERAL
The HST (hydrostatic transmission) is comprised of a pair of the variable capacity pump and the fixed capacity
motor, the charge pump, the oil filter cartridge, the check and high pressure relief valves, the charge relief valve, etc.
The HST is directly tied to the transmission case. The pulley of the engine output shaft and the HST drive pulley
are connected by the belt so that the engine power is transmitted to the HST. The HST drive pulley drives the HST
input shaft so that the pump in the HST is driven. The output power from the motor in the HST is transmitted to the
transmission by 14T gear of the motor output shaft.
The rotation direction and speed of the motor output shaft is changed by the movement of the HST lever (trunnion
shaft), which is moved by the main shift lever in the operator's seat via the HST rod.
The hydraulic oil of the HST is used the oil in the hydraulic oil tank. The hydraulic oil tank is used in conjunction
with other hydraulic devices, but the HST is equipped with the dedicated oil filter and the oil filter cartridge (10 microns
mesh) separated from the other hydraulic circuits.
(1) HST
6-M1
(1) Pump Shaft (Input Shaft) (4) Check and High Pressure (6) Check Valve (9) Fixed Capacity Motor
(2) Oil Filter Cartridge Relief Valves (7) Orifice (10) Motor Shaft (Output Shaft)
(3) Charge Pump (5) Variable Capacity Pump (8) Charge Relief Valve (11) Oil Cooler
9Y1210019TRM0001US0
6-M2
6-M3
6-M4
CONTENTS
1. TROUBLESHOOTING.................................................................................................................6-S1
2. CHECKING AND ADJUSTMENT ................................................................................................6-S3
3. DISASSEMBLING .......................................................................................................................6-S4
[1] DISASSEMBLING AND ASSEMBLING OF HST ..................................................................6-S4
1. TROUBLESHOOTING
CAUTION
• Do not disassemble the HST unless necessary. When HST trouble is suspected, perform the following
troubleshooting and checking, confirm the cause and then disassemble, while paying attention to the
following items.
1. Do not use the wire brush or the sand paper on the sliding surface of the hydraulic portion as it is precisely
processed. Remove dust with compressed air. Wash with the hydraulic oil.
2. Check the damage, wear and breakage for the sliding portions of each part. If detected, exchange both sliding
and slided parts as an assembly parts.
3. Do not wash the seal parts with a washing solvent designed for use with the metal parts. Remove the dust with
the compressed air. Soak the seal parts in hydraulic oil. Preferably, change the seal parts for new ones.
6-S1
9Y1210019TRS0001US0
6-S2
6-S3
3. DISASSEMBLING
[1] DISASSEMBLING AND ASSEMBLING OF HST
Charge Pump
1. Remove the pump cover. Remove each outer rotor, inner rotor
and the key.
9Y1210019TRS0004US0
6-S4
2. Remove the fixed swash plate (3), the output shaft (2) and the
input shaft (4).
(2) Output Shaft (4) Input Shaft
(3) Fixed Swash Plate
9Y1210019TRS0007US0
6-S5
CONTENTS
1. MECHANISM.............................................................................................................................. 7-M1
[1] GENERAL ............................................................................................................................ 7-M1
[2] CONTROL CONTENTS ....................................................................................................... 7-M2
1. MECHANISM
[1] GENERAL
Meter Panel
The meter panel is equipped with 5 alarm lamps (the
water temperature alarm, the charge alarm, the engine
oil pressure alarm, the grain full alarm, and the tailings
reprocessing auger clogging alarm).
Turning the main switch from OFF to ON, it lights up
the charge alarm lamp and the engine oil pressure alarm
lamp, and it sounds continuously the electronic buzzer.
Starting the engine, it stops the electronic buzzer
and turns off the charge alarm and engine oil pressure
alarm lamps.
Further, the engine oil pressure alarm lamp turns ON
and the electronic buzzer sounds continuously when the
engine is stopped to prevent you from forgetting to return
the main switch to the OFF position.
9Y1210019WSM0001US0
7-M1
Charge Alarm
When the charge signal from the IC regulator in the
alternator (2) is ON (approx. 0 V) while the engine runs
at idling revolution speed or higher, the charge alarm
lamp (1) turns ON. It does not sound neither the
electronic buzzer nor the horn.
(1) Charge Alarm Lamp (2) Alternator
(Built-in IC Regulator)
9Y1210019WSM0003US0
7-M2
7-M3
7-M4
Back Alarm
Setting the main shift lever to the backward position,
it turns ON the back switch (1), and it sounds the back
buzzer (2) intermittently.
(1) Back Switch (2) Back Buzzer
9Y1210019WSM0007US0
7-M5
CONTENTS
1. CIRCUIT DIAGRAM
8-M1
2. WIRING DIAGRAM
8-M2
CONTENTS
1. CHECKING..................................................................................................................................8-S1
[1] POWER SUPPLY, GROUND ................................................................................................8-S1
[2] STARTER DEVICE ...............................................................................................................8-S2
[3] CHARGING DEVICE .............................................................................................................8-S4
[4] LIGHT DEVICE......................................................................................................................8-S5
[5] RELAY...................................................................................................................................8-S6
[6] SENSOR ...............................................................................................................................8-S6
[7] HORN, BUZZER....................................................................................................................8-S8
[8] ALARM UNIT .........................................................................................................................8-S8
1. CHECKING
• The following inspection is a way of judging whether a sensor or actuator is defective or whether the problem lies
with the wiring.
Basically, the inspection should be conducted while the relevant connector is disconnected.
9Y1210019ELS0001US0
Work light 25 A
1. Inspect fuses in the fuse case.
(Reference)
• There are the spare fuses (10 A, 15 A, 25 A) in the fuse case.
(1) Fuse Case
9Y1210325ELS0001US0
Ground
1. Inspect whether the ground wire is securely connected to the
machine body.
9Y1210019ELS0004US0
8-S1
8-S2
8-S3
8-S4
8-S5
[5] RELAY
Work Light Relay, Starter Relay, Dust Discharge Fan Relay
5H276-41250 relay (C terminal)
Measured items Measurement Factory specification
Coil Terminal 3 - Terminal 5 Conduction
Terminal 1 - Terminal 2 Infinity
Terminal
Terminal 1 - Terminal 4 Conduction
[6] SENSOR
Tailings Reprocessing Auger Rotation Detection Sensor
5K200-71130 sensor assembly (rotation)
Measurement Factory specification
4 times of ON and OFF per one
Terminal 1 - Terminal 2
rotation of sensor shaft
8-S6
Horn Switch
38240-32410
Switch condition Measurement Factory specification
Push Terminal 1 - Terminal 2 Conduction
Free Terminal 1 - Terminal 2 Infinity
8-S7
8-S8
CONTENTS
1. SPECIFICATIONS...................................................................................................................... 9-G1
2. TIGHTENING TORQUE ............................................................................................................. 9-G2
3. SPECIAL TOOLS ....................................................................................................................... 9-G3
1. SPECIFICATIONS
Model V2403-M-DI-TE2-CKMS1
Type Vertical type water-cooled 4-cycle diesel
Number of cylinders 4
Bore × stroke 87 × 102.4 mm
Total displacement 2.434 L
Type of combustion chamber Direct injection type
44.1 kW / 2700 rpm
Output
60 PS / 2700 rpm
Firing order 1-3-4-2
Rotation direction Counterclockwise (viewed from the flywheel side)
Fuel Injection Pump Bosch K type mini-pump
Primary valve opening pressure: 18.6 MPa (190 kgf/cm2)
Fuel injection pressure
Secondary valve opening pressure: 22.6 MPa (230 kgf/cm2)
Compression ratio 20.2
Fuel used Diesel fuel
Applicable lubricant Diesel Engine SAE15W-40 CF
Lubricant capacity 9L
Coolant capacity 8.5 L
Dry weight 188 kg
Starting system Electric starting with starter motor
Starter motor 12 V 2.0 kW
(Electrical) charging generator 12 V 720 W
9Y1210325END0001US0
9-G1
2. TIGHTENING TORQUE
Many screws and nuts used in the engine parts are specialized, and tightening torque significantly influences the
performance and durability of the engine. Make sure to use a torque wrench to properly tighten the screws and nuts
shown in the following table. When multiple screws and nuts are used to tighten a single part (e.g., cylinder head),
apply half the prescribed torques first for temporary tightening, then tighten using the prescribed torques.
9-G2
3. SPECIAL TOOLS
Compression Tester for Diesel Engine
Code No.
• 07909-39081 (Assembly)
• Adaptor L code No. : 07909-31301
• Adaptor K code No. : 07909-31291
• Adaptor M code No. : 07909-31311
Application
• To measure the compression pressure (for the glow plug)
(1) Gauge (4) Adaptor K
(2) Hose (5) Adaptor L
(3) L joint (6) Adaptor M
9Y1210019END0004US0
Oil Pressure Tester for Engine
Code No.
• 07916-32032
Application
• To measure the lubricant pressure
(1) Gauge (5) Adaptor 2
(2) Cable (6) Adaptor 3
(3) Screw joint (7) Adaptor 4
(4) Adaptor 1 (8) Adaptor 5
9Y1210019END0005US0
9-G3
9-G4
9-G5
CONTENTS
1. ENGINE BODY
[1] HEAD COVER
Cylinder Head Cover
The cylinder head cover (1) is lifted by the rubber
packing (2) approx. 0.5 mm from the cylinder head to
reduce the noise of combustion from the cylinder head.
(1) Cylinder Head Cover (2) Rubber Packing
9Y1210019ENM0002US0
[3] CRANKCASE
Crankcase
The tunnel type of the crankcase with unitary
construction provides great rigidity to the crankshaft
bearing.
The crankcase has a hollow core (1) of cooling water
passage already cast inside the cylinder-to-cylinder
water jacket. It has improved the cooling performance by
flowing smoother cooling water.
(1) Hollow Core
9Y1210019ENM0004US0
9-M1
9-M2
2. LUBRICATING SYSTEM
[1] GENERAL
General of Lubricating System
The engine oil lubricates friction parts after the oil strainer (8) removes large dirt, the oil pump (7) pumps it up,
and the engine oil filter cartridge (16) removes foreign objects.
The lubrication of friction parts is performed using the forced-feed lubrication by the oil pump (7) and the splash
lubrication by the leaked oil from the forced-feed parts.
The forced-feed lubrication is employed for the crankshaft (6), the connecting rod (14), the camshaft (12), the
rocker arm shaft (3), the idle gear (5) and the turbocharger. The splash lubrication is employed for the piston pin (17),
the fuel camshaft, the tappet (11) and the push rod (10).
9Y1210019ENM0020US0
9-M3
9-M4
3. COOLING SYSTEM
[1] GENERAL
General of Cooling System
The engine cooling system uses a forced-feed circulation type operated by the water pump (2). The coolant
temperature is properly maintained by the thermostat (4). The coolant, which is sucked in from the lower tank of the
radiator (1) by the water pump (2), cools the cylinders and combustion chamber as it runs through the water jacket in
the crankcase (6) and the cylinder head (5) before returning to the radiator (1).
Further, a bottom bypass system is used to improve cooling performance. When the coolant temperature is low
in the engine, the thermostat (4) is kept closed, and the coolant directly enters the pump, bypassing the radiator (1)
via the bypass pipe to help raise the temperature by circulating within the engine.
When the coolant temperature reaches the valve opening temperature (71 °C), the thermostat (4) will open to let
the coolant run through the radiator (1) to perform cooling.
(1) Radiator
(2) Water Pump
(3) Fan
(4) Thermostat
(5) Cylinder Head
(6) Crankcase
9Y1210019ENM0011US0
9-M5
9-M6
4. FUEL SYSTEM
[1] GENERAL
General of Fuel System
The fuel feed pump (7) performs the fuel suction from the fuel tank (1) through the water separator (5) and the
fuel filter cartridge (6) to send the fuel injection pump (4).
The fuel injection pump (4) subsequently pressurizes fuel to the fuel injection nozzles (3) in accordance with the
fuel injection timing of each cylinder in the engine, and injects fuel to the combustion chamber.
(1) Fuel Tank (3) Fuel Injection Nozzle (5) Water Separator (Sedimenter) (7) Fuel Feed Pump
(2) Fuel Return Pipe (4) Fuel Injection Pump (6) Fuel Filter Cartridge
9Y1210019ENM0013US0
9-M7
[4] GOVERNOR
Governor
The engine uses a mechanical all-speed governor
that utilizes the balance between the centrifugal force of
the steel ball (6) and the tension of the governor spring 1
(4), 2 (3), and the fuel injection amount is controlled
across the rotation range from idling to the maximum
revolution.
The torque spring (7) is built in the fork lever 1 (1)
and contributes to a mechanical toughness with higher
torque under an overload situation by increasing the fuel
injection amount.
(1) Fork Lever 1 (5) Maximum Speed Adjustment
(2) Fork Lever 2 Screw
(3) Governor Spring 2 (6) Steel Ball
(4) Governor Spring 1 (7) Torque Spring
(8) Control Rack
9Y1210019ENM0016US0
9-M8
Turbocharger Body
The turbocharger comprises the turbine housing (8), the turbine wheel (7), the compressor housing, the
compressor wheel (10), and bearing housing, etc.
The turbocharger is mounted to the exhaust manifold, and the exhaust gas is accelerated and blown against the
turbine wheel (7) as it enters the turbine housing (8) to rotate the turbine wheel (7). When the turbine wheel (7) rotates,
the compressor wheel (10) that is installed on the same shaft will rotate simultaneously to compress and supply the
air to the combustion chamber.
As the turbine wheel (7) and the compressor wheel (10) rotate approx. 200000 times max. on the same shaft,
they are supported by a full floating type bearing, and a thrust bearing (2) is provided to receive the axial load.
The lubrication for the bearings is operated by the diversion of lubricants from the lubricants passage to the
bearing housing ; the lubricants subsequently return to the oil pan.
9Y1210019ENM0018US0
Boost Control
This turbocharger is equipped with the waste gate system that controls boost at the high revolutions.
To exert the effect of the turbocharger at low and medium speeds, the system is designed to improve the torque
at low and medium speeds by operating at high revolutions to increase the boost, and supply a large volume of air to
the combustion chamber.
If the engine revolution speed keeps increasing in this condition, however, the durability of the engine and the
turbine may be compromised due to the excessive increase of the boost. When the boost reaches the set pressure,
the release control system is activated by making the boost bypass the turbine of the exhaust gas.
9Y1210019ENM0019US0
9-M9
CONTENTS
1. TROUBLESHOOTING.................................................................................................................9-S1
2. SERVICING SPECIFICATIONS (V2403-M-DI-T)........................................................................9-S6
3. ENGINE BODY..........................................................................................................................9-S11
[1] SEPARATING ENGINE.......................................................................................................9-S11
[2] CHECKING AND ADJUSTMENT ........................................................................................9-S14
(1) Valve Clearance ............................................................................................................9-S14
(2) Compression Pressure ..................................................................................................9-S15
[3] DISASSEMBLING AND ASSEMBLING ..............................................................................9-S15
(1) Cylinder Head and Valve...............................................................................................9-S15
(2) Fuel Injection Pump.......................................................................................................9-S20
(3) Gear Case .....................................................................................................................9-S23
(4) Timing Gear and Camshaft ...........................................................................................9-S24
(5) Piston and Connecting Rod...........................................................................................9-S25
(6) Crankshaft .....................................................................................................................9-S28
[4] SERVICING .........................................................................................................................9-S31
(1) Cylinder Head................................................................................................................9-S31
(2) Timing Gear...................................................................................................................9-S35
(3) Piston, Connecting Rod and Crankshaft .......................................................................9-S37
(4) Crankcase .....................................................................................................................9-S43
4. LUBRICATING SYSTEM...........................................................................................................9-S45
[1] CHECKING..........................................................................................................................9-S45
[2] SERVICING .........................................................................................................................9-S45
(1) Oil Pump........................................................................................................................9-S45
5. COOLING SYSTEM ..................................................................................................................9-S47
[1] CHECKING..........................................................................................................................9-S47
[2] DISASSEMBLING, ASSEMBLING AND SERVICING ........................................................9-S47
6. FUEL SYSTEM..........................................................................................................................9-S49
[1] FUEL INJECTION NOZZLE ................................................................................................9-S49
(1) Checking and Adjustment..............................................................................................9-S49
[2] FUEL INJECTION PUMP ....................................................................................................9-S50
(1) Checking and Adjustment..............................................................................................9-S50
7. ELECTRICAL SYSTEM.............................................................................................................9-S51
[1] STARTER MOTOR .............................................................................................................9-S51
(1) Disassembling and Assembling.....................................................................................9-S51
(2) Servicing........................................................................................................................9-S51
[2] ALTERNATOR ....................................................................................................................9-S53
(1) Disassembling and Assembling.....................................................................................9-S53
(2) Checking and Maintenance ...........................................................................................9-S55
8. TURBOCHARGER ....................................................................................................................9-S58
[1] CHECKING..........................................................................................................................9-S58
[2] COMPLETE REPLACEMENT OR REASSEMBLY .............................................................9-S59
1. TROUBLESHOOTING
Reference
Symptom Probable Cause Solution
Page
The Engine Does Not Engine body
Start Incorrect valve clearance (low compression Adjust valve 9-S14
pressure) clearance
Compression leakage from the cylinder to the Replace the cylinder 9-S17
outside (low compression pressure) head gasket
Tighten the cylinder 9-S15 to
head bolt, the glow 9-S17
plugs and the fuel
injection nozzle
holders
Compression leakage in the combustion Replace the piston 9-S27
chamber (low compression pressure) rings
Incorrect valve timing (low compression Inspect the timing 9-S24
pressure) gear
Incorrect valve seat contact Replace the valve 9-S19
spring
Repair the valve seat 9-S33 to
contact 9-S34
Seizure the crankshaft, the camshaft, the piston, Repair or replace 9-S24,
or the bearing 9-S29
Increased combustion chamber volume (low Correct the valve 9-S31
compression pressure) recessing amount
Fuel system
No fuel (in the fuel tank and the fuel pipe) Fill up the fuel –
The fuel with high viscosity is used Replace with the –
designated fuel
The fuel with low cetane number is used Replace with the –
designated fuel
The water is mixed in the fuel Replace with the –
designated fuel
The fuel filter cartridge is clogged Replace the fuel filter 1-S20
cartridge
Fuel leakage from the fuel injection pipe nut Tighten the nut 9-S16
The fuel pipe is clogged Clean or replace –
Defective the fuel injection nozzle Replace 9-S16,
9-S50
Incorrect fuel injection timing Adjust 9-S50
The fuel injection pump is defective Replace assembly 9-S20,
9-S50
The engine stop wire is defective Inspect and adjust or 1-S31
replace
Electrical system
Low battery capacity Replace with the –
battery with the
designated capacity
Battery over-discharge Charge or replace –
9-S1
Reference
Symptom Probable Cause Solution
Page
The Engine Does Not The starter motor is defective Repair or replace 9-S51 to
Start 9-S53
Defective or faulty wiring Inspect and repair –
Defective the main switch Repair or replace –
Blown the fuse Replace after solving –
problem
Fuel system
The control rack of fuel injection pump is fixed Repair the fuel 9-S20,
injection pump or 9-S50
replace assembly
Electrical system
Defective or faulty wiring Inspect and repair –
The Engine Speed is Intake / exhaust system
Irregular, and the The air cleaner is clogged Clean the air cleaner 1-S19
Exhaust Gas is White element using the
or Blue compressed air, or
replace
Fuel system
The fuel filter cartridge is clogged Replace the fuel filter 1-S20
cartridge
Fuel leakage from the fuel injection pipe nut Tighten the nut 9-S16
The fuel injection nozzle is defective Replace 9-S16,
9-S50
The fuel return pipe is clogged Correct the bend or –
clean
The fuel injection pump is defective Replace assembly 9-S20,
9-S50
Engine body
The piston ring and the piston are worn out Replace the piston 9-S27,
ring and the piston 9-S38
Worn cylinder Repair the cylinder 9-S43
Increased combustion chamber volume (low Correct the valve 9-S31
compression pressure) recessing amount
Lubricating system
The oil is oversupplied Reduce oil to the –
specified amount
Fuel system
The fuel injection timing is incorrect Adjust 9-S50
Intake / exhaust system
The oil return pipe is deformed or clogged Inspect and clean or –
replace the oil return
pipe
9-S2
Reference
Symptom Probable Cause Solution
Page
The Exhaust Gas is Engine body
Black or Dark Gray, Overload Reduce the load –
or the Output is
Shortage Compression leakage from the cylinder to the Tighten the cylinder 9-S16,
outside head bolts, the glow 9-S17
plugs and the fuel
injection nozzle
holders
The engine moving parts (piston and crank) are Repair or replace –
slightly seizured
Fuel system
The low grade fuel is used Replace with the –
designated fuel
The fuel filter cartridge is clogged Replace the fuel filter 1-S20
cartridge
The fuel injection timing is incorrect Adjust 9-S50
The fuel atomizing state is incorrect Replace the fuel 9-S16,
injection nozzle 9-S49
assembly
The fuel injection amount is not uniform Replace the fuel 9-S20,
injection pump 9-S50
assembly
Intake / exhaust system
The air cleaner is clogged Clean or replace the 1-S19
air cleaner element
The Engine Oil is Engine body
Overconsumed Oil leakage from the tightening points and plugs Tighten to the –
prescribed torque
The crankshaft oil seal, O-ring or the gasket are Replace –
defective
The valve stem seal is defective Replace the seal 9-S19
The Piston ring gaps are set to the same Change the gaps 9-S26 to
direction direction 9-S27
The oil ring is worn out or stuck Replace 9-S26 to
9-S27
The piston ring groove is worn out Replace the piston 9-S26,
and the piston rings 9-S27,
9-S29
The Fuel is Mixed in Fuel system
the Engine Oil The fuel injection pump is defective Replace the fuel 9-S20,
injection pump 9-S50
assembly
The Water is Mixed in Engine body
the Engine Oil The cylinder head gasket is broken Replace 9-S17
The cylinder head is cracked Replace 9-S17
The o-ring and the packing in the water passage Replace 9-S23
between the gear case and the crankcase are
damaged
9-S3
Reference
Symptom Probable Cause Solution
Page
The Engine Oil Lubricating system
Pressure is Low The Oil is shortage Replenish the oil to 1-S11
the specified amount
Poor oil quality Replace with the 1-S11
designated oil
The Oil filter cartridge is clogged Replace the oil and 1-S20
the oil filter cartridge
The relief valve is defective Repair or replace 9-S45
The oil clearance is excessive in metals Replace the metal, 9-S38 to
the bushing or the 9-S42
shaft
The oil passage is clogged Clean –
The oil pump is defective Replace 9-S45 to
9-S46
The assembly of oil hole and plug is defective or Inspect and repair –
failed
The Engine Oil Lubricating system
Pressure is High Low oil temperature Keep operating until –
the oil temperature
rises
Poor oil quality Replace with the –
designated oil
The relief valve is defective Repair or replace 9-S45
Engine Overheating Cooling system
The fan belt is loose or cut Adjust or replace 1-S23
The coolant is low Replenish to the 1-S17
specified amount
The radiator net and the radiator fin are clogged Clean –
The coolant is dirty Replace the coolant 1-S17
The radiator and the radiator cap are defective Inspect and replace 9-S47
The cooling water passage is clogged Clean –
The cooling air passage is insufficient Make sure of –
sufficient cooling air
passage
The thermostat is defective Replace 9-S47
The mechanical seal of the water pump is Replace 9-S48
defective
9-S4
Reference
Symptom Probable Cause Solution
Page
Engine Overheating Engine body
Continuous overload operation Reduce the load –
The cylinder head gasket is broken Replace 9-S17
(decreased coolant)
The tightening of the cylinder head bolt is Tighten with the 9-S17
insufficient prescribed torque
Lubricating system
The oil is shortage Replenish oil to the 1-S11
specified amount
Fuel system
The low grade fuel is used Replace with the –
designated fuel
The fuel injection timing is incorrect Adjust 9-S50
The Battery Electrical system
Discharge is Too The fan belt is loose Adjust or replace 1-S23
Much
Deteriorated battery Replace –
The electrolytes is shortage Supply the distilled –
water and electrical
charging
Defective or faulty wiring Inspect and repair –
The alternator and the regulator are defective Repair or replace 9-S53 to
9-S57
The Charge Lamp Electrical system
Does Not Light Up Defective or faulty wiring Inspect and repair –
The alternator and the regulator are defective Repair or replace 9-S53 to
9-S57
Blown fuse Replace –
The Charge Alarm Electrical system
Lamp Does Not Turn The fan belt is loose or cut Adjust or replace 1-S23
OFF
Defective or faulty wiring Inspect and repair –
The alternator and the regulator are defective Repair or replace 9-S53 to
9-S57
9Y1210552ENS0001US0
9-S5
9-S6
9-S7
9-S8
9-S9
9-S10
3. ENGINE BODY
[1] SEPARATING ENGINE
Separating Engine
1. Separate the reaper. (See page 2-S12.)
2. Separate the feeder convertor. (See page 2-S15.)
3. Remove the operator's seat.
4. Drain the engine oil.
5. Drain the coolant.
6. Drain the oil in the hydraulic oil tank.
7. Remove the fuel tank.
8. Disconnect the negative cable of the battery (1).
(1) Battery
10. Open the dustproof cover (4), and remove the radiator net, the
dustproof cover stay, the grain bag hanger (5) and the front and
rear sides of the engine cover.
(4) Dustproof Cover (5) Grain Bag Hanger
11. Remove the mounting bolts of the engine frame (6) and remove
the engine frame (6).
(6) Engine Frame
(To be continued)
9-S11
13. Remove the fuel filter cartridge (9) and the water separator (10)
together with the stay (11) that mounts them.
(9) Fuel Filter cartridge (11) Stay
(10) Water Separator
19. Remove the wire harnesses of the alternator (16) and the starter
motor (17).
20. Remove the wire harnesses of the water temperature sensor
(15) and the engine oil pressure switch (18).
(15) Water Temperature Sensor (17) Starter Motor
(16) Alternator (18) Engine Oil Pressure Switch
(To be continued)
9-S12
9-S13
Firing order : 1 → 3 → 4 → 2
Cylinder No. 1 2 3 4
Valve
IN. EX. IN. EX. IN. EX. IN. EX.
sequence
No.1 cylinder
compression
O O O O
Top Dead
Center
No.4 cylinder
compression
P P P P
Top Dead
Center
9-S14
CAUTION
• Turn the engine for 2 to 3 seconds before measuring, to
make sure that the engine runs smoothly.
1. After running the engine to warm it up, stop the engine, remove
the air cleaner and the muffler and remove all the glow plugs.
2. Connect a compression tester (adaptor K,
code No. 07909-31291) for the diesel engine to the glow plug
hole of the cylinder to measure the pressure.
3. While pulling the engine stop knob, run the starter motor for five
seconds, and read the value at which the gauge needle stops.
Perform measuring at least twice and judge getting the average
value.
2.94 to 3.24 MPa
Factory specification
30 to 33 kgf/cm2
Compression pressure
2.35 MPa
Allowable limit
24 kgf/cm2
Pressure difference
Allowable limit Within 10 %
among cylinders
Measurement conditions :
The battery is fully charged (engine speed 250 to 270 rpm)
Specified valve clearance
9Y1210019ENS0017US0
9-S15
9-S16
9-S17
9-S18
9-S19
9-S20
9-S21
9-S22
9-S23
9-S24
Crank Gear
1. Remove the crank gear (1) with the gear puller (2).
2. Remove the feather key.
(1) Crank Gear (2) Gear Puller
9Y1210019ENS0035US0
9-S25
9-S26
9-S27
(6) Crankshaft
Flywheel
1. Install the flywheel stopper to fix the flywheel (1).
2. Remove 2 mounting screws (2) of the flywheel first.
3. Install the flywheel guide screws (3) as another part with a
proper length to 2 holes of screws which were removed.
4. Remove the rest the mounting screws (2) of the flywheel.
5. Install other long screws into the screw holes on the outer
circumference surface of the flywheel so that the flywheel can
be held by hand.
6. Slowly remove the flywheel (1) in along with the flywheel guide
screws (3).
(When reassembling)
• Wipe all dirt and dust off the mounting surface the of the
crankshaft for the flywheel (1).
• Apply the oil to the flywheel mounting screws (2).
98.0 to 107.8 N·m
Tightening torque Flywheel mounting screw
10.0 to 11.0 kgf·m
9-S28
9-S29
9-S30
[4] SERVICING
(1) Cylinder Head
Flatness of Cylinder Head
1. Clean the cylinder head surface.
2. Measure 6 clearances of A to F shown in the figure with the
straight edge tool and the thickness gauge.
3. If the measurement exceeds the allowable limit, replace the
cylinder head. The valve recessing and the valve seating must
be inspected at this stage.
Flatness of cylinder head Allowable limit 0.05 mm / 100 mm
9Y1210019ENS0043US0
Valve Recessing
1. Clean the cylinder head surface, the valve and the valve seat,
and measure the valve recessing amount with inserting the
valve into the valve guide.
2. If the measurement exceeds the allowable limit, replace the
valve, and lap the valve after correcting the valve seating.
Factory specification 0.65 to 0.85 mm
Valve recessing
Allowable limit 1.2 mm
9Y1210019ENS0045US0
9-S31
Outside diameter of
Factory specification 7.960 to 7.975 mm
valve stem
9Y1210019ENS0046US0
Inside diameter of
Factory specification 8.015 to 8.030 mm
valve guide
9-S32
Correction of Valve
IMPORTANT
• Before repairing valves, check the clearance between the
valve stem and the valve guide, and replace the valve if the
measurement exceeds the allowable limit.
1. Use a valve refacer to repair the valve.
2. After the repair, measure the valve recessing, and replace the
valve if the measurement exceeds the allowable limit.
Intake valve : 45 °
Valve face angle Factory specification
Exhaust valve : 45 °
9Y1210019ENS0049US0
Correction of Valve Seat
IMPORTANT
• The clearance between the valve guide and the valve stem
must be within the allowable limits as the valve seat will be
repaired relative to the valve guide. If the clearance
exceeds the allowable limit, the valve seat should be
repaired after replacing the valve guide and reaming to
achieve the factory specification.
• If a valve seat cutter is used to ream the seat surface, make
sure to select an appropriate size for the valve diameter.
1. Repair the seat surface roughly with a valve seat cutter of 45 °
for intake and exhaust valves.
2. Mount the valve and check the contact of the valve face and the
valve seat with red lead primer.
3. With the 15 ° valve seat cutter, ream the top portion of the valve
seat until it starts to hit the surface of the valve face center.
4. Repair the seat surface again by a 45 ° valve seat cutter and
visually inspect the valve contact.
5. Repeat procedures 3 and 4 until proper contact is achieved.
IMPORTANT
• The valve recessing must be within the factory
specification after the valve seat repair.
Width of valve seat
Factory specification Intake / exhaust 2.12 mm
surface
9-S33
Inside diameter of
Factory specification 14.000 to 14.018 mm
rocker arm
Outside diameter of
Factory specification 13.973 to 13.984 mm
rocker arm shaft
9Y1210019ENS0055US0
9-S34
Outside diameter of
Factory specification 23.959 to 23.980 mm
tappet
9Y1210019ENS0056US0
Bend of Push Rod
1. Place the push rod on a V-block (measurement tool).
2. Measure the bend of the push rod.
3. Replace any push rods that exceed the allowable limit.
Bend of push rod Allowable limit 0.25 mm
9Y1210019ENS0057US0
9Y1210019ENS0058US0
Side Clearance of Idle Gear
1. Set the dial gauge on the idle gear.
2. Measure the side clearance by moving the idle gear back and
forth.
3. If the measurement exceeds the allowable limit, replace the idle
gear collar.
Side clearance of idle Factory specification 0.12 to 0.48 mm
gear Allowable limit 0.9 mm
9Y1210019ENS0059US0
9-S35
Oil Clearance between Idle Gear Bushing and Idle Gear Shaft
1. Measure the inside diameter of the idle gear bushing and the
outside diameter of the idle gear shaft to calculate the oil
clearance.
2. If the measurement exceeds the allowable limit, replace the
bushing.
Oil clearance between Factory specification 0.025 to 0.066 mm
idle gear bushing and
idle gear shaft Allowable limit 0.10 mm
Bend of Camshaft
1. Put the camshaft on the V-block on the level surface plate, and
set the dial gauge perpendicular to the journal at the center of
the camshaft.
2. Measure the amount of runout by slowly rotating the camshaft.
The bend is half amount of the runout.
3. Replace the camshaft that exceeds the allowable limit.
Bend of camshaft Allowable limit 0.01 mm
9Y1210019ENS0063US0
9-S36
9-S37
Outside diameter of
Factory specification 25.002 to 25.011 mm
piston pin
9Y1210019ENS0067US0
Replacement of Small End Bushing
1. Replace the bushing with the special tools (see page 9-G4).
IMPORTANT
• After pressing the bushing into the connecting rod, make
sure that the inside diameter of the bushing is within 25.025
to 25.040 mm and there is no deformation of the bushing.
• The oil hole should pass through the connecting rod and
the bushing.
Further, make sure that there is no burr on the bushing
side.
(A) Removal (B) Press-in
9Y1210552ENS0006US0
9-S38
9-S39
Inside diameter of
Factory specification 47.000 to 47.046 mm
crankpin bearing
Outside diameter of
Factory specification 46.959 to 46.975 mm
crankpin
CAUTION
• When tightening the connecting rod cap, make sure to fix
the crankshaft to prevent rotation.
44.1 to 49 N·m
Tightening torque Connecting rod cap
4.5 to 5.0 kgf·m
(Reference)
• Undersize bearing
Undersize 0.2 mm 0.4 mm
A 3.3 to 3.7 mm radius 3.3 to 3.7 mm radius
B 1.0 to 1.5 mm radius 1.0 to 1.5 mm radius
C 46.759 to 46.775 mm 46.559 to 46.575 mm
9-S40
Outside diameter of
Factory specification 59.921 to 59.940 mm
crankshaft journal
Inside diameter of
Factory specification 59.980 to 60.039 mm
crankshaft bearing 1
(Reference)
• Undersize bearing
Undersize 0.2 mm 0.4 mm
A 2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
B 1.0 to 1.5 mm radius 1.0 to 1.5 mm radius
C 59.721 to 59.740 mm 59.521 to 59.540 mm
9-S41
Outside diameter of
Factory specification 59.921 to 59.940 mm
crankshaft journal
Inside diameter of
Factory specification 59.980 to 60.025 mm
crankshaft bearing 2
CAUTION
• When tightening the big end of the connecting rod, make
sure to fix the crankshaft to prevent rotation.
46.1 to 51 N·m
Tightening torque Bid end of connecting rod
4.7 to 5.2 kgf·m
(Reference)
• Undersize bearing
Undersize 0.2 mm 0.4 mm
A 2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
B 1.0 to 1.5 mm radius 1.0 to 1.5 mm radius
C and D 59.721 to 59.740 mm 59.521 to 59.540 mm
9-S42
(4) Crankcase
Inside Diameter of Cylinder
1. With the cylinder gauge, measure the inside diameter of the
cylinder at 6 points shown in the figure. And calculate the
difference between the maximum and minimum values of the
cylinder inside diameter.
Inside diameter of Factory specification 87.000 to 87.022 mm
cylinder Allowable limit 87.17 mm
9-S43
Finish roughness of
Factory specification Hone Rz = 2.2 to 3.0
honing process
9-S44
4. LUBRICATING SYSTEM
[1] CHECKING
Engine Oil Pressure
1. Inspect the engine oil amount.
2. Remove the engine oil pressure switch, and install the oil
pressure tester (see page 9-G3).
Mounting: PT1/8
3. Start the engine and wait until it warms up.
(Increase the oil temperature to 85 to 95 °C.)
4. Measure the pressure at idling and rated revolutions.
5. If the measurement is lower than the allowable limit, inspect the
oil filter, the oil pump, the oil passage and the oil clearance of
the crankshaft, etc.
98 kPa
At idling 1.0 kgf/cm2
Factory or more
specifica-
tion At rated
294 to 441 kPa
Engine oil pressure revolutions
3.0 to 4.5 kgf/cm2
(2600 rpm)
At rated
Allowable 245 kPa
revolutions
limit 2.5 kgf/cm2
(2600 rpm)
(When reassembling)
14.7 to 19.6 N·m
Tightening torque Engine oil pressure switch
1.5 to 2.0 kgf·m
9Y1210552ENS0009US0
[2] SERVICING
(1) Oil Pump
Clearance between Inner Rotor and Outer Rotor
1. Align the convex parts of the inner and outer rotors, and
measure the clearance with the thickness gauge.
2. If the measurement exceeds the allowable limit, replace the
rotor assembly.
Clearance between inner Factory specification 0.03 to 0.14 mm
rotor and outer rotor Allowable limit 0.2 mm
9Y1210019ENS0083US0
9-S45
9-S46
5. COOLING SYSTEM
[1] CHECKING
Inspection of Water Leakage from Radiator
1. Pour the specified amount of the coolant into the radiator.
2. Warm up the engine.
3. Attach the radiator tester, and apply pressure up to 137 kPa
(1.4 kgf/cm2).
4. Check there is no water leak. If the water leak is found, replace
or repair the radiator.
Inspection of water No leaks at 137 kPa
Factory specification
leakage from radiator (1.4 kgf/cm2)
9Y1210019ENS0086US0
Inspection of Radiator Cap
1. Install the radiator tester to the radiator cap, and pressurize to
88.3 kPa (0.9 kgf/cm2). It is normal if the radiator cap maintains
59 kPa (0.6 kgf/cm2) or more for 10 seconds. Replace if the
defective parts.
Maintain 59 kPa
(0.6 kgf/cm2) or more for
Inspection of radiator cap Factory specification 10 seconds after applying
pressure at 88 kPa
(0.9 kgf/cm2)
9Y1210019ENS0087US0
9-S47
9-S48
6. FUEL SYSTEM
[1] FUEL INJECTION NOZZLE
(1) Checking and Adjustment
Nozzle Fume Condition
CAUTION
• When inspecting using the nozzle tester, testing
atomization may harm the skin, so do not approach the
mist.
1. Set the fuel injection nozzle on the nozzle tester.
2. Spray fuel from the nozzle, and inspect the atomized fume
condition.
3. If the atomization is lopsided or directional, replace the fuel
injection nozzle assembly.
(Reference)
• For the atomization test, test with the hand lever operation
speed on the nozzle tester using 4 to 6 strokes or quicker per
second.
• If the lever operation of the nozzle tester is slow, the 2-steps
open valve nozzle atomization will be rough compared to the
ordinary nozzles.
(A) 4 to 6 times or quicker per second (B) 3 times or less per second
9Y1210019ENS0091US0
9-S49
(Reference)
• Check the fuel injection timing if the fuel injection pump has
been replaced.
• If the fuel injection timing is too fast, add the shim
If the fuel injection timing is too slow, remove the shim
A shim of 0.20 mm thickness changes the crank angle approx.
2 °.
(1) Delivery Holder (4) Angle Mark 10 °
(2) Timing Gauge Needle (5) Angle Mark 20 °
(3) T.D.C. Mark 1TC
9Y1210019ENS0093US0
Identification of Shims
9-S50
7. ELECTRICAL SYSTEM
[1] STARTER MOTOR
(1) Disassembling and Assembling
Motor
1. Disconnect the lead wire (9) from the magnetic is switch
assembly (8).
2. Remove the screw (6) and remove the end frame (4), the yoke
(2), and the armature (1).
3. Remove the screw (5), and remove the brush holder (3) from
the end frame (4).
(When reassembling)
• Apply grease to spline A of the armature (1) end.
(1) Armature (7) Nut
(2) Yoke (8) Magnetic Switch
(3) Brush Holder (9) Lead Wire
(4) End Frame
(5) Screw A : Spline
(6) Screw
9Y1210019ENS0095US0
Magnetic Switch
1. Remove the mounting screw of the magnetic switch cover (1).
2. As shown in the figure on the left, remove the overrunning clutch
(2), the ball (3), the spring (4), the gear (5), the roller (6), and the
retainer (7).
(When reassembling)
• Apply grease to the teeth surface of the gear (5), the
overrunning clutch (2), and the ball (3).
(1) Magnetic Switch Cover (5) Gear
(2) Overrunning Clutch (6) Roller
(3) Ball (7) Retainer
(4) Spring
9Y1210019ENS0096US0
Plunger
1. Remove the end cover (1).
2. Remove the plunger (2).
(1) End Cover (2) Plunger
9Y1210019ENS0097US0
(2) Servicing
Motor Test
CAUTION
• The starter may move unexpectedly if it is not secured.
Make sure to secure the starter to the vice when checking.
1. Remove the connecting lead wire from C terminal, and connect
the lead wire directly to the battery's positive terminal.
2. Connecting the battery's negative terminal to the body of the
starter motor for approx. 1 second, confirm that the motor is
running smoothly.
9Y1210019ENS0098US0
9-S51
Commutator
1. Check that the commutator surface of the brush contact has no
dirt, burnout damage or stepped abrasion.
2. Light stepped abrasion can be repaired using the fine sand
paper.
3. Measure the outside diameter of the commutator, and replace
the armature if the measurement exceeds the allowable limit.
4. If the mica (3) undercut depth exceeds the allowable limit, repair
using a saw blade.
Make sure to remove any burr resulting from repairs to the
segment (1) corner.
Outside diameter of Factory specification 35 mm
commutator Allowable limit 34 mm
Wear of Brush
1. If the contact surface of the brush is affected by dirt or dust, use
the sandpaper to clean and adjust.
2. Measure the length of the brush (A) .
3. Replace the brush, the brush holder and the yoke if the length
of brush (A) exceeds the allowable limit, or the brush has
damage that may cause a significant decrease of the direct
contact surface area with the commutator.
Factory specification 15.0 mm
Length of brush (A)
Allowable limit 9.0 mm
9-S52
Armature Coil
1. Check the conduction between the commutator and the
armature core.
2. Replace the armature if the conduction is detected.
9Y1210019ENS0103US0
Feed Coil
1. Check the resistance value between the lead wire (1) and brush
(2).
2. It is a normal if the resistance value is 0 Ω.
3. Check the conduction between the brush (2) and the yoke (3).
4. If no conduction detected, this is correct.
5. Replace the yoke (3) if defective.
(1) Lead Wire (3) Yoke
(2) Brush
9Y1210019ENS0104US0
[2] ALTERNATOR
(1) Disassembling and Assembling
Pulley
1. Fixing the hexagonal part of the shaft with the box wrench,
loosen the pulley nut, and remove the pulley.
IMPORTANT
• Make sure to use the hexagonal box wrench. The
dodecagon type may break the corners and result in slip.
58.3 to 78.9 N·m
Tightening torque Pulley mounting nut
5.95 to 8.05 kgf·m
9Y1210019ENS0105US0
9-S53
Brush Holder
1. Remove the screws and the brush holder (1).
(1) Brush Holder
9Y1210019ENS0107US0
IC Regulator
1. Remove the screws and IC regulator (1).
IMPORTANT
• Due to the screw lengths being different, make sure to
arrange the removed screws and make sure that they are
reattached to their original position.
(1) IC Regulator
9Y1210019ENS0108US0
Rectifier
1. Remove the rectifier (1) screw and the stator leading line, and
then remove the rectifier (1).
(1) Rectifier
9Y1210019ENS0109US0
9-S54
Retainer Plate
1. Remove the screws, and then remove the retainer plate (1).
(1) Retainer Plate
9Y1210019ENS0112US0
9-S55
9-S56
(Reference)
• The rectifier quality cannot be determined by the resistance
value in the flow direction. Based on the diode characteristics,
the current direction is subject to considerable change
depending on the electrical voltage, so the tester display
depends on the differences in the tester type and the resistance
range. Consequently, the quality of the rectifier can be
determined based on the degree of difference in resistance
value in the flow and reverse directions.
(A) Red (+) (B) Black (–)
9Y1210019ENS0120US0
9-S57
8. TURBOCHARGER
[1] CHECKING
Inspection of Exhaust Gas Leaks from Turbine
• Inspect the exhaust gas leaks at the exhaust inlet and outlet
ports of the turbine housing (1).
• If the leak is significant, retighten the screws and the nuts, or
replace the gasket.
(1) Turbine Housing
9Y1210019ENS0121US0
9-S58
9-S59
KUBOTA Corporation Printed in Japan 2010. 08, S, El, EI, e Code No.9Y111-05530